EIA/EMP REPORT For Proposed Expansion of Ammonia...

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EIA/EMP REPORT

For Proposed Expansion of

Ammonia-Urea Fertilizer Plant & CPP at Udyog Nagar Industrial

Area, Panki, Kanpur, UP

M/s. Kanpur Fertilizers & Cement

Limited

August 2015

EIA Consultant:

EQMS INDIA PVT. LTD. INDIA 304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower, Community Centre, Karkardooma, Delhi – 110092 Phone: 011-30003200, 30003219; Fax: 011-22374775 Website: www.eqmsindia.com ; E-mail – [email protected]

http://www.eqmsindia.com/

mailto:[email protected]

EIA/EMP Report of Proposed Expansion Project of Kanpur Fertilizers & Cement Limited

EQMS INDIA PVT. LTD. i

Table of Contents

Executive Summary ........................................................................................................................... x Chapter 1. Introduction and Background ...................................................................................... 1

1.1. Project Proponent ............................................................................................................... 1 1.2. Proposed Project ................................................................................................................ 2 1.3. Justification of the Project ................................................................................................... 3 1.4. Purpose of the Study .......................................................................................................... 4 1.5. Regulatory Frame Work ..................................................................................................... 4 1.6. Scope & Methodology of the study ..................................................................................... 4 1.7. Approved ToR for EIA Study by MoEF- EAC ...................................................................... 6 1.8. Public Heraing .................................................................................................................. 10 1.9. Sturcture of the Report ..................................................................................................... 10

Chapter 2. Project Description .................................................................................................... 12 2.1. About the Project .............................................................................................................. 12 2.2. Existing Ammonia Plant .................................................................................................... 14

2.2.1. Basic of Design ......................................................................................................... 14 2.2.2. Feedstock Specification ............................................................................................. 14 2.2.3. Production Specification ............................................................................................ 14 2.2.4. Utilities & Services Available (at the B/L) ................................................................... 15 2.2.5. Ammonia Plant Process ............................................................................................ 16 2.2.6. Ammonia Storage ...................................................................................................... 24 2.2.7. Boiler Feed Water and Steam System ....................................................................... 25

2.3. Ammonia Process Description - Expanded Plant .............................................................. 26 2.3.1. Front-End Section Debottlenecking ........................................................................... 27 2.3.2. Compressors Debottlenecking ................................................................................... 29 2.3.3. Back-End Section Debottlenecking ............................................................................ 29 2.3.4. CO2 Removal Revamping .......................................................................................... 30 2.3.5. CO Conversion – HTS Internals Revamp .................................................................. 31 2.3.6. Revamp in Synthesis Loop- Ammonia Converter....................................................... 32 2.3.7. Operating Parameters /Specifications after Modifications .......................................... 33

2.4. Existing Urea Plant: .......................................................................................................... 34 2.4.1. Utilities Available ....................................................................................................... 34 2.4.2. Urea Process Description .......................................................................................... 36

2.5. Urea Process Description: Expanded Capacity ................................................................ 49 2.5.2. CO2 Compression ...................................................................................................... 57 2.5.3. Synthesis Unit ........................................................................................................... 57 2.5.4. High Pressure Pumps ................................................................................................ 58 2.5.5. Decomposition and Absorption Units ......................................................................... 59 2.5.6. Finishing Unit ............................................................................................................. 59 2.5.7. Hydrolyser Stripping Unit ........................................................................................... 60 2.5.8. Steam Network .......................................................................................................... 60 2.5.9. Major Requirements for Urea Revamp / Capacity Expansion .................................... 60 2.5.10. Expanded Capacity Urea (3033 TPD) – Operation Parameters ................................. 61 2.5.11. Plant/Process Performance ....................................................................................... 61 2.5.12. Revamped & Expanded Urea Plant Equipment List ................................................... 62

2.6. Utilities ............................................................................................................................. 64 2.6.1. Raw Material Requirement & Storage ........................................................................ 64 2.6.2. Land .......................................................................................................................... 64 2.6.3. Power ........................................................................................................................ 68 2.6.4. Water ......................................................................................................................... 68 2.6.5. Fuel Requirement ...................................................................................................... 70 2.6.6. Employment: ............................................................................................................. 70


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2.7. Captive Power Plant ......................................................................................................... 70 2.8. Environmental Aspects ..................................................................................................... 73

2.8.1. Water Pollution .......................................................................................................... 73 2.8.2. Air Pollution ............................................................................................................... 75 2.8.3. Solid/ Hazardous Waste Generation .......................................................................... 78 2.8.4. Noise Pollution .......................................................................................................... 78 2.8.5. Fugitive emission ....................................................................................................... 78 2.8.6. Green Belt Development ........................................................................................... 79

2.9. Charter on Corporate Responsibility for Environment Protection (CREP) Guidelines ... 79 2.10. Total Cost ......................................................................................................................... 81 2.11. Energy Conservation Measures ....................................................................................... 81 2.12. OHS Status ...................................................................................................................... 84 2.13. CSR Activities .................................................................................................................. 86

Chapter 3. description of environment ........................................................................................ 88 3.1. Introduction ...................................................................................................................... 88 3.2. State of the Environment (Regional) ................................................................................. 88

3.2.1. Topography & Geology .............................................................................................. 88 3.2.2. Climate and Rainfall .................................................................................................. 89 3.2.3. Seismic Consideration ............................................................................................... 90 3.2.4. Hydrogeology ............................................................................................................ 91 3.2.5. Land Use: .................................................................................................................. 94 3.2.6. Micro-meteorology ..................................................................................................... 98

3.3. Baseline Environment..................................................................................................... 100 3.3.2. Air Environment ....................................................................................................... 102 3.3.3. Noise Environment .................................................................................................. 108 3.3.4. Water Environment .................................................................................................. 110 3.3.5. Soil Environment ..................................................................................................... 116 3.3.6. Biological Environment ............................................................................................ 122 3.3.7. Socio-Economic Environment .................................................................................. 132

Chapter 4. IMpact assessment and prediction .......................................................................... 143 4.1. Introduction .................................................................................................................... 143 4.2. Potential Impacts during Project Implementation ............................................................ 143

4.2.1. Impact on Air Environment ...................................................................................... 143 4.2.2. Impact on Land Environment ................................................................................... 144 4.2.3. Impact on Ambient Noise Level ............................................................................... 144 4.2.4. Impact on Water Quality .......................................................................................... 144 4.2.5. Impact on Soil Environment ..................................................................................... 145 4.2.6. Impact due to Solid Waste / Hazardous Waste ........................................................ 145 4.2.7. Impact on Terrestrial Ecology .................................................................................. 145 4.2.8. Impact on Socio-Economic Environment ................................................................. 146 4.2.9. Site Security & Safety .............................................................................................. 147 4.2.10. Health and Well being of Construction Workers ....................................................... 147

4.3. Potential Impacts during Project Operation ..................................................................... 147 4.3.1. Impact on Air Environment ...................................................................................... 147 4.3.2. Impact on Land Environment ................................................................................... 158 4.3.3. Impact on Ambient Noise Level ............................................................................... 158 4.3.4. Impact on Water Quality .......................................................................................... 159 4.3.5. Impact on Soil Environment ..................................................................................... 160 4.3.6. Impact due to Solid Waste/ Hazardous waste .......................................................... 160 4.3.7. Impact on Terrestrial Ecology .................................................................................. 160 4.3.8. Impact on Socio-Economic Environment ................................................................. 161 4.3.9. Foul Odour Problem ................................................................................................ 162

Chapter 5. Environment Management Plan & Environmental Monitoring program ................... 163 5.1. Introduction .................................................................................................................... 163 5.2. Environment Management Plan ..................................................................................... 163


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5.2.1. Air Environment ....................................................................................................... 163 5.2.2. Water Environment .................................................................................................. 164 5.2.3. Solid and Hazardous Waste Management ............................................................... 164 5.2.4. Noise Environment .................................................................................................. 165 5.2.5. Occupational Health Program .................................................................................. 165 5.2.6. Biological Environment ............................................................................................ 165 5.2.7. Land Environment ................................................................................................... 167 5.2.8. Socio-economic Environment .................................................................................. 168 5.2.9. Charter on Corporate Responsibility for Environmental Protection (CREP) ............. 168 5.2.10. Environmental Management Cell ............................................................................. 168 5.2.11. Environmental Monitoring Plan ................................................................................ 169 5.2.12. Environmental Budget ............................................................................................. 169

Chapter 6. Hazards Evaluation & Risk Assessment ................................................................. 170 6.1. Introduction .................................................................................................................... 170 6.2. Hazard Identification ....................................................................................................... 170

6.2.1. Hazardous Materials to be Stored at the Plant ......................................................... 170 6.2.2. Characteristics of Hazardous Materials ................................................................... 170

6.3. Methodology, Approach and Damage Criteria for Risk Assessment ............................... 172 6.3.1. Damage Criteria ...................................................................................................... 172 6.3.2. Acid and Alkali Hazards ........................................................................................... 173

6.4. Selected Failure Cases .................................................................................................. 173 6.4.2. Rupture in NG Line .................................................................................................. 174 6.4.3. Failure of Ammonia Line .......................................................................................... 175 6.4.4. Chlorine Cylinder Leakage ...................................................................................... 176

6.5. General Control Measures ............................................................................................. 177 6.5.1. Flammable Gas Fires .............................................................................................. 177 6.5.2. Consequence Analysis ............................................................................................ 177

6.6. Recommendations ......................................................................................................... 178 6.6.1. LDAR program :-- ................................................................................................... 178 6.6.2. Fugitive Emission Control Guidelines :-- ............................................................... 179 6.6.3. Hazardous Liquids Spillage ..................................................................................... 179

6.7. Occupational Exposure Mitigation Planning .................................................................... 179 6.8. Other Recommended Measures for Safe Operation of the Plant .................................... 180

6.8.1. Personal Protective Equipment ................................................................................ 181 Chapter 7. On site emergency plan .......................................................................................... 184

7.1. Introduction .................................................................................................................... 184 7.2. Probable Hazards & Risk ............................................................................................... 184 7.3. Objectives ...................................................................................................................... 184 7.4. Emergency Management Plan ....................................................................................... 185 7.5. Responsibilities & Role of Key Personnel ....................................................................... 186 7.6. Outside Organizations if involved in assisting during On-site Emergency ....................... 196

Chapter 8. Summary and Conclusions ..................................................................................... 198 8.1. Prelude ........................................................................................................................... 198 8.2. Regulatory Compliance .................................................................................................. 198 8.3. Baseline Conditions ........................................................................................................ 198 8.4. Environmental Impacts and Mitigation Measures ............................................................ 198 8.5. Recommendations ......................................................................................................... 199

Chapter 9. Disclosure of Consultants Engaged ........................................................................ 202


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List of Tables

Table 1.1 : ToR Compliance Status ................................................................................................. 7 Table 2.1 : Details of Environmental Setting (10 km Radius).......................................................... 12 Table 2.2 : Natural Gas Composition ............................................................................................. 14 Table 2.3 : Equilibrium Conditions for Inlet Ammonia Concentration .............................................. 21 Table 2.4 : Major Equipment List for Expansion vis a vis existing .................................................. 28 Table 2.5 : Major Modifications in Synthesis Loop ......................................................................... 32 Table 2.6 : Equipment List for Existing Urea Plant ......................................................................... 48 Table 2.7 : Operation Parameters for Expanded Urea Capacity ..................................................... 61 Table 2.8 : Urea Product Quality .................................................................................................... 61 Table 2.9 : Equipment List – Revamped & Expanded Area ............................................................ 62 Table 2.10 : Compressors – Synthesis Gas, Air & CO2 Compressors ............................................ 63 Table 2.11 : HP Carbamate Condenser ......................................................................................... 63 Table 2.12 : Stripper ...................................................................................................................... 63 Table 2.13 : Auxilliary Urea Reactor ............................................................................................... 63 Table 2.14 : Bulk Storages ............................................................................................................. 64 Table 2.15 : Area Break-up ............................................................................................................ 64 Table 2.16 : Water Consumption ................................................................................................... 68 Table 2.17 : Technical Details of Captive Power Plant ................................................................... 70 Table 2.18 : Details of Gaseous Emissions – Existing ................................................................... 76 Table 2.19 : Details of Gaseous emissions after Modernisation and Expansion ............................. 77 Table 2.20 : Hazardous waste (Existing Plant) ............................................................................... 78 Table 2.21 : Expected Hazardous waste (Expansion) .................................................................... 78 Table 2.22 : CREP Compliance ..................................................................................................... 79 Table 2.23 : Capital Cost and Recurring Expenditure on Environmental Protection ....................... 81 Table 3.1 : Geological Succession in Kanpur Nagar District........................................................... 89 Table 3.2 : Climate Data for Kanpur ............................................................................................... 90 Table 3.3 : Land use category in the Study Area............................................................................ 95 Table 3.4 : Summary of Climatic Condition at the Site ................................................................... 98 Table 3.5 : Details of Sampling Locations .................................................................................... 102 Table 3.6 : Ambient Air Quality Status around the Project Site in 10-km Radius .......................... 104 Table 3.7 : National Ambient Air Quality Standards (CPCB), 2009 .............................................. 105 Table 3.8 : Ambient Noise Levels in the Study Area, dB (A) ........................................................ 108 Table 3.9 : Standard of Ambient Noise Level as per CPCB Guidelines ........................................ 110 Table 3.10 : Damage Risk Criteria for hearing loss, Occupational Safety & Health Administration

(OSHA) regulations ............................................................................................................... 110 Table 3.11 : Monitoring Methodology of Water ............................................................................. 111 Table 3.12 : Physical and Chemical Characteristics of Ground Water Samples ........................... 112 Table 3.13 : Physical and Chemical Characteristics of Surface Water Samples........................... 115 Table 3.14 : Area under Major Field Crops (As per latest figures 2011-12) .................................. 117 Table 3.15 : Production and Productivity of Major Crops (Average of last 5 years) ...................... 118 Table 3.16 : Physicochemical Characteristics of Soil ................................................................... 118 Table 3.17 : List of Tree Flora Recorded in the Study Area .......................................................... 124 Table 3.18 : List of Shrub Flora Recorded in the Study Area........................................................ 125 Table 3.19 : List of Herb/Grass Flora Recorded in the Study Area ............................................... 125 Table 3.20 : Common Mammalian Fauna Recorded in the study area ......................................... 126 Table 3.21 : List of Avi-Fauna Recorded in the study area ........................................................... 127 Table 3.22 : List of Herpetofauna Recorded in the study area...................................................... 128 Table 3.23 : Phyotoplankton community recorded from the study area ........................................ 129 Table 3.24 : Phyotobenthos community recorded from the study area ......................................... 131 Table 3.25 : Macroinvertebrate fauna recorded from study area along with functional feeding

groups .................................................................................................................................. 132 Table 3.26 : List of Fish Fauna Recorded in the study area ......................................................... 132


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Table 3.27 : Village-wise Population Details ................................................................................ 133 Table 3.28 : Tehsil-wise Infrastructure Details ............................................................................. 139 Table 4.1 : Details of Gaseous Emissions – Proposed Expansion ............................................... 149 Table 4.2 : Stack Parameters – Proposed Expansion .................................................................. 149 Table 4.3 : Summary of Maximum 24-hour GLC due to the Proposed Expansion Project ............ 150 Table 4.4 : Summary of Maximum GLC at Monitoring Locations .................................................. 150 Table 5.1 : List of Plant species to be planted .............................................................................. 167 Table 5.2 : Environmental Monitoring Program ............................................................................ 169 Table 5.3 : Capital Cost and Recurring Expenditure on Environmental Protection ....................... 169 Table 6.1 : Bulk Storage Details ................................................................................................... 170 Table 6.2 : Hazardous Materials (MSIHC Rules, 1989) ................................................................ 171 Table 6.3 : Effects due to Incident Radiation Intensity .................................................................. 172 Table 6.4 : Thermal Radiation Impact to Human .......................................................................... 173 Table 6.5 : Likely Accident Scenario ............................................................................................ 173 Table 7.1 : Probable Hazards ...................................................................................................... 184


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List of Figures Figure 1.1 : Project Location ............................................................................................................ 3 Figure 1.2 : EIA Methodology ........................................................................................................... 6 Figure 2.1 : Projection Location Map (Source: Google Earth) ....................................................... 13 Figure 2.2 : Process Flow Steps in Ammonia Manufacture ............................................................ 23 Figure 2.3 : Natural Gas Purification Upstream Reforming ............................................................. 27 Figure 2.4 : GV Low-Energy CO2 Removal Scheme ..................................................................... 30 Figure 2.5 : Axial-Radial Distribution Concept ................................................................................ 32 Figure 2.6 : HEC Process .............................................................................................................. 51 Figure 2.7 : Conventional Total Recycle Plant revamped with the HEC Concept ........................... 54 Figure 2.8 : HEC Process Scheme ................................................................................................ 56 Figure 2.9 : Plant Layout ................................................................................................................ 65 Figure 2.10 : CPP Layout ............................................................................................................... 66 Figure 2.11 : Pictures of the Existing Plant ..................................................................................... 68 Figure 2.12 : Water Balance Diagram for Expanded Capacity of Fertilizer Plant ............................ 69 Figure 2.13 : Typical Flowsheet of Electric Power Generation Plant .............................................. 72 Figure 2.14 : Effluent Treatment Scheme....................................................................................... 74 Figure 3.1 : Seismic Hazard Zone of Uttar Pradesh ....................................................................... 91 Figure 3.2 : Canal and River System Map of Kanpur Nagar ........................................................... 94 Figure 3.3 : Land use statistics of the proposed site ...................................................................... 96 Figure 3.4 : Land use/ Land cover Map of the proposed site .......................................................... 97 Figure 3.5 : Wind Rose (Post-monsoon Season) ........................................................................... 99 Figure 3.6 : Wind Class Frequency Distribution (Post-monsoon Season) .................................... 100 Figure 3.7 : Sampling Locations in the Study Area ....................................................................... 101 Figure 3.8 : Statistical Comparison of PM2.5 Concentration (Post-monsoon Season) ................. 106 Figure 3.9 : Statistical Comparison of PM10 Concentration (Post-monsoon Season) .................... 107 Figure 3.10 : Statistical Comparison of SO2 Concentration (Post-monsoon Season) ................... 107 Figure 3.11 : Statistical Comparison of NOx Concentration (Post-monsoon Season) .................. 108 Figure 3.12 : Statistical Comparison of Ambient Noise ................................................................. 109 Figure 3.13 : Identification of aquatic spp ..................................................................................... 129 Figure 3.14 : Number of Phytoplankton species in each taxonomic class .................................... 130 Figure 3.15 : Number of phytobenthos species in each taxonomic class in the study area .......... 131 Figure 3.16 : Tehsil-wise Population of the Study Area ................................................................ 134 Figure 3.17 : Tehsil-wise SC Population in Study Area ................................................................ 135 Figure 3.18 : Tehsil-wise ST Population in Study Area................................................................ 135 Figure 3.19 : Gender-wise Distribution of Literacy and of Illiteracy in Study Area ......................... 136 Figure 3.20 : Worker Participation Ratio in Study Area ................................................................ 136 Figure 3.21 : Main worker Participation Ratio in Study Area ........................................................ 137 Figure 3.22 : Marginal worker Participation Ratio in Study Area ................................................... 137 Figure 3.23 : Photographs of the surveyed villages ...................................................................... 142 Figure 4.1 : Isopleth for SOx ........................................................................................................ 153 Figure 4.2 : Isopleth For NOx ....................................................................................................... 154 Figure 4.3 : Isopleth For PM10 ...................................................................................................... 155 Figure 4.4 : Isopleth For PM2.5 ..................................................................................................... 156 Figure 4.5 : Isopleth For NH3 ....................................................................................................... 157 Figure 6.1 : Rupture in NG Line ................................................................................................... 174 Figure 6.2 : Failure in Ammonia Line ........................................................................................... 176 Figure 6.3 : Chlorine Cylinder Leakage ........................................................................................ 177 Figure 7.1 : Existing Organizational Structure at KFCL Facility .................................................... 185


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List of Annexures

Annexure I - ToR letter

Annexure IIA - GAIL letter

Annexure IIB - GAIL letter

Annexure IIIA - Water Supply Letter

Annexure IIIB - Water Supply Letter

Annexure IV - AAQ Pictures and Baseline Monitoring Results

Annexure V - Mock drill details

Annexure VI - Justification- Demand Supply Scenario

Annexure VII - Air & Water Consent

Annexure VIII - UPPCB Letter regarding NOC

Annexure IX - Treated Effluent data

Annexure X - Health Check-up form

Annexure XI - Equipment Layout- ETP

Annexure XII - Agreement Letter for disposal of HW

Annexure XIII - Fuel Supply Agreement

Annexure XIV - PH Proceeding along with photographs.

Annexure XV - PH action plan along with budgetary allocation and time bound schedule of implementation


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Abbrevation

AAQ Ambient Air Quality AAQMS Ambient Air Quality Monitoring Station ADM Additional District Magistrate APC Ammonia Process Condensate APTI Air Pollution Tolerance Index Asstt. Assistant BA Breathing Appratus BFW Boiler Feed Water BOD Biological Oxygen Demand CCR Central Control Room CGWA Central Ground water Authority CHC Community Health Center CII Confederation of Indian Industries CO Carbon Monoxide CPCB Central Pollution Control Board CPP Captive Power Plant CSR ` Corporate Social Responsibility CT Cooling Tower dB Decibel DCS Distributed Control System Dept. Department DM De Mineralization DMP Disaster Management Plan EC Environment Clearance ECC Emergency Control Centre EHS Environment, Health & Safety EIA Environmental Impact Assessment EMP Environmental Management Plan ENE East- North- East ETP Effluent Treatment Plant FAI Fertilizers Association of India FRP Fiberglass Reinforced Plastics GAIL Gas Authority of India Limited GLC Ground Level Concentration GM (O) General Manager (Operation) GOI Government of India HC Hydro Carbon HDPE High Density Polyethene HR, Admn & CD Human Resources, Administration and Community Development HRSG Heat Recovery Stream Generator HTAS Haldor Topsoe HTS High Temperature Shift converter IS Indian Standards ISCST Industrial Source Complex - Short Term ISO International Standard Organization IVRI Indian Veterinary Research Institute JUBVPL M/s. Jaypee Uttar Bharat Vikas Pvt. Ltd. KFCL Kanpur Fertilisers & Cement Limited KBR Kellogg Brown & Root KVA Kilovolt-Ampere LDPE Low Density Polyethylene LTS Low Temperature Shift Converter


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MAGP Modern Agro Growth Programme Mbgl Meters below Ground Level MINAS Minimum National Standards MoEF Ministry of Environment & Forests MSDS Material Safety Data Sheet MSRL Mild Steel Rubber Linned MTPD MetricTons per Day MW Mega Watt NDT Non-Destructive Testing NG Natural Gas NGO Non - Government Organization NH3 Ammonia NNW North-North-West NOC No Objection Certificate NOx Nitrous Oxide P&QA Process & Quality Assurance PGRU Purge Gas Recovery Unit PHC Primary Health Center PT Prilling Tower PVC Poly Vinyl Chloride QC&E Quality Control & Environment RO Reverse Osmosis RSPM Respiratory Suspended Particulate Matter SBU Strategic Business Unit SG Stream Generation SGP Steam Generation Plant SGWA State Ground Water Authority SH State Highway SHG Self Help Group SO2 Sulphur Dioxide SOx Sulphur Oxides SPM Suspended Particulate Matter Sr. Senior ST Scheduled Tribe STP Sewage Treatment Plant TC Total Cloud TDS Total Dissolved Solids TERI The Environment Research Institute TOR Terms of Reference TS Technical Services TSDF Treatment, Storage, and Disposal Facility UP Uttar Pradesh UPC Urea Process condensate UPPCB Utter Pradesh Pollution Control Board USEPA United State Environment Protection Agency WNN West-North-North ZnO Zinc Oxide


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EXECUTIVE SUMMARY

Project Proponent & Proposed Project

Kanpur Fertilizers & Cement Ltd. (KFCL) a wholly owned subsidiary of M/s. Jaypee Uttar Bharat Vikas Pvt. Ltd. (JUBVPL) which in turn is a 50:50 Joint Venture formed between R.P. Goenka Group through M/s. ISG Traders Ltd. and M/s. Jaiprakash Associates Ltd., through its subsidiary M/s. Jaypee Fertilizers & Industries Ltd.

The existing fertilizer complex having Ammonia – Urea Fertilizer of 1245 / 2046 TPD along with 12 MW CPP at Panki, Kanpur was set up by M/s. ICI Ltd. in 1969. Subsequently the company was taken over by M/s Duncan Industries Ltd. However, the Fertilizer plant has been lying closed since 2002 due to economic reasons.

Further the board of M/s. Duncan Industries Ltd. in its meeting held on 17.06.2010 has approved the participation of M/s. Jaypee Fertilizers & Industries Ltd. (a Jaypee Group Co.) as a strategic investor for the revival and rehabilitation of the company’s fertilizer unit at Panki, Kanpur through JUBVPL, the JV Co. of M/s. Jaypee Fertilizers & Industries Ltd., and M/s. ISG Traders Ltd.

Jaypee group is a well-diversified industrial conglomerate in India with a turnover of over Rs.18000 crores commenced its operations in mid sixties. Four decades later, with growth and diversification, the group is engaged in the businesses of Engineering & Construction, Cement, Private Hydropower, development of Expressways, Real Estate and Hospitality. With a professional management team and a competent technical cadre, the Group employs a total workforce of over 30,000.

It is 3rd largest cement producer in India with an operational capacity of 27.90 MTPA. It’s

has computerized process control cement plants at various location of Central and Northern region of India.

Proposed Project

KFCL is proposed to Modernize and Increase the existing capacity of Ammonia- Urea Plant from 1245 MTPD to 1800 MTPD and Urea plant from 2046 MTPD to 3033 MTPD to produce 1.05 MTPA of Urea within existing premises of Ammonia-Urea Fertilizer Complex at Udyog Nagar Industrial Area, Panki, Distt. Kanpur, Uttar Pradesh.

Existing Captive Power Plant of 12 MW capacity is very old and inefficient and hence, it is proposed to dismantle the existing Captive Power Plant. A new coal based 95 MW Captive Power Plant (CPP) having configuration of 1x60 MW + 1x35 MW capacity is being proposed to meet the entire requirement of Fertilizer complex.

Capital cost of the proposed modernization & expansion of Fertilizer plant is estimated as Rs. 583 crores and Captive Power Plant is Rs. 500 crores.

The proposed modernization cum expansion project is a brownfield project and hence no alternate site examination is needed. Expansion is proposed within the existing plant premises. The land is already under industrial use. Hence, no alternative sites have been examined.


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Existing fertilizer complex is having 243.4387 acres of lease hold land located in Udyog Nagar Industrial Area, Panki, District Kanpur in Uttar Pradesh.

No additional land required for the proposed expansion which will be installed within the boundary limit of existing fertilizer complex. The land is already in industrial use and is located in Udyog Nagar industrial area, Panki, Kanpur of Uttar Pradesh. Hence there will not be any changes in land use.

Proposed project location and surrounding environmental setting is as below:

S. No. Particular Details 1 Plot No. Udyog Nagar Industrial Area, Panki, Kanpur. (UP) 2 Location Near Kanpur 3 District Kanpur 4 Latitude/Longitude 260 27’ 02.1” N

800 15’ 08” E 5 Elevation ~130 mabove MSL 6 Defense Installations Ordinance Factory at 2.5 km; IAF Aerodrome- 7.5 km;

E 7 Ecological Sensitive Areas/ Protected

Areas as per Wildlife Protection Act 1972 (National Parks / Wild life sanctuaries / bio-sphere reserves / tiger reserves)

There are no Ecologically Sensitive Areas/Protected areas within 10 km radius from the Plant Site.

8 Reserved/Protected Forest There are no reserved/protected forests within 10 km radius from the Plant Site.

9 Nearest National Highway NH-2 (~ 1 km) 10 Nearest Water Body Ganga River : 8.91 km, NE

Pandu Nadi : 1.38 km, SSW Lower Ganga Canal : 1.82 km, N

11 Nearest Archeological important places There are no archeological places within 10 km radius from the Plant Site.

12 Nearest Rail Head Panki (2 km) 14 Nearest Airport Chakeri, Kanpur (12 km; NE) 15 Seismic Zone Seismic zone –II as per IS 1893 (part1) 2002

The key facilities for the proposed expansion project are as below:

Ammonia Plant

Each Ammonia plant out of the three existing plants (capacity each train- 415 MTPD) is proposed to be expanded for production of 600 MTPD Ammonia with necessary debottlenecking and addition of rotating equipment such as Synthesis Gas Make Up and Recycle compressor and Air compressor for one train. The three Ammonia plants have two synthesis and One Air compressor. After revamp, there will be three old synthesis gas compressors for each of the two Ammonia Plants. The third Ammonia plant will have a new synthesis gas and recycle compressor. This will also have a new process air compressor, which will have capacity to supplement incremental air requirement for the remaining two Ammonia plants also.

Urea Plant

The existing Urea plants are three in number and are based on Toyo Koatsu Total Recycle C improved process. Each plant has a Urea prills production design capacity of 682 MTPD.


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It is proposed to establish a new HEC Urea process train & integrate the same with the existing Urea plants A, B & C. A customized process configuration for optimum use of the existing Decomposition, Concentration , Crystallization and Prilling sections will be designed and engineered by Casale during detail engineering stage. However, a preliminary configuration for the broad understanding is presented in Figure 2.7.

The new HEC Synthesis (A “once through process”) will process about 1800 MTPD of

urea. Line A and Line B will decompose and recycle the load corresponding to about 900 MTPD each, till downstream the oxidizers.

From each line A & B 200 MTPD will be sent to the crystallization in line C. Total urea capacity will be expanded from 2046 MTPD to 3033 MTPD.

Captive Power Plant (CPP)

KFCL is proposing expansion of Ammonia – Fertilizer Complex to 1800 / 3033 capacity and the maximum estimated demand of power is approximately 90 MW connecting load / average 78 MW operational loads. However existing captive power plant of 12 MW capacity meets a smaller amount of requirement. Hence it is proposed to dismantle the existing Captive Power Plant of 12 MW and setting up a 95 MW Coal based Captive Power Plant having configuration of (1x60 MW + 1x35 MW) based on Indian / Imported coal to meet the power requirement.

The requirement of raw material and utilities for the proposed project has been worked out on the basis of rated capacity operation of the plants. The main raw material for the proposed plants is natural gas and utility is raw water. The requirements of these inputs for 1800 MTPD ammonia and 3033 MTPD urea plants are summarized in Table below:

Sl. No. Raw Material/Utilities Unit Requirement 1.0 Natural Gas (through GAIL existing Pipeline) MMSCMD 2.05 2.0 Water (Lower Ganga Canal) m3/ day 21600 3.0 Coal (Indian/Imported) MTPA 0.4

Pollutants Generation, Treatment and Disposal

Gaseous Emissions

The KFCL plant will have eleven continuous sources of emission after expansion.

In Existing Plant:

The gaseous emission of the KFCL existing plant is through ten number of main stacks viz. Ammonia reformer stack (three nos.), Process Air Natural Gas Heater (three nos.), Prilling tower (three nos.) and CPP Boiler stack. The emission from continuous stacks is well within the stipulated norms.

Liquid Effluents

In this project, water would be required for industrial use, domestic & gardening purposes. Although, there will be some wastewater generation due to industrial process, the water generated from washing and scrubbing will be recycled back in the process to the extent possible.


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There are two no. Hydrolyser Stripper Unit (HSU) in the existing Urea plants. Their capacity is 35 m3/hr. & 60 m3/hr. for decomposition of ammonical waste into Ammonia, Carbon dioxide and water vapour. These gases are recovered in the process plant to ensure zero discharge stringent measures were in place to avoid effluent generation at source. The condensate produced from the HSU is used as cooling tower make up.

KFCL has already modernized the Effluent Treatment Plant (ETP) facilities for the requirements of expanded capacity in advance. The proposed expansion project along with existing plant will generate 180 m3/hr. effluents which will be treated in the ETP. Out of 180 m3/hr, 155.21 m3/hr of treated effluents will be recycled back to plant. Reject water from ETP will be used for dust suppression in coal stockpile area and horticulture. Balance of 0.79 m3/hr sludge will be disposed off through Common Hazardous Waste Treatment Storage and Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project. (UPWMP) (Refer Figure 2.14). Thus KFCL propose to follow “Zero

discharge” philosophy. Industrial wastewater after treatment will be effectively utilized in

process and for horticulture/ green belt development.

Solid Waste

KFCL being an environmentally conscious organization has always stressed on pollution prevention rather then pollution Control. It has insisted on the protection and enrichment of the environment, conservation of the natural resources. To strengthen the waste management system, different types of wastes are identified along with proper disposal mechanisms.

There will be no major increase in hazardous waste generation due to the proposed expansion project that would be causing harm to the environment. Details about Hazardous Waste generation in existing plant and after expansion and its disposal are given in Table 2.20 and 2.21 respectively.

Sludge generated from proposed ETP will be 0.79 m3/hr sludge will be disposed off through Common Hazardous Waste Treatment Storage and Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project. (UPWMP).

The important solid waste is fly ash (684 tons/day) generated from CPP. Entire fly ash generated will be used as pozzolonic material in Cement Grinding Unit (in house) for PPC production. Bottom ash is also proposed to be used after decantation of water in the cement manufacturing process.

Noise

The proposed expansion will not generate significant noise. Noise generating machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.

Green Belt:

Greenbelt area of about 81 Acres which constitutes more than 33% of the total area of 243.4387 Acres is proposed. Till now 55 Acres of greenbelt and plantation has been achieved with 8800 no. of trees.

CREP


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KFCL will adhere to CREP points as applicable to it. The details are as given in Table 2.22.

Environmental Status of Plant Site and Study Area

Site Characteristics: Topography & Geology

The Kanpur Nagar district lies in middle of Uttar Pradesh State. It lies between 25°55’ &

27°-North latitude and 79°30’ & 80°35’-East longitudes. The total geographical area of the district is 3155-sq.km with three (03) numbers of Tehsils and the numbers of blocks viz. Kalyanpur, Bidhnu, Sarsaul, Bilahaur, Kakwan, Sivrajpur, Chaubepur, Patara, Bhitrgaon and Ghatampur. The major part of the area is almost a flat plain with some minor undulations. The river Ganga and Yamuna with their tributaries form the drainage system as Dendritic Type.

Kanpur metropolis forms a part of Ganga sub -basin in the Central Indo- Gangetic Plain. It exhibits more or less a flat topography with the master slope from north-west to south-east. The average elevation of land surface is 125 m..MSL. The area is drained by the river Ganga and its tributary Pandu. The area of city has been geomorphologically divided into two units.

(i) Low lands or Younger Alluvial Plain &

(ii) Up lands or Older Alluvial Plain

The project region lies in Indo-Gangetic Alluvial plain. The deposition of this alluvial commenced after the final phases of the Shiwaliks and has continued all through the Pleistocene up to the present. The Gangetic alluvial plain was formed as peripheral foreland basin consequent to the collision tectonic process of the Himalaya and still under the influence of compressional stress.

The district lies in the Ganga basin which is formed of alluvium of the early quaternary period. In the district, no hard or consolidated rock exposures are encountered. The main constituents (sand, silt and clay) of alluvium occur in variable proportions in different sections. The mineral products of the district are saline earth from which salt petre & salt are derived and limestone conglomerates.

Water Resources and Water Quality

The annual rainfall data from meteorological department in the district is 821.9 mm. The winter rains are uncertain. Light showers may occur during December and January.

Hydrogeology

The Kanpur Nagar District is part of Indo Gangetic Plain. The silt, gravel, and sands of different grades are main water bearing formations. The ground water occurs under unconfined condition in phreatic zones and under confined condition in deeper zones. The sedimentological constitution of the subsurface granular zones shows remarkable variation in the depth and the nature of occurrence in north and southern part of the district. In southern part specially along Yamuna river, feldspar-quartz, Jaspar sands and gravel (Morum) are the main constituents of the granular zones that occurs comparatively at shallow levels i.e. 24 to 57-mbgl whereas in the northern parts along the Ganga river, these reworked sedimentary formations are existing at deeper levels i.e. 265 to 310-mbgl. The provenance of these sedimentary formations is mainly Bundelkhand Granite Complex


EQMS INDIA PVT. LTD. xv

of Archean age and Vindhyan Sandstone of Puranas. In the northern part the silt and clay sediments forming thin lensoid beds are frequently occurring in depth

Climate & Meteorology

The average annual rainfall in the district is 821.9 mm. The climate is sub humid and it is characterized by hot summer and general dryness except in the south west monsoon. About 90% of rainfall takes place from third week of June to September. During monsoon surplus water is available to deep percolation to ground water. May and early part of June constitute the hottest part of the year. The mean daily maximum temperature in May is 41.7°C. The mean daily minimum temperature is 27.2°C and maximum temperature rises up to 45°C or over. With the onset of the monsoon in June the day temperature drops down appreciably. The January is the coldest month with mean daily maximum temperature at 22.8°C and mean daily minimum temperature at 8.6°C. The mean monthly maximum temperature is 32.2°C and mean monthly minimum temperature is 19.5°C. During monsoon season the relative humidity is high and in summer season, humidity is less. The mean monthly morning relative humidity is 69% and mean monthly relative humidity is 50%. The winds are generally light with some strength in force during summer and early monsoon season. The mean wind velocity is 9.6 kmph. The potential Evapotranspiration is 1660.9 mm.

Meteorological study exerts a critical influence on air quality as it is an important factor in governing the ambient air quality. The meteorological data recorded during the study period is used for interpretation of the baseline information as well as input for air quality simulation models. Meteorological data was collected for the post-monsoon months of October through December, 2014.

The wind rose diagram for the study area is shown in Figure 3.5 and the wind class frequency distribution is shown in Figure 3.6. The analysis of the average wind pattern shows predominant winds from W and NW with wind frequencies of 19.85% and 11.15%, respectively. Calm conditions were prevailed for 29.86% of the total time. Average wind speed was observed as 1.26 m/s during the study period.

Air Quality

Preliminary air sampling and monitoring was carried out in post monsoon season to establish air quality of the study area. The project site situated at industrial area so it surrounded with various industry & situated near NH-2 so basic source of air pollution is emission from industries, vehicular emission, dust from the unpaved tracks and windblown from the open agricultural land during harvesting. Sampling locations were located based upon climatological wind pattern.

Based on the above, six (6) sampling locations were selected given in Table 3.5.

PM2.5 Concentration (Post-monsoon Season): PM2.5 level was found ranging from 41 to142 µg/m3. The highest PM2.5 levels were found near the Project site (142 µg/m3) while the lowest levels was found at village Singpur Kathar (41 µg/m3). The average PM2.5 levels are within the NAAQS levels for industrial, Residential, Rural and other Areas (60 µg/m3) at villages Singpur Kathar and Bhauti Khera.

PM10 Concentration (Post-monsoon Season): PM10 level were found ranging from 86 to 217 µg/m3. The highest PM10 levels were found near the Project site (217 µg/m3) while the


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lowest levels was found at village Singpur Kathar (86 µg/m3). The PM10 in the study area is contributed mainly by industrial emissions, vehicular emissions, re-suspected dust from paved/unpaved roads and open areas as well as from industrial activities. The average PM10 levels are within the NAAQS levels for industrial, Residential, Rural and other Areas (100 µg/m3) at village Singpur Kathar only.

NAAQS norms for residential areas are always met for NH3, SOX, and NOx and for SPM/RSPM they could not be met due to local phenomenon.

Noise

The noise level at all residential locations were found lower than the ambient noise standards. At the project site it was found to be lower than the ambient noise standards.

Environmental Impact Assessment

Topography and Soils

The proposed KFCL plant modernisation and expansion will have some construction activities and as such both construction phase will have very limited impact (within the plant boundary limit only). The operation phases will have no impact on the topography and soils of the study area.

Air Quality

During the operation of the proposed expansion project/ plant, source of emissions are from 11 stacks. The existing sources of emission i.e. Reformers in Ammonia Plant, NG heaters, Prilling Tower in Urea Plant and CPP Boiler will be emitting NOx and SOx (from Reformer and Process Air Natural Gas Heaters), SPM and NH3 (from Prilling Tower) and SOx, NOx and SPM (from CPP boilers). The summary of GLC at monitoring station from the proposed expansion marked in Table below.

Incremental increase in ground level concentration due to modernisation and expansion project has been predicted using the 'Industrial Source Complex - Short Term Version 3 (ISCST-3)' comes out to be:

Summary of Maximum GLC at Monitoring Locations from the Proposed Modernization and Expansion

Location Rise in

GLC (g/m3)

Max. Background Concentration

(g/m3)

Impact from Project (g/m3)

NAAQS (g/m3)

Near the Project Site

SOx 0.00 12.00 12.00 80 NOx 0.02 26.10 26.12 80 PM10 0.02 217.00 217.02 100 PM2.5 0.01 142.00 142.01 60 NH3 0.04 46.70 46.74 400

Daboli

SOx 13.35 13.60 26.95 80 NOx 13.68 27.30 40.98 80 PM10 3.48 175.00 178.48 100 PM2.5 1.39 74.00 75.39 60 NH3 8.31 24.40 32.71 400

Gujeni SOx 8.33 12.70 21.03 80 NOx 12.74 19.60 32.34 80


EQMS INDIA PVT. LTD. xvii

Location Rise in

GLC (g/m3)


(g/m3)


NAAQS (g/m3)

PM10 5.83 215.00 220.83 100 PM2.5 2.33 88.00 90.33 60 NH3 14.34 27.20 41.54 400

Singpur Kathar

SOx 0.02 12.30 12.32 80 NOx 0.02 25.70 25.72 80 PM10 0.00 86.00 86.00 100 PM2.5 0.00 41.00 41.00 60 NH3 0.01 25.70 25.71 400

Panki

SOx 2.55 12.30 14.85 80 NOx 3.41 26.30 29.71 80 PM10 1.07 187.00 188.07 100 PM2.5 0.43 82.00 82.43 60 NH3 2.61 23.80 26.41 400

Bhauti Khera

SOx 5.36 13.30 18.66 80 NOx 5.33 26.60 31.93 80 PM10 1.20 139.00 140.20 100 PM2.5 0.48 47.00 47.48 60 NH3 2.86 21.90 24.76 400

As is evident from the table above, there will be no adverse impacts on the surrounding area from just the proposed project. It should be noted that the project impacts for maximum PM10 are less than 6% of NAAQS and less than 0.02% of NAAQS for PM2.5. The ambient quality of the surrounding area however has high PM10 and PM2.5. Highly efficient air pollution control systems will be adopted to mitigate particulate matter as well as gaseous emissions in the ambient environment. Electrostatic precipitators (ESP) with 99.9% efficiency are proposed to control the particulate emissions from the proposed expansion project and limit the particulate matter emissions to 50 mg/Nm3. Low NOx burners with a control efficiency of 70% are proposed to control NOx emissions from the proposed expansion project.

Noise

The operation of expanded capacity of KFCL plant will have no adverse impact on noise generation because quality machines are being added. The new machines will have latest technology and features for low energy consumption, less noisy and eco-friendly. The plantation done all around the plant helps in attenuation of sound waves and as such has created a natural barrier for sound spreading.

Water Resources and Water Quality

Water Resources

Water requirement for Expanded Plant is around ~ 21,200 m3/day including 400 m3/day for domestic purpose. The total water consumption after proposed expansion project will be therefore 21,600 m3/day. The total fresh water in plant consumption has been reduced due to recycle of 3725 m3/day treated effluents and recycle of treated domestic effluents from STP for dust suppression and Green belt development. The water will be drawn from existing source i.e. Lower Ganga canal. Necessary approval / clearance from UP Government is attached.

Water Quality


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KFCL has already modernized the Effluent Treatment Plant (ETP) facilities for the requirements of expanded capacity in advance. The proposed expansion project along with existing plant will generate 4320 m3/day effluents which will be treated in the ETP. Out of 4320 m3/day, 3725 m3/day of treated effluents will be recycled back to plant. Balance only 19 m3/day as sludge will be disposed off through Common Hazardous Waste Treatment Storage and Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project. (UPWMP) (Refer Figure 2.14). Thus KFCL propose to follow “Zero

discharge” philosophy. Industrial wastewater after treatment will be effectively utilized in

process and for horticulture/ green belt development. There will be no impact on Surface or Ground water bodies.

Climatology and Meteorology

The little construction activities and operation of the proposed KFCL expansion plant will have no impact on climatology and meteorology of the study area.

Land Use

The impacts on land environment are generally physical impacts due to change in topography, soil erosion, etc. KFCL is not carrying any construction activities outside the premises. The construction activities within the premises are not going to alter the topography of the area and as such adverse impacts are not going to take place.

The construction and operation of the proposed expansion of KFCL plant will have no impact on the land use in the study area as no fresh land is being acquired for the plant or township.

Biological Environment

The proposed Construction and Operation of the plant will have no impact on ecology of the study area. However, growth of plantation and development of green belt at the site is likely to improve flora at the site.

Demographic and Socio-economic

The proposed operation of the plant will have no adverse impact on the demography, agricultural pattern and other socio-economic conditions. However, the operation of proposed expansion plant will have slightly positive and beneficial impact on the status of job opportunities (due to some fresh intake of staff (limited numbers only), increased inflow of raw materials and out flow of products and other commercial activities) and increase in industrial and commercial activities.

Risk Assessment

KFCL fertilizer plant uses a number of hazardous chemicals, namely NG, NH3, Chlorine, Acids, fuels (Coal mainly) etc. The Naphtha will no more will be used. The use of these chemicals is inevitable. KFCL has MSDS and understands the risks associated with these chemicals. Adequate control measures have been taken by the KFCL to prevent any dangerous incident.

KFCL plant has a qualified and trained safety manager along with supporting staff / equipment to assist plant personnel working in the plant & to take all the safety precautions while carrying out various tasks. KFCL has provided PPE to operating personnel (as per requirement) for carrying hazardous activities.


EQMS INDIA PVT. LTD. xix

All the employees are being retrained through refresher in Fire & Safety training twice in a year.

Regular health check of staff is carried out as per norms. Health reports are available to the staff for the information.

Disaster Management Plan

On-site DMP is prepared to minimize the damage to plant machinery and personnel for the selected accident scenarios. A copy of the DMP has been submitted to factory inspector.

Mock drills for the selected emergencies have been carried out, weak links in the system noted and need full actions have been taken.

On-site DMP also discusses suitable management procedures to handle emergencies caused by accidental release or spill of toxic or inflammable material or fire.

Environmental Management Plan

Air Environment

In order to mitigate the adverse environmental impact due to the operation at expanded / increased capacities following measures are recommended:

Close watch and control on the quality of raw material NG (S < 0.1 ppm) as increase in sulphur content will be immediately reflected in increased SOx emission and may affect the process also.

The control measures through proper upkeep; preventive maintenance and good house-keeping will considerably reduce the fugitive emission.

Monitoring of fugitive emission should be continued at human receptive points as per existing practice.

Existing schedule monitoring system for air pollutants like SOx, NOx, ammonia and SPM should be continued.

Leakages {of gases / liquids/ dust} should be checked and promptly attended.

Water Environment

The treatment philosophy adopted by KFCL (Zero Effluent Discharge) will give very good results. The treated effluent quality has also considerably improved. The existing system and efforts to conserve water and treatment of effluents should continue and new efforts should be directed to:

“Control of pollutant at source” practices should continue.

Increase the use of treated effluents in horticulture and green belt developments.

The treated sewage should be utilized for irrigation in farm house whenever required.

Excess use of pesticide and herbicide (in green belt) should be avoided as they can cause ground water contamination.

Water is a precious commodity and it should be conserved.


xx

Awareness program should be continued to increase the interest among employees for conservation of water.

Water harvesting schemes should be taken up (after study) where ever possible.

Climatology and Meteorology

The construction and operation of the proposed expansion of KFCL plant will not affect meteorology and Climatology of the study area and as such no management plan will be required.

Green Belt


Block plantation of same species of trees is not a healthy practice as it may cover the entire area if single tree is affected with diseases. Such type of plantation should be avoided in future.

The trees, which have attained their age, should be cut and new trees should be planted.

Some indicator species of SO2, NOx & NH3 should be planted near the pollution causing units. These plants would act as a early warning system. The species are well known.

Proper maintenance is required for the avenue trees such as:

o Avenue trees should not block the view of road or building. This is necessary from safety and security point of view.

o The distance of avenue trees should not be less than 4 to 5 meters.

o The road curbs should not have trees rather shrubs.

Environment Monitoring Plan

Additional points in EMP have been proposed.


EQMS INDIA PVT. LTD. 1

CHAPTER 1. INTRODUCTION AND BACKGROUND

1.1. Project Proponent

Kanpur Fertilizers & Cement Ltd. (KFCL) a wholly owned subsidiary of M/s. Jaypee Uttar Bharat Vikas Pvt. Ltd. (JUBVPL) which in turn is a 50:50 Joint Venture formed between R.P. Goenka Group through M/s. ISG Traders Ltd. and M/s. Jaiprakash Associates Ltd., through its subsidiary M/s. Jaypee Fertilizers & Industries Ltd.

The existing fertilizer complex having Ammonia – Urea Fertilizer of 1245 / 2046 TPD along with 12 MW CPP at Panki, Kanpur was setup by M/s. ICI Ltd. in 1969. Subsequently the company was taken over by M/s Duncan Industries Ltd. However, the Fertilizer plant has been lying closed since 2002 due to economic reasons.

Further the board of M/s. Duncan Industries Ltd. in its meeting held on 17.06.2010 has approved the participation of M/s. Jaypee Fertilizers & Industries Ltd. (a Jaypee Group Co.) as a strategic investor for the revival and rehabilitation of the company’s

fertilizer unit at Panki, Kanpur through JUBVPL the JV Co. of M/s. Jaypee Fertilizers & Industries Ltd. and M/s. ISG Traders Ltd.

Jaypee group is a well-diversified industrial conglomerate in India with a turnover of over Rs.18000 crores commenced its operations in mid sixties. Four decades later, with growth and diversification, the group is engaged in the businesses of Engineering & Construction, Cement, Private Hydropower, development of Expressways, Real Estate and Hospitality. With a professional management team and a competent technical cadre, the Group employs a total workforce of over 30,000.

It is 3rd largest cement producer in India with an operational capacity of 27.90 MTPA. It’s has computerized process control cement plants at various location of Central and

Northern region of India.

Proposed Project Justification

India will need to increase its food grain output to 280 million TPA in 2020 from the current level of 241 million TPA. The arable land is currently 49% of total land and only a limited arable land can be increased in future due to increased urbanisation. Increased use of fertilizers in a balanced way is one major requirement & need of the hour. Due to stagnancy in indigenous production of urea imports have grown to almost 20% of demand in 2010. There is a huge gap between demand & supply of Urea in India & same calls for creation of additional urea capacity at Kanpur. KFCL Kanpur has been producing Urea since May 17, 2013. It has been decided by Jaypee Group Management to immediately plan & implement expansion of the existing production capacity of Urea to a technical feasible extent.

KFCL is proposed to Modernize and Increase the existing capacity of Ammonia- Urea Plant from 1245 MTPD to 1800 MTPD and Urea plant from 2046 MTPD to 3033 MTPD to produce 1.05 MTPA of Urea within existing premises of Ammonia-Urea Fertilizer Complex at Udyog Nagar Industrial Area, Panki, Distt. Kanpur, Uttar Pradesh.



Existing Captive Power Plant of 12 MW capacity is very old and inefficient and hence, it is proposed to dismantle the existing Captive Power Plant. A new coal based 95 MW Captive Power Plant (CPP) having configuration of 1x60 MW + 1x35 MW capacity is being proposed to meet the entire requirement of Fertilizer complex.

Capital cost of the proposed modernization & expansion of Fertilizer plant is estimated as Rs. 583 crores and Captive Power Plant is Rs. 500 crores.

1.2. Proposed Project

The proposed modernisation cum expansion project is a brownfield project and hence no alternate site examination is needed. Expansion is proposed within the existing plant premises. The land is already under industrial use. Hence, no alternative sites have been examined.

Existing fertilizer complex is having 243.4387 acres of lease hold land located in Udyog Nagar Industrial Area, Panki, District Kanpur in Uttar Pradesh.

No additional land required for the proposed expansion which will be installed within the boundary limit of existing fertilizer complex. The land is already in industrial use and is located in Udyog Nagar industrial area, Panki, Kanpur of Uttar Pradesh. Hence there will not be any changes in land use.

Proposed expansion plant will be set up with using off-sites and utilities in the existing plant with capacity augmentation wherever necessary. Project Location is shown in Figure 1.1.



Figure 1.1 : Project Location

1.3. Justification of the Project

India will need to increase its food grain output to 280 million TPA in 2020 from the current level of 241 million TPA. The arable land is currently 49% of total land and only a limited arable land can be increased in future due to increased urbanisation. Increased use of fertilizers in a balanced way is one major requirement & need of the hour. Due to stagnancy in indigenous production of urea imports have grown to almost 20% of demand in 2010. There is a huge gap between demand & supply of Urea in India & same calls for creation of additional urea capacity at Kanpur. KFCL Kanpur has been producing Urea since May 17, 2013. It has been decided by Jaypee Group Management to immediately plan & implement expansion of the existing production capacity of Urea to a technical feasible extent.



1.4. Purpose of the Study

As per the Ministry of Environment, Forest & Climate Change (MoEFCC), Government of India EIA Notification 2006 and as amended on December 1, 2009, the proposed Expansion Project need to take environmental clearance prior to commissioning of the plant. The proposed project is covered under Category 'A' as per the Schedule of EIA Notification and hence requires environmental clearance from Environmental Impact Assessment Authority (EIAA) of MoEF, New Delhi.

This Environmental Impact Assessment (EIA) study undertaken is mainly focused on identification of existing environmental conditions of the project, its impact on pre and post commissioning. A detailed prediction of all environmental impacts associated with the various activities during the construction and operation phases of the proposed modernisation – expansion plan suggesting suitable measures to navigate the observed adverse environmental impacts. The study also aims at reflecting the acceptability of the project to different stakeholders and at incorporating the concerns raised by them into impact assessment and of the subsequent Environmental Management Plan (EMP). These all mentioned above are part of the Environment Impact Assessment (EIA) project Study.

1.5. Regulatory Frame Work

The plant operation has been subjected to other procedural and compliance monitoring programme viz. annual consents under Water (Prevention and Control of Pollution) Act, 1974; Air (Prevention and Control of Pollution) Act, 1981; authorization under Hazardous Waste (Management & Handling) Rules, 1989/ 2000; Environment (Protection) Act, 1986; requirements and statutory norms as per UP Pollution Control Board etc. The production level of this plant has been as per the clearances/consents.

In addition to environmental regulatory compliance, KFCL is also complying with following

other statutory rules and regulations:

Fuels and other hazardous (Inflammable & Explosives) materials storages (As per

Chief Controller of Explosives, Nagpur; rules and guide lines)

Labour laws and Safety guide lines as per Labour Commissioner, Government of Uttar

Pradesh,

Boiler Regulations as per Chief Inspector of Boilers, ESIC etc.

1.6. Scope & Methodology of the study

This study is aimed at providing a deeper insight into the proposed Expansion Project and its various environmental components. The present study area for the environmental impact assessment is within 10 km radius of the location of the project. The methodology used for the study is given below:

i. Monitoring and collection of baseline data for various environmental components as per the MoEF guidelines.

ii. Identification and quantification of significant environmental impacts due to the project and associated activities.



iii. Evaluation of impacts due to proposed activities and preparation of an environmental impact statement.

iv. Preparation of appropriate Environmental Management Plan (EMP) encompassing strategies for minimizing identified adverse impacts along with budgetary provisions to be made by the project authorities for implementation of mitigation measures.

v. Delineation of post Environmental Quality Monitoring Programme (EQMP) along with organizational setup required for monitoring the effectiveness of mitigation measures.

The flow diagram showing methodology adopted for the EIA study has been presented in Figure 1.2.



Figure 1.2 : EIA Methodology

1.7. Approved ToR for EIA Study by MoEF- EAC

The application for the scoping of the said project has been submitted to the Expert Appraisal Committee (EAC), MoEFCC, New Delhi. Presentation to EAC for the scoping of the project (Terms of Reference (ToR) approval for EIA study) was held on



29th April, 2014, in the 18th Reconstituted EAC (Industrial) Meeting. The EAC has issued the ToR for the EIA study on 25th November, 2014, vide Letter No. F. No. J-11011/30/2014-IA II (I). Copy of the same has been annexed as Annexure I. The EIA study has been conducted in-line with the approved ToR by EAC (MoEF) and taking into consideration the structure of the report given in the EIA Notification 2006. The compliance to the approved TOR has been presented in Table 1.1:

Table 1.1 : ToR Compliance Status

ToR No.

Points Raised in ToR Compliance reply

1 Executive summary of the project. Attached in the Report 2 Justification of the project Section 1.3 and Annexure VI 3 Promoters and their background Section-1.1 4 Regulatory Framework Section -1.5 5 A map indicating location of the project and distance from

severely polluted area Figure -1.1

6 Project location and plant layout Figures- 1.1 /2.1 / 2.9/2.10 7 Infrastructure facilities including power sources Section 2.6 8 Total cost of the project along with total capital cost and

recurring cost/annum for environmental pollution control measures.

Section 2.10

9 Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests etc,

Figure-2.1

10 Present land use based on satellite imagery for the study area of 10 km radius.

Section 3.2.5

11 Location of National Park/ Wild Life Sanctuary/ Reserve Forest within 10 Km radius of the project.

None; Table 2.1

12 Detail of the total land and break-up of the land use for green belt and other uses.

Table -2.15

13 Environmental Clearance for the existing unit issued by the Ministry, Consent to Operate and Authorization accorded by the UPPCB along with point-wise compliance report.

Annexure VII

14 Copy of NOC/Consent to Establish for the existing unit. Annexure VIII 15 Compliance to the conditions stipulated in the NOC granted by

the SPCB. Annexure VII

16 Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, compliance to the notice(s).

No notice received under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts

17 Data for the stack emissions, fugitive emissions, water requirement and water balance chart, wastewater generation, treated effluent quality, re-utilization and disposal of solid/hazardous waste for the existing unit.

Section 2.6; Section 2.8

18 List of products along with the production capacities and list of solvents and its recovery plan.

Product : Proposed Urea Production ( 1.05 MTPY) with Natural Gas as Feed. No solvent is being used.

19 Detailed list of raw materials required and source, mode of storage and transportation.

Section 2.6.1/ Section 2.6.5

20 Availability of raw materials e.g. gas Section 2.6.5/ Annexure IIA and IIB

21 Policy regarding Naptha use. Quality to be used. Existing and proposed expansion of Ammonia –Urea Fertilizer Plant is based on Natural Gas (NG)



ToR No.


Naphtha will no more be used in the Plant

22 A note on the viability of the project in absence of non-availability of gas.

In case of non supply of NG from GAIL plant has to be shut down.

23 Details of the existing fertilizer plant. Section -2.2/ Section 2.4 Section 2.7

24 Manufacturing process details along with the chemical reactions and process flow chart.

Section -2.2/ Section 2.4 Section 2.7

25 Action plan for the transportation of raw material and products. Section -2.6.5 Natural Gas (NG) is raw material for manufacturing Urea is received from M/s Gail through pipeline. Coal is received through truck and rail wagons. Augmentation of existing transportation mode will be done for capacity enhancement project.

26 Ambient air quality monitoring and stack emission data for the relevant parameters including PM10, PM2.5, SO2, NOx, CO, NH3, HC (Methane and Non-methane), urea and VOCs for all the stacks for the existing fertilizer plant.

Section 2.8.2

27 Data for surface and ground water, treated effluent quality data, noise pollution and solid waste management for the existing plant should also be included.

Table 2.20; Table 2.23; Annexure IX Table 3.12 and Table 3.13

28 Air pollution control measures proposed for the effective control of gaseous emissions within permissible limits.

Section 2.8.2

29 Plant-wise air pollution control measures proposed for the control of emissions from all the sources particularly uncontrolled NOx emissions and method to control NOx.

Section -2.8.2

30 Name of all the solvents to be used in the process and details of solvent recovery system.

No solvent is being used in the process

31 Details of water and air pollution and its mitigation plan. Section – 2.8; Section- 5.2 32 Action plan to control ambient air quality as per NAAQES

Standards notified by the Ministry on 16th September, 2009. Section -2.8.2; Section- 5.2.1

33 An action plan to control and monitor secondary fugitive emissions from all the sources.

Section-2.8.5

34 Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modeling for proposed plant.

Section – 4.3.1

35 Details of water requirement for existing and proposed expansion. Water balance chart including water intake, effluent generated, recycled and reused and discharged is to be provided.

Section – 2.6.4 ; Section- 2.8.1

36 Action plan to reduce fresh water requirement. Methods adopted/to be adopted for the water conservation should be included.

Section 2.8.1; Section – 5.2.2

37 Permission for the drawl of existing and proposed water requirement from the competent authority.

Anexure IIIA and IIIB

38 Design details of the ETP and STP as well as air pollution control equipment (Bag filters/ wet scrubber etc.). Installation of Continuous TOC analyzer to holding tank before discharge of effluent.

Section- 2.8.1; Annexure XI; Zero Effluent Discharge

39 Action plan for Zero discharge of effluent should be included. Section -2.8.1 40 Ground water monitoring minimum at 6 locations should be

carried out. Geological features and Geo-hydrological status of Section -3.2.4; Section -3.3.4



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the study area and ecological status (Terrestrial and Aquatic). 41 The details of solid and hazardous wastes generation, storage,

utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste.

Section- 2.8.3

42 Precautions to be taken during storage and transportation of hazardous chemicals should be clearly mentioned and incorporated.

KFCL has adopted the safe practices at site as per MSDS for handling hazardous chemicals and TREM Card during transportation; Detailed On-site emergency plan is given in Chapter 7

43 Plan for the implementation of the recommendations made for the fertilizer plants in the CREP guidelines must be prepared and included.

Section -2.9

44 Authorization/ Membership for the disposal of solid/hazardous waste in TSDF.

Hazardous waste is disposed through UPCB, CPCB or MoEF, Govt. of India approved agencies as per prescribed norms. KFCL has taken the membership of Common Hazardous Waste Treatment Storage & Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project (UPWMP) (A division of Ramkey Enviro Engineers Limited) and reached a legal agreement for HW collection, transportation, treatment & disposal at UPWMP CHW –TSDF Site. Agreement is attached as Annexure XII

45 An action plan to develop green belt in 33% area. Section 2.8.6 46 Action plan for rainwater harvesting measures at plant site

should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.

No bore wells or wells are dug in the Plant to meet the water requirement as it will be met from existing water allocation of 15 cusecs from lower Ganga Canal, Kanpur. KFCL has huge water reservoirs spreading over 20 acres of land which keep the water table high through percolation. In addition, Rain Water Harvesting from Roof Tops and Storm Drains to recharge the Ground Water is in progress and scheduled to be completed by Jun 2015.

47 Occupational health of the workers need elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring should be carried out.

Section 2.12

48 Socio-economic development activities shall be in place. Section 2.12 49 Detailed Environment management plan (EMP) with specific Section – 5.2;Section – 5.2.12



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reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.

50 EMP should include the concept of waste-minimization, recycle/ reuse/ recover techniques, Energy conservation, and natural resource conservation.

Section 2.11; Section – 5.2

51 Any litigation pending against the project and/ or any direction/ order passed by any court of Law against the project, if so, details thereof.

No litigation pending against the project and/ or any direction/ order passed by any court of Law against the project,

52 Public hearing issue raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

Public hearing details are provided As a Chapter 1 in Section No….. and Annexure

1.8. Public Heraing

M/s Kanpur Fertilizer ad Cement Limited (KFCL), Panki Industrial Area, Kanpur-208022 (U. P.) has proposed an expansion of Ammonia- Urea Plant from existing capacity of 1245 MTPD to 1800 MTPD and Urea Plant capacity from 2046 MTPD to 3033 MTPD and modernization of the plant and 60 MW and 35 MW Capacity Captive Power Plant set up and for obtaining Environmental Clearance, Public Hearing has been organized on date 14.07.2015 at 2:00 pm in State Inter College, Bhaunti, Kanpur. Minutes of the meeting and action plan are enclosed as an Annexure XIV & XV.

1.9. Sturcture of the Report

This EIA report has been prepared on the basis of available on-site primary data (survey/monitoring) and secondary/literature data. The EIA report contains project features, baseline environmental setup, assessment of environmental impacts, and formulation of mitigation measures, environmental management and monitoring plan with risk & disaster management plan.

The report would include 9 Chapters excluding Executive Summary, which is included at the beginning of the report. The structure of the EIA Report with necessary tables, drawings and annexure is as follows:

Chapter 1: Introduction

This chapter provides background information on need of project, need of EIA study and brief of the project. The scope and EIA methodology adopted in preparation of EIA report have also been described in this Chapter. It also covers the identification of project & project proponent, brief description of nature, size, and location of the project.

Chapter 2: Project Description

This chapter deals with the project details of the proposed Expansion of Ammonia – Urea Fertilizer Plant with Captive Power Plant, with type of project, need for the project, location, size & magnitude of operation including associated activities required by and for the project, proposed schedule for approval and implementation, technology and process description including technical details of raw material, quality and quantity etc.



Chapter 3: Description of the Environment

This chapter presents the existing environmental status of the study area around the proposed project including topography, drainage pattern, water environment, geological, climate, transport system, land use, flora & fauna, socio-economic aspects, basic amenities etc. Environmental assessment of the proposed project site in regard to its capability to receive the proposed new development is also discussed in this Chapter.

Chapter 4: Impact Assessment and Prediction

This chapter describes the overall impacts of the proposed project activities and underscores the areas of concern, which need mitigation measures. It predicts the overall impact of the proposed project on different components of the environment viz. Air, Water, Land, Noise, Biological, and Socio-Economic.

Chapter 5: Environmental Management Plan and Environmental Monitoring Program

This chapter details the inferences drawn from the environmental impact assessment exercise. It describes the overall impacts of the proposed activities during construction and operation phases and underscores the areas of concern, which need mitigation measures. It also provides mitigation and control measures for environmental management plan (EMP) for minimizing the negative environmental impacts and to strengthening the positive environmental impacts of the proposed project. Technical aspects of monitoring the effectiveness of mitigation measures have been given in this Chapter.

Chapter 6: Hazard Evaluation and Risk Assessment

This chapter details the risks associated with the project activities and storage of hazardous chemicals.

Chapter 7: On-site Emergency Plan

This chapter provides the proposed on-site emergency plan to handle any emergency situation at the plant site. KFCL Has got an exhaustive “Emergency Preparedness

Plan (EPP)” and carrying out Mock Drill for various likely incidence scenarios.

Chapter 8: Summary & Conclusion

This chapter provides the summary and conclusions of the EIA study of the proposed project with overall justification from implementation of the project and also explanation of how, adverse effects will be mitigated.

Chapter 9: Disclosure of Consultants Engaged

This chapter provides the disclosure of consultants engaged to carry out the EIA study along with other additional studies.



CHAPTER 2. PROJECT DESCRIPTION

2.1. About the Project

The demand of the product among the local farmers, is one of the strong factor besides contribution to the agricultural growth of the country, considered by Kanpur Fertilizers and Cement Limited (KFCL) in the setting of Ammonium-Urea Fertilizer complex at Udyog Nagar Industrial Area, Panki, District Kanpur.

To strengthen the economy of operations, it is proposed to expand the capacity of the Plant from 1245 MTPD Ammonia to 1800 MTPD and urea production capacity is proposed to be increased from 2046 MTPD to 3033 MTPD, to produce 1.05 MTPA of urea by addition/replacement/revamping of the certain equipment for optimization of the Plant. It is further proposed that a Captive Power Plant of 1x60 MW and 1x35 MW (cumulative capacity of 95 MW) will be set up to meet the entire power requirement of the Fertilizer Unit on sustained and continuous basis.

M/s KFCL propose plant area profile that includes latitude and longitude of the site are presented in the following Table 2.1:

Table 2.1 : Details of Environmental Setting (10 km Radius)

Particular Details Plot No. Udyog Nagar Industrial Area, Panki, Kanpur. (UP) Location Near Kanpur District Kanpur Latitude/Longitude 260 27’ 02.1” N

800 15’ 08” E Elevation ~130 m above MSL Defense Installations Ordinance Factory at 2.5 km; IAF Aerodrome-

7.5 km; E Ecological Sensitive Areas/ Protected Areas as per Wildlife Protection Act 1972 (National Parks / Wild life sanctuaries / bio-sphere reserves / tiger reserves)

There are no Ecologically Sensitive Areas/Protected areas within 10 km radius from the Plant Site.

Reserved/Protected Forest There are no reserved/protected forests within 10 km radius from the Plant Site.

Nearest National Highway NH-2 (~ 1 km) Nearest Water Body Ganga River : 8.91 km, NE

Pandu Nadi : 1.38 km, SSW Lower Ganga Canal : 1.82 km, N

Nearest Archeological important places There are no archeological places within 10 km radius from the Plant Site.

Nearest Rail Head Panki (2 km) Nearest Airport Chakeri, Kanpur (12 km; NE) Nearest Town/ Tourist Place Kanpur (12 kms (NE)) Nearest Municipal Corporation Kanpur Nagar Palika Seismic Zone Seismic zone –II as per IS 1893 (part1) 2002

Location of the project in village survey map has been presented in Figure 2.1. The project site is directly accessible from National Highway No. 2. The project site is regular in shape.



Figure 2.1 : Projection Location Map (Source: Google Earth)



2.2. Existing Ammonia Plant

2.2.1. Basic of Design

Each Ammonia plant out of the three existing plants is proposed to be expanded for production of 600 MTPD Ammonia with necessary debottlenecking and addition of rotating equipments, such as Synthesis Gas Make Up and Recycle compressor and Air compressor for one train. The three Ammonia plants have two synthesis and One Air compressor. After revamp, there will be three old synthesis gas compressors for each of the two Ammonia Plant. The third Ammonia plant will have a new synthesis gas and recycle compressor. This will also have a new process air compressor, which will have capacity to supplement incremental air requirement for the remaining two Ammonia plants also.

2.2.2. Feedstock Specification

The design of the plant is based on the use of Natural Gas having the following specifications:-

Table 2.2 : Natural Gas Composition

Sl. Component Mol. wt. Normal Lean Rich 1. Nitrogen 28.016 0.01 0.10 0.14 2. Carbon Dioxide 44.010 0.10 0.10 4.33 3. Hydrogen Sulphide <=10 <=10 <=10 4. Methane 16.042 98.39 98.64 80.75 5. Ethane 30.068 1.40 1.15 11.04 6. Propane 44.094 0.10 - 2.71 7. i-Pentane - <0.01 0.07 8. n-Pentane - <0.01 0.06 9. i-Butane - - 0.38

10. n-Butane - - 0.46 11. Hexane Plus - - 0.06

C: H ratio w/w: 3.005 - 3.381

2.2.3. Production Specification

2.2.3.1 Ammonia

The Ammonia production will contain not less than 99.5% mole of ammonia. The composition of Ammonia product will be, as given below:- Ammonia : 99.50% mole Water : 0.16% mole Hydrogen : 0.04% mole Methane : 0.25% mole Other dissolved gases : 0.05% mole

The product shall be available in the liquid state in the temperature range of 26.90C and at a pressure of 21.3 kg/cm2g.

2.2.3.2 Carbon Dioxide



Each Ammonia plant will make available a minimum of 769.61 TPD of 100 % Carbon Dioxide gas ( for 600 TPD - 100 % Ammonia production ) for conversion into Urea at not less than 95.63% purity at a temperature of 35 0C and at a pressure of 0.57 kg/cm2g.

The composition of Carbon Dioxide gas to Urea plant will be, as given below:-

Carbon Dioxide : 95.63% mole Water : 3.56% mole Nitrogen : 0.11% mole Hydrogen : 0.70% mole

2.2.4. Utilities & Services Available (at the B/L)

Additional DM Water may be required over & above the existing facilities (150 m3/hr. at 200 C and a pressure of 4.24 kg/cm2). The same will be clubbed with CPP Utilities.

2.2.4.1 Condensate

Additional hot steam condensate suitable for boiler feed water will be returned from the Urea Plants over and above 64 TPH of Condensate at 890 C & 2.07 kg/cm2 g pressure, available from old Urea plants.

2.2.4.2 Cooling Water Circulation & Make-up

One additional cooling tower of 4500 M3/hr will be needed over & above existing facilities. Addition of 60 M3/hr of Make-up water is estimated over & above the existing.

2.2.4.3 Steam

Upto 70 TPH of steam at a pressure of 15.14 kg/cm2g is available from the Auxiliary Boiler (CPP) for use during plant startup. No additional Boiler requirement is envisaged.

2.2.4.4 Electricity

81 MVA at 11 KV, 50 cycles, 3 phase is supplied to the existing complex. Additional connected power load requirement is estimated at 15 MW. The combined power requirement will be available from the CPP of 60 + 35 MW capacity.

2.2.4.5 Emergency Power

500 KW at 415 V 50 cycles, 3 phase will be available from a standby generator. This will only be used for lighting and for instruments.

2.2.4.6 Instrument Air

4000 m3/hr of oil free, dry air at a pressure of 6-7 kg/cm2g will be needed. The same shall be tapped from the Process Air compressor. However, another Air reservoir & Air dryer facilities will be needed.

2.2.4.7 Process Air

The same shall be made available by the new Process Air Compressor to be installed for meeting the requirements of expanded Ammonia production facilities.

2.2.4.8 Inert Gas



A PSA Nitrogen plant of 600 Nm3/hr with a new Ammonia cracker for making available required Hydrogen & De-oxidation Hydrogen requirement for high purity Nitrogen product is envisaged.

2.2.5. Ammonia Plant Process

Introduction

The original design of the three Ammonia Plants was based on ICI process with Naphtha as feedstock and also as fuel. In line with Government of India’s declared policy, switchover of feedstock and fuel Naphtha o Natural Gas was done for all the three plants. It is important to mention here that the main process steps for Ammonia manufacturing starting with Naphtha or natural gas as feedstock and fuel are the same. However, during implementation of changeover from naphtha to natural gas, aspects of energy saving and efficiency improvement were incorporated. The aspect of compatibility of the design and engineering for expanded capacity Urea production of 1.05 MMTPA was also duly considered.

It is important to emphasize here that the basic framework of manufacturing and processing steps for Ammonia remained same for both i.e. Ammonia plants based on naphtha and with natural gas, but with change of certain design and operating parameters. These changes are necessary to meet the following objectives:-

Process loop pressure reduction, wherever feasible Pressure loop reduction Modernization of equipments and internals for improved energy efficiencies Avoiding waste generation and losses Minimizing / elimination of effluent streams Plant layout simplifications Piping layout simplifications Minimizing shut down and hook-up period Optimum capital and operating cost for process units, utilities and offsites Augmentation of automation and DCS control in an optimum manner.

The revised portions of the process with natural gas as feedstock and fuel are described below.

The main process steps are:-

For Natural gas Reforming

a) Natural gas desulphurization

b) Primary reforming of NG with steam.

c) Secondary reforming for residual methane from Primary Reforming.

For Synthesis Gas Purification

a) CO Shift conversion reaction.

b) CO2 Removal.

c) Methanation for removal of methane.

Ammonia Synthesis



a) Synthesis gas compression.

b) Catalytic conversion of synthesis gas to ammonia.

c) Recovery of ammonia from Synthesis Convertor outlet gas.

d) Recovery of ammonia from purge gas.

NATURAL GAS DESULPHURISATION

The primary reforming catalyst is poisoned by sulphur and for this reason all sulphur compounds have to be removed from the natural gas feedstock to the reformer. The maximum allowable sulphur content is 0.5 ppm. Natural gas can contain sulphur compounds such as hydrogen sulphide (H2S), mercaptans (RSH), disulphides (R2S2) and thioethers (R2S). However, the Natural Gas made available by GAIL at Plant Battery Limit is almost free from these impurities. Still, KFCL has made provision of necessary desulphurization facilities.

The natural gas is desulphurized in two stages:

Preliminary hydrogenation of “nonreactive” sulphur compounds. In the

presence of hydrogen to about 380°C and passing over a cobalt-molybdenum catalyst, the “nonreactive” sulphur compounds are transformed in H2S. The

chemical reactions taking place in the hydrogenation stages are summarized as follows :

RSH + H2 → RH + H2S

R2S + 2H2 → 2RH + H2S

R2S2 + 3H2 → RH + 2H2S

Absorption of H2S. Followings the hydrogenation od sulphur compounds the formed H2S is absorbed by the zinc oxide according to the following reaction:

ZnO + H2S → ZnS +. H2O

For natural gas desulphurization 16 m3 of catalyst ZnO/Mo2O3/CuO are loaded in the desulphurization converter.

NATURAL GAS PRIMARY REFORMING The desulphurized natural gas is reacted with steam over reforming catalyst to generate a gas mixture containing hydrogen, carbon monoxide, carbon dioxide and some unreacted methane. Primary Reformer is a rectangular insulated structure containing vertically supported tubes filled with catalyst. There are 33 tubes in 4 rows, filled with NiO catalyst. There are 5 rows of burners with 9 burners in each row. The mixture gas leaves the primary reformer at 775ºC and 28.2 kg/cm2g pressure.

Two main reforming reactions are:-

CH4 + H2O ↔ CO + 3H2 (1)

CO + H2O ↔ CO2 + H2 (2)

Reaction (1) proceeds to the extent that equilibrium is achieved at the outlet of Primary Reformer. For this purpose, external heat up around catalyst laden tubes is provided. The fuel fired is Natural Gas itself in the modern and highly efficient burners with low



excess air requirement. The overall reaction lead up to the production of CO, CO2, & H2 is highly endothermic. Therefore, high temperatures and lower pressures favor lower methane concentrations in the reformer outlet gas.

Some excess steam is used to prevent the formation of carbon and sometimes to reduce the required reaction temperature.

At steam ratio higher than design, more heat is required in the furnace per unit of gas production. As mentioned above carbon will not be deposited on the catalyst at design ratio or above. The licensor Casale has specified steam to carbon ratio as 3.0.

The formation of carbon on the primary reformer catalyst may occur by thermal decomposition of hydrocarbons. Usually this carbon can be removed with a mixture of steam and air.

The make gas leaves the primary reformer at 775° C and 28.2 kg/cm2g pressure. The reforming reaction absorbs large quantities of heat and the waste heat in the form of two streams, the reformed gas and the flue gas, is used to provide heat for the remainder of the process.

Exit temperature is the operating variable that has the most pronounced effect on the reaction equilibrium. This variable is controlled by regulating the amount of fuel fired in the furnace.

FLUE GAS HEAT RECOVERY

Flue gas leaves the reformer furnace box at its base at 900 – 1000 °C and is then cooled to approximately 160 °C in a series of heat exchangers located in the convection from the furnace. Flue gas Boiler HP Steam of 37.0 kg/cm2 g is raised in this boiler. The flue gases are cooled down from 745°C to 319°C. Flue gas Economizer Boiler feed water at 168.4°C is heated to 192°C in this Economizer. The flue gases are cooled down from 319°C to 246°C. Combustion air Heater Combustion air required for primary reformer furnace is heated from ambient temperature to about 160°C in this heater. An electrically driven centrifugal combustion air fan provides the necessary combustion air for the furnace burners.

The flue gas is drawn from the flue gas duct and delivered to the flue gas stack at approximately 160°C by the flue gas fan.

SECONDARY REFORMING The gas outlying the primary reformer enters the secondary reformer where the conversion of residual methane is continued in autothermal condition. The heat need for further reforming of methane is generated by burning of methane and part of reformed gas. At a pressure of 31.5 kg/cm2g and a temperature of 485°C, process air flows to the Secondary Reformer. The process air provides the needed oxygen for this



burning. The quantity of air admitted is so controlled which will elevate the temperature of gases exiting at 957º C. Leaving the combustion zone of the reactor the flow passes through the catalyst bed to enter a chamber at the bottom of the reactor.

In secondary reformer, the design concentration of CH4 is further reduced from 7.65 mol% (wet basis) to 0.30 mol% (wet basis).

CO CONVERSION

The gas from the Secondary Reformer contains up to 8.95 mol% (wet basis) carbon monoxide. This is reduced to about 0.19 mol% (wet basis) by converting CO to CO2 over catalyst according to the following reaction:

CO + H20 ↔ CO2 + H2

This conversion, called shift Reaction, is carried out in two stages. The bulk of the CO is reacted over a High Temperature iron oxide/chromium catalyst where the CO concentration is reduced to 2.13 mol% and the final reduction of CO to approximately 0.19 mol% is achieved over a Low Temperature zinc oxide/copper oxide catalyst. This reaction is exothermic and the gas leaves the HT Shift Converter at about 416°C.

The High Temperature Shift Convertor is provided with Casale’s patented internals. The main features are:-

an axial-radial flow path of the gas crossing the catalyst; The use of small-size, more active catalyst.

The above features lead to the reduction in pressure drop, the stability of the pressure drop with operation time, the better performance of the shift converter, the superior gas distribution and the extended catalyst life.

After CO conversion in HT Shift Reactor, the residual CO is further converted to CO2 in Low Temperature Shift Reactor. The LT Shift catalyst is extremely sensitive to sulphur. Therefore, during the initial startup and prior to entering the LT Shift converter, the gas from the HT Shift converter passes through a zinc oxide catalyst bed where any residual sulphur is removed.

CO2 REMOVAL

The Process Gas from the LT Shift Converter enters the CO2 Absorber, where it is treated in counter current with the absorbing solution coming from the regeneration section. The absorption is carried out in two stages: at the first stage, the bulk of CO2 is absorbed; at the second stage a reduced stream of strongly regenerated cold solution is utilized to get a very low CO2 slippage due to the very low CO2 vapor pressure of the lean solution. The gas from the LT Shift converter contains up to 13.20 mol% (wet basis) CO2. This is reduced to about 0.05% mol% by scrubbing solution. The CO2 gas is recovered from the rich hot potassium carbonate solution by steam stripping and subsequently used as feed for the Urea Plants.

CO2 gas flow rate for each Ammonia Stream is 11947 Nm3/hr i.e. 22639 kg/hr with Pressure 0.5 kg/cm2 g to 0.65 kg/cm2 g and Temperature 35°C to 45°C.

Composition of CO2 gas being exported to Urea Plant is as follows:-:

CO2: 99.12 vol. (dry basis)



N2: 0.11 vol. (dry basis)

H2: 0.77 vol. (dry basis)

H2O: 3.92 vol.

The absorption of CO2 into K2CO3 / KHCO3 solutions is controlled by the reaction:

K2CO3 +CO2+H2O ↔ 2 KHCO3

K2CO3 concentration is 30% w/w. Normally the K2CO3 concentration is to be kept between is 26– 28% b.w. Vanadium pentoxide is add in the solution, minimum 6.4% (calculated as V+5) as corrosion inhibitor.

METHANATION

The gas from CO2 Removal section cannot be allowed to travel to Ammonia Synthesis, further CO+CO2 content must be reduced below 5 ppm to avoid the ammonia synthesis catalyst poisoning. The Methanator catalyst enables conversion of the remaining carbon oxides with hydrogen to form water and methane.

The gas is heated to about 260°C and passed over a nickel based methanation catalyst which hydrogenates the carbon oxides to methane as follows:

CO + 3H2 → CH4 + H2O + 49.27 kcal

CO2 + 4H2 → CH4 + 2H2O + 39.43 kcal

Normally the above reactions proceed essentially to completion. Both methanation reactions are exothermic and heat is recovered through generation of LP Steam.

AMMONIA SYNTHESIS

The synthesis reaction is: 3H2 + N2 ↔ 2NH3

Demisted gas after methanation is compressed in to 3-stage reciprocating compressors from 21.9 kg/cm2g and 41.5°C to 270 Kg/cm2g and 122.4°C.

The presence of inert gases reduces the percentage of ammonia actually obtained. Thus, high pressure and low temperature give the highest conversion (equilibrium concentrations of ammonia). However, at low temperature, the reaction is slower and equilibrium is not approached so quickly. Hence there is an optimal temperature profile for the catalyst. The other factors affecting the production rate of ammonia are catalyst activity, space velocity over the catalyst, and composition of converter inlet gas.

(a) Catalyst activity

The activity of the promoted iron oxide catalyst is at a maximum about one month after its initial reduction. It decays slowly thereafter due to the poisons, and the effects of time and temperature. As activity is/lost, the purge from the loop must be increased, and eventually a point is reached where it is more economic to change the catalyst.

The poison usually occurring from O2, H2O, CO and CO2, each of which is equally harmful, and sulphur compounds. The plant is designed on the basis of 5 ppm CO + CO2 maximum in the gas to synthesis, these being the main poisons. The catalyst temperatures in any part of the bed are restricted to 520°C maximum in order to minimize the catalyst deactivation due the overheating.



(b) Converter Inlet Gas

The space velocity of gas through ammonia synthesis catalyst is very important for ammonia production. Increasing the space velocity increases the ammonia output. At very low space velocities, the ammonia produced is approximately proportional to the space velocity, while at very high space velocities the output increases very little as the space velocity is increased.

The inlet ammonia concentration is determined by the condensation temperature equilibrium conditions being as follows:

Table 2.3 : Equilibrium Conditions for Inlet Ammonia Concentration

Loop Pressure kg/cm2

150 250 350

Condensation Temp. 0°C

4.60% 3.37% 2.85%

10°C 6.39% 4.75% 3.98% 20°C 9.50% 6.50% 5.45% 30°C 12.80% 8.75% 7.20%

The condensation temperature can have a considerable effect on the converter performance. The ratio of hydrogen to nitrogen also affects the rate of reaction. The optimal ratio is about 3.0:1, but this is not critical.

AMMONIA RECOVERY

The condensed ammonia from the synthesis loops contains dissolved gases which are liberated along with small quantities of ammonia let down for flashing. By operating in two stages, a higher separation efficiency is obtained than with a single stage. For efficient operation it is necessary to recover the ammonia from" the Purge gas and from the Flash gas. This is achieved by water washing at two pressures and finally stripping and rectifying the dilute ammonia solution from the absorbers. The incondensable gases, mainly hydrogen, are recycled to be used as fuel in the primary reformer.

The purge gas from all three ammonia plants goes to the HP absorber and is scrubbed with 2871 kg/h of water. This absorber operates at a pressure of 41.5 kg/cm2g. The washed gas is sent to be mixed to natural gas fuel and burnt to primary reformer burners.

Composition of purge gas being used as fuel is as follows:-:

CH4: 12.27 mol%

N2: 20.86 mol%

H2: 60.79 mol%

Ar: 5.90 mol%

H2O: 0.18 mol%



The flash gas from the ammonia let down vessels from all three ammonia plants joins the flash stream from ammonia storage and enters the LP absorber. The LP ammonia absorber is working at 9.5 kg/cm2g and the gas leaving the LP absorber top is sent to fuel gas header.

Composition of flash gas being used as fuel is as follows:-:

CH4: 20.74 mol%

N2: 22.69 mol%

H2: 49.85 mol%

Ar: 5.93 mol%

H2O: 0.78 mol%



Figure 2.2 : Process Flow Steps in Ammonia Manufacture



2.2.6. Ammonia Storage

The storage facility comprises two 1500 tons capacity fully refrigerated tanks capable of storing liquid ammonia at -33°C.

2.2.6.1 Holding Duty

When there is no ammonia import to the storage, the duty is termed holding. Heat gained by the refrigerated storage tank through the insulation causes boil off of ammonia vapour. In order to maintain the tank contents at -33°C, it is necessary to compress this vapour, condense, expand and return it to the tank.

For this duty 20% of the capacity of one the three 2-stages reciprocating compressor (AOJ-504) is required. The ammonia vapour generated due to heat leak is compressed in the first stage of the compressor. The vapour from the stage goes to the flash vessel (AO-F-504). The vapour bubbles through the liquid already present. The heat given out by cooling, the vapour will vaporiser some of the liquid. The liquid level in the vessel is controlled by letting the liquid ammonia down to the storage tank. Part of the cooled gas is fed back to the first stage suction through a bypass controlled by the back pressure and the remainder is compressed in the second stage of the compressor. The second stage suction pressure is controlled by bypassing the second stage delivery gas back to the suction. The compressed gas from the second stage delivery is cooled and condensed in the water cooled ammonia condenser (AO-G-503). The condensed ammonia goes to the ammonia receiver and then returned to the flash vessel where it is let down in pressure. The returned condensed ammonia will partially flash in the flash vessel.

2.2.6.2 Let Down Duty

Three 2-stages reciprocating compressors are each capable of providing the required refrigeration for 0.6 TPH liquid ammonia let down to the storage tank.

The liquid ammonia from the ammonia let-down vessel goes to the ammonia flash vessel. The flow of liquid ammonia to the flash vessel is controlled by the level in the flash vessel. The liquid ammonia will flash in this vessel causing a reduction in temperature. The ammonia from the flash vessel is sent to one of the storage tanks, the flow of which is controlled from the pressure in the storage tank. The vapour released due to flash and due to heat leaks is compressed in the first stage of the ammonia storage compressor. The compressed vapour from the first stage of the compressor is cooled in the flash vessel by bubbling the vapour through the liquid already present in the vessel. The vapour from the flash vessel goes to the catch pot prior to entering the suction of the second stage of the compressor for removing the entrained liquid ammonia. The second stage suction pressure is controlled by bypassing the second stage delivery. The compressed vapour is cooled and condensed in the water cooled ammonia condenser. The condensed ammonia with the non-condensables goes to the ammonia receiver where the noncondensables are separated and purged continuously to the LP absorber. The condensed ammonia is returned to the flash vessel. The liquid ammonia from the let-down vessel contains dissolved uncondensable gases which will be flashed in the flash vessel.



2.2.6.3 Liquid Ammonia Export

The centrifugal ammonia pumps (AO-J-501 A & B), one working one spare, are provided for the transfer of liquid ammonia from the storage tank. Each pump is capable of handling 8.0 TPH. The liquid ammonia from these pumps goes either to the rail filling station or to the urea plant.

2.2.7. Boiler Feed Water and Steam System

The boiler feed water and steam generation system is integrated with the process flow to such an extent that a simplified flow diagram is drawn up.

2.2.7.1 Boiler Feed Water System

The main source of boiler feed water are boiler feed make-up from the demineralization plant, steam condensate from ammonia and urea plants and process condensate. The make-up BFW is preheated to 95 0C in the undeaerated boiler feed water heater (AC-304) before going to deaerator (A-F-601). In the deaerator, the make-up BFW is stripped free to oxygen by counter current contact with steam. Process condensate from the underated BFW catch pot (A-F-301) goes to the process condensate stripper (A-F-602) where it is counter currently stripped free of ammonia and CO2 using steam. The stripper overhead steam goes to the regenerator. The stripped condensate, containing about 5 p.p.m. of CO2 and 5 p.p.m. of ammonia goes to the storage section of the deaerator. Steam condensate from ammonia and urea plants is fed to the deaerator. The deaerated make-up water is mixed with the process and steam condensate. The level in the deaerator is controlled by varying the make-up water rate. The water from the deaerator satisfies BFW requirements of one ammonia and one urea plant.

The BFW from deaerater is doped continuously with NaOH/Na2SO3 solution. Caustic is added to maintain a pH of 9.5-10.5 and Na2SO3 is added to absorb the residual oxygen. An intermittent supply of sodium hexametaphosphate (Calgen) is added to water to prevent calcium salts depositing out in the boiler tubes, should thereby any calcium slip from the demineralization plant. The doped BFW is pumped by the BFW pump (A-J-601) to the converter effluent/ BFW exchanger (AC-401) where the BFW is heated to 170°C. Part of the BFW goes to the shift generator (A-C-302) and to the CPP (A-B-601) where 15.14 kg/cm2 g pressure saturated steam is raised. The remaining BFW is flow controlled from the level in the HP boiler drum and is heated to 220°C in the flue gas Economiser (A-B-206) before entering the HP boiler drum (A-F-201). The water from the HP boiler drum circulates naturally through the flue gas boiler (A-B-203) and through the make gas generator where 37 kg/cm2g pressure steam is raised.

2.2.7.2 Steam System

There are three different steam pressure levels in the plant viz. 37 kg/cm2g, 15.14 kg/cm2g & 3.54 kg/cm2g. Hereinafter, these will be referred to as HP, IP & LP steam respectively.

2.2.7.2.1 HP Steam

HP steam is raised in the flue gas boiler and in the make gas generator. A major part of the saturated steam is superheated to 480°C in the primary and secondary super



heaters (A-B-208 and A-B-204). A bulk of this superheated steam is used for reforming naphtha. Only a small part of this steam is used to drive the boiler feed water pump turbine. A small part of the surplus HP saturated steam goes to the still re boiler (AO-C-404) where it is condensed and the condensate is returned to the deaerator. The remaining surplus steam is let down into the IP steam main.

2.2.7.2.2 IP Steam

Saturated IP steam is raised in the HP Shift generator (A-C-302) and in the auxiliary boilers (A-B-601). Some of this steam is let down into the LP main to maintain the LP main pressure. Only a small part is used in the stripper reboiler (AO-C-204) and for atomizing the fuel to the reformer and to the fired heaters. The remainder is exported to the urea plant.

2.2.7.2.3 LP Steam

This steam main is fed by the boiler feed water pump turbine exhaust system and by the IP let down steam. The mixed steam from the above two sources has a high degree of superheat. The superheat is removed in the LP steam desuperheater (A-C-604) using the BFW at 109°C from BFW pump delivery. The desuperheated LP steam is supplied to the steam heated reboiler (A-C-305) to the process condensate stripper (A-F-602) and to the deaerator.

2.3. Ammonia Process Description - Expanded Plant

The three ammonia lines will be revamped to fulfil the stoichiometric requirements of Ammonia and CO2 for producing 1.05 million ton Urea per year. It is estimated that the Ammonia requirement will be 0.6192 MMTPA and CO2 gas requirement shall be 0.7942 MMTPA. Following modifications in Front End & Back End sections would be carried out in the existing three Ammonia plants which are based on ICI process. Complete process description and design features appear in PFR.

The first step planned was restart of Ammonia plants (3 Nos.) in January 2012 with Naphtha as feedstock and fuel. However, due to statutory requirement of feedstock switchover from Naphtha to Natural Gas by the end date June 2013, the strategy & planning was changed for restart. It was decided to carry out phased execution of the project for feedstock conversion from Naphtha to Natural gas and Energy Saving by December 2013 as Phase - I. It was also decided that implementation of Phase – II for Capacity Expansion shall be initiated as soon as Environmental Clearance is available & the HEC technology is tied up for Urea. The details of the expanded capacity of the process plants are as indicated below:

Ammonia plants (3 trains) from 415 TPD to 600 TPD. Urea plants (3 trains) from total capacity 2046 TPD to 3033 TPD.

All the modifications that are necessary to increase the capacity of the plants will also have “Energy Saving measures” as integral part. All the new pieces of equipments to

be installed for capacity expansion in Ammonia plants shall be designed accordingly. The major objectives of the revamp for restoration of original design capacity & Energy Saving are listed below:

Process loop pressure reduction, wherever feasible Pressure drop reduction



Modernization of equipments and internals for improved energy efficiencies Avoiding waste generation and losses Minimizing / elimination of effluent streams Plant Layout simplifications Piping layout simplifications Minimizing shut down and hook – up period. Optimum capital and operating cost for process Units, Utilities and Offsites Augmentation of automation & DCS control in an optimum manner.

(During restart phase, DCS control has already been implemented for the base plant)

The process modifications for revamp and energy saving are a must before any expansion of production capacity can be implemented. At the same time, these will also facilitate expansion of Ammonia plant capacity if constraints in compression of synthesis gas, process air, CO2 in terms of flow are removed. Therefore, the process modification is briefly described as follows.

2.3.1. Front-End Section Debottlenecking

Natural gas available at battery limit is mixed with part of the syngas from the first stage of make-up gas compressor for desulphurized hydrogen and then preheated in a new dedicated fired heater. Feed gas is then fed to a new desulphurization unit, in order to remove the sulphur compounds from the gas. Desulphurizer unit contains Co-Mo catalyst for hydrogenation and ZnO absorbent. All the three plants have individual NG Desulphurization facility.

Figure 2.3 : Natural Gas Purification Upstream Reforming

Desulphurized gas is mixed with steam at about 480°C and then is fed to reforming tubes. For Primary Reformer, it is estimated that the heat flux on the tubes is within an acceptable value (<65,000 kcal/h-m2).

Reformed gas at about 8000C is reacted with process air coming from process air compressor and in the secondary reformer, where methane is further converted into synthesis gas. CH4 slip from secondary reformer is 0.25% on wet basis. Secondary

Plants

To ammonia

Natural gas

From B.L.

Hydrogen for

Desulphurization NG Fuel

Desulphurization



reformer burner will be replaced with Casale proprietary design to reduce flame length at the increased capacity (during capacity expansion).

Downstream secondary reformer the gas is cooled in boiler AC-201, and then is fed to CO-shifting section. Part of BFW from pumps A-J-601A/B is mixed with synthesis gas upstream each shift converter, in order to control the inlet temperature to HTS and LTS.

HTS internals revamping has already been done under Energy Saving measures. LTS internals have also been revamped to CASALE axial-radial design to reduce front end pressure drop even at higher load, increase plant reliability and minimize CO slip.

Synthesis gas downstream LT shift with 0.2% CO slip on dry basis is sent to CO2 removal unit. It is envisaged that the removal of carbon dioxide with existing equipment is feasible with the modifications using the Giammarco-Vetrocoke low-energy process.

Downstream the CO2 removal the synthesis gas has less than 800 ppm CO by volume and it is split into two streams: part is sent to methanation unit to convert the carbon monoxide into methane before the synthesis loop; the remaining part is recycled to burners as fuel (about 10%).

It is estimated that additional water cooler downstream the air cooler will be installed to cool down the synthesis gas to 400C before the make-up gas compressor AJ-401, overcoming the shortage of existing air cooler AC-309.

Major modifications are indicated in Table 2.4.

Table 2.4 : Major Equipment List for Expansion vis a vis existing

Sl. No.

Existing Major Equipments

Details Additional / Modifications for

Capacity Expansion in Ammonia

1 Primary Reformer

Reformer tubes (132 nos.)

Existing equipments will be utilized

Burners 45 nos.

ID Fan 1 no.

FD Fan 1 no.

Flue gas Boiler 1 no.

Air Heater 1 no.

BFW Heater 1 no.

Steam Super heater

2 PA & NG Heater Existing equipment will be

utilized

3 Desulphurization unit

One unit for each plant Existing equipment will be

utilized

4 Secondary Reformer

Burner Replacement of Burners

(3 Nos.)

5 Process air compressor

One compressor for each Ammonia plant

One New Process Air Compressor



Sl. No.

Existing Major Equipments

Details Additional / Modifications for

Capacity Expansion in Ammonia

7 Carbon Di oxide Removal

LP Regenerator

Existing equipments will be utilized

CO2 Booster

LP Stripper O/H Condenser

Flash Gas Chiller

8 Ammonia Synthesis Loop

Synthesis Gas Compressor

One new Synthesis Gas Compressor

Synthesis Convertor

Waste heat boiler

Purge gas chiller

Flash gas chiller

Steam Vent silencer

2.3.2. Compressors Debottlenecking

This is foreseen as a major bottleneck in realization of the expanded capacity. Because of the layout constraints it is not possible to install single machines serving the 3 Ammonia plants. Therefore, the following approach is planned.

The two Synthesis gas compressors (A/B) of Ammonia plant III shall be relocated & one each added to serve the existing two compressors for Ammonia plant I and II respectively, in new compressor house

Air compressor of Ammonia plant III is relocated to serve Ammonia plant I and II in the same new compressor house

New synthesis gas compressor (centrifugal) and air compressor (centrifugal or integrally geared) are installed in Ammonia plant III.

The above approach shall enable capital cost optimization & simplification of operations for the expanded capacity.

Only one synthesis gas compressor and one air compressor need to be added

Total shut down time for compressor modifications is minimized

Higher Ammonia production realization may be enabled with new rotating equipments.

2.3.3. Back-End Section Debottlenecking

The Ammonia plants synthesis loops have been studied by Casale and the following debottlenecking measures have already been implemented.

Ammonia Casale converter internals

New waste heat boiler

Additional hot gas-gas exchanger



The only additional equipment that needs to be upgraded for the capacity increase is the loop water cooler (C-402 A/B). Water coolers (A/B) of Ammonia plant III shall be relocated to serve Ammonia plant I and II respectively, while a new unit will be installed in Ammonia plant III.

2.3.4. CO2 Removal Revamping

The CO2 removal section for all the three Ammonia plants has already been revamped based on the licensed technology – Giammarco-Vetrocoke Low-energy process. The energy consumption has been brought from 1000 KCal/Nm3 of CO2 to 750 KCal/Nm3. The outlines of the process are described in Figure 2.4.

Figure 2.4 : GV Low-Energy CO2 Removal Scheme

The concept of the GV low-energy process is a two-stage scheme with two separate strippers working at different pressures – a high pressure (HP) stripper and a low pressure (LP) stripper.

Part of the rich solution from the absorber (about 60% of the total circulation) is introduced into the top of the HP stripper, while the remainder is let down in pressure by about 1 kg, pressure into the LP stripper.

The heat for regeneration is supplied to the HP stripper only by a process gas reboiler and / or by direct / indirect steam. The semi lean solution withdrawn from the midpoint of the HP stripper feeds the midpoint of the LP stripper, from which, after releasing steam by flashing, it is pumped to the lower zone of the absorber.

The lean solution is fed from the bottom of the HP stripper to the bottom of the LP stripper and thence, after releasing steam by flashing, is cooled and pumped to the top of the absorber.

The pressure difference between the HP and LP strippers is such that sufficient flashed steam is produced to strip out the CO2 from the rich solution fed to the top of the LP stripper, achieving the same FC of the semi lean solution withdrawn from the HP stripper.

The benefits of this process are:



Low Steam to Carbon (S/C) ratio (3.3 to 3.6).

Enhanced CO2 separation – two stage stripping.

No Steam to steam reboiler is needed.

Smaller hookup time.

Separated CO2 can be compressed by both an ejector and a blower. A blower for CO2 has been installed in each of the three Ammonia plants.

Downstream the CO2 removal the synthesis gas has CO2 concentration of 500 ppm. It is sent to methanation unit to convert the carbon monoxide into methane before the synthesis loop.

The reduction of the steam to A1-C-305 frees more steam for export (3.7 TPH), allowing a saving in external boilers (coal saving) of 154,000 KCal/MT. Some saving is also expected due to possible reduction of Steam Carbon ratio. The same may help in reduction of firing fuel requirement in the Primary Reformer.

2.3.5. CO Conversion – HTS Internals Revamp

The main features of CASALE patented design are:

An Axial-radial flow path of the gas crossing the catalyst.

The use of small-size, more active catalyst.

Very low gas velocities in the catalyst.

Among the main advantages, the reduction in pressure drop, the stability of the pressure drop with operation time, the better performance of the shift converter, the superior gas distribution and the extended catalyst life. The gas distribution is controlled by the distributors and not by the catalyst bed. The axial-radial converter pressure drop will not be affected by catalyst deactivation, or by poor catalyst distribution due to improper loading.

The result is a safer operability of the converter (steady pressure drop) and stable pressure drop all along the catalyst life. The axial-radial baskets have no drawbacks when compared with pure axial converters w.r.t. converter operation, catalyst loading and catalyst life.

In an axial-radial catalyst bed the gas distribution is such that most (about 90%) of the gas passes through the catalyst bed in a radial direction, resulting in a much lower pressure drop when compared with the axial flow.

The balance flows downward through a top layer of catalyst in an axial direction, thus eliminating the need for a top cover of the catalyst beds. The gas flow through the catalyst is controlled by perforated walls at the inlet and at the outlet, where most of the bed pressure drop is concentrated.



Figure 2.5 : Axial-Radial Distribution Concept

The main advantages of the axial radial technology are:

The expected pressure drop of the converter (nozzle to nozzle), is lower than 0.3 bar, a value far out of reach for a series of axial reactors.

The pressure drop value will be stable with time, as it does not depend on catalyst age or possible bad misdistributions.

Increased catalyst.

The reactor will also be able to cope much better with water carry over from the upstream.

2.3.6. Revamp in Synthesis Loop- Ammonia Converter

The identified major modifications in the Synthesis Loop of all the three Ammonia plants have been implemented & commissioned. The details are:-

Table 2.5 : Major Modifications in Synthesis Loop

Modification Description New Ammonia Converter

Internals Casale’s internals, 3-Bed-Quench-Interchanger with bottom exchanger

Additional waste heat boiler

Installed downstream ammonia converter, in order to produce steam at 20 Kg/cm2

Additional Gas / Gas Exchanger

Installed downstream the existing BFW preheater to heat up the converter inlet gas and increase steam production.

The revamping of existing convertors of the three Ammonia plants has been done with a 3-bed quench interchanger convertor. The existing electrical heaters have also been replaced with new one fitted on top shell closure and placed in central position within the converter cartridge inside the first catalyst bed inside the interchanger. This enables the loading of increased catalyst volume for realization of expanded Ammonia capacity & energy saving. Necessary inter connected piping joining new process equipments has been provided. New Hot gas / Gas exchanger and Ammonia coolers have been provided. These changes are expected to enable realization of the following objectives:

a. Optimal thermodynamic catalyst distribution in multi-bed cartridge and maximum filling of catalyst inside the cartridge for high conversion and low pressure drops.



b. Highest efficiency of each bed, specific to the axial-radial technology, facilitating complete utilization of the catalyst volume.

c. An axial-radial flow of the gas stream through the catalyst bed at much lower pressure drop than a conventional design.

d. Use of small-size catalyst (1.5-3 mm) with higher activity compared to the large-size catalyst and this ensures 100% utilization of the catalyst.

New hot gas-gas exchanger has been placed in series with existing A3-C-403 in order to increase gas temperature to synthesis converter up to 90ºC. This will also increase outlet temperature from converter, in order to enhance heat recovery in new waste heat boiler placed downstream the converter. This new exchanger is kettle type, producing 9.1 ton/h of 20 bar steam and it is fed with BFW preheated in existing exchanger A3-C-401. This corresponds to a saving of 400,000 kcal/MT of ammonia as coal in external boilers.

To measure the inlet and outlet temperature of all beds there are bundles of thermocouples, introduced from the converter top. The bed inlet temperature is measured at least in one point of each bed, while the outlet temperatures are measured in two or three points.

All new CASALE cartridge parts are in AISI-type 321 austenitic stainless steel of pressure vessel quality, which is ASTM A240-TP321 for plates, ASTM A336 F321 or ASTM A182 F321 for forging etc. For ensuring high reliability the wire meshes, the expansion bellows and thin sheets (<3mm) are in Inconel 600 Alloy material of construction. The internal exchangers are in AISI-type 321. All cartridge parts are designed providing the proper clearances to allow for free thermal expansion.

Performance in the existing Ammonia plant

The Hydrogen / Nitrogen ratio at converter inlet shall be maintained 3 for realizing optimum Ammonia synthesis loop performance. The following performance data was indicated by Casale for 415 MTPD capacity Ammonia production.

Production : 415 MTPD

Loop pressure: 260 Kg/cm2

Inert content upstream converter: 14% mol

Ammonia at converter inlet: 4.5% mol.

Delta ammonia across converter: 15.1% mol

Temperature at converter outlet: 2950 C

2.3.7. Operating Parameters /Specifications after Modifications

After completion of revamp & modification for expanded capacity the following new operating parameters are expected.

2.3.7.1 CO Conversion & CO2 Removal

Specific regeneration heat, not higher than (kcal/Nm3 CO2) : 785 CO2 purity from AF-302, not lower than (dry % vol.) : 99%



Dry gas composition at LTS converter outlet (item AD-303) : o CO2 (% mol) : 23.2 (± 0.15%) o (Ar + H2 + N2 + CO + CH4) : 76.8 (± 0.15%)

Dry gas flow rate at LTS outlet (item AD-303), before quenching (if any), not more than 120949 Nm3/hr. Steam to Carbon molar ratio in the outlet gas is 1.7143.

Gas temperature at LTS outlet (AD-303) before quench : 221.8 0C Gas pressure at Absorbers inlet (item AE-301) (kg/cm2g) : 23.5 (± 0.5 kg/cm2g) Gas temperature at Absorbers inlet (item AE-301) (0C) : 120 (max.) Steam from condensate stripper (AF-602) to AE-306 : 3000 kg/h (at 1.3 kg/cm2g) Ambient air temperature (0C): 35 (max.)

2.3.7.2 HTS Revamping

Expected Operational Parameters Inlet pressure (bar g) : 25.7 Converter inlet temperature (0C) : 340 Converter inlet flowrate (wet gas) (Nm3/hr) : 119953 Converter inlet gas composition

o H2 : 38.15 mol% o N2 : 15.34 mol% o CO : 08.91 mol% o CO2 : 04.91 mol% o CH4 : 00.34 mol% o Ar : 00.21 mol% o H2O: 32.14 mol%

HTS Converter – Pressure Drop Converter pressure drop (from inlet to outlet nozzle) (bar): ≤0.4 (guarantees)

2.3.7.3 Ammonia Synthesis Loop after expansion

For 600 MTPD capacity Ammonia production, the estimated operating parameters for the loop are:

Production : 600 MTPD Loop pressure : 326 Kg/cm2 Condensation temperature : 4 0C Inert content upstream converter : 14 % mol Ammonia at converter inlet : 4.0 % mol. Delta ammonia across converter : 20.84 % mol Temperature at converter outlet : 331 0C Purge flow rate : 178 kmol/hr. Pressure drop in the convertor : 04.2 kg/cm2

2.4. Existing Urea Plant:

2.4.1. Utilities Available



2.4.1.1 Instrument Air System

Air station supplies maximum rate of 4472 Nm3/hr of air at 8.4 kg/cm2g. Upto 2795 Nm3/hr is used as an Instrument Air having dew point less than -30 0C and pressure of 7.8 kg/cm2g.

There are 5 nos. of oil free, two stage double acting water cooled reciprocating Instrument Air Compressor to deliver 1575 Nm3/hr of air at 8.4 kg/cm2(g).

If the Instrument air delivery pressure falls below 7.2 kg/cm2(g), supply of plant maintenance air is tripped. The system then utilizes the excess air (max. of 1500 Nm3/hr) from Process Air compressor to augment the supply of Instrument air.

There are 2 nos. of oil free, two stage double acting water cooled reciprocating Instrument Air Compressor in CPP to deliver 518 kg/hr of air at 8.4 kg/cm2(g).

2.4.1.2 Raw Water

Raw Water from Lower Ganges Canal is pumped into Raw water Reservoir by means of four centrifugal pumps, 3 of 350 m3/hr and 1 of 450 m3/hr. Out of this, only 2 pumps are kept running.

There are 2 reservoirs each of 75 million gallons and 30 million gallons respectively. From the reservoir, water is pumped out at a rate of 700 m3/hr by means of reservoir pumps.

After removal of suspended matter from raw water by means of flocculation followed by filtration, the filtered water is stored in 1200 m3 underground clear well.

2.4.1.3 Demineralised Plant

Degasser Tower: (1 unit in Old & 1 in New WTP) Rubber lined steel tower of 2 m dia.x 4 m height, containing 8.5 m3 of rasching rings. 4 nos. of Degassed water pumps of 100 m3/hr to pump degassed water to Cation Exchange unit.

Cation Exchange Unit: (2 Units in Old & 2 in New WTP) Rubber lined steel pressure vessel of 2.44 m dia.X 2.80 m height, containing 8.33 m3 of Zeo-Karb resins. Regeneration is done with hydrochloric acid.

Anion Exchange Unit: (2 Units in Old & 2 in New WTP) Rubber lined steel pressure vessel of 1.98 m dia. X 2.75 m height, containing 5.15 m3 of De-Acidite resins. Regeneration is done with 5% of caustic soda solution. The treated water is then passed to the two demineralised water storage tanks, 200 m3 each, which is pumped by 4 nos. of DM water export pumps of 100 m3/hr.

2.4.1.4 Cooling Towers

There are eight cooling water systems (including CPP Cooling towers) as per details given below:

1. Old (No. 1 & 2) Ammonia & Offsites Cooling Tower of 3 cells and cooling water circulation rate is 5170 m3/hr and Design Range is 12 0C.

2. Old (A&B) Urea Cooling Tower of 3 cells and cooling water circulation rate is 6985 m3/hr and Design Range is 8.5 0C.

3. Surface Condenser Cooling Tower for Urea B Plant of 1 cell and cooling water circulation rate is 1448 m3/hr and Design Range is 10 0C.



4. New (No. 3) Ammonia & Offsites Cooling Tower of 2 cells and cooling water circulation rate is 3000 m3/hr and Design Range is 90 C.

5. New (C) Urea Cooling Tower of 3 cells and cooling water circulation rate is 5350 m3/hr and Design Range is 70 C.

6. Sigma Cooling Tower (for Urea A Plant Surface Condenser & Howden No. 1&2) of 3 cells and cooling water circulation rate is 3000 m3/hr and Design Range is 10 0C.

7. HSU Cooling Tower of 1 cell and cooling water circulation rate is 1500 m3/hr and Design Range is 100 C.

8. CPP Cooling Tower of 2 cells and cooling water circulation rate is 800 m3/hr and Design Range is 80 C.

2.4.1.5 Steam Generation Plant

The Captive Power Plant has 2 nos. of Coal fired Boilers of MHI make spreader stoker type, each of max capacity 70 TPH to generate superheated steam of 105 Kg/cm2g and 500°C. The Steam passes through Steam Turbine of BHEL make to generate 12 MW power.

The steam coming from the exhaust of the turbine approx. @100TPH at 17.5 Kg/cm2g design pressure is exported to Urea plant to produce fertilizer and 12 MW power is used to cater the plants power requirement.

Coal requirement of CPP is 750 TPD of blended Coal of Grade B & C or Washery Grade.

A separate Polished Water production unit was set up near the CPP to produce high purity water (silica <0.02 ppm) to feed the high pressure boilers.

All the Boilers were certified by IBR in the past prior to start up.

2.4.1.6 Raw materials & Bulk Storages

The main raw material and process fuel was Naphtha. For CPP coal was used. The main storages for the raw material, fuel and finished goods are as below:

Naphtha Tanks : 10000 MT x 1 (Process Naphtha) o 5000 MT x 1 (Process Naphtha) o 2500 MT x 1 (Process Naphtha) o 5000 MT x 1 (Fuel Naphtha) o 2500 MT x 1 (Fuel Naphtha) o 2000 MT x 1 (Sweet Naphtha)

Ammonia Storage Tank : 1500 MT x 2 with 12 inch WC pressure, insulated, concrete outer wall, 3 refrigeration compressor package to receive 18 TPH liquid Ammonia at 30 0C

Coal Storage yard : 18000 Ton Urea Silo: 25000 MT.

2.4.2. Urea Process Description

2.4.2.1 Introduction



The plant is a Toyo Koatsu total recycles “C” process designed to produce 682 TPD of

prilled urea. It is divided into three completely independent parallel streams. Two streams A & B are operated from the same control room and the third one from another independent control room.

For convenience of description, each streams of the plant is divided into four sections, namely, Synthesis, Decomposition, Recovery and Finishing. These sections are closely inter-related.

2.4.2.2 Synthesis Section

Major equipments in this section include CO2 compressor, recycle solution and liquid NH3 injectors, NH3 preheater and the reactor.

CO2 gas, liquid NH3 and recycle Carbamate solution are compressed and fed separately to the base of the reactor which operates at about 190 0C and 230 kg/cm2g. Ammonium carbamate is first formed and thereafter it is decomposed to give urea and water. The reaction products, namely urea, water; NH3 and CO2- whether free or combined as carbamate, are expanded through a letdown valve into the high pressure decomposer.

2.4.2.3 Decomposition Section

In this section the equipment consists of the high pressure decomposer, low pressure decomposer, gas separator and oxidiser in series.

Heat is supplied to each of these vessels to decompose ammonium carbamate and drying off NH3 and CO2 from the Urea solution. The off-gases are absorbed in the recovery section. Having passed through each of these vessels in turn, the urea leaves the oxidiser as 70% solution in water and almost completely free from NH3 and CO2.

2.4.2.4 Recovery Section

To deal with the unconverted NH3 and CO2, there is the following equipment, High pressure absorber, low pressure absorber, gas condenser, NH3 recovery reservoir and NH3 recovery absorber.

Off-gases from the decomposition section vessels are absorbed in their respective absorbers, namely from high pressure decomposer to high pressure absorber/absorber cooler, from low pressure decomposer to low pressure absorber and from gas separator to gas condenser. The heat of absorption and subsequent reformation of ammonium carbamate is removed from the absorber by means of cooling water. In case of high pressure absorber cooler, however, a circulating urea slurry stream from finishing section is also used to remove heat. The gas condenser is fed with mother liquor from the finishing section and with make-up water. The solution from the gas condenser is used as absorbent solution in low pressure absorber; from there it goes to high pressure absorber cooler and from there back to the reactor. An overhead NH3 gas stream from the high pressure absorber is condensed in the NH3 condensers and returned to the NH3 recovery reservoir.

2.4.2.5 Finishing Section



The equipment includes filter, vacuum evaporator, crystalliser, centrifuges, driers, cyclones, melter, prill heads, fluidising cooler and trommel.

Urea solution from the oxidiser [passes through the filter into the vacuum evaporator where water flashes of. The solution then flows down into the crystalliser. Part of heat required to evaporate water is obtained from the high pressure absorber cooler by means of a slurry stream which circulates from the crystalliser through the high pressure absorber cooler to the vacuum evaporator. Urea crystals are separated from the mother liquor by means of centrifuges and then dried and conveyed to the top of the prilling tower in a hot air stream. Most of the mother liquor is returned to the crystalliser system, a small part being sent to the gas condenser as a purge to reduce the biuret content of the product. At the top of the prilling tower, the urea crystals are separated from the air stream in cyclones and then melted. Molten urea flows to the prill heads from which it forms into spherical drops which solidify and cool as they fall down the tower. Further cooling is done in a fluidising cooler sited in the tower base and prills then overflow in to a trommel where the oversize material is separated from the product. The oversize prills are returned in solution to the process while the product goes forward to storage or packing.

2.4.3. Description of the Process

2.4.3.1 Synthesis Section

Urea is synthesised in the reactor DC-101A/B under high pressure (230 kg/cm2g) and temperature (190° C) from CO2 gas, liquid ammonia and recycle carbamate solution. The temperature and pressure in the reactor and the molecular ratio of NH3 to CO2 are so selected that maximum conversion to urea is achieved with minimum cost.

The reaction to form urea takes place in two stages. The NH3 and CO2 first react to form ammonium carbamate and this reaction is fast and highly exothermic. The ammonium carbamate then undergoes a slower, slightly endothermic breakdown to form urea and water. Both stages are reversible and shown below:

2NH3 + CO2 NH4CONH2 NH2CONH2 + H2O Ammonia carbon ammonium urea water

Dioxide carbamate

Since the reaction proceeds in two stages, the selection of reaction parameters for optimum yield of urea is very complex. The main parameters affecting the reaction are temperature, pressure, feed composition, reactor shape and internals, and residence time.

High temperature favours the endothermic breakdown of carbamate to urea and so the operating temperature is selected to be as high as possible consistent with minimum corrosion troubles. As conversion to urea increases, so the amount of recycle solution decreases.

The breakdown of carbamate to urea and water takes place only in the liquid phase and therefore the pressure in the reactor must be maintained at a value greater than the vapour pressure of the reaction mixture at the operating temperature.



Apart from this stipulation, pressure has very little effect on the reaction. A higher pressure does, however, help to reduce the amount of CO2 slip that results from incomplete mixing of CO2 and NH3 at the reactor inlet.

Feed composition is an externally complex matter to discuss. Two main features need to be mentioned:

The amount of water in the recycle solution- from the point of view of carbamate breakdown too urea, the water in the recycle solution should be minimum since any extra water will decrease the possible conversion to urea. On the other hand, the solubility of carbamate in liquid NH3 is very low and, therefore some water is necessary to take carbamate into solution as it is formed from CO2 and NH3. In practice the minimum amount of water is recycled.

The excess NH3 - this is a matter of experience and about 100% excess is used.

What is required of a urea reactor is that it provides a good mixing region for the formation of carbamate and then a plug flow region for slower breakdown to urea. The combined fluids after three feed streams nozzles flows slowly (1.0 cm/sec) upwards through the rest of the cylindrical reactor.

The residence time allowed is 21 minutes on the basis of the economics of approach to equilibrium conversion of carbamate to urea. The rate of reaction, of course, falls off rapidly as the equilibrium conversion is approached and this gives 57% conversion of total CO2 fed to the base of the reactor.

CO2 from the ammonia plant is pressure controlled by PICA-102 and fed to the solution of the compressor GA0-101AB where it is compressed to 230 kg/cm2. The flow rate is measured at the suction of the compressor and manually controlled with reference to FR-101AB. A small amount of air is fed via FI-102AB to suction of the second stage. This air is to protect the nozzles and lining of the reactor against corrosion and the amount is 0.2% in the CO2. The compressor is provided with inter-stage coolers but no after-cooler. The temperature of the CO2 feed to the reactor is about 1300 C.

Liquid NH3 is supplied from the ammonia plants at 17 kg/cm2. It passes through a strainer STR-403 AB and is fed to the recovery ammonia reservoir FA-401A at a rate controlled by LRCA-406 AB. There, this fresh NH3 mixes with recycle NH3 from the ammonia condensers EA-404A-F and the purge ammonia condenser EA-405 AB. From the reservoir NH3 is pumped by ammonia booster pump GA-404AB(C) through a strainer STR-402 A(C) B (D) to the suction of the liquid NH3 injectors GA-101A-D(E). The booster pump also supplies NH3 to the recovery section of the plant. There are normally no injectors per stream on line and they deliver NH3 at 230 kg/cm2. The NH3 passes through the ammonia preheater EA-101 AB where steam condensate is used to provide heat before NH3 is fed to the reactor. The condensate comes from the 5 kg/cm2 heating duties on the plant and after being used in ammonia pre heater it is returned to the ammonia plants as boiler feed water. The NH3 feed rate to the reactor is set on FRC-103 AB with reference to FR-101AB so that the correct molecular ratio of NH3 to CO2 is maintained. The injectors are all fixed speed machines and the desired NH3 rate to the reactor is obtained by returning NH3 from the delivery header to the reservoir. The by-pass rate is controlled by FRC-103 AB.



Recycle carbamate solution from the high pressure absorber cooler EA-403 AB is pumped by circulating pump for cooler GA-403 A(C)B(D) through a strainer STR-401 A(C)B(D) into the suction header of the recycle pump, GA-102 A,B,C. An excess of solution is pumped so that there is always a recirculation to the high pressure absorber cooler. This prevents solidification of carbamates in the lines. Normally one pumps per stream running and they deliver solution at 230 kg/cm2. All the pumps are high speed machines and the desired feed rate to the reactor is obtained by returning solution from the delivery header to the suction header. The by-pass rate is determined by LRCA-401 AB, the level controller of the high pressure absorber cooler.

The desired reactor pressure (230 kg/cm2) is maintained by PRCA-101 AB and the desired reactor temperature (1900 C) is obtained by regulating the amounts of NH3 preheat. HC-101AB, which controls the flow of condensate, is provided for this purpose.

The reaction products leaving the reactor are urea, water, ammonium carbamate and excess NH3. This solution is letdown in pressure through PRCV-101AB, the letdown valve into the high pressure decomposer DA-201AB. The solution undergoes adiabatic flash after the letdown valve and much of excess NH3 is vaporised and some of the carbamate is decomposed to NH3 and CO2 gas. The stream entering the high pressure decomposer is therefore a gas/liquid mixture at about 1200 C.

2.4.3.2 Decomposition

In this section, the product mixture from the reactor is processed to remove NH3 and CO2 and leave an aqueous urea solution. This is achieved by the application of heat and a stepwise reduction in pressure as the solution passes through the high pressure decomposer, the low pressure decomposer, the gas separator and the oxidiser. A multi-stage pressure reduction is employed so as to minimise the water evaporated with the NH3 and CO2. This leads to lower steam consumption and a minimum recycle of water to the reactor.

Both the high pressure decomposer and the low pressure decomposer consist of two parts; the upper part, DA-201AB and DA-202AB, is a stripping column containing four sieve plates and the lower part, EA-201 and EA-202AB, is a steam heated thermosyphon reboiler. Both the gas separator aid oxidiser parts of the gas separator DA-203AB are simple capacity vessels in which a tube bundle for steam heating is immersed in the urea solution, i.e. they correspond to single stage stripping columns or to the reboiler stage of distillation columns.

The gas/liquid mixture from the reactor DC-101AB flows into the top of the high pressure decomposer DA-201AB where the flash gas separates from the liquid. The liquid then flows down over four sieve plates counter current to the gas stream generated by the reboiler EA-2O1AB. By this means, most of the remaining carbamate is decomposed and the NH3 and CO2 is stripped from the liquid. This NH3 and CO2 leaves the top of the decomposer together with the flash gas and passes to the high pressure absorber cooler EA-403AB. Let-down of the urea solution is controlled by LICA-201AB and the solution temperature is maintained at 1550 C by TRC-201AB which regulates the amount of 11 Kg/cm2 steam fed to the reboiler ( N.B. It is important that this temperature of 1550 C should not be greatly exceeded or severe corrosion will



result). Corrosion is minimized by the continuous addition of small quantity of air to the urea solution line inlet the reboiler. The pressure in the decomposer is controlled at 18Kg/cm2g from PIC-403AB on the top of the ammonia recovery absorber EA-406AB, through the ammonia condensers and the high pressure absorber/absorber cooler. The steam condensate level in the shell of the reboiler is controlled by LIC-202AB and it is vital that this level be maintained for 11 Kg/cm2 steam will pass to the low pressure decomposer reboiler.

The low pressure decomposer operates on the same principles as the high pressure decomposer. Urea solution which has flashed adiabatically on let down from the high pressure, decomposer enters the upper part of the low pressure decomposer DA-202AB, There the flash gas separates and the urea solution is further stripped of NH3 and CO2 as it passes over the sieve plates counter-current to the gas stream generated by the reboiler EA-2O2AB. The gas stream leaves the top of the decomposer and passes to the low pressure absorber while the urea solution letdown is controlled by LICA-203AB. The temperature of the solution is controlled at 130 0C by TRC-202 AB which regulates the 5 Kg/cm2 steam supply to the reboiler. Roughly 31% of the reboiler heat requirement is supplied by letting clown the 11 Kg/cm2 steam condensate from the high pressure decomposer reboiler. The condensate level in the shell of the reboiler is maintained by LIC-204AB. The pressure in the decomposer is controlled at 1.9 Kg/cm2 by PICA-402AB on the low pressure absorber. Corrosion in the decompoer is minimized by the addition of a small quantity of air to the solution flowing into the reboiler, as for ‘the high pressure decomposer.

From the low pressure decomposer the urea solution passes to the upper part of the gas separator DA-203AB which operates at 1120 C and 0.3 Kg/cm2 G. The sensible heat of the solution is normally sufficient to provide the necessary evaporation but a tube bundle is provided so that TIC-203AB can, if necessary, maintain the required temperature by allowing 5 Kg/cm2 steam into the tubes. The overhead gases pass to the gas condenser. Pressure is controlled by PICA-203AB and level by LICA-205AB which lets down urea solution into the lower part (the oxidiser) of the gas separator. The oxidiser operates at 110°C and atmospheric pressure. Here air is blown into the solution by the air blower GB-201AB through a sparger pipe in the base of the vessel to oxidize and therefore make more easily filterable any heavy metal impurities present in the urea solution. The temperature is controlled by TIC-201AB using 5 Kg/cm2 steam in the tube bundle. Heat is needed to evaporate some water as the air leaves the solution saturated with water vapour. Small amounts of NH3 and CO2 are also tripped and the contaminated air stream is sent to vent stack. Urea solution of about 70% wt. concentration and containing only traces of NH3 and CO2 is sent to the finishing section, the level being controlled by LICA-206AB in a way described later.

2.4.3.3 Recovery Section

The off-gas from the decomposition section are dealt with in the recovery section so as to provide a total recycle of the NH3 and CO2 that left the reactor unconverted.

Overhead gas from the gas separator is condensed and absorbed in the gas condenser EA-401AB. This is a horizontal vessel containing cooling water tubes and it operates at 550o C. and atmospheric pressures. The temperature is controlled by TIC-402AB which regulates the amount of cooling water flowing through the tubes. The



absorbent solution consists of mother liquor from the finishing section, together with some make-up water. The mother liquor rate is controlled by FIC-294AB and the makeup water feed by LICA-403 AB, the actual rate being indicated by FI-404AB. Vent gas from the ammonia recovery absorber EA-405AB is also sent to the gas condenser and sparged with the gas separator gases into the solution, There will thus be some non-condensable gases present. These gases consist of the inerts originally in the CO2 supply to the plant, together with the air added to the CO2 at the compressor and the anti-corrosion air added to the high pressure decomposer and high pressure absorber. This gas mixture is scrubbed by the condensate feed in a small packed section on top of the gas condenser so that it may be vented to stack containing the minimum amount of NH3. The vent gas is continuously monitored by O2RA-401AB in order to prevent the presence of an explosive mixture. If necessary, extra inert gas may be added to bring the .mixture out of the explosive region.

Solution from, the gas condenser is pumped by the low pressure absorbent pump GA-401A(C) B (D) into the low pressure absorber EA-402AB. Here the overhead gas from the low pressure decomposer is sparged into the solution and condensed and absorbed. The pressure in the vessel is maintained at.1.5 Kg/cm2 G by PICA—402AB which regulates the cooling water flow through the tubes. The corresponding temperature of 45 0C is recorded by TR-0036AB-6.

The pressure in the low pressure absorber is one of the most important process variables. A pressure much higher than design will result in insufficient decomposition in the low pressure decomposer, thus putting a greater burden on the gas separator. A pressure much lower than design will allow more evaporation of water in the low pressure decomposer, thereby diluting the recycle carbamate solution. Solution level is controlled by.LICA-402AB which adjusts the amount of solution fed from the gas condenser. Inert gases (mainly air) in the low pressure decomposer off-gas are further scrubbed by the dilute solution feed from the gas condenser in a small packed column on top of the absorber before being vented to the stack. Venting of the inerts is controlled by HC-402AB which also acts as a controlled emergency blow-off. The concentration of CO2 in the solution leaving the absorber is analysed regularly and maintained at about 10% wt. (1.5 litres/25 cc. solution). If the concentration is markedly, different from this figure then the pressure in the high pressure decomposer should be adjusted slightly so that the balance of the decomposition is shifted as required.

The high pressure absorption system consists of a horizontal vessel, the high pressure absorber cooler EA-403AB which contains cooling water and urea slurry tubes, and a vertical vessel, the high pressure absorber DA-401AB which contains a packed section and five bubble cap trays. In these vessels, all of the CO2 and part of the NH3 in the high pressure decomposer off-gas is absorbed. The absorbent liquor is a combination of solution from the low pressure decomposer, liquid NH3 and aqueous NH3. The absorption of the CO2 is achieved in the following three steps:

Gas from the high pressure decomposer enters through a sparger pipe and bubbles through the solution in the high pressure absorber cooler. Here about 70% of’ the CO2 is absorbed. The heats of absorption and formation of carbamate are removed by cooling water and a circulating urea slurry stream



from the finishing section. The temperature is controlled at 100 0C by TRC—

401AB which regulates the cooling water flow.

Unabsorbed gas passes into the base of the high pressure absorber and the remaining 30% of the CO2 is scrubbed out in the packed section by counter-current contact with dilute carbamate solution. Solution from the low pressure absorber is pumped by the high pressure absorbent pump GA-402A(C) E(D) at a rate set by FIC-403AB and mixed With a liquid NH3 stream, The heat of mixing is removed by a cooling water jacket (subsequently called the mixing cooler) as the solution flows to the high pressure absorber to be distributed over the packing. The liquid NH3 rate is set on FIC-402AB so that the temperature of the gas leaving the packed section is maintained at about 60 0C. This ensures that only trace quantities of CO2 are carried forward to the next step.

Aqueous NH3 (77% wt) is pumped from the ammonia recovery absorber EA-406AB to the top tray of the five bubble cap trays provided. Here the last traces of CO2 are absorbed and the gas leaving the top of the high pressure absorber is almost pure NH3. The temperature of this gas is controlled at 50 0C, by adjusting on FIC-401AB the amount of liquid NH3 fed as reflux to the top tray.

The solution level in the high pressure absorber cooler is controlled by LRCA-401AB which acts on the bypass valve from the delivery of the recycle solution injectors. It is very important that this level should be correctly maintained. If it is too low, not enough absorption and heat removal will take place. If it is too high, solution will be carried over in the gas stream to the base of the high pressure absorber. This leads to high temperature and CO2 breakthrough in the absorber. If not corrected immediately, the plant will have to be shut down to wash out the whole of the ammonia recovery system — this can take up to three days. Also, some corrosion of piping, vessels and the liquid NH3 injectors will take place because of carbamate in the recycled NH3. Corrosion of the high pressure absorber and absorber cooler vessels is minimised by the continuous addition of a small quantity of air to the liquor line connecting the two vessels.

Solution is pumped from the high pressure absorber cooler by circulating pump for cooler GA-403A(C) B(D) to the suction of the recycle solution injectors GA-102A-D(E) in a manner described previously. The CO2 concentration in the recycle solution is maintained at 30% wt. (5.5 litres/25 cc. solution) by adjusting the setting on FIC-403AB. This indirectly changes the amount of make-up water to the gas condenser.

NH3 gas from the top of the high pressure absorber passes through the mist separator DA-402AB, where entrained liquid is removed, and flows to the ammonia condensers EA-404A-F to be condensed. When the cooling water temperature becomes higher than 30.5°C, the purge ammonia condenser EA-405AB should be put into operation. As NH3 is condensed, the inert’s fraction increases and the condensing temperature of

NH3 falls. It is economical to use a 2nd-stage condenser with fresh cooling water to complete the desired condensation. The liquid NH3 is returned to the ammonia



reservoir FA-40IAB where it mixes with the fresh feed NH3 before being pumped to the reactor.

The inert gases are withdrawn from the top of the ammonia condensers and passed through the ammonia reservoir to the ammonia recovery absorber EA-4066AB. This consists of three horizontal absorbers vertically in series to provide a multi- stage counter-current absorption of most of the NH3 from the inerts, Water is pumped by the water pump GA-406AB(C) into the top absorber while the inerts, saturated with NH3 gas, pass through a sparger pipe into the bottom absorber. The temperature in the absorbers is maintained at about 44 0C, by cooling water. The liquor level in the top and centre absorbers is fixed by overflow and the level in the bottom absorbex is controlled by LICA-407AB which regulates the amount of aqueous NH3 liquor pumped by the aqueous ammonia pump GA-405AB(C) to the top of the high pressure absorber. The pressure of the vent gas from the ammonia recovery absorber is controlled at 16.5 Kg/cm2 G by PIC-403AB which is the only pressure controller for the whole of the high pressure decomposition and recovery system. The vent gas is sent to the gas condenser, for further NH3 removal before passing to stack.

2.4.3.4 Finishing Section

In this section 70% urea solution is processed, via the crystal route, to product urea prills having low buiret and water contents.

The urea solution is the oxidiser contains oil and heavy metal oxides. It must therefore be filtered before it can be further processed. The filter FD-201 A(C) B(D) is a pressure precoated leaf type and there is a space filter per steam. This allows one to be cleaned and precoated while the other is on line. Diatomaceous filter aid and water are added to the mixing tank for filter FB-201 AB and the dilute suspension is circulated by the filter pump GA-201 A(C) B(D) through the filter and back to the mixing tank. The precoat layer is thereby built up on the leaves of the filter. An essential feature of precoat filter operation is always to maintain a good flow of solution through the leaves so that the precoat does not drop off. Urea solution is pumper from the oxidiser by the filter pump and part of filtered solution is returned to the oxidiser. The amount sent forward to the crystalliser system is determined by LICA-206AB, the level controller for the oxidiser.

The crystalliser FS-201AB consists of two parts. The upper part is a vacuum evaporator equipped with vacuum generator EE-201AB and the lower part is the crystalliser where growth of crystals suspended in mother liquor takes place. Urea solution from the filter is mixed with a circulating urea slurry stream and returned mother liquor from the centrifuges and fed to the vacuum evaporator. The evaporator operates at 86 mmHg. Absolute and 60-650C and water flashes off from the feed stream. The amount of water to be evaporated is that produced in the urea formation reaction plus the differential amount of that added to and removed from the process in various places so that the water balance over the plant is maintained. Heat for evaporator of this water is obtained from three sources (A) sensible heat from the feed solution which is at about 1100C. (25%), (B) latent heat of urea crystallisation (25%), (C) heat picked up by a circulating slurry stream from the high pressure absorber cooler (50%). The circulating slurry stream is pumped off from the lower vessel by the circulating pump for crystalliser GA-202A(C) B(D). Part of the slurry is passed through



the high pressure absorber cooler where heat is picked up (50% by sensible heat of temperature rise and 50% by latent heat of dissolving crystal). The rest of the slurry is remixed with it after the high pressure absorber cooler. This is to control the degree of super-saturation of urea that results when the water flashes off from the slurry in the vacuum evaporator. If the super-saturation is too high, fine crystals will be formed and the super-saturation is therefore not available to the growing crystals. Hence the mean crystal size would be much smaller. The vacuum in the evaporator is controlled by PRCA-204AB which regulates the amount of air bled into the vacuum generator system. Care should be taken with the level in the evaporator, indicated by LIA-207AB. If it is too high, carryover of solution will occur.

Supersaturated urea solution flows down the barometric leg from the vacuum evaporator into the lower vessel which operates at atmospheric pressure. The growing crystals are kept in suspension by the continuous up flow of solution created by the circulating slurry stream take-off just below the working level. The vessel is conical in shape so that it acts as a classifier, i.e. small crystals are lifted to the surface and therefore stay in the system for the further growth while large crystals settle to the bottom. An agitator is provided in order to prevent crystal build-up on the walls of the crystalliser. The level in the lower vessel is indicated by LIA-208AB and the crystal density in the slurry is recorded by DR-201 AB. A crystal density of 35% wt. in the slurry is aimed at. This allows good centrifuge operation while still giving easy handling of the slurry.

Hot water jacketing is provided throughout the crystalliser system to prevent solidification on the walls of vessels and piping. The hot water, which is steam condensate from the melter, is circulated from the hot water tank FA-203AB by the hot water pump GA-205AB. The water temperature is maintained around 80 0C by manually regulating the 5 Kg/cm2. Steam supply to the sparger in the base of the hot water tank.

Slurry is taken from the bottom of the crystalliser and pumped by the slurry feed pump GA-203A(C)B(D) to the centrifuges. To avoid chokes, excess slurry is pumped and this is returned to the top of the lower crystalliser vessel. There are three centrifuges GF-201A-F per stream and it is expected that they will normally all be returning to give design output. The slurry feed rate to each centrifuge is controlled by remote manual operation of HC-202A-F in the control room while watching the level in the crystalliser and Amp I-202A-F, the ammeters for each centrifuge. In the centrifuges, urea catalyst is separated from the motor liquor.

The mother liquor flows down into the motor liquor tank FA-202AB in which a steam coil is provided to prevent crystallisation of the liquor. It is then pumped from the mother liquor tank by the mother liquor pump GA-204AB(C). Part is sent to the gas condenser at a rate set on FIC-204AB to prevent biuret accumulation in the crystalliser system. The remainder is returned to the crystalliser slurry circulation stream at a rate controlled by LIC-209AB, the level controller for the mother liquor tank.

Two principles lie behind the use of the crystal route to low biuret prills:



1. Urea crystallises preferentially out of the mother liquor. The biuret stays in solution provided its concentration is prevented from rising too high. The mother liquor purge ensures this.

2. The mother liquor purge is sent via the gas condenser back to the reactor. There the conditions are such that the part of the biuret is converted to urea according to the following equilibrium reaction:-

NH3 + NH2CONHCONH2 2 NH2CONH2

Ammonia biuret urea

The ratio of biuret to urea in the feed from the oxidiser is 0.6%, that in the mother liquor purge 3.5% and that in the crystal discharged from the centrifuge 0.1%. The only biuret left in the crystal comes from the mother liquor film adhering to the crystal surface.

Crystal from each centrifuge drops into the screw conveyor for centrifuge JD-201A-F and is then conveyed by No. 1 belt conveyor JD-301AB and No. 2 belt conveyor JD-302AB to the fluidising drier which forms the base of pneumatic drying system FF-207AB. Filtered air is blown by the forced fan for drier GB-301AB through the air heated for drier EC-301AB into the base of fluidising drier. Its temperature exit the heater is maintained at 110⁰C by TRCA-301AB which regulates the 5 kg/cm2 steam supply to the heating tubes. Pressure in the drier, indicated by PI-302AB, is maintained at the slight vacuum so that crystal is not blown back out through the entry grid. The drier is provided with a pneumatically operated rake which removes any crystal lumps from the bed and drops them into the screw conveyor for drier JD-304A-D. From there the lumps are discharged into the dissolving tank FA-302 set in the floor.

The moisture content of the crystal is reduced from 1.5% to about 0.5% in the fluidising drier and is then further reduced to 0.25% as the crystal is blown up the pneumatic pipe to the tower top. The temperature of both crystal and air is almost the same at this stage. The air temperature is recorded by TR-302AB and should be about 65 ⁰C. At the tower top the crystal is separated from the air stream in the cyclone FC-301AB and drops into the screw conveyor for melter JD-303AB from which it drops into the melter EA-301AB. The air passes on to the induced fan for drier GB-302AB and then through the dust separator FD-304AB., where it is scrubbed by a water spray to remove urea dust, to atmosphere.

Both the forced and induced fan for drier are fixed speed machines. The pressure balance in the drying stream is controlled by adjustment of the damper so that the pressure in the fluidising drier is maintained at just below atmospheric pressure. There is a manually operated damper exit the forced fan for drier and a damper exit the induced fan for drier which is operated by remote manual control HC-301AB.

In the melter the crystal is rapidly melted on specially shaped steam heated tubes. The temperature of the molten urea should be as little as possible above the melting point and its residence time in the melter should be as low as possible. This is to minimise the increase in biuret content that results from melting the crystal. The melter is provided with an agitator which distributes the crystal feed uniformly over the tubes. The head of crystal above the tubes may be estimated by observing on AmpI-301AB



the current taken by the agitator. The rate of melting may be adjusted accordingly by altering the setting of PIC-306AB. this controls the pressure and hence the condensing temperature of the steam in the melter tubes.

Molten urea flows down to the head tank FA-301AB. through the strainer FD-301AB. From the head tank it is sent to the prill heads PF-301A-P which have many small holes in them. The resulting jets of molten urea are unstable and breakdown to give spherical droplets. Most of the droplets have a diameter in the range half to twice the mean prill diameter, which is roughly twice the diameter of the prill head holes. Eight heads per stream are provided and of these, seven are required for design output. The number is service at any one time is determined by reference to LRA-301AB, the level recorder for the head tank.

The spherical droplets cool and solidify to form prills as they fall down the prilling tower through the up-flowing air. The air rate is determined by the combination of tower height, prill dag forces, air buoyancy created by heat removal from the prills and inlet and exit air pressure losses since the tower operates on the natural draught principle. The inlet air pressure losses may be varied but this only gives a very limited control of the air rate. Part of the air comes from the blower for fluidising cooler GB-303AB and the remainder enters the tower base round the fluidising cooler directly from atmosphere. The prills are further cooled on the fluidising cooler FD-302AB in the tower base and then send to storage and packing by belt conveyor after passing through the trammel FD-303AB. Oversize prills and agglomerates of small prills are separated from the product in the trammel and dropped into the dissolving tank FA-302.

Urea dust is removed from the tower exit air stream before the air discharges to atmosphere. A dust chamber surrounds the top of the tower shaft and the reduced air velocity in this chamber allows fine urea particles to settle out. Dilute urea solution, formed by dissolving the separated dust, fills the trough in the bottom of the dust chamber. Solution from the dust separator on the exit drier air flows down into this trough and a circulation of solution back to the inlet air duct to the dust separator is provided by the circulating pump for prilling tower GA-302AB. solution overflows from the trough and is piped down the tower. At the tower base, it is sent to the gas condenser or to the dissolving tank. Water make-up to the scrubbing system and for outer duties at the tower top is pumped up the tower by the water pump for prilling tower GA-301A (B).

The production rate of urea prills is measured by WIS-AB (weighing indicator summator) on the conveyor belt from trammel to storage.

2.4.3.5 Temporary storage and Solution Recovery Systems

It is convenient to describe these systems separately although they form an integral part of the main process.

A. Two storage tanks per stream are provided, one for carbonated ammonia liquor and very dilute urea solution (ammonia carbonate solution tank FA-402AB) and one for concentrated urea solution (ammonia carbonate solution tank FA-402CD). The principle of operation is to drain solution from the main process into these tanks as rapidly as required and then to feed it back gradually into



the main process when this is possible. The ammonia carbonate solution pump GA-407AB takes solution from either tank and feeds it back to the relevant process vessel.

1. FA-402AB

The drain line from the reactor, high pressure decomposer and low pressure decomposer joins the drain line from the gas condenser, low pressure absorber, high pressure absorber cooler, high pressure absorber and drain separator. The common drain line then feeds any drain liquor to this tank.

All the liquid effluents from the finishing section are collected in the separation pit and the settled solution is sent by the effluent filter pump GA-502 through the effluent filter FD-501A(B) to this tank. Solution in this tank is pumped to the gas condenser.

2. FA-402CD

The drain line from the concentrated urea solution feed line from filter to crystalliser joins the drain line from the delivery of the slurry pump. The common line then feeds the draining to this tank. The tank is provided with a steam coil to prevent solidification of this content.

Solution in this tank is pumped to the oxidiser or to the crystalliser lower vessel.

B. Urea solution from the finishing section is also returned to the main process for recovery of the urea as mentioned earlier. Dilute solution from the tower top scrubbing system flows by gravity to the gas condenser at a rate indicated by FI-405AB or to the dissolving tank. Oversize prills and spillage from the packing shed are dissolved in this tank and the more concentrated solution is sent by the dissolving tank pump GA-303 A(P) either to the oxidiser or to the mother liquor tank. The level in the dissolving tank is controlled by LX-303 which is a level on/off switch for the pump motor.

If dilute solution is sent to the gas condenser then concentrated solution is sent to the oxidiser. If the dilute solution is sent to the dissolving tank then the concentrated solution may be sent to either the oxidiser or the mother liquor tank.

Table 2.6 : Equipment List for Existing Urea Plant

Tag Number Description Tag Number Description XU-GB-101 CO2 Compressor XU-EA-301 Melter XU-EA-404 Ammonia condenser XU-GB-302 Induced Fan for dryer XU-EA-405 Purge Ammonia

Condenser XU-JD-303 Screw Conveyer for Melter

XU-GA-404 A,B Ammonia Boost up Pump

XU-FD-304 Dust Separator

XU-GA-101 A,B Liquid Ammonia feed Pump

XU-FA-301 Head tank

XU-EA-101 Ammonia Preheater XU-FD-301 Strainer for head tank XU-GA-403 AB Circulating pump for

cooler XU-FD-302 Fluidising cooler



Tag Number Description Tag Number Description XU-GA-102 AB Recovered Solution

Feed Pump XU-FD-303 Trommel

XU-DA-201 High Pressure Decomposer

XU-GA-302 AB Circulation pump for Prilling Tower

XU-DA-202 Low Pressure Decomposer

XU-FE-301 Dust Chamber

XU-DA-203 Gas Separator XU-GA-301 AB Water pump for Prilling Tower XU-DC-101 Reactor XU-GA-303 AB Dissolving Tank Pump

XU-EA-201 AB Reboiler for High Pressure Decomposer

XU-FA-601 Process Condensate Tank

XU-EA-202 AB Reboiler for Low Pressure Decomposer

XU-DA-601 Process Condensate stripper

XU-EA-406 Ammonia Recovery Absorber

XU-EA-604 Pre heater for XU-DA-601

XU-EA-401 High Pressure Absorber Cooler

XU-EE-602 Second steam Ejector

XU-DA-401 High Pressure Absorber

XU-EE-601 First Steam Ejector

XU-EA-402 Low Pressure Absorber

XU-EA-601 First Surface Condenser

XU-GA-402 AB High Pressure Absorbent pump

XU-FA-305 Pump Tank for XU-GA-301

XU-DA-402 Mist Separator XU-DA-602 Finishing Absorber XU-FA-401 NH3 Reservoir XU-EA-603 Third Surface Condenser

XU-GA-406 AB Water pump XU-EA-602 Second Surface Condenser XU-GA-405 AB Aqua Ammonia Pump XU-GB-401 Off Gas Blower

XU-FD-201 Filter XU-FA-403 Off gas Absorbent Tank XU-GA-201 AB Filter Feed Pump XU-GA-408 AB Off gas absorbent Pump XU-FA-201 AB Crystalliser XU-EA-407 Off gas Condenser XU-GA-202 AB Circulation Pump for

Crystalliser XU-GA-409 AB Circulating pump for off gas

Absorber XU-GA-203 AB Slurry Feed Pump XU-GA-401 AB Low Pressure Absorbent Pump

XU-GF-201 Centrifuge XU-EC-302 Air heater for Fluidising Cooler XU-FA-202 Mother Liquor Tank XU-GB-303 Blower for Fluidising Cooler

XU-GA-204 AB Mother Liquor Pump XU-DA-403 Off Gas Absorber XU-FF-301 Pneumatic Dryer XU-EA-408 Off Gas Absorber Final Cooler XU-GB-301 Forced fan for Dryer XU-EA-409 Off Gas Absorber cooler XU-EC-301 Air Heater for dryer XU-GA-601 AB Process Condensate pump XU-FA-302 Dissolving Tank XU-GB-304 ID fan for Prilling Tower XU-FC-301 Cyclone XU-FD-305 Filter for Prilling Tower

XU-FJ-302 Spray Nozzle for XU-FD-305

2.5. Urea Process Description: Expanded Capacity



The existing Urea plants are three in number and are based on Toyo Koatsu Total Recycle C improved process. Each plant has a Urea prills production design capacity of 682 MTPD.

It is proposed to establish a new HEC Urea process train & integrate the same with the existing Urea plants A, B & C. A customized process configuration for optimum use of the existing Decomposition, Concentration , Crystallization and Prilling sections will be designed and engineered by Casale during detail engineering stage. However, a preliminary configuration for the broad understanding is presented in Figure 2.6.

The new HEC Synthesis (A “once through process”) will process about 1800 MTPD of

urea. Line A and Line B will decompose and recycle the load corresponding to about 900 MTPD each, till downstream the oxidizers.

From each line A & B 200 MTPD will be sent to the crystallization in line C.



Figure 2.6 : HEC Process



PROCESS SCHEME

The write up provided here describes the major process planning steps for integrated operation of the existing Urea Plant A , B and C ( the three Urea plants ) with the new HEC process train ( as offered by Casale) for additional Urea production . (Existing name plate design capacity of 3 x 682 TPD will be raised to a total production of 3033 TPD i.e. an increase of 987 TPD )

Line C will continue to run as per its original design but at lower load. It will be fed with an amount of NH3 and CO2 corresponding to a plant load of 300 MTPD. In this way every existing crystallizer will continue to work for its original design, at about 700 MTPD.Some revamp measures for the existing equipments of Urea plant for restoration of original design features & “Zero discharge” requirements will also be

implemented.

The main concept of the HEC process is to obtain most of the urea product in a "once-through" reaction section. In the absence of recycle water, the conversion of carbamate to urea is favoured and a high conversion of CO2 to urea in single pass (75 to 80%) is obtained. The remaining amount of residual carbamate is decomposed, condensed and recycled as aqueous solution to a second reaction section (operating at lower pressure), which converts it to urea at a lower conversion efficiency. A typical value is 55%. However, Casale will fix exact conversion value after completion of BEP.

By feeding all the fresh reactants to the high-pressure reactor without any aqueous recycle, most of the product (75-80%) is obtained at high conversion efficiency and only a small amount (20-25%) at reduced efficiency. The weighted average conversion efficiency results in the 70-76% range. Consequently, the amount of steam required by the decomposition section in Urea plant is greatly reduced.

The "Once-Through" reaction section designed by CASALE for the HEC process and integrated with existing conventional total recycle plant consists of the following key equipments :-

The carbamate condenser, a U-tube, kettle type heat exchanger where part of the ammonium carbamate is formed and part of reaction heat is taken out, generating steam (with a pressure as high as 9 ata), in order to control the temperature of the primary reactor.

The primary reactor, usually fitted with Casale High Efficiency Trays operates in the following conditions :

NH3 / CO2 : 3.6 H2O / CO2 : 0 Outlet temperature : 195 0C

Pressure : 240 ata

CO2 conversion : 74 % (may change after BEP)



The existing reactor of second Urea plant train is proposed to be operated as second reaction section with Casale’s High Efficiency Trays and is expected to achieve the following conditions.

NH3/CO2 : 4.5

H2O/CO2 : 1.3

Outlet temperature : 190 0C

Pressure : 155 ata

CO2 conversion : 55 %

All the CO2 feed required for 3033 TPD Urea productions enters the "once-through" reaction section and reacts with stoichiometric quantity of Ammonia.



Figure 2.7 : Conventional Total Recycle Plant revamped with the HEC Concept



HEC process claims to achieve the following features:

Very high (average) CO2 conversion, i.e. ab. 74%

Very low H2O/CO2 ratio, i.e. 0.3.

Low specific steam consumption

Small size of all the decomposition and recycle equipment i.e. the size of HP Decomposer and Carbamate condenser.

The HEC process scheme shall be integrated in the existing urea plant trains as shown in Figure 2.8. The Urea revamp scheme shall include necessary modifications / revamp of the existing equipments. Major modifications as preliminary assessment are as follows, section wise.



Figure 2.8 : HEC Process Scheme



2.5.2. CO2 Compression

It has been assessed by Casale that the existing three CO2 compressors can deliver compressed CO2 gas corresponding to a Urea plant load of maximum 3 x 682 TPD = 2046 MTPD Urea production. For balance CO2 requirement for additional Urea production of 987 TPD, A new CO2 Gas Compressor , having sufficient capacity with some cushion is envisaged. The passivation air at the CO2 compressor suction will be increased to cope to the new O2 content in the CO2 flow going to the Synthesis Section.

2.5.3. Synthesis Unit

The revamped Urea plant with expanded capacity (3033 TPD) will have a common synthesis section for the existing three Urea plants. Two reactors will be reused as primary reactors, working at 230 kg/cm2g & fed only with CO2 feed from the compressors together with the ammonia recovered in the three sections and pumped via GA-101.

A "once through" loop consisting of the existing Reactors DC-101 from line A and line B and of a new HP Carbamate Condenser EA-91 + Mixing TX-91, and a new synthesis section consisting of a new HP Stripper EA-92 and of a new Auxiliary Reactor DC-91 are planned in accordance with the requirements of the HEC (High Efficiency Combined) process. Existing Reactors and New HP carbamate Condenser will work at 230 kg/cm2g, while the new HP Stripper and New Auxiliary Reactor will work at 155 kg/cm2g. Fresh CO2 and NH3 is proposed to be fed directly to the "once through" section. CO2 coming from existing CO2 compressor will have O2 around 0.3% on volume basis for passivation of HP equipments.

The NH3 to "Once through" section is preheated in the existing Ammonia Preheater EA-101, using hot condensate and a small quantity of steam as heating medium, in order to recover heat as in the existing configuration.NH3 and CO2 fed to the "once through" section are mixed in the mixing TX-91, immediately upstream of the new Carbamate Condenser EA-91. This is a Kettle type heat exchanger.NH3 and CO2 react quickly in the tubes, releasing heat, which is in part recovered as 4.5 kg/cm2g steam. The hot carbamate stream from EA-91 flows to the Reactor 1151, where the residence time is enough to convert about 73% of the CO2 to urea.

Urea solution comes out from Reactors DC-101 A/B through a new down comer and is split at 50% and feeds the existing HP decomposer Columns DA-201 flashing at 17 kg/cm2g. The vapors coming out from DC-101 A/B top are sent to the bottom of the EA-92: this allows O2 contained into inerts, fed with CO2, to passivate Stripper and, downstream, new reactor DC-91 also.

The carbamate solution coming from the three couples of HP Carbamate Pumps GA-102 is sent to the new Auxiliary Reactor DC-91, together with vapors coming from the Stripper EA-92 and with a small quantity of preheated NH3. This is a completely new reactor with lining in 25Cr/22Ni/2Mo equipped with HET (High Efficiency Trays) trays inside. The CASALE-Dente tray design and the residence time provided in the reactor are enough to convert about 53% of the CO2 into Urea. Urea solution coming out from Auxiliary Reactor DC-91- feeds the HP Stripper. The New HP Stripper EA-92 is a



falling-film type decomposer, using 25 kg/cm2 g steam as heating medium on the shell side, coming from the new saturator FA-97. The HP stripper facilitates:

a) Decomposition of carbamate and stripping ammonia from the urea solution, purifying the solution

b) Send vapors to provide the necessary heat to the Auxiliary Reactor DC-91.

Urea solution at about 30% will come out from the bottom of the stripper at around 2020 C.

The total urea production splitting is planned between “Once through” (72%) and the

new Urea Reactor (28%). The other conditions are described for both streams.

a. 72% of urea production in the once through reactor – Operating / Design conditions P : 230 kg/cm2g T : 1900 C N/C : 3.4 H/C : 0 CO2 conversion : 73%

b. 28% of urea production in the new reactor – Operating / Design conditions

P : 155 kg/cm2g T : 1890 C N/C : 3.37 H/C : 1.3 CO2 conversion : 53%

The liquid outlet of the Stripper EA-92, (earlier flashing down at about 17 kg/cm2g), is sent to the existing HP Decomposer Column DA-201 in the line C. The vapor coming out from the new reactor DC-91 is directly mixed with a part of carbamate from pumps GA-402 in line A and in line B. These are sent to the new Medium Pressure Condenser EA-93 (working at about 15 kg/cm2g) for recovering the unreacted Ammonia and CO2.

The inerts are washed in the packed bed located above the new condenser by fresh condensate in order to remove the last traces of ammonia, and then be discharged to atmosphere. Keeping separated the synthesis inert stream from the downstream units allows reducing the quantity of inerts in Ammonia recovery section with following benefits:

Minimize the amount of emission to air Improve the condensation efficiency in HP and LP Coolers

The carbamate from EA-93 is then split and pumped to the HP Absorbers DA-401 by means of the new pumps GA-91 A/B.

2.5.4. High Pressure Pumps



Line A and line B

The quantity of ammonia and CO2 fed to decompositions sections and to be recovered are expected to be lower. Hence, no changes are envisaged.

Line C

The conversion in auxiliary reactor DC-91 is significantly lower, compared to the primary reactor DC-101 A/B. The installation of Stripper EA-92 allows improving the carbamate decomposition with the results that the amount of ammonia and CO2 fed to the DA-201 in line-C are controllable for sustained operations.

For this reason the HP Ammonia Pumps is likely to continue to work as per present conditions also for the revamped / expanded capacity. The load to carbamate pumps is slightly lower but discharge pressure may be only 155 kg/cm2g instead of the present 230 kg/cm2g. Prima-facie, these machines appear to be suitable to operate at increased plant load and no new addition or revamp is called for.

2.5.5. Decomposition and Absorption Units

The operating conditions and the equipment arrangement will continue to remain as per existing arrangement except two modifications in Line A & Line B.

1. A part of the carbamate solution from GA-402 will be sent to the new MP Condenser E-91 for improving the condensation of the ammonia vapors contained in the inert stream coming from the reactor DC-91.

2. The urea solution at discharge of filter pumps GA-201 will not be fed to the Crystallizer as per existing arrangement, but will be sent to the new common urea solution tank FA-91.

Due to the increased plant capacity, the existing pumps GA-201 A/B are expected to become undersized. Therefore, these pumps may be either refurbished or replaced with new.

2.5.5.1 Line C

Since the urea solution fed to this line will be significantly different in quantity compared with the line A&B. the following revamp measures are proposed:-

1. An additional condenser EA-402 installed downstream of the existing EA-402 in order to increase the condensation at LP section.

2. The pumps GA-402 A/B will be revamped so as to cope the new plant load as for the line A&B.

3. The discharge of filter pumps will be sent to the new Tank FA-91. Further, since the load to GA-201 will strongly increase considerably, in comparison with design capacity, an additional GA-201 C sized for full load would be installed. The existing pumps GA-201 A/B will be kept as spare.

2.5.6. Finishing Unit

A new common prilling tower will be installed in place of the existing two towers for A&B train. The new tower will be equipped with a de-dusting system for minimizing the emissions.



The three existing Crystallizers unit and relevant equipment will continue to operate as they are expected to meet the capacity as per reconfiguration.

The additional urea solution will be concentrated in the new evaporation section, including:

1st Evaporation stage

2nd Evaporation stage

Urea solution is fed to the 1st Stage Evaporator EA-95. EA-95 is a shell and tubes fed by 4.5 kg/cm2g steam (produced from new HP Carbamate Condenser EA-91) as heat medium.

The mixed flow coming out from 1st Stage Evaporator at about 130 0C and 0.3 kg/cm2.a is separated in the Separator 1st Stage Evaporator FA-95. Urea Solution at about 95% flows to the existing 2nd Stage Evaporator EA-96 operating at lower pressure of 0.03 kg/cm2.a.

Also the EA-96 is a shell and tubes exchanger fed by 4.5 kg/cm2g steam (produced from new HP Carbamate Condenser EA-91) as heat medium. The stream coming out from 2nd stage Evaporator EA-402 at about 1400C and 0.03 kg/cm2g is separated in the Separator 2nd stage Evaporator FA-96. Urea Melt at around 99.7% will be sent to the new Prilling Tower through the new Urea Melt Pumps GA-96 A/B. It will be mixed with the melted crystal downstream the melter, before feeding to the prilling bucket.

2.5.7. Hydrolyser Stripping Unit

The section will treat all the process condensate produced in the plant, with a design load of about 48 TPH (actual operating load – 65 TPH). The effluent from the modified urea trains A, B & C is not expected to go beyond the above mentioned quantity.

No modifications appear necessary even after the revamping.

2.5.8. Steam Network

The original scheme has been kept with the three level steam headers (at 25, 14 and 7 kg/cm2g).

The new HP Stripper has been inserted on the header of 25 kg/cm2g. The condensate from its saturator FA-97 will be used as condensate feed to the HPCC EA-91.

A new low pressure steam header (operating at 4.5 kg/cm2g) is proposed to be installed to distribute the steam produced by the New HP Carbamate Condenser EA-91.

This steam will be used for the new vacuum section (evaporators and vacuum ejectors) and also for the stripper of HSU, in order to maximize the reuse of steam recovered in HPCC and saving the import of 7 kg/cm2g.

2.5.9. Major Requirements for Urea Revamp / Capacity Expansion

(i) One Common HEC synthesis for the three lines. (ii) Line A & B decompositions process the urea solution from primary reactor. (iii) Line C decomposition fed with urea solution from auxiliary reactor. (iv) New Vacuum Section for concentrating the extra capacity of urea.



(v) Additional CO2 Compressor (vi) New Auxiliary Reactor (vii) New HP stripper, new HP carbamate condenser (viii) New Vacuum Section (ix) New Prilling Tower (capacity about 2300 MTPD) (x) Some other small modifications (pumps etc.)

2.5.10. Expanded Capacity Urea (3033 TPD) – Operation Parameters

Table 2.7 : Operation Parameters for Expanded Urea Capacity

Parameter Expected Performance after

Revamping Plant Capacity (MTPD) 3033 Ammonia Consumption per ton of Urea, T / T 0.580 CO2 gas consumption per ton of Urea , T / T 0.740 Urea Reactor Temperature (0C) 195 / 189 CO2 Conversion 73 / 53 Steam Consumption 25 kg/cm2g steam (t/hr) 48.7 13 kg/cm2g steam (t/hr) 63.66 7 kg/cm2g steam (t/hr) 38.6 Total (t/hr) 150.96 Specific Consumption (kg/t U) 1196 Cooling Water Consumption Addl. Circulation water estimate for expn., m3/hr

4114

Total Circulation water , m3/hr 17902 Specific Consumption , m3 / t Urea 141.8 Electric Consumption(*) Additional Estimated Power for expansion Connected running load, kW ( 0.85 PF ) Additional KWH per hour for expanded cap.

5000 4272

Total (KWh/hr) 19713 Specific Consumption (KWh/t of U) 156.1 Energy Consumption G.Cal per ton of Urea 1.3

2.5.11. Plant/Process Performance

Urea Production (total) : 3033 MTD Energy reduction (total) : 0.85 Gcal/MT of Urea

(From the best average realized from the plant before October 18, 2005)

Table 2.8 : Urea Product Quality

Parameter Value Unit Comments



Total Nitrogen Content 46.4 %, wt. on dry basis Minimum Biuret Content 0.5 %, wt. Maximum Moisture Content 0.25 %, wt. Maximum Particle size distribution Not less than 90% of the material shall pass through 2.8 mm

Indian Standard sieve and not less than 80% shall be retained down 1 mm Indian Standard sieve

2.5.12. Revamped & Expanded Urea Plant Equipment List

Table 2.9 : Equipment List – Revamped & Expanded Area

Sl. Item Tag Description Qty. Remarks Reactor

1. DC-101 A/B Primary Reactor 2 To be modified 2. DC-91 Auxiliary Reactor 1 New Equipment with

HET Exchangers

3. EA-91 HP Carbamate Condenser 1 New 4. EA-92 HP Stripper 1 New 5. EA-93 MP Condenser 1 New 6. EA-95 First Vacuum Evaporator 1 New 7. EA-96 Second Vacuum Evaporator 1 New 8. EA-402 bis LP Absorber Pre-Cooler 1 New Separator

9. FA-91 Urea Solution Tank 1 New 10. FA-92 Buffer Tank 1 New 11. FA-95 First Vacuum Separator 1 New 12. FA-96 Second Vacuum Separator 1 New 13. FA-97 Steam Saturator for EA-92 1 New 14. FA-98 Condensate Separator for EA-95 1 New 15. FA-99 Condensate Separator for EA-96 1 New

Pumps / Compressor 16. GB-101 D CO2 Compressor 1 New 17. GA-91 A/B MP Carbonate Pump 2 New 18. GA-92 A/B Urea Solution to Crystallizer Pump 2 New 19. GA-93 A/B Process Condensate Pump 2 New 20. GA-95 A/B Urea Solution Pump 2 New 21. GA-96 A/B Urea Melt Pump 2 New 22. GA-201 A/B Filter Pump 4 (line

A/B) To be modified

23. GA-201 C Additional Filter Pump 1 (line C) New 24. GA-402 C HP Absorber Pump 1 (line C) New

Miscellaneous 25. TX-91 Mixing Tee 1 New

Package 26. Prilling Tower (including fans,

dedusting system ecc.) New

27. Vacuum Package (including ejectors & condenser)

New

2.5.12.2 Major Specifications of Long Lead Items – 6 Nos.



(a) Compressors – Synthesis Gas, Air & CO2 Compressor

Table 2.10 : Compressors – Synthesis Gas, Air & CO2 Compressors

Sl. Description Units Synthesis Gas Compressor Air Compressor CO2

Compressor 1. Fluid handled Synthesis Gas Air CO2 + Inerts

2. Composition H2:74%,N2:25%, CH4/Ar/H2O=1%

N2: 74, O2: 20, Ar: 1%,H2O=5 %

CO2: 98%vol, Inerts: 2%vol

3. Volumetric flow rate at suction NM3/hr 72’000 26’000 About 15500

4. Weight flow rate Kg/hr. 28’000 32’700 About 30000 5. Inlet Pressure Kg/cm2.g 17.5 0 0.25 6. Inlet Temperature 0C 40 40 35 7. Outlet Pressure Kg/cm2.g 308 36 235 8. BKW estimated KW 9500 5400 About 3300 9. Drive Type Electric Motor Electric Motor Electric Motor

(b) HP Carbamate Condenser

Table 2.11 : HP Carbamate Condenser

Sl. Description Units Shell Side Tube Side 1. Fluid Circulation Steam/Condensate NH3-CO2-Carbamate 2. Operating Pressure Kg/cm2.g 4.5 230 3. Operating Temperature 0C 155 177 4. Material of Construction Carbon Steel 25Cr-22Ni-2Mo 6. Heat Transfer Area M2 About 1500 7. Empty Weight MT About 95

(c) Stripper

Table 2.12 : Stripper

Sl. Description Units Shell Side Tube Side 1. Fluid Circulation Steam NH3-CO2-H2O-Urea 2. Operating Pressure Kg/cm2.g 23 158 3. Operating Temperature 0C 224 204 4. Material of Construction Carbon Steel 25Cr-22Ni-2Mo

6. Heat Transfer Area M2 About 1200 7. Empty Weight MT About 115

(d) Auxiliary Urea Reactor

Table 2.13 : Auxilliary Urea Reactor

Sl. Description Units Data

1. Operating Pressure Kg/cm2.g 158 2. Operating Temperature Top 0C 188 3. Operating Temperature Bottom 0C 188



Sl. Description Units Data

4. Reactor Volume M3 About 120 5. Overall Height m About 35 6. Material of Construction Carbon Steel 7. Lining Material 25Cr-22Ni-2Mo 8. Details of Internals HET 9. Erection Weight MT 300

2.6. Utilities

2.6.1. Raw Material Requirement & Storage

The main raw materials required for the present manufacturing process of Ammonia /urea is natural gas (2.05 MMSCMD) which will be supplied by Gail. GAIL’s letter in

this regard is attached as Annexure-II.

In case of non supply of NG from GAIL plant has to be shut down. Naphtha no more will be used. Some of the raw materials/by product/intermediate product/ fuel will be stored in bulk as given below:

Table 2.14 : Bulk Storages

S. No Material Storage Details 1 Product Urea Silo- 25000 MT

2 Ammonia Ammonia Storage Tank : 1500 MT x 2 with 12 inch WC pressure, insulated, concrete outer wall, 3 refrigeration compressor package to receive 18 TPH liquid Ammonia at 30 0C

3 Coal Coal Storage yard : 18000 MT 4 Hydrochloric Acid 2X40 MT, 2X32 MT, 1X16 MT 5 Caustic Lye 1X40 MT, 1X16 MT 6 Chlorine 4 X 100 kg Cylinders

6X900 kg Cylinders 7 HSD 2 x 15KL

2.6.2. Land

No additional land to be acquired for the proposed expansion. The total land requirement for the proposed expansion is available within the existing plant located at Udyog Nagar Industrial area, Panki, Kanpur of Uttar Pradesh.

The break-up of the land has been presented in Table 2.15 and layout plan of the Plant site and CPP has been presented in Figures 2.9 and 2.10 respectively.

Table 2.15 : Area Break-up

Particular Area ( Acres) Ammonia –Urea Plant 151.4387 CPP 11 Green belt 81 Total 243.4387



Figure 2.9 : Plant Layout



Figure 2.10 : CPP Layout



The existing infrastructure shall be upgraded to cater to the requirements of the proposed expansion project where ever necessary.

Existing Plant Water Reservoir

Existing Greenbelt



Aerial View of the Existing Plant

Figure 2.11 : Pictures of the Existing Plant

2.6.3. Power

KFCL is proposing expansion of Ammonia – Fertilizer Complex to 1800/3033 capacity and the maximum estimated demand of power is approximately 90 MW connecting load / average 78 MW operational loads. However existing captive power plant of 12 MW capacity meets a smaller amount of requirement. Hence it is proposed to dismantle the existing Captive Power Plant of 12 MW and setting up a 95 MW Coal based Captive Power Plant having configuration of (1x60 MW + 1x35 MW) based on Indian / Imported coal to meet the power requirement.

2.6.4. Water

Water requirement for Expanded Plant is around ~ 21200 m3/day including 400 m3/day for domestic purpose. The total water consumption after proposed expansion project will be therefore 21600 m3/day. The total fresh water in plant consumption has been reduced due to recycle of 3725 m3/day treated effluents and recycle of treated domestic effluents from STP for dust suppression and Green belt development. The water will be drawn from existing source i.e. Lower Ganga canal. Necessary approval / clearance from UP Government is attached.

Letter from Govt. of UP (Jt. Secretary) for restoration of water supply from Lower Ganges Canal, Kanpur is enclosed as an attachment in Annexure-III.

Table 2.16 : Water Consumption

S. No. Water Consumption Particulars Quantity (m3/day)

1 Fertilizer Plant & Captive Power Plant (existing) 15168 2 Domestic Consumption 400 3 Proposed Captive Power Plant 1500 4 Proposed expansion 3300 Total 21600* *21600 m3/day takes into account the evaporation losses from the raw water reservoir and water treatment plant.



Figure 2.12 : Water Balance Diagram for Expanded Capacity of Fertilizer Plant



2.6.5. Fuel Requirement

Feed/Fuel natural gas for process - 2.05 MMSCMD; Source – GAIL’s existing pipeline

Fuel for CPP Boilers -Coal – 0.4 MTPA - Applied for coal linkage with Ministry of Coal / Imported Coal will be used as temporary arrangement. Fuel supply agreement is attached as Annexure XIII

2.6.6. Employment:

During construction, approximately 350 (direct and indirect) skilled workers for expansion and 400 workers for CPP expansion shall be employed.

The present manpower is approximately 1160 persons and after expansion, the manpower shall be approximately 1240 persons for the proposed expansion and another 80 workers will be hired for the CPP expansion. Unskilled and semi skilled (after training) will be hired preferably from in and around the Plant. Engineers, managerial staff and technical experts will be preferably hired from nearby area, else from other part of India.

2.7. Captive Power Plant

KFCL is proposing expansion of Ammonia – Fertilizer Complex to 1800 / 3033 capacity and the maximum estimated demand of power is approximately 90 MW connecting load / average 78 MW operational loads. However existing captive power plant of 12 MW capacity meets a smaller amount of requirement. Hence it is proposed to dismantle the existing Captive Power Plant of 12 MW and setting up a 95 MW Coal based Captive Power Plant having configuration of (1x60 MW + 1x35 MW) based on Indian / Imported coal to meet the power requirement.

Coal will be fired in high pressure boiler to produce steam which will be fed to steam turbine which will drive the generator connected rigidly to it. The power output from the generator through appropriate electrical system will be fed to the plant substation for distribution. Air-cooled condenser will be considered for condenser cooling system.

a. Installation of Air-cooled condenser reduces the precious water requirement to a large extent.

b. The ash will be collected in dry form and pneumatically conveyed to ash silos and send to nearby cement manufacturing units of Jaypee Group to make PPC.

c. Bottom ash is also to be used after decantation of water in the cement manufacturing process.

Table 2.17 : Technical Details of Captive Power Plant

S.No

DETAILS OF EQUIPMENT/

CONFIGURATION

1X60 MW

1X35 MW

A BOILER 1 Stoker/ AFBC / CFBC CFBC AFBC 2 Nos. of Boiler 1 1 3 Maximum Continuous Rating 250 TPH 170TPH 4 Superheated Steam

Pressure 110 ata 87 ata



S.No

DETAILS OF EQUIPMENT/

CONFIGURATION

1X60 MW

1X35 MW

5 Superheated steam Temperature

540±50C 515±30C

4 Feed Water inlet Temperature

2350C 2000C

5 Fuel Indian/ Imported Coal Indian/ Imported Coal B STEAM TURBINE 1 No. of Turbine 1 1 2 Type Condensing Condensing 3 Inlet Steam Pressure 105 ata 84 ata 4 Inlet steam Temperature 5350C 5100C 5 Condenser Vacuum 0.22 kg/cm2(a) 0.22kg/cm2 6 Generated Power( MCR) 60 MW at 11KV,PF=0.8 35 MW at 11KV,PF=0.8 7 Nos. of Bleed 4 [ 2:HP;1 LP;1LP] 4 [ 2:HP;1 LP;1LP] C GENERATOR 1 Type Synchronous Generator with

cooled Air circuit which cooled by Water cooled Housing(CACW)

Synchronous Generator with cooled Air circuit which

cooled by Water cooled Housing(CACW)

2 Rated Capacity 60 MW 35 MW 3 Rated Power Factor 0.8 lagging 0.8 lagging 4 Voltage 11 KV 11KV 5 Frequency 50 Hz 50Hz 6 No. of phase 3 3 7 Insulation Class F ( Temperature Rise limit to

Class B) F( Temperature Rise limit to

Class B) 8 Winding Connection Wye Wye 9 Grounding Resistance grounding Resistance grounding

10 Speed 1500 rpm 1500 rpm D AIR COOLED CONDENSER 1 Nos. of Condenser 1 1) 2 Type Forced Draft Forced Draft 3 Steam Inlet Quantity 4 Steam Inlet Pressure 0.22 kg/cm2(a) 0.22 kg/cm2(a) E COAL REQUIREMENT

(INDIAN COAL) Approx. 55 TPH Approx. 20 TPH

NOTE: The GCV of Coal have been selected as 3200 Kcal/Kg F ASH GENERATION Approx. 25 TPH Approx.10 TPH a. Fly Ash 20 TPH 8.5 TPH b. Bottom Ash 5 TPH 1.5 TPH

G MAKE-UP WATER REQUIREMENT Cooling Water 35 m3/hr 20 m3/hr DM Water 5.50 m3/hr 3 m3/hr

H EFFLUENT GENERATION 800 M3/day I MANPOWER REQUIRED 80 persons during operation phase and 400 during Erection

phase APPROX. COST OF

PROJECT Approx. 500 crores including civil construction cost but

excluding land cost L LAND AREA REQUIRED 300 MX150M excluding Fuel Handling Area



Figure 2.13 : Typical Flowsheet of Electric Power Generation Plant



2.8. Environmental Aspects

The original Ammonia plant trains of 415 TPD capacity (3 nos.) and Urea plant – 682 TPD capacities have been revamped or are undergoing revamp with incorporation of process technology, aimed at reduction of:

Use of water for cooling and process purposes

Maximization of recycling / reuse wherever possible

Reduction /elimination of generation of gaseous effluents / emissions quantity

Elimination or reduction of effluents gases such as CO2 , SO2 and NOx

Switch over to environment friendly Natural gas as fuel as against Naphtha (used earlier ) and also for reduction of CO2 level in the flue gases

Use of less excess air with incorporation of modern and technologically advanced burners for reduction of SPM levels and NOx levels.

Incorporation of process design modifications for attaining “Zero Discharge”

conditions for liquid effluents in line with the current environmental stipulations & norms.

The process technologies selected and incorporated during Revamping and Energy Saving projects for Ammonia and Urea and later for expansion of production capacities for Urea (HEC Process of Casale) and Ammonia (Casale Ammonia process ) shall ensure the same in “Letter & Spirit”.

2.8.1. Water Pollution

In this project, water would be required for industrial use, domestic & gardening purposes. Although, there will be some wastewater generation due to industrial process, the water generated from washing and scrubbing will be recycled back in the process to the extent possible.

There are two no. Hydrolyser Stripper Unit (HSU) in the existing Urea plants. Their capacity is 35 M3/hr & 60 M3/hr for decomposition of ammonical waste into Ammonia, Carbon dioxide and water vapour. These gases are recovered in the process plant to ensure zero discharge stringent measures were in place to avoid effluent generation at source. The condensate produced from the HSU is used as cooling tower make up.

KFCL has already modernized the Effluent Treatment Plant (ETP) facilities for the requirements of expanded capacity in advance. Zero liquid effluent discharge schemes are presented as below:



Figure 2.14 : Effluent Treatment Scheme



M/s Ion Exchange India Limited has recently completed work on installation of a large 180 m3/hr effluent intake capacity Effluent Treatment plant for handling effluents ,containing Ammonium salts, Ammonia, DM water regeneration liquor , Cooling towerblowdown , Boiler / Waste Heat Boiler blowdown , Oily waste , Urea contamination, ifany in a process stream etc. The abovementioned ETP plant has Reverse Osmosis (RO) membrane units for minimizing non- hazardous treated effluent quantityto be discharged after the expanded Fertilizer plant capacity comes into operation. Itis important to point out here that the liquid effluent discharged (within permissible limits& treated effluent standards) in the past was of the order of 200-275 m3/hr. However, thesame is considerably reduced now due to implementation of the scheme forseparate collection of different types of effluent streams, their segregation, and their specific treatment for achieving desired norms of treated effluent quality.

The new ETP plant will also ensure reduction in the quantity of the effluent. The maximum quantity of the effluent after implementation of expansion may not exceed estimated 180 m3/hrand the new ETP is fully capable for the same.

KFCL has also requisitioned the services of M/s Ion exchange India Limited forsetting up a new Sewage Treatment Plant before discharging the sanitary wasteout of the complex into the sewer system. The treated effluent shall totally comply with the requirements of quality specifications for the treated effluents, prescribed by CPCB / MOEF/ UPPCB etc. It is important to point out that shortcomings of old facilities have been studied indepth by KFCL Experts / Ion exchange India Ltd. Effluent collection and segregation has been redesigned for the entire complex and plans have been executed so as tominimize / optimize the effluent quantity for treatment in the ETP. Storm water drain has been rerouted/ reconfigured so as to avoid contamination of rain water with anytype of the effluent.

Effluent treatment facilities for the proposed Captive Power Plant (CPP) will be integrated with the existing ETP with suitable modifications in the hardware. A provision exists for incremental addition to the effluent processing capacity.

2.8.2. Air Pollution

The major gaseous emissions generated inside the plant are usually from Process stacks, Prilling Towers, product handling in Bagging Plant, vehicle movement etc.The SPM levels from the Prilling towers top and the Ammonia concentration from Prilling towers top and high pressure section vent is within the UPPCB norms. The new coal fired boilers were provided with Electro Static Precipitators in 1992 to reduce fly ash carry over.

It is important to mention here that during NG Switchover and Energy saving project, all burners of the Primary reformer in the three Ammonia plants have been replaced with ‘State of the Art’ Zeeco burners with low NOx level, less excess air.

NG with nearly zero sulphur content is environmental friendly fuel and also raw material.

Urea Dust: Source of urea dust is from the respective prilling towers of the urea streams A, B & C. The urea A & urea B streams, which are of older design (1967-68) have dust emission of the order of 250~300 mg/Nm3. In the urea C (installed &



commissioned in 1981) the urea dust emission is of the order of less than 50 mg/Nm3. Since the MINAS for old urea plants was fixed as 150 mg/Nm3. A condensate spray has been installed and commissioned in the dust chambers of prill towers A & B to bring down the dust emission in compliance with MINAS.

Scrubbing System installed at Prllling Tower C Top: There are 88 number of filters (size 1790 mm x 1800 mm made of polyurethane foam) operating at 40°C and 50 mm WG pressure. When the urea dust laden air passes through the filters, all the dust is absorbed in the solution. Clean air coming out of the filter is released into the atmosphere with the help of five fans provided for the purpose.

Acoustic granulators have been installed on the Prilling Towers. This has further improved the quality of emission from the Prilling Towers.

Fugitive Emission Control:

Carbamate Tank Vent Gas Scrubbing System: A scrubber has been installed in the vent line from the carbamate tank to the ammonia vent stack to prevent ammonia going into the atmosphere. In this system the vapours generated in the carbamate tank during heating the solution pass through the scrubber. Any ammonia present in the vapours / gas mixture gets absorbed while bubbling through the treated water in the tank. Treated water is fed continuously to the tank and ammonia solution from the tank is transferred to the nitrogenous effluent system.

The drainage system for transferring the nitrogenous effluent generated in urea plant from various points through covered channels to the nitrogenous effluents pit has been replaced by a close piping network. This has reduced the NH3 concentration in the working area of the plant.

In CPP these will include modern ‘State of the Art’ pollution control equipments such

as ESP, Flue gas cleaning system and blow-down liquid treatment etc.

During 1994, company installed three ambient air-monitoring stations along with one meteorological tower. The equipment was purchased from Enviro Tech. Instruments Pvt. Limited, New Delhi. These air-monitoring stations are in working conditions and shall be used for monitoring quality of air.

Existing project stack data and details are as given below

Table 2.18 : Details of Gaseous Emissions – Existing

Sr. No.

Stack Name Emission Concentration mg/Nm3

Stack Height

(m)

Flow Rate

Nm3/hr

Stack Temp (0C)

Stack gas

Velocity (m/s)

Stack Dia

at top (m)

SPM SO2 NOx No. of Stack

1. Primary Reformer

Stack 1 NA B.D.L. 38.0 03 45.7 64030 159.5 6.8 2.3 Stack 2 NA B.D.L. 23.0

Stack 3 NA B.D.L. 31.0 2. Process

Air Natural Gas Heater

Stack 1 NA B.D.L. 25.1

03 43.3 9817 130 5.3 1.04 Stack 2 NA B.D.L. 15.0

Stack 3 NA B.D.L. 16.0



Sr. No.

Stack Name Emission Concentration mg/Nm3

Stack Height

(m)

Flow Rate

Nm3/hr

Stack Temp (0C)

Stack gas

Velocity (m/s)

Stack Dia

at top (m)

SPM SO2 NOx No. of Stack

3. CPP Boiler-2 102.38 198.6 58 01 61.0 78000 157 7.3 2.3 4. Prilling

Tower (A & B)

Urea A Concentration of Urea Dust 46.33 mg/Nm3

03 70.0 310000

60

2.19 14.404*

Concentration of NH3 32.6 mg/Nm3

Urea B Concentration of Urea Dust 35.33 mg/Nm3

2.09 14.404*


5. Prilling Tower C Concentration of Urea Dust 13.6 mg/Nm3

35 2.49 13.1749*


* Equivalent Dia. (M) of Umbrella Portion of Prilling Tower

Table 2.19 : Details of Gaseous emissions after Modernisation and Expansion

Sr. No.

Stack Name Stack Height

(m)

No. of Stack

Flow Rate Nm3/hr

Stack Temp (0C)

Stack gas Velocity

(m/s)

Stack Dia

at top (m)

1. Primary Reformer

Stack 1 45.7 3 92200 159.5 9.763 2.3 Stack 2

Stack 3 2. Process Air

Natural Gas Heater

Stack 1 43.3 3 14100 130 6.8 1.04 Stack 2

Stack 3 3. CPP Boiler 1 125

2 1578783 140 20 6.5

4. CPP Boiler 2 84 124047.5 150 17 2 5. Prilling

Tower (A & B)

Urea A

70.0 3 446000 60

0.7603 14.404* Urea B 0.7603 14.404*

6. Prilling Tower C 35 0.9087 13.1749* * Equivalent Dia. (M) of Umbrella Portion of Prilling Tower

Sr. No. Stack Name

No. of Stack

Flow Rate

Nm3/hr

Stack Temp (0C)

Pollutant Conc.

mg/Nm3

SPM SOX NOX NH3

1. Primary Reformer

Stack 1

3 92200 159.5

-- -- <200 --

Stack 2 -- -- <200 --

Stack 3 -- -- <200 --

2. Process Air Natural Gas Heater

Stack 1

3 14100 130

-- -- <200 --

Stack 2 -- -- <200 --

Stack 3 -- -- <200 --



3. CPP Boiler 1 Stack 1 2

1578783 140 50 ~ 418 100 ppm

--

4. CPP Boiler 2 Stack 2 124047.5 150 50 ~ 1935 100 ppm

--

5. Prilling Tower

Urea A

3 446000 60

<50 -- -- 50

(A & B) Urea B <50 -- -- 50

6. Prilling Tower C 35 <50 -- -- 50

2.8.3. Solid/ Hazardous Waste Generation

There will be no major increase in hazardous waste generation due to the proposed expansion project that would be causing harm to the environment. Details about Hazardous Waste generation in existing plant and after expansion and its disposal are given in Table 2.20 and 2.21 below respectively.

Table 2.20 : Hazardous waste (Existing Plant)

Hazardous waste Annual Quantity (Approx)/ Annum

Proposed Disposal Mode

Used and scrap batteries 49 No’s Sold to Approved Vendors Transformer Oil 23.1 KL Sold to Approved Vendors Spent Catalyst :Ni; Cu; Zn; Mo; Fe Based 98.0 m3 Sold to Approved Vendors

Table 2.21 : Expected Hazardous waste (Expansion)

Expected Hazardous waste (Expansion Stage)

Annual Quantity (Approx)/ Annum

Proposed Disposal Mode

Used and scrap batteries 70 No’s Sold to Approved Vendors Transformer Oil 33.0 KL Sold to Approved Vendors Spent Catalyst :Ni; Cu; Zn; Mo; Fe Based

141 m3 Sold to Approved Vendors

Sludge generated from proposed ETP will be 0.79 m3/hr sludge will be disposed off through Common Hazardous Waste Treatment Storage and Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project. (UPWMP).

The important solid waste is fly ash (684 tons/day) generated from CPP. Entire fly ash generated will be used as pozzolonic material in Cement Grinding Unit (in house) for PPC production. Bottom ash also is proposed to be used after decantation of water in the cement manufacturing process.

2.8.4. Noise Pollution

The proposed expansion will not generate significant noise. Noise generating machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.

2.8.5. Fugitive emission

The main sources of fugitive emissions are Coal dust in CPP and urea product handling in urea plant and bagging plant. Adequate measures will be taken to suppress and control dust at these two places. In addition leakages from pumps,



compressors, and flange leakages will be controlled through LDAR measures. Other measures include:

i. All trucks will be transported after covering from the top. ii. Coal unloading will be done by mechanized unloading system. iii. Dust collectors will be in line with unloading hoppers. iv. Material handling in the plant will be done in closed conveyors. v. All the trucks being used for transportation of raw material and final product

shall be checked for "Pollution under Control" certificate prior to their entry to the plant premises.

vi. Storage of raw material in dedicated sheds to avoid fugitive emissions. vii. Speed of vehicles inside the factory premises will be controlled.

2.8.6. Green Belt Development


2.9. Charter on Corporate Responsibility for Environment Protection (CREP) Guidelines

KFCL will adhere to CREP points as applicable to it. The details are as given below:

Table 2.22 : CREP Compliance

No. Guidelines KFCL Compliance Waste WaterManagement

1.

Efforts will be made for conservation of water ,particularly with a target to have consumption less than 8, 12 & 15 m3/tonne of urea produced for plant based on gas, naphtha and fuel oil, respectively In case of plants using naphtha and gas both as feed stocks, water consumption target of less than 10 m3/tonne will be achieved. An action plan for this will be submitted by June 03 and targets will be achieved by March 04.

KFCL will comply to have consumption less than 8 m3 / ton of Urea.

2 Use of Arsenic for CO2 absorption in Ammonia Plant and Chromate based Chemicals for cooling systems, which is still continuing in some industries, will be phased out and replaced with non – arsenic and non- chromate systems by Dec-2003. In this regard, action plan will be submitted by Jun-2003.

We do not have Arsenic based CO2 absorber in Ammonia Plant. We have selected Non Chromate Treatment for our Cooling water system.

3 Adequate treatment for removal of oil, chromium (till non-chromate based cooling system is in place) and fluoride will be provided to meet the prescribed standards at the source (end of respective process unit) itself. Action plan will be firmed up by Jun-2003for compliance by Mar-2004.

We have provided oil skimmer for the removal of oil in waste water. Since we do not have chromate based treatment for our cooling water, no chromate removal system is required.

4 Proper and complete nitrification and de-nitrification will be ensured, whenever such process is used for effluent treatment by Sep-2003.

Not Applicable

5 Ground Water monitoring around the storage facilities and beyond the factory premises will be carried out at regular intervals particularly for pH,

Ground water monitoring around the storage facilities and beyond the factory premises are being carried



No. Guidelines KFCL Compliance fluoride. out at a regular interval of 3

months ( particularly for pH , fluoride etc. )

6 No effluent arising from process plants and associated facilities will be discharged to the storm water drain. The quality of storm water will be regularly monitored by all the industries.

We have segregation scheme for effluents generate. We have independent storm water drain around the complex which does not intermingle with any type of effluent. The quality of storm water is being monitored regularly.

7 The industries where waste water/ effluent flows through the storm water drains even during dry season will install continuous systems for monitoring the storm water quality for pH, NH3& fluoride. If required, storm water will be routed through effluent treatment before discharging. An action plan will be submitted by June 2003 and necessary action will be taken by June 2004.

We have segregation scheme for effluents generate. We have independent storm water drain around the complex which does not intermingle with any type of effluent. The quality of storm water is being monitored regularly.

Air Pollution Management 1 All the upcoming urea plants will have urea prilling

towers based on natural draft so as to minimize urea dust emissions

The new Prilling Tower in the expansion project shall comply with this requirement.

2 The existing urea plants particularly the plants having forced draft prilling towers will install appropriate systems (for example scrubber etc.) for achieving existing norms of urea dust emissions. In this regard, industries will submit action plan by Jun-2003 and completion of necessary action by June-2004.

Appropriate systems have already been installed to achieve exiting norms of Urea dust emissions.

3. The Sulphuric Acid plants having SCSA system will switch over DCDA system by Mar-2004. To meet the emission standard for SO2 as 2.0 kg/tonne of H2SO4 produced. An action plan for this will be submitted by June-2003.

Not Applicable.

4. Sulphuric Acid plants having DCDA system will improve the conversion and absorption efficiencies of the system as well as the scrubbers to achieve SO2 emission of 2.0 kg/tonne of Acid produced, in case of plants having capacity above 300tpd & 2.5 kg/tone, in case of plants having capacity up to 300tpd. An action plan will be submitted by Jun-2003and emission levels will be complied by Sep-2004.

Not Applicable

5 Stack height for Sulphuric plants will be provided as per the guidelines and on the basis of normal plant operations (and not when the scrubbers are in use) by June-2003. The scrubbed gases are to be let out at the same height of the stack.

Not Applicable

6 An action plan for providing proper dust control systems at rock phosphate grinding unit in phosphoric acid plants/single super phosphate plants, so as to achieve particulate emission levels of 150mg/nm3 will be submitted by Sep-2003 and complied with by Mar-2004.

Not Applicable

7 Particulate as well as gaseous fluoride will be monitored and adequate control systems will be installed by Jun-2004to achieve the norms on total fluoride emissions (25mg/nm3).

Not Applicable



No. Guidelines KFCL Compliance 8 Continuous SO2 emission monitoring systems will

be installed in sulphuric acid plants (having capacity 200tpd and above) by Mar-2004. Action plan for this will be submitted by Jun-2003.

Not Applicable

9 Regular monitoring of ambient air quality with regard to SO2, NOx, and PM, SO3, fluoride and acid mist will be carried out.

Ambient air quality is monitored regularly for applicable parameter like PM, SO2, NOx, & NH3. There is no source of SO3, fluoride and acid mist in the process scheme adopted in KFCL Kanpur

Solid Waste Management 1

Gypsum will be effectively managed by providing proper lining, dykes with approach roads and monitoring of ground water quality around storage facilities. Accumulated gypsum will be properly capped. In this regard, action plan will be submitted by June-2003& for compliance by Dec-2003.

Not Applicable.

2

An action plan for proper handling, storage and disposal of spent catalyst having toxic metals will be submitted by Jun-2003 and implemented by Sep-2003. The industry will also explore recovery /by- back of spent catalyst by Sep-2003.

Spent catalyst will be sold to venders approved by CPCB / MoEF/SPCB as per Hazardous Waste Rule and If there is no such approved parties are available, same shall be given to approve TSDF.

3 Carbon slurry, sulphur muck and chalk will be properly managed and disposed of in properly designed landfill either with in premises or in common facility. Action plan on this will be submitted by June-2003 & implemented by Mar-2004.

Not Applicable

4 Existing stock of chromium and arsenic bearing sludge will be properly disposed by Dec-2003. Industries will also explore recovery of chromium from the sludge. CPCB will provide guidelines for the proper disposal of the sludge.

Not Applicable

2.10. Total Cost

Capital cost of the proposed modernization & expansion of Fertilizer plant is estimated as Rs. 583 crores and Captive Power Plant is Rs. 500 crores. Capital and recurring expenditure on environmental protection measures are tabulated in Table 2.23.

Table 2.23 : Capital Cost and Recurring Expenditure on Environmental Protection

S No Activity Capital in Crores Recurring Cost/ Year (Crores)

1 ETP 9.50 0.60 2 STP 2.00 0.12 3 ESP 12.50 0.875 4 Hold Up Tank & Hydrolyser Stripper 24.00 10.00 5 Environment Monitoring Stations 2.30 0.125 6 Green Belt Development 0.12 0.006 7 Miscellaneous 0.18 0.009 Total 50.60 11.735

2.11. Energy Conservation Measures

Energy and other resouces conservation gets top priority at KFCL.



All energy conservation measures implemented are focussed on:

Reduction of heat release from the manufacturing process.

Increase the efficiency of steam system from the usable process waste heat

All process and equipment modifications in Ammonia plant aim to achieve:-

Process loop pressure reduction

Pressure drop reduction in packed columns, catalytic reactors, control valves, pipelines etc.

Improvement of mechanical efficiency in the rotating equipments

Change of internals in Columns and Reactors , minimizing flow obstructions

Avoiding waste generation and losses

Minimizing / elimination of effluent streams

Augmentation of automation & DCS.

Zero Effluent discharge and reduction in emissions

Brief details of various schemes implemented are as follows:

1. Feed Stock Changeover from Naphtha to Natural Gas

The project for change of feedstock from naphtha to Natural gas was completed and Ammonia plant was restarted in May, 2013. The advantages realized are:

Low overall energy consumption per ton of Ammonia as Feed and also as Fuel.

No Storage of highly flammable (Naphtha) at Site and therefore no emission of naphtha vapours.

No surplus CO2 venting in atmosphere due to lower hydrogen to carbon ratio in Natural Gas (as compared to Naphtha). This enables recovery of Ammonia, CO2 and Urea from waste process streams in the Urea Plant.

Reduction in emission into the atmosphere due to reduction in steam requirement for Primary reformer (due to reduced steam to carbon ratio).

2. Hydrolyser Stripper Unit

All nitrogenous effluents generated on site are collected in the Hold-up tank (Capacity–

18000 m3) and fed to Hydrolyser Stripper Unit for treatment. The Hydrolyser Stripper Unit is having effluent treatment capacity of 60m3/hr. The recovered solution is recycled back to urea plant for further processing and for making urea. The effluent coming out of stripper column contains <2 ppm NH3 and 4 ppm urea is well within the norms. This enables recovery of water from process effluent streams from the Plants and use of the same as ‘Make-up Water’.

-

3. PSA Nitrogen

The Nitrogen requirement during start up is met by cracking stored Ammonia. To save Ammonia cracking and energy thereby, a PSA Nitrogen plant of 600 Nm3/hr, 99.9 %



purity has been installed. The PSA Nitrogen plant requires only atmospheric air at intake, at a pressure of 20 Kg/cm2g.This results in saving internal energy consumption by avoiding Ammonia cracking (which was being practiced when Naphtha was used as feedstock).

4. Schemes Implemented In Ammonia Plant

Change of Primary Reformer burners: The old burners were making use of vaporized Naphtha and fuel gas with 25% excess air. These were changed with improved design Zeeco burners (27 Central burners with heat release of 2.0 Gcal/hr and 18 Lateral burners with 1.2 Gcal/hr heat release) for providing better heat flux distribution around endothermic reaction zone of the catalyst tubes. The excess air in the new Zeeco burners was only 10%.

CO2 Recovery section: Synthesis gas downstream, LT shift with 0.20% CO slip on dry basis is sent to CO2 removal section. The energy consumption in this section, based on study of relevant past operational data was assessed as 1000 Kcal/Nm3. Potential was foreseen for energy reduction through the following:

Specific overall regeneration heat reduction in the CO2 removal section by 35%.

Improving the quality of CO2 by lowering Hydrogen contents to 0.30%.

Lowering steam to carbon ratio from 3.6 to 3.0 mol/mol

The Giammarco-Vetrocoke Low-energy process was implemented for CO2 Recovery section of Ammonia plant which achieves the above stated objectives.

Ammonia Synthesis Circuit Revamp: The revamp includes change of Convertor internals, change of existing catalyst with high activity and small size catalyst, addition of new hot gas/ gas exchanger, waste heat boiler for Ammonia trains 1 & 3 only (WHB was already available in train 2), necessary piping, instrumentation, insulation etc.

The changes in the Ammonia synthesis loop for recovering extra NH3 synthesis reaction heat per pass (as compared to earlier design used in Ammonia plant based on Naphtha).

Very brief mechanical details for some major equipment are indicated below:

New Waste Heat Boiler

Specific steam production in new WHB (in Ammonia plant trains 1 & 3) per MT NH3 is 0.475 t. This new kettle type exchanger is expected to produce a max. of 9.1 ton/h of 20 bar steam with BFW preheated in existing exchanger (A3-C-401) and corresponds to a saving of 400’000 kcal/MT of ammonia as coal, in CPP boiler.

Hot Gas / gas Exchanger

Hot Gas / Gas Exchanger has been added in upstream side to Ammonia convertor (in the three Ammonia plants) and has been placed in series with the existing exchanger (C-403) so as to increase the gas inlet temperature up to 90ºC. This will increase outlet temperature of the gases from Ammonia converter and enhance heat recovery in the



new waste heat boilers (in Ammonia trains 1 & 3) and already existing WHB in Ammonia train 2.

Installation of Off Gas Recovery (OGR) Unit

In order to minimize air pollution, the Company under took construction of OGR Units for urea ‘A’ & ‘B’ streams in 1986 and both were commissioned in 1987.

Each Off Gas Recovery Unit is consisting of Off Gas Absorber, which is 750 mm dia and 8200mm height. The absorber column is packed with polypropylene rings. In the absorber, the ammonia absorption takes place from gas to water at a 400C and 0.40 Kg/cm2 pressure. The other vessels are Off Gas Condenser, Off Gas Absorber tank, Off Gas Absorber Cooler and Off Gas final Cooler. It also has Off Gas Blower, Off Gas Absorber Pump and Circulation Pump. Ammonia bearing gas streams coming from Low-pressure Absorber, Oxidiser, and Gas Condenser are combined together and pass through OGR unit. The effluent gas stream from the OGR is basically mixture of air and inert gases having ammonia concentration well below 100 ppm, which is finally discharged into the atmosphere via high vent stack.

2.12. OHS Status

Fertilizer Plant at Panki, Kanpur was established in 1969. Being a continuous Chemical Process Plant, maintaining Safety, Health and Environment is most essential. From inception, Safety standards of this Plant are well laid out, well maintained and Employees are well trained and the Plant remained nearly incident free. However due to closure of Plant from 2002 to 2013, lot of effort had put in to bring the Plant to Very High Safety Standards.

Details of Occupational, Health and Safety issues are lay down under the following heads :-

A. Safety Organization.

B. Functions of Safety Department.

C. Safety Procedures & Measures.

D. Safety Equipment.

E. Safety Training.

F. Emergency Plans.

Safety Organisation

KFCL has Fire & Safety department in the Plant headed by Manager for Safety and Manager for Fire Services. They have qualified and experienced safety Engineers and lower staff. This office functions under Plant Head.

There is a Central Safety Committee and four Safety Sub-committees one for each Department / wing like, Ammonia, Urea, Captive Power Plant and Off site facilities.

The Central committee is an apex body which coordinates the activities of all sub-Committees and decides on all matters pertaining to the entire factory. Each Committee and Sub Committee comprises of equal number of workmen and managements.



Each Sub Committee deliberates on safety aspects relating to their areas of work. Safety Engineers participates in all sub-committee meetings to provide needed assistance.

Functions of Safety Dept

A full fledged fire and safety section has been functioning since inception of the factory for looking after all safety related matters. Various activities undertaken by the section are as follows:

o Hazard Identification & Risk Assessment Safety section involves in hazard identification through surveys, inspections, audits, HAZOP studies and accident investigations. Removal of the hazards or ensuring adequate protection against the hazard is the responsibility of the plant personnel. o Monitoring of Safety Measure in the Plant. Safety Section personnel visit the Plant continuously and monitor implementation of Safety Measures and keep notifying and rectifying their observations.

o Safety Equipment. Safety section personnel ensure availability of essential respiratory protection equipments in the plants, their serviceability, maintenance, issue, usage and replacement.

o Training. Training of all new employees and periodic refresher training to all existing employees.

Safety Measures & Procedures.

Safety Equipment to handle all types of emergencies is made available in the Plant.

A. Safety Procedures. Safety procedures for undertaking repair & maintenance jobs and operations are well laid out. Every repair and maintenance job need to be undertaken only after the written permission of Safety Department. In critical case, repairs and maintenance jobs are carried out in the presence of personnel of Safety Department.

B. Safety Measures.

I. Safety deptarment initiates preventive measures to be practiced for Occupational Health and Safety aspects of workers. The Section has formulated safety codes to be followed for various types of job.

II. Copies of the same are made available to concerned persons. Posters/ Banners Signage etc highlighting safety measures to be followed are displayed at different locations.

III. Number of inbuilt safety monitoring measures have been installed in the Plant like online Ambient Air Monitoring System, Hydrant Head Monitor, Steam Lances, and Windsocks etc. Also, adequate measures have been incorporated in the plants for control of noise and vibrations from different equipments.



IV. Medical centre is located within the premises for providing the health care and for attending to injuries and for routine health monitoring of the workers. A state of art ambulance service is also available round the clock. Proper medical care facilities are also provided by the company to the employees and periodically medical check-up of the workers is being done and records maintained.

Safety Equipment.

All general and specific safety equipment is made available in the Plant for every employee, labour and contract worker. Some of the equipment is installed in the Plant like emergency showers. Some of the special equipment used in the Plant is given below:-

A. Canister gas masks are issued for using against any possible leakages of

Ammonia and Chlorine gases. These masks are used every time workers has to operate in the areas of these gases.

B. Compressed Air Breathing Apparatus are issued and used before entering any vessels or pits which have less oxygen or have toxic gases. It can be used for about 30 minutes for taking emergency actions or for rescuing trapped employees.

C. Full face air line masks are used for operating in toxic areas for long durations.

Safety Training.

Every newly inducted individual is trained on Safety by Safety section before assigning any job. Similarly all old employees are given periodic refresher training. Training courses are organized frequently to educate the workers about importance and practices of safety measures poster indication toxic substances their tolerances limits, effects and first aid measures are also displayed at important location safety showers; Wind Indicator socks are installed in all area of the plants. protective boot; helmet; Apron; Gloves; Goggles; Ear plug and Muffs etc are ready available in all plant in sufficient numbers.

2.13. CSR Activities

Kanpur fertilizers & Cement Ltd. took over this Fertilizer Plant in 2012 which was declared sick and remained closed for over 10 years from 2002 to 2012. After herculean effort and spending over Rs. 1400 Cr, all 3 units of the Plant were re-commissioned between May 2013 to May 2014. Though company has achieved 100 % production, but is yet to earn profits.

The proponent is already committed to CSR activities through its group of companies. Already the existing CSR programs implement the various activities for socio-economic development of surrounding villages near plants and mines, through Comprehensive Rural Development Program (CRDP) by Jaiprakash Sewa Sansthan (non-profit trust).

Jaiprakash Sewa Sansthan (JSS), a ‘not-for-profit Trust’ promoted by Founder

Chairman of the Jaypee Group, has been established to discharge its responsibility towards the society. The sansthan functions with a holistic approach for overall socio-economic development. Set-up in 1993 the trust aims to realize the corporate



philosophy of “Growth with a Human Face” and try to help reduce the pain & agony in

society.

Proposed Activities for Social and Inclusive Development:

The development activities needs to taken up, based on the requirement of the people in the area. The basic requirement of the community needs to be strengthened by extending health care, educational facilities and infrastructure development. Company proposes to undertake following activities for social and inclusive development of surrounding area:-

A. Education of children from disadvantaged sections of society living in the neighborhood.

B. Skill Building / Vocational training of youth who have technical aptitude for a period of 6 months to 3 years.

C. Preference to unskilled / skilled persons living in the neighborhood in casual employment till they find suitable livelihood.

D. Periodic medical Camps in the neighboring villages and offer medicines to under privileged persons.

E. Construction of Roads from neighboring villages to Main Road.

Budgetary Allocation

Based on expectations of profit from ensuing year, company proposes to spend Rs 80 lacs per during ensuing year as per the following breakdown :-

A. Health: 40 lacs Mobile Medical van services for periodic checkup of villagers Medical Camps :

A. Education/ Trainingl : Rs 25 Lacs

B. Other activities : 15 lacs

Fixing of Hand Pumps andBuild Toilets



CHAPTER 3. DESCRIPTION OF ENVIRONMENT

3.1. Introduction

Anthropogenic activities specifically related to industrial sector are expected to cause impacts on environmental quality in and around the project location. However, the intensity of environmental impacts from a specific project depends on several factors such as the type of process, fuel combustion, etc. The present study is to establish the baseline status and assess the potential impacts from the project. The Baseline environmental study has been carried out by M/s EQMS India Pvt. Ltd., during Post-monsoon Season (1st October, 2014 through 31st December, 2015).

To evaluate environmental impacts from the project, it is essential to monitor the environmental quality prevailing in the surrounding area prior to implementation of the project. The environmental status within the study zone is used for identification of significant environmental issues to be addressed in the impact assessment study. The impacts from this project on its surrounding environment are mainly regulated by the nature of pollutants, the quantities discharged to the environment, existing environmental quality, assimilative capacity of the surrounding environment and topography and terrain of the project site as well as the surrounding area.

In order to identify and establish the extent of likely impact, it is essential to assess existing environmental parameters with regards to various environmental aspects namely as follows;

3.2. State of the Environment (Regional)

3.2.1. Topography & Geology

The Kanpur Nagar district lies in middle of Uttar Pradesh State. It lies between 25°55’

& 27°-North latitude and 79°30’ & 80°35’-East longitudes. The total geographical area of the district is 3155-sq.km with three (03) numbers of Tehsils and the numbers of blocks viz. Kalyanpur, Bidhnu, Sarsaul, Bilahaur, Kakwan, Sivrajpur, Chaubepur, Patara, Bhitrgaon and Ghatampur. The major part of the area is almost a flat plain with some minor undulations. The river Ganga and Yamuna with their tributaries form the drainage system as Dendritic Type.

Physiography

Kanpur metropolis forms a part of Ganga sub -basin in the Central Indo- Gangatic Plain. It exhibits more or less a flat topography with the master slope from north-west to south-east. The average elevation of land surface is 125 m.a.m.s.l. The area is drained by the river Gange and its tributary Pandu. The area of city has been geomorphologically divided into two units.

(i) Low lands or Younger Alluvial Plain &

(ii) Up lands or Older Alluvial Plain.

The Low land or Younger Alluvial Plain has been identified as flat to gently sloping and slightly undulating terrain of large areal extent, formed by river deposition, and is limited along river Ganga with the breadth not exceeding 5 km. The sediments comprise of Recent unconsolidated alluvial material of varying lithology. The fluvial



land-forms such as palaeochannel, meander scar and oxbow lakes are common features.

Further west of Younger Alluvial Plain is the area of stable upland which has been produced by extensive deposition of older alluvium comprising of coarse to fine sand, silt and clay. The patches of salt encrustations have been reported in the area around Panki and Chakeri.

Geology of the Region

The project region lies in Indo-Gangetic Alluvial plain. The deposition of this alluvial commenced after the final phases of the shiwaliks and has continued all through the Pleistocene up to the present. The Gangetic alluvial plain was formed as peripheral foreland basin consequent to the collision tectonic process of the Himalaya and still under the influence of compressional stress.

The district lies in the Ganga basin which is formed of alluvium of the early quaternary period. In the district, no hard or consolidated rock exposures are encountered. The main constituents (sand, silt and clay) of alluvium occur in variable proportions in different sections. The mineral products of the district are saline earth from which salt petre & salt are derived and limestone conglomerates.

Geomorphology of the Study Area

The Kanpur Nagar district is part of Indo Gangetic Plain. The clay, silt, gravel and sands of different grades are main sedimentary constituents. The generalized geological succession is as follows (Table 3.1).

Table 3.1 : Geological Succession in Kanpur Nagar District

Period Age Land Form (Geomorphology)

Rock Type

Quaternary Upper Pleistocene to Recent

Newer Alluvium Fine Sand and Clays

Lower Pleistocene to Upper Pleistocene

Older Alluvium Sand of different grades and clay mixed with Kankar

………………………Unconformity………………. Bundelkhand Granite (Archean), Vindhyan Sandstone(Proterozoic) (Source: Compilation of Stratigraphic Lexicon of Quaternary Sediments of Indo-Gangetic Alluvium, Geological Survey of India, Northern Region, Lucknow, 1996-97)

3.2.2. Climate and Rainfall

The average annual rainfall in the district is 821.9 mm. The climate is sub humid and it is characterized by hot summer and general dryness except in the south west monsoon. About 90% of rainfall takes place from third week of June to September. During monsoon surplus water is available to deep percolation to ground water. May and early part of June constitute the hottest part of the year. The mean daily maximum temperature in May is 41.7°C. The mean daily minimum temperature is 27.2°C and maximum temperature rises up to 45°C or over. With the onset of the monsoon in June the day temperature drops down appreciably. The January is the coldest month with mean daily maximum temperature at 22.8°C and mean daily minimum temperature at



8.6°C. The mean monthly maximum temperature is 32.2°C and mean monthly minimum temperature is 19.5°C. During monsoon season the relative humidity is high and in summer season, humidity is less. The mean monthly morning relative humidity is 69% and mean monthly relative humidity is 50%. The winds are generally light with some strength in force during summer and early monsoon season. The mean wind velocity is 9.6 kmph. The potential Evapotranspiration is 1660.9 mm.

Table 3.2 : Climate Data for Kanpur

Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year

Record high °C (°F)

28 (82)

34 (93)

41 (106)

44 (111)

46 (115)

48 (118)

41 (106)

38 (100)

38 (100)

36 (97)

32 (90)

28 (82)

48 (118)

Average high °C (°F)

18 (64)

24 (75)

30 (86)

38 (100)

40 (104)

42 (108)

36 (97)

34 (93)

32 (90)

30 (86)

25 (77)

20 (68)

33 (91)

Average low °C (°F)

6 (43)

12 (54)

14 (57)

20 (68)

22 (72)

25 (77)

26 (79)

23 (73)

22 (72)

16 (61)

12 (54)

7 (45)

15 (59)

Record low °C (°F)

−3 (27)

6 (43)

7 (45)

15 (59)

17 (63)

20 (68)

21 (70)

18 (64)

19 (66)

15 (59)

9 (48)

0 (32)

−3 (27)

Precipitation mm

(inches)

23 (0.91)

16 (0.63)

9 (0.35)

5 (0.2)

6 (0.24)

68 (2.68)

208 (8.19)

286 (11.26)

202 (7.95)

43 (1.69)

7 (0.28)

8 (0.31)

881 (34.69)

Source: IMD

3.2.3. Seismic Consideration

According to the Vulnerability Atlas of India, Kanpur (Urban) district lies in moderate earthquake risk zone (Zone III). It may experience damage of MSK-VII category. Though the earthquake risk for the district is moderate, most of the houses in Kanpur have not incorporated building by-laws, and do not have adequate structural strength to withstand even a moderate earthquake. So the earthquake will adversely affect a large number of houses and business. It will disrupt the normal urban life and traffic for a considerable length, with a serious impact on business and livelihood. According to Global Seismic Hazard Assessment Program (GSHAP) data, the state of Uttar Pradesh falls in a region of moderate to high seismic hazard. The seismic hazard zone of Uttar Pradesh is given in Figure 3.1.



Figure 3.1 : Seismic Hazard Zone of Uttar Pradesh

(Source-http://asc-india.org/maps/hazard/haz-uttar-pradesh.gif)

3.2.4. Hydrogeology

The Kanpur Nagar District is part of Indo Gangetic Plain. The silt, gravel, and sands of different grades are main water bearing formations. The ground water occurs under unconfined condition in phreatic zones and under confined condition in deeper zones. The sedimentological constitution of the subsurface granular zones shows remarkable variation in the depth and the nature of occurrence in north and southern part of the district. In southern part specially along Yamuna river, feldspar-quartz, Jaspar sands and gravel (Morum) are the main constituents of the granular zones that occurs comparatively at shallow levels i.e. 24 to 57-mbgl whereas in the northern parts along the Ganga river, these reworked sedimentary formations are existing at deeper levels i.e. 265 to 310-mbgl. The provenance of these sedimentary formations is mainly Bundelkhand Granite Complex of Archean age and Vindhyan Sandstone of Puranas. In the northern part the silt and clay sediments forming thin lensoid beds are frequently occurring in depth.



Depth to Water Level

The prevailing hydro geological conditions and geomorphology controls the water table configuration. The water level measured four times in a year in C.G.W.B. National Hydrograph Network Stations in Kanpur Nagar district. There are eleven hydrograph stations in Kanpur Nagar district. The pre-monsoon period (year 2007) depth to water level varies from 2.20 to 27.13-mbgl whereas in post-monsoon period it varies from 2.08 to 27.13-mbgl. The depth to water level is shallow along canal command area while it is deeper along river Yamuna.

Water Level Fluctuation

In year the water level fluctuation varies from 0.0 to 1.70-m.

Long Term Water Level Trend

The long term water level trend for last ten years (1998-2007) shows annual declining trend in 14 numbers of hydrograph stations. It varies from 10-cm/y to 88-cm/y. Only one hydrograph station Motipura showing annual rising trend (11cm/y). In pre-monsoon period three hydrograph stations shows rising trend & these are Naramau (07-cm/y), Motipura (19 cm/y) and Chubepur (43-cm/y) and rest are showing declining trend which varies from 4 to 63-cm/y. In post monsoon period except Motipura all hydrograph stations are showing declining trend and it varies from 4 to 84-cm/y.

Ground Water in Study Area

The main source of ground water recharge in the study area is rain water which infiltrates into the ground through various litho-logical horizons present in the study area. Secondary source of recharge is due to seepages of surface irrigation water applied to agricultural fields through the various distributaries of Ganga Canal.

The movement of ground water depends upon the porosity and permeability of soil and local topography of the area whereas the direction of movement depends upon the hydrolic gradient. The maximum infiltration of rain water occurs in porous and permeable zone of geological formation where the topography is almost plain.

Aquifer Parameters & Specific Yields

In the district shallow aquifer in the depth range of 20 to 96-mbgl has been 'tapped' or utilized through cavity and strainer wells. The specific yield of unconfined aquifer is 12 %. The deep drilling down to basement by C.G.W.B. (503-mbgl at Panki) has revealed the existence of potential granular zones in the depth range of 250 to 450-mbgl. The trans-missivity of deeper aquifer varies between 1705 to 6000-sq.m per day.

Status of Water Table in the District:

The general ground water flow direction is from northwest to southeast similar to flow of river. The direction of flow is mainly governed by the topography and hydrological characteristics of different rock formation.

Hydrology

Introduction

Water resources in the study area can be broadly classified into two categories:



Surface Water Bodies: Rivers, stream, canal, etc. which include the River Ganga.

Ground Water Bodies: It includes shallow aquifers as well as deep aquifers. The only source of recharging for surface water and ground water resources is precipitation (rainfall). The study area receives maximum rainfall during southwest monsoon which extends from June to September.

Ground Water Resources:

The block wise estimation of Ground Water Resources has been done as per GEC-1997 Methodology. As on 31.3.2004 the Net Annual Ground Water Availability of the district is 926.61-MCM. The existing Gross Ground Water Draft is 623.93-MCM. The stage of ground water development is 67.33% (Table-5). The Net Ground Water Availability for future irrigation development is 286.28-MCM. The Shivrajpur Block is in semi critical category. All other blocks are in safe category.

Status of Ground Water Development

The stage of ground water development in the district is 67.33%. The maximum development is in the Sivrajpur block (86%) and minimum is in Ghatampur Block (50.19%). In the district cavity and strainer type bore well are feasible for irrigation. The depth of bore well varies from 20 to 96-mbgl. The average depth of this structure is 32-mbgl. Due to reasonable construction and maintenance cost, easy feasibility and private ownership these structures are popular in the area for irrigation. Along the course of Yamuna river in southern most part of the district comparatively deeper strainer well of 90 to 96-mbgl tapping mostly medium sand and 'Murom' are also common. These have discharge of 1075 to 1500-lpm. In the rest part of the district shallow cavity type bore well of 20 to 53-mbgl are common in which fine to medium sand is tapped. The discharge is up to 600-lpm.

The depth of state irrigation tube well varies between 150 to 250-mbgl. The discharge is up to 2500-lpm. There are 54160-bore well and 293 state tube well in the district. The irrigation by ground water is 96636-ha. The irrigation by bore wells and state tube wells are 91611-ha & 5026-ha respectively. The maximum numbers of state tube wells are in Ghatampur block.

The C.G.W.B. has constructed deep exploratory tube wells down to 500-meter in the district for irrigation and drinking purpose. In these deep tube wells suitable granular zones are tapped between 250-400-mbgl with the yield from 2500-3900-lpm.

At present 74% of irrigation is through ground water. The net availability of ground water for future development is 28628-ha.meter. If 50-cm column water required for crop an additional 57,256-ha can be irrigated by utilizing (developing) above resources. As per land use pattern (2005-06) Net sown area is 185667-ha and Net irrigated area is 130333-ha. Hence 55,334-ha area is without irrigation facility. This can be fulfilled by utilizing net ground water available for future development.

Drainage Pattern

Improper management of drainage system in the district creates water logging problems. The existing system of storm water drainage comprises 23 nalas, which carry most of the storm water to river Ganga and Pandu. These drains have also



added to the pollution level in the city when the solid waste flushed away with the rainwater. The FPR suggested that the existing system of drainage is lacking in its utility because most of the dirt, debris, dung and are thrown in these drains, which blocks the drainage system in the city. For this project the responsibilities are assigned to Jal Nigam and Awas Vikas and KNN for repair and improvement in the drainage system.

The district is drained by the River Ganges & Yamuna. The area falls in the Doaba belt of the River Ganga and Yamuna. The Lower Ganga Canal passes through the district to the southwest and the River Ganges to the East. There are several other small nallahs and channels of the canal systems which drain the area and fulfill the water requirement for agriculture as well as potable. In the Doaba region the flow of water is from northwest to southeast. The vegetation in the study area is of dry deciduous type. Figure 3.2 presents the canal and river system map of the District.

Figure 3.2 : Canal and River System Map of Kanpur Nagar

(Source-http://www.mapsofindia.com/maps/uttarpradesh/rivers/kanpurnagar-river-map.jpg)

3.2.5. Land Use:

http://www.mapsofindia.com/maps/uttarpradesh/rivers/kanpurnagar-river-map.jpg



The basic purpose of land use pattern and classification in an EIA study is to identify the manner in which different parts of land in an area are being utilized or not utilized. Remote sensing data provides reliable accurate baseline information for land use mapping as it is a rapid method of acquiring up-to-date information of over a large geological area.

A systematic digital image interpretation approach was used to delineate the land use classes. The present study was focused on demarcating boundaries of different land use/land cover units from an analysis of different types of colour registrations of land use/land cover units from satellite imagery. An area around the 10 Km radius of the proposed project was determined by using buffer operation of the GIS software. GIS software (ARC GIS 9.3) was used for the study. The digital image processing is done in Image processing software ERDAS 9.1. Multi-spectral supervised classification using the maximum likelihood algorithm followed by smoothing and editing of pixels was performed in that platform. Satellite data which is used to make Land use and Land cover of the area is LISS III (23.5 meters) and Land sat 4-5 Thematic mapper (30 meters resolution). The area contains different types of land cover and land use:-

Agricultural land Settlement Open grass & shrub land Vegetation Water body Barren land

Land use / land cover map of 10 km study area has been show in Figure 3.4. The total agricultural land represents around 52% of from the whole land cover. The settlement surrounding the proposed project area covers about 29% of the area. Open grass and shrub land covers about 8% of the total area. Vegetation and water bodies cover only 6% and 2.4% of the total area. Barren land is covering 2% of the study area. Table 3.3 and Figure 3.3 shows land use categories with the respective percentages in the study area.

Table 3.3 : Land use category in the Study Area

Land use/ land over classes Area (Sq km) Area in Percentage Agricultural land 163.5 51.99%

Water body 7.58 2.41% Open grass and shrub land 26.21 8.33%

Settlement 90.83 28.88% Vegetation 19.37 6.16% Barren land 6.99 2.22%

Total 314.48 100



Figure 3.3 : Land use statistics of the proposed site

52%

3%

8%

29%

6% 2%

Landuse Class

Agricultural land Water body

Open grass and scrub land Settlement

Vegetation Barren land



Figure 3.4 : Land use/ Land cover Map of the proposed site

(Source: glovis.usgs.gov)



3.2.6. Micro-meteorology

Meteorological study exerts a critical influence on air quality as it is an important factor in governing the ambient air quality. The meteorological data recorded during the study period is used for interpretation of the baseline information as well as input for air quality simulation models. Meteorological data was collected for the post-monsoon months of October through December, 2014.

Utmost care was taken to ensure that the stations were free from obstructions to free flow of winds. Wind speed, wind direction, temperature and relative humidity data was collected daily on an hourly basis during the study period. The summary of the climatic conditions collected during the study period are tabulated in Table 3.4.

Table 3.4 : Summary of Climatic Condition at the Site

Month Parameters Temp (°C) RH (%) October Max 35 100

Min 16 33 Mean 25.80 73.48

November Max 32 100 Min 9 25 Mean 19.35 69.92

December Max 29 100 Min 3 24 Mean 15.73 72.61

(Source: Field Survey)

The wind rose diagram for the study area is shown in Figure 3.5 and the wind class frequency distribution is shown in Figure 3.6. The analysis of the average wind pattern shows predominant winds from W and NW with wind frequencies of 19.85% and 11.15%, respectively. Calm conditions were prevailed for 29.86% of the total time. Average wind speed was observed as 1.26 m/s during the study period.



Figure 3.5 : Wind Rose (Post-monsoon Season)

(Source: Interpretation of Meteorological Data)



Figure 3.6 : Wind Class Frequency Distribution (Post-monsoon Season)

(Source: Interpretation of Meteorological Data)

3.3. Baseline Environment

The environmental status of the local vicinity at 10 km radial zone around the project site has been studied during the post monsoon season and the details are given Table 3.5 and Figure 3.7 in the following sub sections;



Figure 3.7 : Sampling Locations in the Study Area

(Source: Google Earth & SOI Toposheet)



Table 3.5 : Details of Sampling Locations

Sample Code Location Distance (Km) Direction Air

A01 Near the Project Site 0 - A02 Dabauli 2.90 E A03 Panki 2.4 NW A04 Gujaini 2.73 SE A05 Singhpur Khather 4 S A06 Bhauti Khera 5 W

Noise N01 Project Site 0 - N02 Dabauli 2.90 E N03 Panki 2.4 NW N04 Gujaini 2.73 SE N05 Singhpur Khather 4 S N06 Bhauti Khera 5 W

Ground Water GW1 Project Site 0 - GW2 Dabauli 2.90 E GW3 Panki 2.4 NW GW4 Cheetipur 3.2 SW GW5 Singhpur Khather 4 S GW6 Bhauti Khera 5 W

Surface Water SW1 Ganga River 9 NE SW2 Pond Near Project

Site 0.3 N

SW3 Pandu River 1.7 SW Soil

S01 Project Site 0 - S02 Dabauli 2.90 E S03 Panki 2.4 NW S04 Cheetipur 3.2 SW S05 Singhpur Khather 4 S S06 Bhauti Khera 5 W

3.3.2. Air Environment

Preliminary air sampling and monitoring was carried out in post monsoon season to establish air quality of the study area. The project site situated at industrial area so it surrounded with various industry & situated near NH-2 so basic source of air pollution is emission from industries, vehicular emission, dust from the unpaved tracks and windblown from the open agricultural land during harvesting. Sampling locations were located based upon climatological wind pattern.

Based on the above, six (6) sampling locations were selected given in Table 3.5.



3.3.2.1 Parameters Monitored and Methods used

The sampling and monitoring has been carried out in post Monsoon (October – December, 2014). Major pollutants, namely particulate matter (PM10, PM2.5), Sulphur Dioxide (SO2), Nitrogen Oxides (NOx), were measured at the monitoring stations as well as Carbon Monoxide (CO), HC & VOCs also monitored. The samples were collected in accordance with the guidelines issued by Central Pollution Control Board (CPCB) under National Ambient Air Quality Standards (NAAQS) as provided in Table 3.7. Monitoring photographs and baseline monitoring results from the Laboratory is attached as Annexure IV.

3.3.2.2 Results of Ambient Air Monitoring

The average of the analytical results of air quality monitoring in the above mentioned are compared with National Ambient Air Quality Standards (NAAQS). The maximum, minimum and average concentrations of the air pollutants are given Table 3.6. Graphical representation of the results is shown in Figure 3.8 through Figure 3.11. The monitoring was carried out twice a week at each location for one complete season (Post Monsoon Season).



Table 3.6 : Ambient Air Quality Status around the Project Site in 10-km Radius

Location

Parameters

PM10 (µg/m³)

PM₂.₅ (µg/m³)

SO2 (µg/m³)

NOx (µg/m³)

CO (µg/m³)

NH3 (µg/m³)

HC (µg/m³) VOC (µg/m³)

Methane Non- methane

Near the

Project Site

Max 280 180 14.8 35.5 2.51 61.0 <0.1 <0.1 <0.1

Min 175 114 8.3 18.3 1.30 35.0 <0.1 <0.1 <0.1

Avg 217 142 12.0 26.1 1.95 46.7 <0.1 <0.1 <0.1

98 Percentile 262 170 14.8 35.2 2.47 59.6 <0.1 <0.1 <0.1

Daboli

Max 210 92 17.0 32.0 0.89 34.0 <0.1 <0.1 <0.1

Min 144 56 10.0 20.0 0.47 16.0 <0.1 <0.1 <0.1

Avg 175 74 13.6 27.3 0.63 24.4 <0.1 <0.1 <0.1

98 Percentile 209 89 16.5 32.0 0.86 33.1 <0.1 <0.1 <0.1

Gujeni

Max 242 112 15.0 23.0 1.07 36.0 <0.1 <0.1 <0.1

Min 174 70 9.0 16.0 0.61 22.0 <0.1 <0.1 <0.1

Avg 215 88 12.7 19.6 0.85 27.2 <0.1 <0.1 <0.1

98 Percentile 240 108 15.0 23.0 1.04 34.2 <0.1 <0.1 <0.1

Singpur Kathar

Max 105 46 16.0 31.0 1.14 30.0 <0.1 <0.1 <0.1

Min 65 29 8.0 21.0 0.73 20.0 <0.1 <0.1 <0.1

Avg 86 41 12.3 25.7 0.91 25.7 <0.1 <0.1 <0.1

98 Percentile 104 46 16.0 30.1 1.13 30.0 <0.1 <0.1 <0.1

Panki

Max 236 104 17.0 34.0 0.93 30.0 <0.1 <0.1 <0.1

Min 144 68 9.0 20.0 0.43 18.0 <0.1 <0.1 <0.1

Avg 187 82 12.3 26.3 0.61 23.8 <0.1 <0.1 <0.1

98 Percentile 230 100 16.5 34.0 0.87 30.0 <0.1 <0.1 <0.1

Bhauti Khera

Max 165 58 17.0 34.0 1.07 28.0 <0.1 <0.1 <0.1

Min 122 40 9.0 21.0 0.64 16.0 <0.1 <0.1 <0.1

Avg 139 47 13.3 26.6 0.83 21.9 <0.1 <0.1 <0.1

98 Percentile 159 57 16.5 33.5 1.04 28.0 <0.1 <0.1 <0.1

(Source: Field Study)



Table 3.7 : National Ambient Air Quality Standards (CPCB), 2009

S. No.

Pollutant TTime

Weighted average

Concentration in Ambient Air Industrial,

Residential, Rural and

Other Area

Ecologically sensitive area

(notified by Central Govt.)

Methods of Measurement

1 Sulphur Dioxide

(SO2), μg/m3

Annual* 50 20 •Improved West and Gaeke Method •Ultraviolet

Fluorescence

24 hours** 80 80

2 Nitrogen Dioxide

(NO2), μg/m3

Annual* 40 30 •Modified Jacob & Hochheiser •Chemiluminescence

24 hours** 80 80

3 Particulate Matter (size less than 10 μm) or PM10

μg/m3

Annual* 60 60 •Gravimetric •TOEM •Beta attenuation

24 hours** 100 100

4 Particulate Matter (size less than 2.5 microns) or PM2.5 μg/m

3

Annual* 40 40 •Gravimetric •TOEM •Beta attenuation

24 hours** 60 60

5 Ozone (O3) μg/m

3 8 hours ** 100 100 •UV photometric

•Chemiluminescence •Chemical method

1 hour ** 180 180

6 Carbon Monoxide

(CO) mg/m3

8 hours** 2 2 Non Dispersive Infra RED (NDIR) Spectroscopy

1 hour** 4 4

7 Ammonia (NH3) μg/m

3 Annual* 100 100 •Chemiluminescence

•Indophenol blue method

24 hours** 400 400

* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at uniform interval. ** 24 hourly/ 8 hourly values should be met 98% of the time in a year. However, 2% of the time, it may exceed but not on two conservative days.

3.3.2.3 Interpretation of result

PM2.5 Concentration (Post-monsoon Season): PM2.5 level was found ranging from 41 to 142 µg/m3. The highest PM2.5 levels were found near the Project site (142 µg/m3) while the lowest levels was found at village Singpur Kathar (41 µg/m3). The average PM2.5 levels are within the NAAQS levels for industrial, Residential, Rural and other Areas (60 µg/m3) at villages Singpur Kathar and Bhauti Khera.



Figure 3.8 : Statistical Comparison of PM2.5 Concentration (Post-monsoon Season)

PM10 Concentration (Post-monsoon Season): PM10 level were found ranging from 86 to 217 µg/m3. The highest PM10 levels were found near the Project site (217 µg/m3) while the lowest levels was found at village Singpur Kathar (86 µg/m3). The PM10 in the study area is contributed mainly by industrial emissions, vehicular emissions, re-suspected dust from paved/unpaved roads and open areas as well as from industrial activities. The average PM10 levels are within the NAAQS levels for industrial, Residential, Rural and other Areas (100 µg/m3) at village Singpur Kathar only.

0

20

40

60

80

100

120

140

160

Near the Project

Site

Daboli Gujeni Singpur Kathar

Panki Bhauti Khera

PM2.5

NAAQS

0

50

100

150

200

250

Near the Project

Site


Panki Bhauti Khera

PM10

NAAQS



Figure 3.9 : Statistical Comparison of PM10 Concentration (Post-monsoon Season)

SO2 Concentration (Post Monsoon Season): The highest level of SO2 was found at Project Vill. Daboli (13.6 µg/m3) whereas lowest level was found at Project site (12.0 µg/m3). The SO2 level of the study area is well under the NAAQS Standard of 80 µg/m3. The main source of SO2 emission is vehicular.

Figure 3.10 : Statistical Comparison of SO2 Concentration (Post-monsoon Season)

NOx Concentration (Post Monsoon Season): The highest level of NOx was found at Vill. Daboli (27.3 µg/m3) whereas lowest level was found at village Gujeni (19.6 µg/m3). The NOx level of the study area is well under the NAAQS standard of 80µg/m3. The main source of NOx emission is industrial & vehicular.

0

10

20

30

40

50

60

70

80

Project Site


Panki Bhauti Khera

SOx

NAAQS

0

10

20

30

40

50

60

70

80

Project Site


Panki Bhauti Khera

Nox

NAAQS



Figure 3.11 : Statistical Comparison of NOx Concentration (Post-monsoon Season)

3.3.3. Noise Environment

Noise after a certain level can have a very disturbing effect on the people and animals exposed to it. Hence, it is important to assess the present noise quality of the area in order to predict the potential impact of future noise levels due to the proposed project.

Noise measurements were done using Cygnet Sound Level Meter Model 2031A. Monitoring was carried out both in the day and night time and accordingly Leq day and night were derived from the monitored data including the peak values.

3.3.3.1 Noise level Results

Noise readings were taken at five different locations within the study area near-by sen-sitive locations. The average noise level are presented vide Table 3.8.

Table 3.8 : Ambient Noise Levels in the Study Area, dB (A)

Locations Location

Code N1 N2 N3 N4 N5 N6 Location

Name Project

Site Daboli Gujeni Bhoti Khera Panki Singpur

Kathar Noise Level (dBA)

Time Hourly Leq Day 6.00 47.4 52.0 45.5 47.2 47.3 43.6

7 52.8 53.4 48.2 51.4 49.8 53.2 8 56.4 56.5 54.3 50.5 51.4 56.8 9 59.5 59.9 56.7 55.1 56.6 50.2

10 57.7 56.6 55.4 53.5 59.5 46.6 11 50.3 54.9 50.8 51.4 51.9 43.5 12 47.8 48.8 42.1 48.2 46.3 45.4 13 47.5 41.5 45.2 51.6 49.2 48.5 14 46.3 42.0 46.5 48.8 44.4 46.2 15 52.3 40.1 48.2 42.2 51.6 48.9 16 47.8 46.4 50.6 46.1 47.8 50.3 17 49.2 49.9 49.3 52.2 53.3 53.4 18 52.6 52.6 50.8 54.1 56.9 49.6 19 52.3 53.5 47.7 51.0 55.6 48.3 20 50.6 51.8 43.1 53.4 52.4 46.1 21 48.8 50.0 42.3 51.6 51.8 45.8

Night 22.00 46.4 46.7 46.7 47.7 46.0 42.6 23 43.5 42.3 44.2 43.4 42.4 41.8



Locations Location

Code N1 N2 N3 N4 N5 N6 Location

Name Project

Site Daboli Gujeni Bhoti Khera Panki Singpur

Kathar Noise Level (dBA)

24 38.1 35.8 39.4 36.6 38.5 41.2 1 33.3 30.5 37.4 34.8 34.4 40.5 2 33.6 28.3 35.7 35.7 32.8 39.8 3 35.3 32.7 39.3 36.9 33.6 39.6 4 39.0 37.6 43.2 42.0 40.5 40.5 5 43.2 40.9 45.3 44.2 43.7 40.3

Leq Day 53.1 53.4 50.7 51.5 53.4 50.2 Leq Night 41.3 40.5 42.9 42.4 41.2 40.9

(Source: Noise Analysis during study period by EQMS Team)

Figure 3.12 : Statistical Comparison of Ambient Noise

0

10

20

30

40

50

60

Project Site Daboli Gujeni Bhoti Khera Panki Singpur Kathar

Leq Day Leq Day Standard Leq Night Leq Night Standard



Table 3.9 : Standard of Ambient Noise Level as per CPCB Guidelines

Area Code

Category of Area /Zone

Limits in dB (A) Leq Day Time

From 6.00 am to 10.00 pm

Night Time From 10.00 pm. to 6.00

am A Industrial area 75 70 B Commercial area 65 55 C Residential area 55 45 D Silence Zone 50 40

3.3.3.2 Damage Risk Criteria for Hearing Loss, Occupational Safety & Health Administration (OSHA) Regulations

Table 3.10 : Damage Risk Criteria for hearing loss, Occupational Safety & Health Administration (OSHA) regulations

Max allowable Exposure duration hour per day Sound pressure level dB(A) 8 90 4 95 3 97 2 100

1.5 102 1 105

0.75 107 0.5 110

0.25 115 No exposure in excess of 115 dB(A) is

permitted.

Observation: The noise level at all residential locations were found lower than the ambient noise standards. At the project site it was found to be lower than the ambient noise standards.

3.3.4. Water Environment

The water resources, both surface and ground water plays an important role in the development of an area. Likewise, the water resources of the area have been studied to establish the current status of water availability and quality in the area.

3.3.4.1 Ground Water Environment

Ground water is used for almost all purposes. Generally, every village has open wells and hand pumps to draw water for domestic uses. Ground water from dug wells, tube wells and hand pumps cater to the drinking water needs of the villages in the region.



3.3.4.1.1 Parameters Monitored and Methods used

The quality of ground water was assessed by taking samples and analysed as per CPCB guidelines. The methodology followed for sampling and analysis is as follows

Table 3.11 : Monitoring Methodology of Water

S. No Parameters Methodology Minimum

Detection Limit 1 pH APHA, Edition 21 (4500 H+ B), pH meter 0.01

2 Temperature APHA Edition 21 (2130 B), Standard Thermometer

1OC

3 Turbidity APHA Edition 21 (2130 B), Nephelophotometric 0.1 NTU

4 TDS APHA Edition 21 (2540 C) Gravimetric 4 mg/l

5 Electrical conductivity APHA Edition 21 (2510 B) Conductivity Meter 1µmoh/cm

6 COD APHA Edition 21 (5220 B), Tetrameter open reflux

4 mg/l

7 BOD 3 days IS 3025 part 44, 1993 Iodometric 5 days APHA edition 21 (5210 B) Iodometric

1 mg/l

8 Chlorides APHA Edition 21 (4500 Cr B) Titrametric 5 mg/l

9 Sulphates APHA Edition 21 (4500 SO2 4 E) Turbid metric 0.1 mg/l

10 Total Hardness APHA Edition 21 (2340 C) Titrametric (EDTA Method)

10 mg/l

11 Ca++ Hardness EDTA titrimetric method (APHA, 1985: pp 199)

-

12 Mg++ Hardness Magnesium by calculation (APHA, 1985: pp 228

-

13 Total Alkalinity APHA Edition 21 (2320 B) Titrametric 10 mg/l

14 Nitrate APHA Edition 16 (418 D) Colorimetric 0.08 mg/l

15 Fluoride APHA Edition 21 (4500 F- D) Colorimetric 0.005 mg/l

16 Sodium APHA Edition 21 (3500 Na- B) Flame Emission Photometric

1 mg/l

17 Potassium APHA Edition 21 (3500 K- B) Flame Emission Photometric

1 mg/l

18 Calcium APHA Edition 21 (3500 Ca- B) Titrametric (EDTA Method)

1 mg/l

19 Magnesium APHA Edition 21 (3500 Mg- B), by difference 2 mg/l

20 Salinity APHA Edition 21 (2520 B), Electrical conductivity Method

-

21 Total Nitrogen APHA. 1975. Method 208D -

22 Total Phosphorous APHA method 4500-P B. -

23 Dissolved Oxygen APHA-1998(pp: 4-129). 5 -

24 Ammonical Nitrogen APHA Edition 21 (4500 NH3) Colorimetric 0.01 mg/l

25 SAR Flame photometric and EDTA Method -

a Arsenic (as As) APHA Edition 21 (3500 As- B) Colorimetric 0.01 mg/l

b Cadmium (as Cd) APHA Edition 21 (3500 Cd), 3111 B, AAS Method 0.001 mg/l

c Chromium (as Cr) APHA Edition 21 (3500 Cr B) Colorimetric 0.001 mg/l

d Copper (as Cu) APHA Edition 21 (3500 Cu B), (3111B), AAS 0.02 mg/l



S. No Parameters Methodology Minimum

Detection Limit Method, Colorimetric

e Cyanide (as CN) APHA 4500 CN-O, ASTM D7237 -

f Iron (as Fe) APHA Edition 21 (3500 Fe-B) Colorimetric 0.01 mg/l

g Lead (as Pb) APHA Edition 21 (3500 Pb-A), AAS Method 0.02 mg/l

h Mercury (as Hg) APHA Edition 21 (3500 Hg), AAS Method 0.001 mg/l

i Manganese (as Mn) APHA Edition 21 (3500 Mn-B) (3111 B), AAS Method/ Colorimetric

0.007mg/l

j Nickel (as Ni) APHA Edition 21 (3500 Ni), AAS Method 0.02 mg/l

k Zinc (as Zn) APHA Edition 21 (3500 Zn-B) (3111 B), AAS Method/ Colorimetric

0.002 mg/l

28 Total Coliform APHA Edition 21 (9221 B), Multiple Tube Fermentation

2 MPN/100ml

29 Faecal Coliforms APHA Edition 21 (9221 E), Multiple Tube Fermentation

2 MPN/100ml

(Source: APHA Standard Methods (20thEdition, 1998))

3.3.4.1.2 Quality of Ground Water (Physical, Chemical & Bacteriological)

Water samples were collected from ground and surface waters covering 10 km radial zone. A total of six (6) samples of ground water and three (3) sample of surface water were taken from different sampling locations including surface and ground water bodies during post monsoon respectively. The samples were analysed for physicochemical parameters, the sampling and analysis of water were carried out as described in standard methods of water and waste water analysis (APHA). The results of water analysis were compared with IS: 10500-1993 drinking water standard to study their suitability for drinking purpose and surface water were classified on basis of CPCB standard. The analytical results of the water samples are shown in Table 3.12.

Table 3.12 : Physical and Chemical Characteristics of Ground Water Samples

S.No. Parameters Project Site Dabauli Bauti

Khera Panki Cheetipur Singhpur Khather

1 Colour (Hazen) Less than 5

Less than 5

Less than 5

Less than 5

Less than 5

Less than 5

2 pH 6.9 7.62 7.2 7.1 7.2 7.2 3 Turbidity NTU 0.1 0.1 0.2 0.3 0.2 0.2

4 Total Dissolved Solids (mg/l) 608.36 392.62 358.45 873.01 906.51 349.07

5 Conductivity (umhos/cm) 908 586 535 1303 1353 521

7 Total Alkalinity (as CaCO3) (mg/l)

552 398 425 590 549 406





8 Total Arsenic (as As) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

9 Fluoride (as F) (mg/l) 0.99 1.2 0.96 1.13 0.93 0.82

10 Total Hardness ( as CaCO3) (mg/l)

516 455 706 581 682 303

11 Calcium (as Ca) (mg/l)

108 87 125 121 112 59

12 Chlorides (as Cl) (mg/l) 22 97 240 29 140 11

13 Copper (as Cu) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

14 Cyanide (as Cn) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

15 Sulphate (as SO4) (mg/l) 16 18 26 57 34 4.4

16 Magnesium (as Mg) (mg/l) 60 58 96 68 98 38

17 Nitrate (as NO3) (mg/l) 4.4 7.5 6.7 2.5 6.9 4.6

18 Iron (as Fe) (mg/l) 0.28 1.23 2.54 0.32 1.65 0.18

19 Lead (as Pb) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

20 Manganese (as Mn) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

22 Mercury (as Hg) (mg/l) 0.001 0.001 0.001 0.001 0.001 0.001

23 Aluminum (as Al) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

24 Phenolic Compounds (as C6H5OH) (mg/l)

0.001 0.001 0.001 0.001 0.001 0.001

25 Selenium (as Se) (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

26 Total Chromimum (as Cr) (mg/l)

0.01 0.01 0.01 0.01 0.01 0.01

27 Cadmium (as Cd) (mg/l) 0.001 0.001 0.001 0.001 0.001 0.001

28 Free Residual Chlorine (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

29 Zinc (as Zn) (mg/l) 0.1 0.1 0.1 0.1 0.1 0.1

30 Sodium (as Na) 12 20 27 16 28 12





(mg/l)

31 Potassium (as K) (mg/l) 5 9 9 7 8 7

32 Anionic Detergent (as MBAS) (mg/l)

0.1 0.1 0.1 0.1 0.1 0.1

33 Mineral Oil (mg/l) 0.01 0.01 0.01 0.01 0.01 0.01

35 Boron (as B) (mg/l) 0.1 0.1 0.1 0.1 0.1 0.1

36 Pesticides Absent Absent Absent Absent Absent Absent

37 Chemical Oxygen demand (mg/l)

5 5 5 5 5 5

3.3.4.1.3 Interpretation of Results

Ground water quality was compared with the drinking water norms (IS 10500: 1993). The values of physico-chemical parameters in ground water samples collected during study period (Post Monsoon) are summarized.

The pH value of drinking water is an important index of acidity or alkalinity. A number of minerals and organic matter interact with one another to give the resultant pH value of the sample. pH levels vary from 6.9 to 7.62 in post monsoon (under acceptable limit 6.5-8.5) . It lies within BIS and WHO standard limits for drinking water quality and are suitable for drinking purpose. Temperature exerts a major influence on the biological activities and growth.

Temperature influences water chemistry, e.g. DO, solubility, density, pH, conductivity etc. water holds lesser oxygen at higher temperatures. Suspension of particles in water interfering with passage of light is called turbidity. Turbidity of water is responsible for the light to be scattered.

Turbidity in natural water restricts light penetration thus limiting photosynthesis, which consequently leads to depletion of oxygen content. Turbidity was not found in any of the ground water sample.

A high value of Conductivity is a measure of the ability of water to pass an electrical current. Conductivity in water is affected by the presence of inorganic dissolved solids. Therefore, EC is considered as an important water quality parameter in assessing drinking water as well as irrigation water. EC is a widely used as indicator for salinity and this has also been used to classify the water under medium saline, low and high saline water. EC levels vary from 521 to 1353 µmho/cm during post monsoon. They also opined that the higher value of EC in groundwater is due to the high dissolved



solids which may subscribe to the conductivity and has a direct bearing on the percentage of total solids.

The level of TDS is one of the characteristics, which decides the quality of drinking water. Total dissolved solids were recorded from 349.07 to 906.51 mg/l found in post monsoon analysis which are under standard limits prescribed by WHO and BIS. Water with fewer residues is less potable and suits for drinking purpose. On the other hand, high level of TDS may aesthetically be unsatisfactory for bathing and washing Ammonical nitrogen is an indicator of organic contamination. In combination with elevated chloride it could indicate the presence of landfill leachate.

In the present study, the amount of sulphate ion is estimated to vary from 4.4 to 57 mg/l post monsoon. The maximum tolerance range for sulphate is 200-400 mg/l. The excess amount of sulphate causes diarrhea. Sulphate produces an objectionable taste at 300-400 mg/l and bitter taste at 500 mg/l.

The total hardness is an important parameter of water quality whether it is to be used for domestic, industrial or agricultural purposes. The hardness values were recorded between 303 to 706 mg/l. WHO and Indian standards permit any value less than 500 mg/l.

The concentration of Fluorides is excess with the permissible limit. The contration of fluoride in ground water during post monsoon were found 0.82 to 1.2 which shows the concentration is exceeding the desirable limits sets (0.01 to 0.05).

3.3.4.2 Surface Water Environment

Surface water sampling and analysis completed during post monsoon period.

3.3.4.2.1 Quality of Ground Water (Physical, Chemical & Bacteriological)

Surface water analysis results of samples collected from River/ Lake is given vide Table 3.13.

Table 3.13 : Physical and Chemical Characteristics of Surface Water Samples

PARAMETERS Ganga River Pond Near project Site

Pandu River

Colour Less than5 Less than5 Less than5 Conductivity (μmhos/cm) 634 361 302 Turbidity (NTU) 5.8 4.3 0.6 pH 6.8 7.9 7.4 Total Dissolved Solids (mg/liter) 412 235 200 Total Hardness ( as CaCO3) mg/liter 387 279 284 Chlorides ( as Cl ) mg/liter 48 17 24 Sulphate ( as SO4 ) mg/liter 126 64 21 Nitrate ( as NO3 ) mg/liter 9 12 4.1 Phosphate (as PO4) mg/liter 1.6 1.89 1.82 Fluoride ( as F )mg/liter 0.5 0.24 0.4 Cadmium (as Cd)mg/liter 0.001 0.001 0.001



PARAMETERS Ganga River Pond Near project Site

Pandu River

Arsenic (as As) mg/liter 0.01 0.01 0.01 Selenium (as Se)mg/liter 0.01 0.01 0.01 Cyanide (as CN) mg/liter 0.01 0.01 0.01 Iron ( as Fe ) mg/liter 0.23 0.21 0.24 Lead ( as Pb ) mg/liter 0.01 0.01 0.01 Copper ( as Cu ) mg/liter 0.01 0.01 0.01 Sodium (as Na) mg/liter 25 17 18 Potassium (as K) mg/liter 12 7 8.5 Zinc ( as Zn ) mg/liter 0.1 0.1 0.1 Total Chromium ( as Cr ) mg/liter 0.01 0.01 0.01 Manganese ( as Mn ) mg/liter 0.01 0.01 0.01 Oil & Grease (mg/liter) 1 1 1 Calcium (as Ca) mg/liter 86 74 76 Magnesium (as Mg) (mg/liter) 42 23 23 Total Alkalinity (mg/liter) 254 249 312 Chemical Oxygen demand (mg/liter) 24 5 5 Bio-chemical Oxygen demand (for 3 days at 270C) (mg/liter)

6 NIL NIL

Dissolved Oxygen (mg/liter) 3.2 2.6 2.8 Phenolic Compounds (as C6H5OH) (mg/liter)

0.001 0.001 0.001

Anionic Detergent (as MBAS)(mg/liter) 0.1 0.1 0.1 Insecticides Absent Absent Absent Total Coliform MPN/100 /liter) 138MPN/100 NIL NIL

3.3.4.2.2 Interpretation of Results

Surface water in the region has been compared with respect to the Surface Water Quality Standards as per IS: 2296:1992 and reveals that surface water is not suitable for drinking purpose.

3.3.5. Soil Environment

Soil is our most important natural resource and a natural resource is anything that comes from the earth and is used by us. We depend on the soil for food, clothing, shelter, minerals, clay & water. Soil is the seat of many macro and micro flora like algae, fungi, earthworms, bacteria etc. These are very beneficial in promoting soil reactions and decomposing the organic matter by which essential nutrients for plants are liberated. Most of the soil is made-up of two main parts:

Tiny bits of mineral particles which come from larger rocks, and humus, which is dark brown in color and consists of decaying remains of plants and animals.

Soil also contains water, air and living organisms, such as fungi, bacteria, earthworms, roundworms, insects, etc. Actually more living organisms live in the soil than above it.



Description of Environment General Characteristics of the Soil in the District The Kanpur Nagar district is part of Indo Gangetic Plain. The clay, silt, gravel and sands of different grades are main sedimentary constituents. The older alluviums, alluvial deposit mostly occurring in the central part were deposited during lower to Upper Pleistocene period. The newer alluviums were deposited during Upper Pleistocene to Recent period mostly occurring along the course of rivers. The soil of the district exhibits a great variety of composition and appearance. The major part of the district consists of ordinary soils known locally as Bhur and Sand on ridges, Matiyar or Clay in depressions and Domat or Loam in the Plains. The 'Reh' prevails in the clay dominant areas.

Agricultural Status (Cropping Pattern) of the District Paddy, maize, pulse crops, wheat, potato and sunflower are the main crops grown over here. In year 2005-06 the Net sown area was 185667.0-ha and Net Irrigated area was 130333.0-ha. The area irrigated by Canal was 32308.0-ha, whereas by ground water is 96636.0-ha (74%). The total length of Canal in the district was 822-km. The total number of state tube wells and boring wells were 293 and 54160 respectively. Table 3.14 and 3.15 shows the detailed agricultural status of the, Kanpur Nagar district.

Table 3.14 : Area under Major Field Crops (As per latest figures 2011-12)

Major Cultivated Crops

Area(,000-ha) Kharif Rabi Summer Total

Irrigated Rain fed

Total Irrigated Rain fed Total

Rice 33.4 nil 33.4 nil nil nil nil 33.4

Maize 0.2 20.9 21.1 “ “ “ “ 21.1 Sorghum 0.1 12.5 12.6 “ “ “ “ 12.6 Wheat nil nil nil 102.8 0.2 103.0 “ 103.0 Gram “ “ “ 1.0 15.6 16.6 “ 16.6 Rapeseed/ Mustard “ “ “ 7.3 6.9 14.2 “ 14.2 Horticultural Crops-Fruits

Area(,000-ha) Total Irrigated Rain fed

Mango 0.1 0.1 nil Guava 0.1 0.1 “ Horticultural Crops-Vegetables Potato 11.5 11.5 “ Onion 0.4 0.4 “ Pea 1.1 1.1 “ Major Fodder Crops

Area, ha Total

Kharif 8976.0 8976.0 Rabi 1974.0 1974.0 Summer 362.0 362.0 Total 11312.0 11312.0 (Source-http://agricoop.nic.in/Agriculture%20Contingency%20Plan/UP/UP75-Kanpur%20Nagar-07.08.2014.pdf)



Table 3.15 : Production and Productivity of Major Crops (Average of last 5 years)

Major Cultivated

Crops

Area(,000-ha) Kharif Rabi Summer Total Crop Residue as

Fodder (,000-tons)

Prodn. (,000 t)

Prod.ty kg/ha

Prodn. (,000 t)

Prod.ty kg/ha

Prodn. (,000 t)

Prod.ty kg/ha

Prodn. (000 t)

Prod.ty kg/ha

Rice 75.5 2286 nil nil nil nil 75.5 2286 nil Maize 29.3 1444 “ “ “ “ 29.3 1444 nil Jowar 15.6 1285 “ “ “ “ 15.6 1285 nil Wheat nil nil 317.1 3107 “ “ 317.1 3107 nil Gram “ “ 21.2 1294 “ “ 21.2 1294 nil Rapeseed/Must

ard “ “ 14.8 1059 “ “ 14.8 1059 nil

(Source-http://agricoop.nic.in/Agriculture%20Contingency%20Plan/UP/UP75-Kanpur%20Nagar-07.08.2014.pdf)

Methodology of Sampling

The soil samples were collected from Six (06) selected locations during Post-monsoon season. The samples collected were homogeneous representative of each sampling location. At random five sub-locations were identified at each location and soil samples were collected from 5 to 15-cm below the surface. It was uniformly mixed before homogenizing the soil samples. The samples about 500-gms were packed in polythene bags labeled in the field with location, number and sent to the laboratory for the analysis of physicochemical parameters.

For studying soil quality environment in the study area, sampling locations were selected to assess the existing soil conditions in and around the existing plant area representing various land use conditions. The homogenized samples were analyzed for physicochemical characteristics.

Analysis of Soil Samples

The soil samples were examined for various physicochemical parameters, to determine the existing soil characteristics of the study area. Soil samples were collected from the vicinity of proposed mine site. Physicochemical characteristics of soil are presented in Table 3.16 given as follows;

Table 3.16 : Physicochemical Characteristics of Soil

S. No.

Parameters Unit Project Site

Dabauli Panki Cheetipur Singhpur Khather

Bhauti Khera

Physical Characteristics 1. Colour - Dark

Brown Brown Yellowi

sh Brown

Brown Brown Dark Brown

2. Texture - Sandy Loam

Sandy Loam

Sandy Loam

Clay Loam Sandy Loam

Sandy Loam



3. Porosity % 46.8 47.9 44.2 51.3 48.3 46.8 4. Bulk Density (BD) gm/cc 1.42 1.38 1.48 1.26 1.35 1.40 5. Moisture % 12.2 11.3 12.7 16.2 12.5 14.4 6. Water Holding

Capacity(WHC) % 35.4 30.2 38.8 40.5 42.4 35.6

7. Particle Size Distribution

I) Sand,(>0.2 mm Dia) % 42 46 40 41 42 40 II) Silt,(0.02 to 0.2 mm Dia) % 36 32 37 32 32 28 III) Clay,(< 0.002 mm Dia) % 22 22 23 27 26 32 8. Permeability cm/hr 8.6 7.5 7.8 4.6 6.2 6.3

Chemical Characteristics 9. pH 20%Slurr

y 7.10 7.40 7.35 7.32 7.52 7.65 10. EC(20%Slurry) µmhos/c

m 108 177 205 201 120 203 11. Organic Carbon (OC) % 0.82 0.89 0.62 1.25 0.86 0.73 12. Organic Matter(OM) % 1.41 1.53 1.06 2.16 1.48 1.26 13. CEC meq/100-

gm 9.5 8.4 8.6 20.8 9.5 8.8 14. Sodium as Na mg/kg 418 561 498 698 612 588 15. Calcium as Ca mg/kg 206 366 294 392 212 244 16. Magnesium as Mg mg/kg 88 116 96 110 95 105 17. Manganese as Mn mg/kg <0.1 0.2 <0.1 <0.1 0.2 <0.1 18. Zinc as Zn mg/kg <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 19. Boron as B mg/kg <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 20. Copper as Cu mg/kg 1.02 1.72 0.98 1.45 1.61 1.23 21. Iron as Fe mg/kg 2.8 2.4 4.6 3.8 4.2 4.5 22. Sulphate as So4 mg/kg 480 582 478 631 832 630 23. Chloride as Cl mg/kg 483 811 724 807 897 862 24. Fluoride mg/kg <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 25. Available Nutrients

i) Nitrogen as N kg/ha 296.5 326.8 298.6 358.4 319.5 312.2 ii) Phosphorus as P kg/ha 18.2 16.6 16.2 22.8 19.7 20.4 iii) Potassium as K kg/ha 166.5 106.8 220.8 266.6 178.5 146.6 26. SAR - 5.1 7.1 7.3 8.6 3.9 8.3

Source: Kamal Enviro & Food Lab. Pvt. Ltd. Gurgaon-Haryana

Interpretation of Analytical Results & Conclusions

Interpretation of Soil Characteristic has been dwelled in following sub-sections;

Physical characteristics of soil

Physical characteristics of soil greatly influence its use and behavior towards plant growth.

Soil Texture

The mineral components of soil are sand, silt and clay, and their relative proportions determine a soil's texture. Properties that are influenced by soil texture, include



porosity, permeability, infiltration, shrink-swell, water-holding capacity, and susceptibility to erosion. The soil in which neither sand & silt nor clay predominates is called "loam". The mineral constituents of a loam soil might be 40% sand, 40% silt and the balance 20% clay by weight. Soil texture affects soil behavior, in particular its retention capacity for nutrients and water. Texturally the soils of study area are observed as Sandy Loam and Clay Loam Soils.

Bulk density

Bulk density of soil relates to the combined volumes of the solids and pore spaces. Soil with a high pore space with loose solid particles will have lower bulk density than those that are more compact and have less pore space. This is directly related to the movement of air and water through soil thus affecting the productivity. The bulk density of the soils was found in the range of 1.26 to 1.48-gm/cm3.

Water Holding Capacity

Water-holding capacity is usually defined as the amount of water that soil can hold. Soil that have fine particles are able to hold more water than coarse soils while rock fragments cannot hold any water and contribute negatively to soil water-holding capacity. The type and composition of soil are the controlling factors in this case. Water Holding Capacity of study area soils was observed as 30.2 to 42.4%.

Permeability

Permeability is the measure of the ability of a soil to transmit water under a unit hydraulic gradient. For a particular soil, it represents its average water transmitting properties, which depends mainly on the number and the diameter of the pores present. The results show Permeability values were found to vary from 4.6 to 8.6-cm/hr under Sandy Loam and Clay Loam textured soil in the study area.

Chemical Characteristics of Soil Soil Reaction Classes and Critical Limits for Macro and Micro Nutrients in Soil

According to Soil Survey Manual (IARI, 1970), the soils are grouped under different soil reaction classes viz; extremely acidic (pH<4.5), very strongly acidic (pH 4.5-5.0 ), strongly acidic (pH 5.1-5.5), moderately acidic (pH 5.6-6.0), slightly acidic (pH 6.1-6.5), neutral (pH 6.6-7.3), slightly alkaline (pH 7.4-7.8), moderately alkaline (pH 7.9-8.4), strongly alkaline (pH 8.5-9.0).The soils are rated as low (below 0.50 %), medium (0.50-0.75 %) and high (above 0.75 %) in case of organic carbon, low (<280-kg/ha-1), medium (280 to 560-kg/ha-1) and high (>560-kg/ha-1) in case of available Nitrogen, low (<10-kg/ha-1), medium (10 to 25-kg/ha-1) and high (>25-kg/ha-1) for available Phosphorus, low (<108-kg/ha-1), medium (108 to 280-kg/ha-1) and high (>280-kg/ha-1) for available Potassium and low (<10-mg/kg-1), medium (10-20-mg/kg-1) and high (>20-mg/kg-1) for available Sulphur (Singh et. al. 2004, Mehta et. al.1988). Critical limits of Fe, Mn, Zn, Cu and B, which separate deficient from non-deficient soils

http://en.wikipedia.org/wiki/Loam

http://en.wikipedia.org/wiki/Ecohydrology#Soil_moisture_dynamics



followed in India, are >4.5,> 2.0,< 0.5,< 0.2 and <0.5-mg/kg-1 respectively. (Follet & Lindsay-1970 and Berger & Truog-1940)

Soil Reaction

Soil pH directly affects the life and growth of plants because it affects the availability of plant nutrients. Between pH 6.0 and 6.5, most plant nutrients are in their most available state. Nitrogen, for example, has its greatest solubility between soil pH 4 and soil pH 8. Above or below that range, its solubility is seriously restricted. It is a measure of acidity and alkalinity and reflects the status of base saturation. The soil pH in the study area ranges from 7.10 to 7.65, thereby indicating the soils are neutral to slightly alkaline.

Organic Carbon and Organic Matter

The effect of soil organic matter on soil properties is well recognized. Soil organic matter plays a vital role in supplying plant nutrients, cation exchange capacity, improving soil aggregation and hence water retention and soil biological activity. The Organic Carbon content of soil varied from 0.62 to 1.25 % (1.06 to 2.16% as Organic Matter), thereby implying that soils are medium to high in organic content.

Macronutrients

Nutrients like nitrogen (N), phosphorus (P) and potassium (K) are considered as primary nutrients and Sulphur (S) as secondary nutrient. These nutrients help in proper growth, development and yield differentiation of plants and are generally required by plants in large quantity.

Available Nitrogen

Nitrogen is an integral component of many compounds including chlorophyll and enzyme essential for plant growth. It is an essential constituent for amino acids which is building blocks for plant tissue, cell nuclei and protoplasm. It encourages aboveground vegetative growth and deep green color to leaves. Deficiency of nitrogen decreases rate and extent of protein synthesis and results into stunted growth and develop chlorosis. Available nitrogen in the surface soils ranges between 296.5 & 358.4-kg/ha thereby indicates that soils are low to medium in available nitrogen content.

Available Phosphorus

Phosphorus is an important component of adenosine di-phosphate (ADP) and adenosine tri-phosphate (ATP), which involves in energy transformation in plant. It is essential component of deoxyribonucleic acid (DNA), the seat of genetic inheritance in plant and animal. Phosphorous take part in important functions like photosynthesis, nitrogen fixation, crop maturation, root development, strengthening straw in cereal crops etc. The availability of phosphorous is restricted under acidic and alkaline soil reaction mainly due to P-fixation. In acidic condition it gets fixed with aluminum and iron and in alkaline condition with calcium. Available phosphorus ranges between 16.2 &



22.8-kg/ha thereby indicating that soils are medium to high in available phosphorus content.

Available Potassium

Potassium is an activator of various enzymes responsible for plant processes like energy metabolism, starch synthesis, nitrate reduction and sugar degradation. It is extremely mobile in plant and help to regulate opening and closing of stomata in the leaves and uptake of water by root cells. It is important in grain formation and tuber development and encourages crop resistance for certain fungal and bacterial diseases. Available potassium in these soils ranges between 106.8 & 266.6-kg/ha thereby is indicating that the soils are low to medium in potassium content.

Micronutrients

Proper understanding of micronutrients availability in soils and extent of their deficiencies is the pre-requisite for efficient management of micronutrient fertilizer to sustain crop productivity. Therefore, it is essential to know the micronutrients status of soil before introducing any type of land use.

Available Manganese

Manganese is essential in photosynthesis and nitrogen transformations in plants. It activates decarboxylase, dehydrogenize, and oxides enzymes. The available manganese content in surface soils ranges between <0.1and 0.2-mg/kg-1. As per the critical limit of available manganese (>2.0-mg/kg-1), most of the study area soils are sufficient in available Manganese in the vicinity of existing / proposed project.

Available Zinc

Zinc plays role in protein synthesis, reproductive process of certain plants and in the formation of starch and some growth hormones. It promotes seed maturation and production. The available zinc in surface soils of the study area was observed as <0.5-mg/kg-1. The critical limit of available Zinc is also <0.5-mg/kg-1.

Available Boron

Boron increases solubility and mobility of calcium in the plant and it act as regulator of K/Ca ratio in the plant. It is required for development of new meristematic tissue and also necessary for proper pollination, fruit and seed setting and translocation of sugar, starch and phosphorous etc. It has role in synthesis of amino acid and protein and regulates carbohydrate metabolism. The available boron content in the soils was observed as <0.5-mg/kg-1. The critical limit for deficiency of the available Boron is also <0.5-mg/kg-1.

3.3.6. Biological Environment



Present study on Biological diversity has been carried out to inventorise the biodiversity exists in the study area of present project, to evaluate the possible impacts on biodiversity due to project activities and suggest effective mitigation measures against the negative impacts.

3.3.6.1 Terrestrial Ecology

Forest and Forest Types

The extent of Natural forests and tree cover in Uttar Pradesh is very low and a total of 21244 km2 forests/tree cover area is recorded in the State which is about 8.82 % of the total state’s geographical area. According to Champion and Seth (1968), state has 6

major forest groups viz. Tropical Dry Deciduous Forests (50.66%), Tropical Thorn Forests (4.61%), Tropical Semi-evergreen Forests (0.21%), Tropical moist Deciduous Forests (19.68%), and Littoral & Swamp Forests (2.35%). Beside these forest groups, a total of 22.49 % of planted forest is also present in the state.

The present project falls in the Kanpur district which accounts for a geographical area of 6176 km2 having 109 km2 forest cover which is about 1.76% of the district’s

geographical area. Most of the forest area exists in the district comes under open forest (97 km2) category followed by moderately dense forest category (12 km2) and there is no dense forest area occurs in the district.1 The District Kanpur lies between the fertile Doab region of the Ganges and Yamuna rivers and a well known Agro-biodiversity rich area of India. Kanpur city and Dehat as a whole has around 5400 hectares of reserved forest area falling under the jurisdiction of the state forest department. Consequently, much of the natural flora and fauna has disappeared over the years due to various anthropogenic pressures. However, the city currently has negligible area under forest. (NGRBA Report, 2014)

The baseline ecological surveys were carried out, based on various secondary sources (Forest Department Data, Scientific Studies etc.) and further validated through various primary surveys, and interviewing local people. Present biological studies were carried out in two zones: core zone [Activity Area] and buffer zone [10 km surrounding the core zone]. The activity area under this project is almost clear ground with no vegetation and already being used for the transportation and other activities under running project.

Flora

The present baseline floristic study has been carried out to inventorise floral composition in the study area. Three sampling locations; one in core zone and two in outer area within the 10 km of core zone (Buffer zone) were selected for carrying out vegetation survey. In order to understand the composition of the vegetation, most of the plant species were identified in the field itself whereas the species that could not be identified a specimen was collected along with their photographs for identification later with the help of available published literature and floras of the region. (Table 3.17 and 3.18)

1 Indian State of Forest Report 2013 (Forest Survey of India, Dehradun)

http://en.wikipedia.org/wiki/Doab

http://en.wikipedia.org/wiki/Ganges

http://en.wikipedia.org/wiki/Yamuna



Core Area (Activity Zone)

The present project area is a vacant piece of land having no vegetation cover and already being Cynodon dactylon used for transportation and for storage under running project. There are some small grassy patches of Cynodon dactylon present in the core area along with few individuals of shrubs like Calotropis procera and Argemone mexicana. The list of plants found in the core zone area is listed in Tables 3.17 through 3.19.

Buffer Area (10 Km surrounding of core area)

The industrial state expands at least upto 1.8 km in each direction from the project area. Beside this area, Kanpur city lies on the north, north-east and east direction whereas agriculture activities are present in the west and south direction. Flora of the buffer area is generally two types; thorny and deciduous. Deciduous flora includes Kanju (Holoptelea integrifolia), Pankar (Ficus sp), Gular (Ficus glomerata), Neem (Azadirachta indica), Shahtoot (Morus alba), Shisham (Dalbergia sissoo), semal (Bombex ceiba), Jamun (Syzium cumini), Bargad (Ficus bengalensis), Pipal (Ficus religiosa), Eucalyptus (Eucalyptus sp) and Mahua (Madhuca indica), etc. Thorny vegetation is generally present in riverine and sandy areas and dominated by Acacia nilotica and Prosopis juliflora. Shruby vegetation of this zone is dominated by Aak (Calotropis procera), Cassia tora, Cassia auriculata, Cassia occidentalis and Lantana camara. In the herbaceous flora, Parthenium hysterophorus, Cynodon dactylon, Argemone mexicana, Cannabis sativa, and Euphorbia hirta were found as dominated species. The list of floral species recorded in buffer zone is presented in Tables 3.17 through 3.19.

Table 3.17 : List of Tree Flora Recorded in the Study Area

S. No. Scientific Name Name Family Core Area

Buffer Area

Secondary Sources

1 Acacia nilotica Babool Fabaceae * * 2 Aegle marmelos Bel Rutaceae

*

3 Albizia lebbeck Siris Fabaceae

* * 4 Azadirachta indica Neem Meliaceae

* *

5 Bauhinia variegate Kachnar Fabaceae

* * 6 Bombax ceiba Semal Malvaceae

* *

7 Cassia fistula Amaltas Fabaceae

* * 8 Dalbergia sissoo Shisham Fabaceae

* *

9 Delonix regia Gulmohar Caesalpiniaceae

* * 10 Emblica officinalis Amla Phyllanthaceae

*

11 Eucalyptus sp Eucalyptus Myrtaceae

* * 12 Ficus bengalensis Bargad Moraceae

* *

13 Ficus glomerata Goolar Moraceae

* * 14 Ficus religiosa Peepal Moraceae

* *

15 Ficus spp Pankar Moraceae

* * 16 Ficus virens White Fig Moraceae

*

17 Hardwickia binata Anjan Fabaceae

* 18 Holoptelea integrifolia Kanju Ulmaceae

* *

19 Leucaena leucocephala Subabool Fabaceae

* * 20 Madhuca indica Mahua Sapotaceae

*

http://en.wikipedia.org/wiki/Phyllanthaceae




Buffer Area

Secondary Sources

21 Mangifera indica Aam Anacardiaceae

* * 22 Morus alba Sahtoot Moraceae

* *

23 Phoenix acaulis Dwarf Palm Arecaceae

* 24 Phoenix sylvestris Khajura Arecaceae

* *

25 Polyalthia longifolia Ashoka Annonaceae

* * 26 Psidium guajava Amrood Myrtaceae

* *

27 Pterospermum acerifolium Kanak Champa Malvaceae

* * 28 Sapindus mukorossi Reetha Sapindaceae

*

29 Saraca asoca Ashoka Caesalpinioideae

* * 30 Schleichera oleosa Kusum Sapindaceae

*

31 Sesbania grandiflora Agati Fabaceae

* 32 Syzygium cumini Jamun Myrtaceae

* *

33 Tamarindus indica Imli Fabaceae

* * 34 Zyzyphus sp Ber Rhamnaceae

* *

35 Prosopis juliflora Bilayati Babool Fabaceae * *

Source: Primary Study+ Secondary Data (Forest Working Plan, Kanpur Social Forestry Division)

Table 3.18 : List of Shrub Flora Recorded in the Study Area


Buffer Area

Secondary Sources

1 Abutilon indicum Atibala Malvaceae

* * 2 Acacia jacquemontii Baonli Fabaceae

* *

3 Agave americana Rambans Agavaceae

* * 4 Cannabis sativa Bhag Cannabaceae

* *

5 Calotropis procera Aak Apocynaceae * * * 6 Cassia auriculata Cassia Caesalpinioideae

* *

7 Cassia occidentalis Cofee Sena Caesalpiniaceae

* 8 Cassia tora Senna Caesalpinioideae * * * 9 Clerodendrum sp glorybower Verbenaceae

* *

10 Datura sp Datura Solanaceae

* 11 Hibiscus rosasinensis Gudhal Malvaceae

*

12 Indigofera sp Indigo Fabaceae

* * 13 Ipomoea carnea Beshrm Convolvulaceae

*

14 Jatropha curcas Jatropha Euphorbiaceae

* * 15 Lantana camara Lantana Verbenaceae

* *

16 Murraya sp Karri pata Rutaceae

* 17 Sida cordifolia Malo Malvaceae

*

18 Solanum xanthocarpum

Solanaceae

* * 19 Xanthium strumarium Cocklebur Asteraceae * * *

Table 3.19 : List of Herb/Grass Flora Recorded in the Study Area

Sl. No. Scientific Name Name Family Core Area

Buffer Area

Secondary Sources

1 Achyranthes aspera Chirchita Amerenthaceae * * 2 Ageratum conyzoides Goat weed Asteraceae

* *

3 Amaranthus viridis Jungle Chaulai Amerenthaceae * * * 4 Argemone mexicana Maxican Poppy Papaveraceae *

*

5 Arundo donax

Poaceae

* * 6 Barleria cristata Blue bell Acanthaceae

*

http://en.wikipedia.org/wiki/Cannabaceae

http://en.wikipedia.org/wiki/Caesalpinioideae

http://en.wikipedia.org/wiki/Caesalpinioideae



Sl. No. Scientific Name Name Family Core Area

Buffer Area

Secondary Sources

7 Boerhavia diffusa Punarnava Nyctaginaceae * * * 8 Brassica campestris Sarso Brassicaceae

*

9 Corchorus aestuans Jute Tiliaceae

* 10 Cucumis melo Musk Melon Cucurbitaceae

* *

11 Cucumis sativus Kheera Cucurbitaceae

* 12 Cynodon dactylon Dub Poaceae * * * 13 Cyperus rotundus Nagar Motha Poaceae

* *

14 Dactyloctenium aegyptium Makra Poaceae

* * 15 Desmodium triflorum Kudaliya Fabaceae

* *

16 Dichanthium annulatum Delhi grass Poaceae

* * 17 Eclipta alba Bhrigraj Asteraceae

*

18 Euphorbia hirta Dudhee Euphorbiaceae * * * 19 Ichnocarpus frutescens Kali Dudhi Apocyanaceae

*

20 Leucas sp

Lamiaceae

* 21 Lycopersicon lycopersicum Tomato Solanaceae

*

22 Melochia corchorifolia Bilpat Malvaceae

* 23 Oldenlandia corymbosa Pitpapra Rubiaceae

*

24 Oxalis corniculata Amrul Oxalidaceae * * * 25 Parthenium hysterophorus Gajar Ghas Asteraceae * * * 26 Pogostemon bengalensis Pacholi Lamiaceae

*

27 Polygonum sp Knot Weed Polygonaceae

* * 28 Saccharum bengalense Sarkanda Poaceae

* *

29 Saccharum munja Moonj Poaceae

* * 30 Saccharum spontaneum Kans Poaceae

* *

31 Sida acuta Wire Weed Malvaceae

* 32 Smilax ocreata

Liliaceae

*

33 Solanum nigrum Makoy Solanaceae

* * 34 Tridax procumbens Ghamra Asteraceae * *

Fauna

In order to study the wild mammals, avifauna, herpetofauna of the project area, a normal systematic transect sampling was done in different strata. Under this sampling, a 2-3 km long transect walks were carried out in the different locations. In addition to the field sampling secondary data and information was also collected through indirect evidences such as calls, signs and trophies of mammals, interviews of local villagers for the presence of various animal species and the Forest Working Plan of the Forest Division (Social Forestry) Kanpur.

Forest Department-Forest Division (Social Forestry) Kanpur reported 31 mammals from the forest division area but our study confirmed the presence of 13 mammalian species in the study area which are listed in Table 3.20.

Table 3.20 : Common Mammalian Fauna Recorded in the study area

S. No. Name Scientific Name Order Family

WPA (S) CS PS SD

1 Bengal Fox Vulpes bengalensis Carnivora Canidae II LC *

2 Blue Bull Boselaphus tragocamelus Artiodactyla Bovidae IV LC * *

http://en.wikipedia.org/wiki/Carnivora

http://en.wikipedia.org/wiki/Canidae

http://en.wikipedia.org/wiki/Even-toed_ungulate

http://en.wikipedia.org/wiki/Bovidae



3 Golden Jackal Canis aureus Carnivora Canidae II LC

* 4 House Srew Suncus murinus Soricomorpha Soricidae NL LC

*

5 Indian Hare Lepus nigricollis Lagomorpha Leporidae IV LC * * 6 Jungle Cat Felis chaus Carnivora Felidae II LC

*

7 Palm Squirrel Funambulus pennantii Rodentia Sciuridae IV LC * * 8 Porcupine Hystrix indica Rodentia Hystricidae IV LC

*

9 Rhesus macaque Macaca mulatta Primates Cercopithecidae II LC * * 10 Small Indian Civet Viverricula indica Carnivora Viverridae II LC

*

11 Indian muntjac Muntiacus muntjak Artiodactyla Cervidae III LC

* 12 Chital Axis ais Artiodactyla Cervidae III LC * * 13 Wild Boar Sus scrofa Artiodactyla Suidae III LC * *

WPA (S)- Schedule as per Wildlife Protection Act, 1972, CS- Conservation Status as per IUCN, PS- Primary Study, SD- Secondary Data (Forest Working Plan/Menon 2014)

Working Plan of Forest Department has been reported 61 bird species in the forest division area but during present study a total of 21 bird species has been recorded in the study area. The common birds recorded from the study area are listed in Table 3.21.

Table 3.21 : List of Avi-Fauna Recorded in the study area

S. No. Name Scientific Name Order CS PS SD 1 Asian koel Eudynamys scolopaceus Cuculiformes LC * * 2 Brahmini Myna Sturnia pagodarum Passeriformes LC * * 3 Cattle Egret Bubulcus ibis Ciconiiformes LC

*

4 Common Babbaler Turdoides caudata Passeriformes LC

* 5 Common Hoopoe Upupa epops Bucerotiformes LC *

6 Common Kingfisher Alcedo atthis Coraciiformes LC * * 7 Common Myna Acridotheres tristis Passeriformes LC * * 8 Common Peafowl Pavo cristatus Galliformes LC

*

9 Common Pigeon Columba livia Columbiformes LC

* 10 Common Tailor Bird Orthotomus sutorius Passeriformes LC

*

11 Drongo Dicrurus caerulescens Passeriformes LC * * 12 Grey Hornbill Ocyceros birostris Bucerotiformes LC

*

13 House Crow Corvus splendens Passeriformes LC

* 14 House Sparrow Passer domesticus Passeriformes LC * * 15 Lesser Goldenback Dinopium benghalense Piciformes LC

*

16 Oriental White Eye Zosterops palpebrosus Passeriformes LC

* 17 Purple Sunbird Cinnyris asiaticus Passeriformes LC

*

18 Red-vented Bulbul Pycnonotus cafer Passeriformes LC * * 19 Red-wattled Lapwing Vanellus indicus Charadriiformes LC * * 20 Rose-ringed Parakeet Psittacula krameri Psittaciformes LC

*

21 Spotted Dove Stigmatopelia chinensis Columbiformes LC * * CS- Conservation Status as per IUCN, PS- Primary Study, SD- Secondary Data (Forest Working Plan/Grimmett et al 2011)

http://en.wikipedia.org/wiki/Canidae

http://en.wikipedia.org/wiki/Soricomorpha

http://en.wikipedia.org/wiki/Soricidae

http://en.wikipedia.org/wiki/Lagomorpha

http://en.wikipedia.org/wiki/Leporidae

http://en.wikipedia.org/wiki/Felidae

http://en.wikipedia.org/wiki/Rodent

http://en.wikipedia.org/wiki/Sciuridae

http://en.wikipedia.org/wiki/Rodent

http://en.wikipedia.org/wiki/Hystricidae

http://en.wikipedia.org/wiki/Cercopithecidae

http://en.wikipedia.org/wiki/Viverridae




http://en.wikipedia.org/wiki/Cuculiformes

http://en.wikipedia.org/wiki/Passeriformes

http://en.wikipedia.org/wiki/Ciconiiformes


http://en.wikipedia.org/wiki/Bucerotiformes

http://en.wikipedia.org/wiki/Coraciiformes

http://en.wikipedia.org/wiki/Galliformes

http://en.wikipedia.org/wiki/Columbiformes

http://en.wikipedia.org/wiki/Bucerotiformes

http://en.wikipedia.org/wiki/Passerine

http://en.wikipedia.org/wiki/Piciformes


http://en.wikipedia.org/wiki/Charadriiformes

http://en.wikipedia.org/wiki/Parrot



Although working plan of forest division 16 species of herpetofauna in the forest division but only two species of lizards and one species of snake has been confirmed from the study area during present study (Table 3.22).

Table 3.22 : List of Herpetofauna Recorded in the study area

S. No. Name Scientific Name Order Family

1 Common House Gecko Hemidactylus sp Squamata Gekkonidae

4 Indian chameleon Chamaeleo zeylanicus Squamata Chamaeleonidae

5 Oriental ratsnake Ptyas mucosus Squamata Colubridae

Allen Forest Zoo (Kanpur Zoo)

The Allen Forest Zoo is located about two kilometers (1.24 miles) from the city’s center

near the Azad Nagar, Indore locality of Kanpur. The zoo is an oasis of green, featuring a natural lake and ancient trees, and encompasses the largest land area of any zoological garden in Asia. It is distributed about 77 hectare of area having various kind of flora and fauna. Mammals at the zoo include White Asian tigers, cheetah, leopard, jaguar, hyena, black bear, grizzly bear, sloth, rhinoceros, hippopotamus, monkeys, langur, baboons, Musk deer, deer, and antelope. ["Allen Forest Zoo". Mapsofindia.com. Maps of India. Retrieved 3 October 2010.] Chimpanzees and orangutans have their own island. Some monkeys and deer are allowed to roam outside the enclosures as natural inhabitants of the zoo. Amphibians at the zoo include Indian gharial. (http://en.wikipedia.org/wiki/Allen_Forest_Zoo).

3.3.6.2 Aquatic Ecology

Ganga River is the potential aquatic body present in the study zone. Near Kanpur, the bed is essentially flat and consists of fine sand. The river channel consists of dynamic system of pools and riffles. Pandu nadi is one of the tributary of Ganga River is flowing about 1.4 km away from the project in SW direction along with Lower Ganga Canal which is about 1.5 km far from the project area towards SE direction. All three water bodies are free flowing and represent lotic ecosystems.

Methodology

Plankton is sampled by sieving 100 litres of water through plankton net mesh size (45 µ). The sieved sample is preserved in 4% formalin for microscopic study. Identifications are performed with the help of standard keys (Edmondson 1959; Prasad & Mishra 1992, Krammer and Lange-Bertalot 1999; 2004; Lange Bertalot 2001, Jaiswal & Tiwari 2003). Phytobenthos are collected by scraping submerged cobble/rock/ boulder/plant/algal substrate. Temporary mounts prepared from the preserved samples are examined under x400 magnification to record the algal (green, blue green etc) flora. Macro-invertebrate fauna is sampled by carefully lifting small boulders, cobbles and

http://en.wikipedia.org/wiki/Squamata

http://en.wikipedia.org/wiki/Gekkonidae

http://en.wikipedia.org/wiki/Chamaeleonidae

http://en.wikipedia.org/wiki/Squamata

http://en.wikipedia.org/wiki/Colubridae

http://en.wikipedia.org/wiki/Azad_Nagar,_Indore

http://en.wikipedia.org/wiki/Cheetah

http://en.wikipedia.org/wiki/Leopard

http://en.wikipedia.org/wiki/Jaguar

http://en.wikipedia.org/wiki/Hyena

http://en.wikipedia.org/wiki/Asian_black_bear

http://en.wikipedia.org/wiki/Grizzly_bear

http://en.wikipedia.org/wiki/Sloth

http://en.wikipedia.org/wiki/Rhinoceros

http://en.wikipedia.org/wiki/Hippopotamus

http://en.wikipedia.org/wiki/Monkey

http://en.wikipedia.org/wiki/Langur

http://en.wikipedia.org/wiki/Baboon

http://en.wikipedia.org/wiki/Deer

http://en.wikipedia.org/wiki/Antelope

http://en.wikipedia.org/wiki/Allen_Forest_Zoo#cite_note-maps_of_india-2



http://en.wikipedia.org/wiki/Chimpanzee

http://en.wikipedia.org/wiki/Orangutan

http://en.wikipedia.org/wiki/Monkey

http://en.wikipedia.org/wiki/Deer

http://en.wikipedia.org/wiki/Amphibian

http://en.wikipedia.org/wiki/Indian_gharial

http://en.wikipedia.org/wiki/Allen_Forest_Zoo



pebbles and washing in a bucket full of water by dipping number of times to dislodge the attached fauna. Soft substratum in the form of clay and silt is sampled with Ekmann dredge. The sediments are sieved to obtain the fauna. Samples are preserved in 5% formalin for laboratory analysis. Macro-invertebrate samples are identified to family and class level with the help of standard keys (Edmondson 1959; Edington & Hildrew 1995). Fish samples are collected by experimental fishing through cast net and gill net and information also gathered from local shops/village markets. The samples are preserved in 10% formalin for species identification with the help of standard keys (Day 1958; Talwar & Jhingran 1991; Jayaram 2002). Fish samples are used for determining the food habits and the environmental resource base.

Observations

Phytoplankton:

A total of 21 species were observed in the river Ganga and Pandu Nadi at Kanpur belonging three different classes; Cyanophyceae, Bacillariophyceae and Chlorophyceae. Out of these, 18 species were observed from the Ganga river, while 9 from Pandu Nadi. Six species were common in the both the water bodies which are tabulated in Table 3.23. Maximum number of species was belonging class Chlorophyceae in both the water bodies followed by Bacillariophyceae and Cyanophyceae (Figure 3.14).

Figure 3.13 : Identification of aquatic spp

Table 3.23 : Phyotoplankton community recorded from the study area

River Ganga River (P1) Pandu Nadi (P2)

Cyanophyceae Anabaena variablis + Aphanocapsa grevillei + + Microcystis major + +

Identification of the aquatic spp



River Ganga River (P1) Pandu Nadi (P2)

Bacillariophyceae Achnanthidium biasolettianum + Achnanthidium exiguum + Achnanthidium minutissimum + + Cymbella excise + Diatoma mesodon + Gomphonema lagenula + Nitzschia capitellata + Synedra ulna + Chlorophyceae Actinastrum hantzschii + Ankistrodenum falcatus + Coelastrum astroideum + Characium sp. + + Pediastrum duplex + + Scenedesmus sp. + Scenedesmus acuminatus + Scenedesmus arcuatus + Scenedesmus bicaudatus + Spirogyra sp. + +

Figure 3.14 : Number of Phytoplankton species in each taxonomic class

Phytobenthos:

Pandu Nadi

Ganga

0

2

4

6

8

10

Cyanophyceae Bacillariophyceae Chlorophyceae

2 3

4 3

6

9

Number of species

Phytoplankton



Pandu Nadi

Ganga

0

10

20

Cyanophyceae Bacillariophyceae Chlorophyceae

0 7 2

1

12

3

Number of species

Phytobenthos

Total 19 species were observed in both aquatic water bodies (river Ganga and Pandu Nadi) belonging three different classes; Cyanophyceae, Bacillariophyceae and Chlorophyceae. The number of species varied in the Ganga and Pandu Nadi. Out of these 17 species were found from the Ganga while 9 from Pandu nadi (Table 3.24). Six species were common in both the water bodies. Class Bacillariophyceae was most dominant class followed by Chlorophyceae and Cyanophyceae (Figure 3.15).

Table 3.24 : Phyotobenthos community recorded from the study area

River Ganga River (B1) Pandu Nadi (B2)

Cyanophyceae Aphanocapsa grevillei + Bacillariophyceae Achnanthidium biasolettianum + Achnanthidium exiguum + Achnanthidium minutissimum + Anomoenies sphaerophora + Anomoenies pediculus + + Cyclotella glomerata + Cymbella parva + + Fragilaria capucina + + Fragilaria rumpens + Gomphonema lagenula + + Gomphonema parvulum + Navicula caterva + Nitzschia fonticola + Synedra ulna + + Chlorophyceae Coelastrum sphaeroporum + Pediastrum duplex + Scenedesmus sp. + Scenedesmus bicaudatus + +

Figure 3.15 : Number of phytobenthos species in each taxonomic class in the study area



Zoo benthos (Benthic Macro-invertebrate fauna)

Under present study, two taxa were observed from the river Ganga belonging to phylum; arthropoda and mollusca. Out of these, Chironomus spp. (75%) was most abundant taxa followed by Physa spp. (25%). Functionally the river Ganga was in heterotrophic condition as gathering collectors (Chironomus spp.) was abundant taxa at Kanpur (Table 3.25).

Table 3.25 : Macroinvertebrate fauna recorded from study area along with functional feeding groups

Phylum/Taxa Functional Feeding Group

Arthropoda Chironomus spp. Gathering collectors Mollusca Physa spp. Scrapers

Fish and Fisheries:

15 species of fish reported by Forest Department in forest division area but a total of 3 fish species has been recorded during the fish catch carried out in river Ganga. (Table 3.26)

Table 3.26 : List of Fish Fauna Recorded in the study area

S. No. Name Scientific Name Order Family CS

1 Rohu Labeo rohita Cypriniformes Cyprinidae LC

2 Catla Catla catla Cypriniformes Cyprinidae LC

3

Eutropiichthys vacha SILURIFORMES SCHILBEIDAE LC

3.3.7. Socio-Economic Environment

The study area of 10 km radial zone mainly falls in the Kanpur Nagar district. There are total 48 villages in study area, 46 of them belongs to tehsil:Kanpur,2 of them in Bilhaur Tehsil.

3.3.7.1 Demographic Profile

Population

Total Population of the Study area as per Census of India, 2011 is 2900899 .The total number of Household being 547762.Total Male Population of the Study area is 1561251 and total Female Population of the Study Area is 1339648 .Village-wise details of population are given in Table 3.27.

http://en.wikipedia.org/wiki/Cypriniformes

http://en.wikipedia.org/wiki/Cyprinidae

http://en.wikipedia.org/wiki/Cypriniformes

http://en.wikipedia.org/wiki/Cyprinidae



Table 3.27 : Village-wise Population Details

Tehsil Village No. of Household

Total Population

Male Population

Female Population

Kanpur

Sujanpur 132 732 407 325 Chhitepur 153 774 419 355 Pankabahadur Nagar

475 2470 1353 1117

Rampur Bhimsen

1369 7359 3903 3456

Partappur Sarsai 65 329 172 157 Singhpur Kathar 128 725 364 361 Gopal Pur 418 2270 1228 1042 Rampur Khas 495 2563 1348 1215 Kaindha 892 4484 2405 2079 Sona 912 4788 2516 2272 Kataraghan Shyam

462 2192 1169 1023

Sachendi Urf Chacheri

3696 19424 10339 9085

Itara 714 3835 2029 1806 Fatehpur Dakshin

327 1874 998 876

Pipauri 698 3981 2108 1873 Patehuri 350 1763 967 796 Senpashchim Para

928 5113 2684 2429

Senpurab Para 784 3855 2040 1815 Dande Ka Purwa 128 653 350 303 Bhairam Pur 1156 6102 3112 2990 Dool 865 4674 2531 2143 Nakatoo 429 2307 1247 1060 Surar 826 4315 2338 1977 Rautepur 395 2103 1138 965 Bhautikhera 240 1441 760 681 Bhisi Jargaon 356 1969 1024 945 Bhautipratappur 1062 6034 3211 2823 Bahera 285 1606 836 770 Nasenia 144 889 467 422 Jhakhara 157 783 416 367 Tikra Kanpur 597 3471 1830 1641 Hora Bangar 168 851 454 397 Hora Kachhar 221 1148 610 538 Pargahi Bangar 179 992 524 468 Kursauli 223 1099 580 519 Naramaukachhar 130 742 389 353 Sambharpur 149 746 398 348 Khyora Katari 836 4366 2350 2016 Katarijiyora Nawab Ganj

39 257 199 58

Mardanpur 692 3454 1887 1567 Meharban Singh Ka Purva

170 977 527 450



Tehsil Village No. of Household

Total Population

Male Population

Female Population

Durjanpur 84 494 263 231 Gambhir Pur Dakshin

71 357 167 190

Kanpur 522805 2768057 1490547 1277510 Naurangabad 257 1379 714 665 Maksooda Bad 758 3928 2057 1871

Total 546420 2893725 1557375 1336350

Bilhaur Durgapur 248 1607 873 734 Pem 1094 5567 3003 2564

Total 1342 7174 3876 3298 Grand Total

547762 2900899 1561251 1339648

Sex Ratio

The Sex Ratio of the Study area is 858. Tehsil-wise population of the study area is represented in Figure 3.16.

Figure 3.16 : Tehsil-wise Population of the Study Area

(Source: Census 2011)

SC / ST Population

A considerable 13 % of the population in the Study Area is constituted by SC/ST, out of which SC population constitutes 13% and rest 0.10 % is constituted by ST Population.There is no ST Population in Bilhaur Tehsil. Comparative graphs of SC/ST Population in Study Area (Tehsil wise) are given in Figures 3.17 and 3.18 respectively.

0

500000

1000000

1500000

2000000

2500000

3000000

Kanpur Bilhaur

Total Population Total Male Population Total Female Population



Figure 3.17 : Tehsil-wise SC Population in Study Area


Figure 3.18 : Tehsil-wise ST Population in Study Area


Literacy Rate

Literacy Rate of the study area is 73% Distribution of male 40% and female literacy rate 33% in the study zone is and respectively. Gender-wise distribution of literacy in each Patwari Circle of Study Area is given in Figure 3.19.

0

100000

200000

300000

400000

Kanpur Bilhaur

Total SC Population Total SC Male Population Total SC Female Population

0

500

1000

1500

2000

2500

3000

3500

Kanpur Bilhaur

Total ST Population Total ST Male Population Total ST Female Population



Figure 3.19 : Gender-wise Distribution of Literacy and of Illiteracy in Study Area


Workers Scenario

Workers Participation Ratio of the main workers is 27%, non workers 66% and 7% is the marginal Workers.

Figure 3.20 : Worker Participation Ratio in Study Area


Main Workers:

Study area consist 2% of Casual labour, 3% of Agricultural, 5% of Household population and 90% of other population.

0

200000

400000

600000

800000

1000000

1200000

Kanpur Bilhaur

Total Male Literacy Total Female Literacy Total Male Illiteracy Total Female Illiteracy

27%

7%

66%

Main workers Marginal workers Non Workers



Figure 3.21 : Main worker Participation Ratio in Study Area


Marginal Workers:

Casual Labour constitutes 3% of total Marginal Worker Population. However,

Agricultural Labours constitutes 7 % of Total Marginal Worker Population

Figure 3.22 : Marginal worker Participation Ratio in Study Area


3.3.7.2 Infrastructure (2001 Census)

Education facilities

2% 3%

90%

5%

Main_CL_P Main_AL_P Main_OT_P Main_HH_P

3% 7%

85%

5%

Marginal_CL_P Marginal_AL_P Marginal_OT_P Marginal_HH_P



There are 76 Primary School, 3 Secondary Schools and 3 Senior Secondary Schools

in Study Area. 1 College exists in the Study Area. Almost all of the villages have at

least one primary School.

Health facilities

7 Allopathic hospitals are present in the study area. There are 4 Primary Health

centres found in the study Area. Several private medical practitioner and community

health workers are also found.

Drinking Water facilities

Villagers depend on groundwater as a source of Drinking water. Hand pumps, tube

wells and tap water are observed in villages

Communication Facilities

There are 11 post office found in the study area. 53 Telephone connections were

encountered in the study area.

Banking Facilities

3 Banks and 1 Credit Societies are found within the 48 Villages of Study Area. Comprehensive List of Infrastructures present in the Study Area is given in Table 3.28.



Table 3.28 : Tehsil-wise Infrastructure Details

Tehsil Village

Primary

School

Middle

School

Secondary Schh

ol

Higher Seconda

ry School

College

Hospital

Dispensary

PHC

PHSC

Post Offic

e

Telephone

Connection

Bank

Credit Societ

y

Source of Water

Kanpur

Sujanpur 1 0 0 0 0 0 0 0 1 0 0 0 0 Well,T.W,Handpump

Chhitepur 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Pankabahadur Nagar 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump Rampur Bhimsen 3 1 0 0 0 1Allope

thic 0 1 1 1 1 0 0 Well,T.W,Handpump

Partappur Sarsai 0 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump Singhpur Kathar 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump

Gopal Pur 1 0 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Rampur Khas 1 0 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Kaindha 1 1 0 0 0 0 0 0 0 1 0 0 0 Well,T.W,Handpump

Sona 5 0 0 0 0 0 0 0 0 0 4 0 0 Well,T.W,Handpump

Kataraghan Shyam 1 1 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump

Sachendi Urf Chacheri 14 1 1 0 0 1Allope

thic

1 Homeopat

hic Dispanasa

ry

0 0 2 15 0 0 Well,T.W,Handpump

Itara 2 1 0 0 0 0 0 0 0 1 0 0 0 Well,T.W,Handpump

Fatehpur Dakshin 1 1 0 0 0 0 0 0 0 0 2 0 0

Well,T.W,Handpump

Pipauri 1 0 0 0 0 0 0 0 0 0 4 0 0 Well,T.W,Handpump

Patehuri 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump



Senpashchim Para 2 0 0 1 1 0 0 0 0 1 1 0 0 Well,T.W,H

andpump Senpurab

Para 0 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Dande Ka Purwa 0 0 0 0 0 0 0 0 0 0 0 0 0

Well,T.W,Handpump

Bhairam Pur 1 1 0 0 0 0 0 0 0 1 1 0 0 Well,T.W,Handpump

Dool 3 0 0 0 0 1Allopethic

1Allopethic dispansary 0 0 0 1 0 0 Well,T.W,H

andpump

Nakatoo 2 1 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Surar 3 0 0 0 0 1Allopethic 0 1 1 0 1 0 0 Well,T.W,H

andpump

Rautepur 2 1 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Bhautikhera 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Bhisi Jargaon 2 1 0 1 0 0 0 0 0 0 0 0 1 A.S

Well,T.W,Handpump

Bhautipratappur 3 1 1 0 0 1Allope

thic 1Allopethic dispansary 1 1 1 1 3 0 Well,T.W,H

andpump

Bahera 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Nasenia 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Jhakhara 1 0 0 0 0 0 0 0 0 0 3 0 0 Well,T.W,Handpump

Tikra Kanpur 1 1 0 0 0 1Allopethic

3Allopethic dispansary 0 0 1 0 0 0 Well,T.W,H

andpump

Hora Bangar 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Hora Kachhar 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Pargahi Bangar 1 0 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,H

andpump

Kursauli 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Naramaukachhar

1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Sambharpur 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump



Khyora Katari 2 0 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Katarijiyora Nawab Ganj 0 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump

Mardanpur 1 0 0 0 0

1 Ayurve

dic

1 Ayurvedic dispansary

1 0 1 1 0 0 Well,T.W,Handpump

Meharban Singh Ka Purva

1 1 1 1 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Durjanpur 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,Handpump

Gambhir Pur Dakshin 1 0 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump

Kanpur - - - - - - - - - - - - - -

Naurangabad 1 0 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Maksooda Bad 1 1 0 0 0 0 0 0 0 0 0 0 0 Well,T.W,H

andpump Total 72 14 3 3 1 7 7 4 4 10 42 3 1

Bilhaur

Durgapur 1 1 0 0 0 0 0 0 0 0 1 0 0 Well,T.W,Handpump

Pem 3 0 0 0 0 0 0 0 0 1 10 0 0 Well,T.W,Handpump

Total 4 1 0 0 0 0 0 0 0 1 11 0 0

Grand total 76 15 3 3 1 7 7 4 4 11 53 3 1

T.W=Tap water,WW=Well water,HP=Handpump,HD=Homeopethic dispensary,A.D=Ayurvedic and Allopethic dispensary,A.S=Agricultural society



Village:Dabouli Village:Panki

Village:Gujaini

Figure 3.23 : Photographs of the surveyed villages



CHAPTER 4. IMPACT ASSESSMENT AND PREDICTION

4.1. Introduction

The possible impact on various components of environment due to the proposed expansion of plant can be assessed in terms of:

Physical and Biological Environment and

Demographic and Socio-economic Environment

For proper assessment of significance and magnitude of environmental changes due to construction and operational phases of the plant, the impacts are analyzed on the 10 km radius study area around the proposed expansion project for each environmental parameter. Impact assessment study for the existing KFCL unit is carried out by predicting net contribution of pollutants (qualitative as well as quantitative) on overall qualitative assessment of various environmental indicators. Prediction of impacts is an important component in environmental impact assessment process. Several techniques and methodologies are in vogue for predicting the impacts due to existing and proposed industrial development on physico-ecological and socio-economic components of environment. Such predictions delineate contribution in existing baseline data for the operational project and superimpose over the baseline (pre-project) status of environmental quality to derive the ultimate (post-project) scenario of the environmental conditions due to the proposed project. The quantitative prediction of impacts lead to delineation of suitable environmental management plan needed for implementation during the construction, commissioning and operational phases of the proposed project in order to mitigate the adverse impacts on environmental quality.

Mathematical models are the best tools to quantitatively describe the cause- effect relationship between source of pollution and different components of environment.

4.2. Potential Impacts during Project Implementation

4.2.1. Impact on Air Environment

The potential impacts on air quality due to the construction of proposed modernisation and expansion will be temporary rise in SPM and RSPM levels likely to result from:

1. Fugitive dust emissions at the construction site

2. Use of unpaved roads and truck tracks by the construction vehicles

3. Operation of the concrete, asphalt and hot mix plants

Besides, SPM and RSPM levels, the air quality impacts will also be due to increase in gaseous emissions like NOx, SO2, and HC. Bulldozers, excavators, cranes, and welding machines etc will contribute to gaseous emissions through use of diesel as fuel. Gaseous emissions viz. NOx, SO2, hydrocarbons are envisaged from these equipment during construction.

Construction activity is limited only to the project site and hence unlikely to cause any change in the ambient air quality around the proposed project. As the emission level is very low and intermittent, quantitative predictions are not possible due to limitations of the dispersion model. Therefore, considering all the air pollutants, it is not expected that air emissions due to construction will exceed air quality standards (NAAQMS).



Sprinkling water on the deposited earth material shall minimize emissions of particulate. The rate of emission of dust, its predicted rates of deposition and the temporary nature of the dust generating activities is expected to be well within acceptable limits. Also vehicles transporting earth and other construction material to the site will be covered to ensure their dust particles do not escape into the air. During construction all earth material will be kept covered to minimize impact on the ambient air quality.

KFCL plant is surrounded with other industries and no agriculture and forestland is near by. There will be little and temporary impact on surrounding area due to project implementation.

4.2.2. Impact on Land Environment

The activities of proposed expansion program will be confined to the project site within the boundary of Plant complex. Actually the modernization and increase in production will be in during construction, top soil generated from various activities like excavation etc. will be stored and preserved to use it during restoration period as far as possible. There will be no disposal of wastewater on land. Hazardous wastes will be stored at earmarked area with impervious flooring, shed and spillage/ leakage collection system to eliminate rainwater contamination, chances of overflow / spillages going on to the land and thus land/ soil contamination. Hazardous wastes will be disposed as per Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2009. The proposed expansion will be in existing plant area. No additional land is required.

KFCL plant is surrounded with other industries and no agriculture and forest land is near by. There will be little and temporary impact on surrounding area due to project implementation. No impact is likely to occur on the land/ soil quality during construction and operation phase in view of above mitigative measures.

4.2.3. Impact on Ambient Noise Level

Noise level of the project area will increase during construction phase due to heavy vehicles movement and other construction activities. The workers will be provided ear plug/ ear muffs, wherever required. The noise level will be localized and will be intermittent during construction stage and hence no significant impact is envisaged. Although there is no specific noise-sensitive fauna has been recorded near to project site but avifauna and small animals can be affected by increased noise level. In such cases they can change their habitat (in KFCL case since it is industrial area, there will be little / temporary impact on surrounding).

4.2.4. Impact on Water Quality

During construction, water will be needed mainly for construction and domestic purpose i.e. for drinking and sanitation. Drinking and sanitation facilities shall be provided to workers and staff during construction. Water will also be needed for sprinkling to reduce dust emission, if any.

The water required in the above activities will be only a fraction of total water required. Moreover, this requirement will be irregular and limited to construction phase only and hence no impact is envisaged during construction phase. The domestic wastewater



generated from the sanitation facility will be led to the existing ETP and hence no impact is envisaged.

4.2.5. Impact on Soil Environment

During construction, top soil generated from various activities like excavation etc will be stored and preserved to use it during restoration period as far as possible. There will be no disposal of wastewater on land. Hazardous wastes will be stored at earmarked area with impervious flooring, shed and spillage/ leakage collection system to eliminate rainwater contamination, chances of overflow / spillages going on to the land and thus land/ soil contamination. Hazardous wastes will be disposed as per the Hazardous Waste Rules.

No impact is likely to occur on the soil quality during construction and operation phase in view of above mitigative measures.

4.2.6. Impact due to Solid Waste / Hazardous Waste

During construction, top soil generated from various activities like excavation etc. will be stored and preserved to use it during restoration period as far as possible. Hazardous wastes (Used oil and other materials) will be stored at earmarked area with impervious flooring, shed and spillage/ leakage collection system to eliminate rainwater contamination, chances of overflow / spillages going on to the land and thus land/ soil contamination are eliminated. Hazardous wastes will be disposed as per the Hazardous Waste Rules. Disposal mechanism of Hazardous wastes will be followed as per norms.

4.2.7. Impact on Terrestrial Ecology

Based on study conducted for ecology in the study area, no rare or endangered terrestrial and aquatic flora/fauna were noted in the study area. The developed greenbelt and green cover in the project area would increase the flora and fauna density in the area at the project site.

The project activity does not require tree cutting during land clearing (as it is in existing plant). Also, the study zone does not have any ecologically sensitive location. Further, mitigative measures discussed in above for air, water, land etc will be taken.

The impacts are summarized below:

RET Species

Recorded/reported floral species from the present study area was assessed for their conservation status by cross-checking with Red Data book of Indian plants (by Nayar and Sastry, 1987-90) and IUCN but none of the plant texa found under RET category of IUCN. Among mammals, all the recorded species come under the Least Concerned (LC) category of IUCN Red Data Book and no species has been categorized under RET category. The Indian Wildlife Protection Act (1972) also scheduled the animals in various categories for given them varying degree of protection and among recorded mammals, no species has been recorded under Schedule-I category. (Table 3.21) Among recorded bird species, one species Pavo cristatus was reported from the study area which comes under the Schedule-I (Part III) of Wildlife Protection Act, 1972. (Table 3.22)

Loss of species/habitat



Present primary study revealed the presence of few shrubs individuals along with some patches of herbs like Cynodon dactylon in the area. These shrub and herb species are more vigorously present in the buffer area of project. Actually the present activity area is a vacant piece of land within the existing premises of the Kanpur Fertilizer Plant and being used for transportation and open storage activity therefore, the project activities will not cause any significant loss of important flora. Primary study also confirmed that core zone of project is not the habitat of any significant faunal species i.e. nests, dens, corridor etc.

Dust Generation

Terrestrial flora can also be affected by the dusty environment to be created due to vehicular movement during construction phase. Increment in the density of the dust particles (SPM) in the atmosphere can affect the surrounding vegetation by blockage and damage to stomata, reduction in chlorophyll content, abrasion of leaf surface or cuticle and all these disturbances ultimately affect photosynthesis process and plant metabolism which leads to reduction in plant growth up to some extent. Dust has an inhibiting growth on plants and creates allergy and respiratory disorder in animals. The soil property and micro flora and fauna are also affected by dust.

Noise Pollution

Noise level of the project area will be increased during construction phase by internal transport system and operation of various machineries. Although there is no specific noise-sensitive fauna has been recorded near to project site but avifauna and small animals can be affected by increased noise level. In such cases they can change their habitat for save nesting and feeding.

Congregation of Labour

Construction activities often require a considerable workforce and associated support services. Manpower required during the construction phase is about 400 people. The daily life activities of this increased human population may contribute to local environmental impacts especially on the biodiversity of the area. They can disturb local biodiversity by collecting firewood and food as well as enhancing recreational activities.

In view of the above, the plant activities are not expected to have any adverse impact on the ecology and biodiversity.

4.2.8. Impact on Socio-Economic Environment

Critical analysis of socio-economic profile of the area vis-à-vis its scenario with proposed project activities indicate that the impacts of the project are expected to be of varying nature.

Direct and indirect job opportunities are expected to be created by the proposed modernization and expansion during operation as well as the construction phases. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. There is a positive effect due to improved communication and health services, which have lead to economic prosperity, better educational opportunities and access to better health and family welfare facilities.



The local economy will receive a stimulus in the form of greater economic growth and avenues for income generation with the arrival of the project. Local quality of life is expected to improve. This factor combined with all other mitigation measures, like proper treatment of wastewater and gaseous emissions and proper disposal of hazardous waste will minimized the adverse impact on ecology and will have a beneficial impact on human settlement and employment opportunities. There will be beneficial impact on the local socio-economic environment. There shall be no displacement of any population in plant area.

4.2.9. Site Security & Safety

KFCL modernization and increase in production is within the existing operational plant. KFCL is having a OHS department and Security system. All possible security and safety measures will be taken to ensure safety and security both during Construction and operation phases.

4.2.10. Health and Well being of Construction Workers

Construction activities often require a considerable workforce and associated support services. KFCL is having a OHS department which will look after the safety and welfare of construction workers through respective contractors. The workers will be provided with all basic amenities i.e. Toilets, rest rooms, canteen etc. facilities. Since KFCL is in Kanpur zone most of the workers are likely to come from near by areas.

4.3. Potential Impacts during Project Operation

4.3.1. Impact on Air Environment

Prediction of impacts of the proposed de-bottlenecking on air environment i.e. ambient air quality was carried out using computer based air quality simulation model known as ISCST3 View 6.2 model of Lakes Environment.

In the present study, the mathematical model that has been used for predictions on air quality includes steady state Gaussian Plume Dispersion model designed for multiple point sources.

The impacts on air quality from any project depend on various factors like design capacity, configuration, process technology, raw material, fuel to be used, air pollution control measures, operation and maintenance. Apart from the above, other activities associated with any project are Operation phase: transportation of raw materials and finished products, storage facilities and material handling within the plant premises may also contribute to air pollution.

The major air pollutants expected to be emitted from KFCL proposed expansion project are Nitrogen oxides (NOx), Sulfur oxides (SOx), Ammonia (NH3), particulate matter less than 10 microns (PM10) and particulate matter less than 2.5 microns (PM2.5). The major sources of continuous emissions from the proposed project are 3 stacks attached to Primary Reformer, 3 stacks attached to Process Air Natural Gas Heater, 2 stacks attached to CPP boiler and 3 stacks attached to the Prilling Tower.

4.3.1.1 Model Details

In the proposed project, prediction of impacts on air environment has been carried out employing mathematical model based on a Steady State Gaussian Plume Dispersion Model designed for multiple point sources for short term. In the present case, Industrial Source Complex Short-term (ISCST3) dispersion model based on



steady state Gaussian Plume Dispersion, designed for multiple point sources for short term and developed by United States Environmental Protection Agency (USEPA) has been used for simulations from point sources.

The hourly wind speed, solar insulation and total cloudiness during day time and wind speed and total cloudiness during night time were used to determine the hourly atmospheric stability classes (defined by Pasquill and Gifford as A to F, A being most unstable and F being most stable). The hourly stability classes were determined based on the technique suggested by Turner.

The predictions for air quality during operation phase were carried out for particulate matter less than 10 microns (PM10), particulate matter less than 2.5 microns (PM2.5), oxides of sulphur (SOx), oxides of Nitrogen (NOx) and ammonia (NH3) concentration using ISCST3.

The options used for short-term computations are:

The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of the mixing layer

Stack tip down-wash is not considered

Buoyancy induced dispersion is used to describe the increase in plume dispersion during the ascension phase

Calms processing routine is used by default

Wind profile exponents is used by default

Flat terrain is used for computation

Pollutants do not undergo any physico-chemical transformation

No pollutant removal by dry deposition

Universal Transverse Meter (UTM) coordinates have been used for computation

A uniform polar grid was used for the computation and extended to 10 km from the center of the proposed project. In addition to that, receptors were also placed at the sampling locations.

4.3.1.2 Emissions

The emission rates and stack parameters for the proposed expansion are listed in Tables 4.1 and 4.2 respectively.

In order to estimate the worst-case scenario, the ground level concentration was computed considering the plant emissions. 24-hourly average ground level concentrations of SOx, NOx, PM10, PM2.5 and NH3 were computed for 24-hour mean meteorological data of post-monsoon season (October through December, 2014).



Table 4.1 : Details of Gaseous Emissions – Proposed Expansion

S. No. Stack Name No. of Stack

Pollutant Conc.

g/s

PM10 PM2.5 SOX NOX NH3

1 Primary Reformer

Stack 1

3

-- -- -- 5.12 --

Stack 2 -- -- -- 5.12 --

Stack 3 -- -- -- 5.12 --

2

Process Air Natural Gas Heater

Stack 1

3

-- -- -- 0.78 --

Stack 2 -- -- -- 0.78 --

Stack 3 -- -- -- 0.78 --

3

CPP Boiler

Stack 1 2

8.77 3.51 183.33 40.71 -

Stack 2 0.69 0.28 66.67 39.74 -

4 Prilling Tower

Urea A

3

2.48 0.99 -- -- 6.19

(A & B) Urea B 2.48 0.99 -- -- 6.19

5 Prilling Tower C 2.48 0.99 -- -- 6.19 Emissions for PM10 are calculated at 40% of SPM and emissions for PM2.5 is calculated at 40% of PM10 emissions. For CPP boiler stacks, emissions for SOx is calculated with the maximum sulphur content of imported coal and coal consumption (55 TPH for 60 MW and 20 TPH for 35 MW) of the Indian coal which represents the worst case scenario.

Table 4.2 : Stack Parameters – Proposed Expansion

S. No. Stack Stack Height

(m)

No. of Stack

Flow Rate

Nm3/hr

Stack Temp (0C)

Stack gas

Velocity (m/s)

Stack Dia

at top (m)

1 Primary Reformer

Stack 1

45.7m 3 92200 159.5 9.763 2.3 Stack 2

Stack 3

2

Process Air Natural Gas Heater

Stack 1

43.3m 3 14100 130 6.8 1.04 Stack 2

Stack 3

3 CPP Boiler

Stack 1 125 m 2

1578783

140 20 6.5

Stack 2 84 m

124047.5 150 17 2

4 Prilling Tower

Urea A

70.0m 3 446000 60

0.7603 14.404*

(A & B) Urea B 0.7603 14.404*

5 Prilling Tower C 35 0.9087 13.1749*

* Equivalent Dia. (M) of Umbrella Portion of Prilling Tower

4.3.1.3 Meteorological Data

The meteorological data consists of wind speed, direction, temperature, humidity, solar radiation, cloud cover and rainfall recorded during the post-monsoon months of



October through December, 2014, on an hourly basis. Wind speed, wind direction and temperature have been processed to extract the 24–hourly mean meteorological data for application in ISCST3.

4.3.1.4 Receptor Locations

A total of about 118 receptors – 112 receptors of which were generated with a polar grid from the center of the proposed project and extended to 10 km. Apart from these receptors, the 6 sampling locations were also taken into account to assess the incremental load on the baseline environmental scenario.

4.3.1.5 Summary of Predicted GLCs

The summary of maximum ground level concentrations (GLCs) for the proposed expansion project and its impact on the study area under the worst meteorological scenario is listed in Table 4.3.

Table 4.3 : Summary of Maximum 24-hour GLC due to the Proposed Expansion Project

Description Concentration (g/m3) SOx NOx PM10 PM2.5 NH3

Maximum Rise in GLC 20.24 21.82 13.60 5.44 33.97 Direction of Occurrence SE SE SE SE SE

Distance of occurence (km)* 4.0 4.0 1.0 1.0 1.0 Maximum Baseline

Concentration reported 13.6 27.3 217.0 142.0 46.7

Total Concentration (Post Project Scenario) 33.84 49.12 230.60 147.44 80.67

Prescribed Standards 80 80 100 60 400 * The distance is measured from center of Plant Boundary to the receptor of maximum GLC.

The above table shows that in the worst case scenario, the maximum ground level concentration due to the proposed expansion project will be in the predominant SE direction and below the prescribed standards for each of the gaseous pollutants modeled. However, post-project GLCs for PM10 and PM2.5 are exceeding the prescribed standards due to higher background concentration because of the surrounding industries. It should be noted that the project impacts for PM10 and PM2.5 are just 13% and 9% of the prescribed standards respectively.

Additionally, the cumulative impact of the proposed expansion project at the monitoring locations within 10 km radius is provided in Table 4.4.

Table 4.4 : Summary of Maximum GLC at Monitoring Locations

Location Rise in GLC

(g/m3)


(g/m3)


NAAQS (g/m3)

Near the Project

Site

SOx 0.00 12.00 12.00 80 NOx 0.02 26.10 26.12 80 PM10 0.02 217.00 217.02 100 PM2.5 0.01 142.00 142.01 60 NH3 0.04 46.70 46.74 400



Location Rise in GLC

(g/m3)


(g/m3)


NAAQS (g/m3)

Daboli

SOx 13.35 13.60 26.95 80 NOx 13.68 27.30 40.98 80 PM10 3.48 175.00 178.48 100 PM2.5 1.39 74.00 75.39 60 NH3 8.31 24.40 32.71 400

Gujeni

SOx 8.33 12.70 21.03 80 NOx 12.74 19.60 32.34 80 PM10 5.83 215.00 220.83 100 PM2.5 2.33 88.00 90.33 60 NH3 14.34 27.20 41.54 400

Singpur Kathar

SOx 0.02 12.30 12.32 80 NOx 0.02 25.70 25.72 80 PM10 0.00 86.00 86.00 100 PM2.5 0.00 41.00 41.00 60 NH3 0.01 25.70 25.71 400

Panki

SOx 2.55 12.30 14.85 80 NOx 3.41 26.30 29.71 80 PM10 1.07 187.00 188.07 100 PM2.5 0.43 82.00 82.43 60 NH3 2.61 23.80 26.41 400

Bhauti Khera

SOx 5.36 13.30 18.66 80 NOx 5.33 26.60 31.93 80 PM10 1.20 139.00 140.20 100 PM2.5 0.48 47.00 47.48 60 NH3 2.86 21.90 24.76 400

Discussion of the impacts at monitoring locations:

SOx: The total impacts from the proposed project indicate maximum SOx concentration of 26.95 µg/m3 at Daboli village with project impacts of 13.35 µg/m3 and baseline contribution of 13.60 µg/m3. The total impact from the project (26.95 µg/m3) is well within the stipulated standard of 80 µg/m3 for industrial as well as residential areas.

NOx: The total impacts from the proposed project indicate maximum NOx concentration of 40.98 µg/m3 at Daboli village with project impacts of 13.68 µg/m3 and baseline contribution of 27.30 µg/m3. The total impact from the project (40.98 µg/m3) is well within the stipulated standard of 80 µg/m3 for industrial as well as residential areas.

PM10: The total impacts from the proposed project indicate maximum PM10 concentration of 220.83 µg/m3 at Gujeni village with project impacts of 5.83 µg/m3 and baseline contribution of 215.00 µg/m3. The total impact from the project (220.75 µg/m3) is exceeding the stipulated standard of 100 µg/m3 for industrial as well as residential areas due to the higher background concentration because of the surrounding industries. It should be noted that the project impacts for PM10 are less than 6%of NAAQS.

PM2.5: The total impacts from the proposed project indicate maximum PM2.5 concentration of 142.01 µg/m3 near the Project Site with project impacts of 0.01



µg/m3 and baseline contribution of 142.00 µg/m3. The total impact from the project (142.01 µg/m3) is exceeding the stipulated standard of 60 µg/m3 for industrial as well as residential areas due to the higher background concentration because of the surrounding industries. It should be noted that the project impacts for PM2.5 are less than 0.02% of NAAQS.

NH3: The total impacts from the proposed project indicate maximum NH3 concentration of 46.74 µg/m3 at the project site with project impacts of 0.04 µg/m3 and baseline contribution of 46.70 µg/m3. The total impact from the project (46.74 µg/m3) is well within the stipulated standard of 400 µg/m3 for industrial as well as residential areas.

As is evident from the table and discussion above, there will be no adverse impacts on the surrounding area from just the proposed project. The ambient quality of the surrounding area however has high PM10 and PM2.5. Highly efficient air pollution control systems will be adopted to mitigate particulate matter as well as gaseous emissions in the ambient environment. Electrostatic precipitators (ESP) with 99.9% efficiency are proposed to control the particulate emissions from the proposed expansion project and limit the particulate matter emissions to 50 mg/Nm3. Low NOx burners with a control efficiency of 70% are proposed to control NOx emissions from the proposed expansion project.

The isopleths for the pollutants are provided in Figures 4.1 through 4.5.

EIA/EMP Report of Proposed Expansion Project of Kanpur Fertilizer & Cement Limited


Figure 4.1 : Isopleth for SOx



Figure 4.2 : Isopleth For NOx



Figure 4.3 : Isopleth For PM10



Figure 4.4 : Isopleth For PM2.5



Figure 4.5 : Isopleth For NH3



4.3.2. Impact on Land Environment Essentially, the two major problems normally faced in impact on land environment due to any development project are:

Diversion of land from designated use to the ‘project use’. Deterioration of land / soil in terms of soil fertility and toxicity.

4.3.2.1 Land Diversion

KFCL expansion project is being located within the existing premises and as such no additional land is required. Since there is no additional land required for KFCL expansion project, no soil erosion or diversion of land is involved.

4.3.2.2 Land Deterioration

Low soil fertility is attributable to either to low levels of nutrients {e.g. nitrogen, phosphorus, potassium etc.} in the soil or their being made unavailable for plant intake in some way. High levels of elements or compounds being present in the soil cause soil toxicity. Some elements, which are essential and beneficial for crops at low concentrations, become toxic to crops at higher concentrations. There can be slight increase in nitrogen content of the soil due to limited plant emission from Urea plant and will have positive impact on the on the plant growing in the area. Proposed expansion project will improve the nitrogen availability in the area and consequently better crop yield.

The solid wastes (coal ash) generated in the plant will be used as pozzolonic materials in Cement Grinding Unit (in-house) for PPC production. The plant operations after KFCL modernization and increase in production project will be similar emission and solid waste and as such not have any impact which is likely to affect soil, or effluents release likely to affect soil. As such soil chemistry is not going to be affected with KFCL proposed expansion project.

4.3.3. Impact on Ambient Noise Level

The sources of noise during the operational phase of the plant are mainly turbines compressors, blowers, pumps and reformer furnaces. The other sources of noise are the movement of vehicles along the road. The proposed modernisation and expansion project will be similar but will have advanced technology and improved equipment both in terms of energy efficiency and less noisy.

4.3.3.1 Impacts due to Transportation

Noise level contributed from light medium and heavy vehicles on the roads can be considerable depending upon the traffic density. The area around the employees and material gates is the traffic- affected areas due to transportation activities. The light vehicles and two wheelers pass at the shift hours only except vehicles of the visitors, which are limited only. The heavy commercial vehicles traffic is limited depending upon the material receipt and dispatch of fertiliser through road transport. The large quantity of fertiliser will be dispatched through railway rakes also.

4.3.3.2 Impact on Community

Equivalent sound levels are often used to describe community exposures to noise. Noise survey was also carried out at six locations outside the plant but within the study area. Equivalent noise levels were measured for residential area and also in other



places in study areas (Chapter - 3). The Leq (day time) for these areas is found to be well within the prescribed limit of 55 dB(A) and similarly Leq (night time) for all locations was within the prescribed limit of 45 dB(A).

The noise level norms in villages of study area are being met with respect to the norms of ‘Ambient Air quality Standards in Respect of Noise’.

The operation of KFCL proposed expansion project will have some noise level and as such will not have any adverse impact on the human settlement around it. The noise will not be audible beyond its boundary limit, particularly due to natural green belt and other measures.

4.3.4. Impact on Water Quality

Water during operational phase is normally required for:

Cooling Water

Boiler Feed Water

Process Water (acid dilution / granulation/ scrubbing/washing etc.)

Domestic and Green Belt

Water requirement for Expanded Plant is around ~ 21200 m3/day including 400 m3/day for domestic purpose. The total water consumption after proposed expansion project will be therefore 21600 m3/day. The total fresh water in plant consumption has been reduced due to recycle of 3725 m3/day treated effluents and recycle of treated domestic effluents from STP for dust suppression and Green belt development.

Letter from Govt. of UP (Jt. Secretary) for restoration of water supply from Lower Ganges Canal, Kanpur is enclosed as an attachment in Annexure-III.

Proposed project will be having most modern ETP ensuring total recycle of treated effluent and adhering to “Zero Effluent” policy. There will not be any adverse impact on

land or any water body.

4.3.4.1 Storm Water

KFCL is having well laid storm water drainage system to drain out rain water during rainy season. No process drain / plant washing or domestic effluent goes to storm water drain.

4.3.4.2 Effluent Generation and Discharge

KFCL has already modernized the Effluent Treatment Plant (ETP) facilities for the requirements of expanded capacity in advance. The proposed expansion project along with existing plant will generate 180 m3/hr effluents which will be treated in the ETP. Out of 180 m3/hr, 155.21 m3/hr of treated effluents will be recycled back to plant. Reject water from ETP will be used for dust suppression in coal stockpile area and horticulture. Balance of only 0.79 m3/hr sludge will be disposed off through Common Hazardous Waste Treatment Storage and Disposal Facility (CHW TSDF) of M/S Uttar Pradesh Waste Management Project. (UPWMP) (Refer Figure 2.14). Thus KFCL propose to follow “Zero discharge” philosophy. Industrial wastewater after treatment will be effectively utilized in process and for horticulture/ green belt development. There will be no impacts on Surface or Ground water bodies.

Proposed modernisation and expansion project will be nearly is zero effluent plant.



4.3.5. Impact on Soil Environment

There will be no disposal of wastewater on land. Hazardous wastes will be stored at earmarked area with impervious flooring, shed and spillage/ leakage collection system to eliminate rainwater contamination, chances of overflow / spillages going on to the land and thus soil contamination. Hazardous wastes will be disposed as per the Hazardous Waste Rules.

No impact is likely to occur on the soil quality during construction and operation phase in view of above mitigative measures.

4.3.6. Impact due to Solid Waste/ Hazardous waste

There are no major source of hazardous waste generation due to the proposed KFCL project that would be causing harm to the environment. The hazardous wastes will be similar to existing plant namely catalyst, used oil, ETP sludge etc. The wastes will be stored in well-designed godowns and disposed off to approved buyers or sent authorized disposal site. The Hazardous waste will not have any adverse impact on soil, land or water bodies.

KFCL has taken the membership of Common Hazardous Waste Treatment Storage and Disposal Facility (CW TSDF) of M/s. Uttar Pradesh Waste Management Project (UPWMP, a division of Ramkey Enviro Engineers Ltd.) and reached a legal agreement of HW collection, transportation, treatment and disposal at UPWMP CHW-TSDF site. Copy of the agreement is attached as Annexure XII.

4.3.7. Impact on Terrestrial Ecology

Based on study conducted for ecology in the study area, no rare or endangered terrestrial and aquatic flora/fauna were noted in the study area. The developed greenbelt and green cover in the project area would increase the flora and fauna density in the area at the project site.

The project activity does not require tree cutting during land clearing. Also, the study zone does not have any ecologically sensitive location. Further, mitigative measures discussed in above for air, water, land etc will be taken.

The impacts are summarized below:

RET Species

Recorded/reported floral species from the present study area was assessed for their conservation status by cross-checking with Red Data book of Indian plants (by Nayar and Sastry, 1987-90) and IUCN but none of the plant texa found under RET category of IUCN. Among mammals, all the recorded species come under the Least Concerned (LC) category of IUCN Red Data Book and no species has been categorized under RET category. The Indian Wildlife Protection Act (1972) also scheduled the animals in various categories for given them varying degree of protection and among recorded mammals, no species has been recorded under Schedule-I category. (Table 3.21) Among recorded bird species, one species Pavo cristatus was reported from the study area which comes under the Schedule-I (Part III) of Wildlife Protection Act, 1972. (Table 3.22)




Present primary study revealed the presence of few shrubs individuals along with some patches of herbs like Cynodon dactylon in the area. These shrub and herb species are more vigorously present in the buffer area of project. Actually the present activity area is a vacant piece of land within the existing premises of the Kanpur Fertilizer Plant and being used for transportation and open storage activity therefore, the project activities will not cause any significant loss of important flora. Primary study also confirmed that core zone of project is not the habitat of any significant faunal species i.e. nests, dens, corridor etc.

Dust Generation

Terrestrial flora can also be affected by the dusty environment to be created due to vehicular movement during operation phase. Increment in the density of the dust particles (SPM) in the atmosphere can affect the surrounding vegetation by blockage and damage to stomata, reduction in chlorophyll content, abrasion of leaf surface or cuticle and all these disturbances ultimately affect photosynthesis process and plant metabolism which leads to reduction in plant growth up to some extent. Dust has an inhibiting growth on plants and creates allergy and respiratory disorder in animals. The soil property and micro flora and fauna are also affected by dust.

Noise Pollution

Noise level of the project area will be increased during operation phase by internal transport system and operation of various machineries. Although there is no specific noise-sensitive fauna has been recorded near to project site but avifauna and small animals can be affected by increased noise level. In such cases they can change their habitat for save nesting and feeding.

In view of the above, the plant activities are not expected to have any adverse impact on the ecology and biodiversity.

4.3.8. Impact on Socio-Economic Environment

Direct and indirect job opportunities are expected to be created by the proposed modernization and increase in production project during operation as well as the construction phases. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. There is a positive effect due to improved communication and health services, which have lead to economic prosperity, better educational opportunities and access to better health and family welfare facilities.

The local economy will receive a stimulus in the form of greater economic growth and avenues for income generation with the arrival of the project. Local quality of life is expected to improve. This factor combined with all other mitigation measures, like proper treatment of wastewater (zero effluent philosphy) and gaseous emissions and proper disposal of hazardous waste will minimized the adverse impact on ecology and will have a beneficial impact on human settlement and employment opportunities. There will be beneficial impact on the local socio-economic environment. There shall be no displacement of any population in plant area

Proposed Activities for Social and Inclusive Development:

The development activities needs to taken up, based on the requirement of the people in the area. The basic requirement of the community needs to be



strengthened by extending health care, educational facilities and infrastructure development. Company proposes to undertake following activities for social and inclusive development of surrounding area:-

A. Education of children from disadvantaged sections of society living in the neighborhood.

B. Skill Building / Vocational training of youth who have technical aptitude for a period of 6 months to 3 years.

C. Preference to unskilled / skilled persons living in the neighborhood in casual employment till they find suitable livelihood.

D. Periodic medical Camps in the neighboring villages and offer medicines to under privileged persons.

E. Construction of Roads from neighboring villages to Main Road.

With these objectives KFCL propose to carry out various activities in the surrounding areas (details given in section 2.13). KFCL has allotted Rs. 80 Lacs for various CSR activities.

4.3.8.1 Positive Impacts

Proposed expansion project of the plant would result in handling of more product and raw material, which will increase manpower requirement at some stages directly, or indirectly resulting in more income of people.

KFCL expansion project would increase requirement from ancillary and auxiliary industries in the vicinity e.g. bagging units.

More income to Government through more taxes on higher amount of production.

4.3.8.2 Negative Impact

Increased traffic on road due to more raw material requirement and more production results in deterioration of road and increase likelihood of accidents.

However these can be handled and safety on roads can be ensured through increased awareness and better management of resources.

Critical analysis of socio-economic profile of the area vis-à-vis its scenario with proposed project activities indicate that the impacts of the project are expected to be of varying nature.

4.3.9. Foul Odour Problem

KFCL existing plant as well as proposed modernization project will have only one material with odour i.e. Ammonia. Ammonia is toxic and stored in large tanks. Naphtha (earlier main raw material) is no more stored (replaced with NG). KFCL is taking all precautions to prevent any ammonia leakage as a safety measure. No odour problem is likely to occur from the proposed project.



CHAPTER 5. ENVIRONMENT MANAGEMENT PLAN & ENVIRONMENTAL MONITORING PROGRAM

5.1. Introduction

Prediction of the potential adverse environmental and social impacts arising from development interventions is at the technical heart of EIA process. An equally essential element of this process is to develop measures to eliminate, offset, or reduce impacts to acceptable levels during implementation and operation of projects. The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental Management Plan (EMP).

Normally, potential impacts are identified early during the initiation of project, and measures to avoid or minimize impacts are incorporated into the alternatives being considered. In this respect, some of the most important measures to protect the environment and local communities become integral to the project design, and may not be reflected in a formal EMP.

KFCL by way of EIA study propose to identify all the likely potential impacts, collect data information and incorporate all the measures necessary to avoid or minimize impacts on surrounding environment. Many of the mitigation measures are already in place as this is the case of expansion of the plant. It is desirable to collect even such information in the EMP to facilitate better assessment and communication as well as improve the systems and technologies to improve mitigation for environmental components having moderate residual impacts.

5.2. Environment Management Plan

Overall objective of EMP:

Prevention: Measures aimed at impeding the occurrence of negative environmental impacts and/or preventing such an occurrence having harmful environmental impacts.

Preservation: Preventing any future actions that might adversely affect an environmental resource or attribute.

Minimization: Limiting or reducing the degree, extent, magnitude, or duration of adverse impacts.

EMP for KFCL to enhance the fertiliser production capacity through expansion project considers the following aspects:

Description of mitigation measures

Description of monitoring program

Institutional arrangements

Implementation schedule and reporting procedures

Institutional framework includes the responsibilities for environmental management as well as responsibilities for implementing environmental measures.

5.2.1. Air Environment

The emission from KFCL proposed modernization expansion project shall be mainly from the various stacks (in Ammonia plant, Urea plant, and Power plant). Fugitive emissions while handling prilled urea will be recovered and recycled (as KFCL has experience of



dust collection and recovery system in bagging plant) or leakages in the plant. Coal / ash dust will be controlled In order to mitigate the adverse environmental impact due to the operation of proposed expansion project. Following measures are recommended:

The control measures (through proper up keep / maintenance) and good housekeeping will considerably reduce the fugitive emission.

Regular dust suppression through water spray at solid storages (coal yard/ ash pits).

Materials and ash should be transported in covered trucks,.

AAQ monitoring of air pollutants SOx, NOx, ammonia, and SPM should be regularly carried out.

Regular monitoring of shop floor environment is to be carried out to control the fugitive emission as well as shop floor safety.

Leakages {of gases / liquids/ dust} should be checked and promptly attended.

5.2.2. Water Environment

KFCL plant should take ample precautions to reduce water consumptions and tackle effluents problem. The KFCL propose to follow philosophy of segregation of effluent streams and treatment near the source and recycle back to the system. KFCL proposed modernisation and expansion project will be “Zero discharge” plant. Efforts should continue and new efforts should be directed to:

Possibility of increased use of treated effluents in horticulture and green belt developments.

Recycle of treated effluents in the system as far as possible (KFCL proposed modernisation and expansion project is going to be “Zero discharge” project).

The treated sewage should be effectively utilized in the plant or for irrigation in green belt.

The use of any chemical to check microbial activity should be avoided, as it would harm the human health and fauna.

Use of pesticide and herbicide should be avoided as they can cause ground water contamination.

KFCL should install three or more piezo metric wells at selected places (one near treated effluent pond) to see and check the ground water contamination.

Water is a precious commodity and it should be conserved.

Rain water harvesting should be taken up at different places.

5.2.3. Solid and Hazardous Waste Management

The proposed expansion project will generate the solid wastes (coal ash) similar (in quality as well as increase in quantity) to the existing system. Entire fly ash generated will be used as pozzolonic material in Cement Grinding Unit (in house) for PPC production.Used catalyst will be sold back to suppliers. However some wastes (oily sludge from machines/ empty bags/ paper/cotton wastes etc.) will be similar and the proposed handling philosophy for the same is to continue. No additional measures are required.



5.2.4. Noise Environment

The statutory national standards for noise levels at the plant boundary and at residential areas near the plant are being and are to be met. The following mitigation measures are proposed to meet the objectives:

The selection of any new plant equipment is to be made with specification of low noise levels. Noise suppression measures such as acoustic enclosures / cabins, buffers and / or protective measures are be provided (wherever noise level is around +80 dB (A) and exposure limits to workers is likely to be more than 8 hours a day) to limit noise levels within occupational exposure limits. Areas with high noise levels are to be identified and segregated where possible and will include prominently displayed caution boards.

However, in areas where noise levels are high and exposure time is less, employees will be provided with ear protection measures like earplugs or earmuffs. Earplug should be provided to all workers where exposure level is > 85 dB (A). The exposure of employees working in the noisy area should be monitored regularly to ensure compliance with the regulatory requirements.

The existing practice of regularly monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures.

The green belt around the plant to attenuate the noise level but instead of block plantation there should be variability in tree height and shape, as this would disperse the sound waves more efficiently. Plant that attenuate should be planted at the noise zone.

5.2.5. Occupational Health Program

KFCL has developed OHS system in the plant as given in Section 2.12. The system is working well and it should be updated based on mock drill response on various critical scenarios evaluation.

5.2.6. Biological Environment


The mitigation measures for each of the impacts identified are proposed below:

RET Species

Although there are various animals recorded/reported from the Allen Zoo which come under RET categories but there is no chance of habitat and feeding disturbance due to present proposed expansion project. The zoo grounds are also professionally maintained by forest conservationists and the zoo includes a veterinary hospital that treats up to 1,400 animals at a time. (Malhotra, Abhina 2010) Since common peafowl species recorded adjacent to villages, and there is no specific habitat and feeding ground is available for the species within the project area therefore no impact will be assumed on the species.


Based on the field observations and interaction with local people and forest officials, it was noticed that the project area does not associated with any National Park/Wildlife Sanctuary/Conservation Reserve and there is no wildlife migratory routes present in the project area. The nearest Dudhwa National Park (UP) and Panna National Park

http://en.wikipedia.org/wiki/Forest

http://en.wikipedia.org/wiki/Conservation_movement



(MP) are about 300 km away from the present project location. Primary study also confirmed that there is no removal of any significant flora from the project area, no removal of praying with pray of predatory animals and no noises disrupting breeding behavior or use of breeding grounds. Improvement in the green cover under a regular plantation programme (Greenbelt Development Programme) will not only increase the plant diversity in the area but also enhance the habitat for wildlife especially for avifauna.

Fly ash/Gaseous/Dust/Noise Pollution

Several gases, dust and Fly Ash produced during the operation of the present project. Fly ash produced after burning coal in the boiler will be collected in ESP and will be conveyed pneumatically to storage silo locate within the plant premises. Entire fly ash generated will be used as pozzolonic material in Cement Grinding Unit (in house) for PPC production. The industry will adopt stack height of as per norms (based on “S”) and will control SPM levels through ESP and NOx through low NOx burners. Development of multi-layer plantation (green belt) around the proposed project area will also help to mitigate gaseous pollution, dust pollution, noise and fly ash pollution within and around the project area.

Congregation of Labour

Manpower is required during the construction (350 people for expansion and 400 people for CPP expansion) and operation phase (80 people for expansion and another 80 people for CPP expansion) which will be managed through: No permanent camping within the project area and nearby vegetated area, provision of fuel for laborers engaged in construction/operation activities, restriction on poaching/hunting of wild animals and removal of any vegetation.

The following activities are proposed under the management plan to mitigate/minimize the pressure on present bio-resources.

Plantation of Native Plant Species

Plantation of Medicinal Value Plant Species

Plantation of Dust Tolerant and Sound Receptor Plant Species

Plantation of Fruit Species to enhance the Food Availability for Wildlife

All the above mention activities can be achieved through greenbelt development by using useful plant species.

Greenbelt Development

A greenbelt will be developed under proposed project areas with the strip of plants along the roadside and around power plant area. The goal of installation a greenbelt would be to maximize both ecological functionality and scenic beauty of the area. The selected species will be indigenous and should have dust & noise tolerant, enhance aesthetics and develop a habitat for wildlife. A plantation of sound and dust receptor as well as aesthetically valuable species is proposed which will help in reduction of pollution (both atmospheric & noise), reduction of stress and beautification of the area. Hardiness, longevity, a minimum of wind through and breakage, attractiveness and minimal maintenance requirement are some qualities of species which are to be taken into consideration during selection. Municipal solid waste generated during construction period & during operation period, as well as from STP will be vermi-



composted and used as manure for green belt development. Greenbelt would be developed in the form of plantation around the Project area, Roadside plantation, and Avenue plantation in adjacent vacant land. By reviewing the various literatures and Central Pollution Control Board guideline for greenbelt development, following plant species has been chosen for greenbelt development listed in Table 5.1.

Table 5.1 : List of Plant species to be planted

S. No. Scientific Name Name Importance

1 Abutilon indicom Atibala OP, MP

2 Acacia nilotica Babool LH

3 Ailanthus ecelsa Mahanimb HI

4 Albezia lebbek Siris HI

5 Albezia procera Siris HI

6 Azadirachta indica Neem NB, SO2 tolerant

7 Bahunia variagata Kachnar HI

8 Bougainvillea spectabilis Bougainvillea AP, DR

9 Butea monosperma Dhak NB

10 Cassia fistula Amaltas AP

11 Dalbergia sissoo Shisham NB

12 Delonix regia Gulmohar AP

13 Dendrocalamus strictus Bans LH

14 Eucalyptus hybrid Eucalyptus HI

15 Ficus benghalensis Bargad DC

16 Grevillea robusta Silver Oak HI

17 Hibiscus-rosa-sinensis Gudhal HI, AP

18 Madhuca longifolia Mahua HI

19 Mangifera indica Aam NB, HI, DC

20 Moringa oleifera Sahjan MP, HI

21 Morus alba Sahtoot HI

22 Nerium odorum Nerium AP, OP

23 Polyalthia longifolia Ashoka AP, OP, IP, DR

24 Syzygium cumini Jamun HI, DC

25 Tectona grandis Sagaun DC

26 Terminalia arjuna Arjun NB

27 Terminalia bellerica Baheda DC, MP DC- Dust Collector, MP- Medicinal Plant, NB- Noise Barrier, HI- Habitat Improvement, AP- Avenue Plant, LH- Live Hedge [Source: CPCB Guideline for Greenbelt Development; Agro climatic Zone- Central Upper Gangatic Plain, Sub Zone- South Western Plain]

5.2.7. Land Environment

The proposed modernisation and expansion project will generate the solid wastes (coal ash) similar (in quality as well as increase in quantity) to the existing system. Entire fly ash generated will be used as pozzolonic material in Cement Grinding Unit (in house) for PPC production. However some wastes (oily sludge from machines/ empty bags/ paper/cotton wastes etc.) will be similar and the proposed handling philosophy for the same is to continue. No additional measures are required.



5.2.8. Socio-economic Environment

As a good corporate citizen and major industry KFCL may consider adopting few more selected villages in developing them as model villages.

Awareness program are to be initiated in immediate neighbouring villages about KFCL plant activities and the various EHS measures undertaken to make the plant safe and environment friendly.

KFCL should finalise the study and start carrying out CSR activities in coordination with district authorities.

5.2.9. Charter on Corporate Responsibility for Environmental Protection (CREP)

KFCL has adopted the Charter on Corporate Responsibility for Environmental Protection (CREP). The compliance of recommendation by charter for fertilizer industries has been presented in detail in Chapter 2.

5.2.10. Environmental Management Cell

KFCL already have an environment management cell headed by a senior executive supported by Manager (EC) and other supporting staff. The laboratory is equipped with necessary sophisticated instruments including:

Gas Chromatographs

Spectrophotometers

pH Meter

Conductivity Meters

Turbidity Meters

Online ambient air monitoring stations – at three locations

Online effluent monitoring station at final discharge point for Ph, Ammonia, etc.

Online stack monitoring station at Reformer and NG/PA stacks for NOx and SOx etc.

Online meteorologoical station – at one location

Flame photometers

MSA meters

Loviband comparator

Oven

BOD incubator

Refrigerator

Furnace

Jar test apparatus

Distillation assembly for determination of COD

Gas flow meters

BOD bottles

A team of well-trained and experienced staff carries out tests in the laboratory.



5.2.11. Environmental Monitoring Plan

KFCL is carrying out environment monitoring and has necessary equipment and associated facilities. However monitoring plan proposed is as follows:

Table 5.2 : Environmental Monitoring Program

Discipline Location Parameter Frequency Remarks Meteorology one Temp. {max.; min.}; Relative

humidity; Rain fall; Wind speed and direction.

Daily Shall be complied

Ambient Air Quality

Five PM10,PM2.5, SO2, NO2 and NH3 Twice a week Shall be complied

Stack Emission

All continuous stacks

NOx&SO2 in Reformer, stacks and NH3 & PM in Prilling Tower

Fortnightly

Shall be complied

Effluents

Final effluents (if any) discharge point

pH, Free NH3, TAN; TKN;NO3;TSS; PO4, Oil-grease; COD; BOD

As & when discharge or utilized for irrigation.

Shall be complied

Sanitary TSS; BOD Weekly Shall be complied

Ground Water Quality

{Peizo metric Wells / Hand pumps}

pH, NO3, Urea & NH3 Monthly Shall be complied

Surface Water Quality (Ganga Canal)

Two

pH, Free NH3, TAN; TKN;NO3;TSS; PO4, Oil-grease; COD; BOD

Monthly Shall be complied

Noise Plant area & neighbouring villages

Day & Night time noise level Monthly

Shall be complied

Health Check Up

All Plant Personnel

Occupational Health diseases Annually Shall be complied

5.2.12. Environmental Budget

The capital cost of equipments for environmental system proposed is around Rs 50.60 Crores and recurring cost will be around Rs. 11.735 Crores.

Table 5.3 : Capital Cost and Recurring Expenditure on Environmental Protection

S No Activity Capital in Crores Recurring Cost/ Year (Crores)

1 ETP 9.50 0.60 2 STP 2.00 0.12 3 ESP 12.50 0.875 4 Hold Up Tank & Hydrolyser Stripper 24.00 10.00 5 Environment Monitoring Stations 2.30 0.125 6 Green Belt Development 0.12 0.006 7 Miscellaneous 0.18 0.009 Total 50.60 11.735



CHAPTER 6. Hazards Evaluation & Risk Assessment

6.1. Introduction

KFCL would be handling all materials at the proposed expansion project. The storage of raw material is planned at the site location itself, so, in an unlikely event of release emergencies, there would be a potential risk to life and properties. Hence, the risk assessment study has been conducted for various parameters that include identification of hazards, to calculate consequence distances, to evaluate safety at the plant and to spell out risk mitigation measures to enhance safety at the plant.

6.2. Hazard Identification

Hazard is defined as a chemical or physical conditions those have the potential for causing damage to people, property or the environment. In this chapter the hazards associated with only the proposed expansion project have been discussed.

The primary step of the Hazard identification is the risk analysis and entails the process of collecting information on:

the types and quantities of hazardous substances stored and handled at the plant,

the location of storage tanks & other facilities, and

potential hazards associated with the spillage and release of hazardous chemicals.

6.2.1. Hazardous Materials to be Stored at the Plant

The major hazardous chemical to be stored at the KFCL site will be Ammonia and Chlorine. Though KFCL has large Naphtha storages (as earlier feed stock) but now they are redundant due to switch over to NG. Naphtha no more will be used.

The bulk storages at KFCL are as given below:

Table 6.1 : Bulk Storage Details

S. No Material Storage Details Remarks 1 Product Urea Silo- 25000 MT

2 Ammonia Ammonia Storage Tank : 1500 MT x 2 with 12 inch WC pressure, insulated, concrete outer wall, 3 refrigeration compressor package to receive 18 TPH liquid Ammonia at 30 0C

3 Coal Coal Storage yard : 16000 MT 4 Hydrochloric Acid 2X40 MT

2X32 MT 1X16 MT

- Area bunded and connected to Neutralising pit

5 Caustic Lye 1X40 MT 1X16 MT

6 Chlorine 4 X 100 kg Cylinders 6X900 kg Cylinders

7 HSD 2 x 15 KL

6.2.2. Characteristics of Hazardous Materials



Important characteristics of the hazardous material (i.e. Ammonia, Chorine, etc.) has been presented below:

KFCL will be using a number of materials but only few are stored in bulk and few chemicals are listed under “List of hazardous and Toxic Chemicals” category under

MSIHC Rules, 1989. The raw materials coming under hazardous category as specified by MSIHC Rules, 1989 (including subsequent amendments) is given in Table below:

Table 6.2 : Hazardous Materials (MSIHC Rules, 1989)

S. No

S. No & Threshold Quantity (TQ in MT) as per MSHIC Rules

Chemical Hazards Remarks

Schedule-1, Part-II

Schedule-2, Part-I

Schedule-3, Part-I

Hazards Toxic

1 Ammonia CAS No:7664-41-7 UN No:1005

31 2 TQ-1: 60 MT TQ-2: 600 MT

105 TQ-1: 50 MT TQ-2: 500 MT

Fire Hazards: Mixing of ammonia with several chemicals can cause severe fire hazards and/or explosions. Ammonia in container may explode in heat of fire. Health Hazards: Vapors cause irritation of eyes and respiratory tract. Liquid will burn skin and eyes. Poisonous; may be fatal if inhaled. Contact may cause burns to skin and eyes. Contact with liquid may cause frostbite.

ERPG-1: 25 ppm ERPG-2: 150 ppm ERPG-3: 750 ppm IDLH: 300 ppm

2 Chlorine CAS No:7782-50-5 UN No:1017 A greenish yellow gas with a pungent suffocating odour. Toxic by inhalation.

119 5 TQ-1: 10MT TQ-2: 25 MT

108 TQ-1: 10MT TQ-2: 25 MT

(Gas); Non Combustible; May ignite other combustible materials (wood, paper, oil, etc.). Mixture with fuels may cause explosion. Health Hazards: Poisonous; may be fatal if inhaled. Contact may cause burns to skin and eyes. Bronchitis or chronic lung conditions

ERPG-1: 1.0 ppm ERPG-2: 3.0 ppm ERPG-3: 20 ppm IDLH: 10 ppm

3 Hydrochloric acid (Gas) CAS No: 7647-01-0 UN No: 1789

313 Not Flammable; Inhalation of fumes results in coughing and choking sensation, and

ERPG-1: 3.0 ppm ERPG-2: 20 ppm ERPG-3:



S. No

S. No & Threshold Quantity (TQ in MT) as per MSHIC Rules

Chemical Hazards Remarks

Schedule-1, Part-II

Schedule-2, Part-I

Schedule-3, Part-I

Hazards Toxic

irritation of nose and lungs. Liquid causes burns

150 ppm IDLH: ---- ppm

4 Sodium Hydroxide CAS No: 1310-730-2 UN No: 1823

571 Not flammable; Corrosive to metals and tissue. Hazardous.

ERPG-1: 0.5 ppm ERPG-2: 5.0 ppm ERPG-3: 50 ppm IDLH: ---- ppm

KFCL is having storage of Ammonia more than threshold quantity and as such it comes under MAH category as per MSIHC Rules, 1989.

6.3. Methodology, Approach and Damage Criteria for Risk Assessment

Consequence analysis is that part of risk analysis, which considers individual failure cases, and the damage caused by the failure cases. It is done to predict the outcome of potentially serious hazardous accidents to man and material in and around the plant boundary limits. The advantages of carrying out consequence analysis are given below:

To improve plant layout To meet statutory requirements Protection of public in the nearby areas Disaster management planning Training tool

The findings of a consequence analysis provide information about hazardous effects resulting from an accidental scenario. In addition, methods for dealing with possible catastrophic events are also provided.

6.3.1. Damage Criteria

In order to understand the damages produced by various scenarios, it is appropriate to discuss the physiological/physical effects of thermal radiation intensities. The thermal radiation due to tank fire usually results in burn on the human body. Furthermore, inanimate objects like equipment, piping, cables, etc. may also be affected and also need to be evaluated for damages. Table 6.3 and Table 6.4, respectively give tolerable intensities of various objects and desirable escape time for thermal radiation.

Table 6.3 : Effects due to Incident Radiation Intensity

Incident Radiation kW/m2

Damage Type

0.7 Equivalent to Solar Radiation 1.6 No discomfort on long duration

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn are likely).

9.5 Pain threshold reached after 8 sec. Second degree burn after



20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting of plastic tubing etc.

Table 6.4 : Thermal Radiation Impact to Human

Exposure Duration

Radiation Energy {1% lethality; kW/m2}

Radiation Energy for 2nd degree burns;

kW/m2

Radiation Energy for 1st degree burns;

kW/m2 10 sec 21.2 16 12.5

30 9.3 7.0 4.0

6.3.2. Acid and Alkali Hazards

Acids and alkali are used in DM Plant, Cooling Tower etc. These chemicals are stored near user points. Both Hydrochloric acid and caustic lye are harmful if comes in contact. Based on the outcome of the risk assessment, following recommendation has been made to avoid any risk associated with the storage and use of acids and alkali in the plant:

Double drain valve shall be provided to acid storage tank. Full body protection shall be provided to operator. Caution note and emergency first aid shall be displayed All employees shall be trained for use of emergency first aid. Safety shower and eye wash shall be provided in storage tank area and plant area. Total close process will be adopted for acid handling. Dyke wall shall be provided to storage tank Tanker unloading procedure shall be prepared. Training programme shall be conducted for safe handling and emergency handling

of Acid. Precautions are to be taken to avoid such incident. Hydrochloric Acid though non fammable but in contact with metal produces

hydrogen gas which is both highly inflammable and explosive. In Storage Tank Area, reaction with water generating fumes shall be displayed and

avoided Suitable extinguishing media-such as dry powder / sand shall be provided. Do not

use water. Personal protective equipment-Fire fighter shall use SCBA and chemical protection

suit Personal protection: complete protective clothing including self-contained breathing

apparatus. Evacuate danger area do not absorb in saw-dust or other combustible absorbents.

6.4. Selected Failure Cases

Few accidental scenarios have been considered and subjected to consequence analysis / damage zone.

Table 6.5 : Likely Accident Scenario

Sl. No. Scenario Vulnerability Zone

Remarks

1. Rupture in NG line

Area close to leak / release

Isolate the line / area; Cool / drench / dilute the source point to prevent ignition.



2. Ammonia line leakage and spillage

Surrounding Area

Isolate the line / area. Approach with gas mask / lifeline. Dissolve in water and store and treat the water gradually.

3. Chlorine Tonner Leakage

Surrounding Area

Isolate the line / area. Approach with gas mask / lifeline. Cover the cylinder with hood, take a vent line from hood to caustic scrubber.

6.4.2. Rupture in NG Line

NG consisting of 98 % methane is the main raw material (Balance higher hydro carbons and other gases) and is used to generate hydrogen to fix atmospheric nitrogen as ammonia. Any leakage in the pipe line {through flange joint / valve/ instrumentation fittings/ welding failure} would result in hazardous situation. NG will be released at pressure (+ 30 kg/cm2) and also at high temperature (depending upon the leakage point in the process).

Ambient Temperature : 350 C

Leak source size : ~ 50 mm

Burning Rate : 577 kg / min.

Incident : Flash fire

Figure 6.1 : Rupture in NG Line

Threat Zone: Threat is modeled for the thermal radiation from jet fire. The threat zones identified are as follows:



Red : 14 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec) Orange : 19 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec) Yellow : 30 meters --- (2.0 kW/(sq m) = pain within 60 sec)

4.0 21 1st degree burn

2.0 31

1.1 40

6.4.3. Failure of Ammonia Line

Liquid ammonia is the main raw material for urea plant. In addition to process hold up in ammonia and urea plant, there is two large ammonia atmospheric storage tank of capacity- 1500 mt. Ammonia has got odour and any leakage can be immediately noticed and calls for an action taken.

Ambient Temperature : 35C Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3

Source Strength: Puddle Diameter : 20 m Puddle Volume : 100 m3 Total Ammount Released : 10,531 kg Release Duration : 60 min

Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:

Red: 1.1 km --- (300 ppm = IDLH) Orange: 1.6 km --- (150 ppm = ERPG – 2) Yellow: 4.4 km --- (25 ppm = ERPG – 1)



Figure 6.2 : Failure in Ammonia Line

6.4.4. Chlorine Cylinder Leakage

Chlorine is used as biocides in cooling water system and water purification Chlorine is highly toxic (IDLH – 10 ppm) Any leakages in the system will cause toxic release which will spread in down wind direction. The dispersion due to I cm (dia.) leakages are considered for modeling as below:

Ambient Temperature : 35C Chlorine IDLH Value : 10 ppm Source Strength : ~ 2 kg/ min Release Duration : 60 min

Threat Zone:Threat is modelled with heavy gas model. The threat zones identified are as follows:

Red : 157 m --- (20 ppm = AEGL*-3 (60 min)2 Orange: 226 m --- (10 ppm = IDLH) Yellow : 526 m --- (2 ppm = AEGL-2 (60 min))

2AEGL – Acute Exposure Guideline Level



Figure 6.3 : Chlorine Cylinder Leakage

6.5. General Control Measures

Since some of the substances in use at KFCL are hazardous with severe fire and explosion potential and also toxic in nature, it is necessary to use appropriate control measures recommended for such substances:

6.5.1. Flammable Gas Fires

Fire control generally consists of directing, diluting and dispersing the inflammable gas/vapor to prevent contact with persons, to prevent it from infiltrating structures if the leak is out door, and to avoid its contact with ignition sources while, if possible, simultaneously stopping the flow of gas. NG is lighter than air it will go up in the atmosphere once its momentum due to pressure gets dissipated. Gas direction, dilution and dispersion require the use of a carrier fluid, and air, water and steam have proven to be practical carriers. Water in the form of spray, applied from hoses or monitor nozzles or by fixed water spray system may act as a good carrier fluid for inflammable vapors/gases.

6.5.2. Consequence Analysis

6.5.2.1 Toxic Hazards



Toxic hazards are mainly due to Ammonia and chlorine gases leakage and their impact can cross the plant boundary (if not controlled in time). The impact due to these products will go up to 1.1 km in worst case (Ammonia case) and 226 m (Chlorine case) and cross plant Boundary.

The other hazards in the plant include (but not limited to):

Other toxic hazards due to acids / other toxic spillages (mainly limited to spillage area only.).

Mechanical hazards due to machines / equipment’s.

Hazards due to individual soft spots like walking casually and noticing a pit and falling or colliding/ stumbling or slipping (not noticing a wet place etc.).

Acid spillage-its impact will be limited to spillage area. The spillage if comes in contact with metal parts will produce hydrogen which is highly flammable gas. Any person moving in area and getting splash will get the injury. In addition the spillage will cause pollution problem. The spillage is to be collected and neutralized for toxic contents before disposal.

6.5.2.2 Fire Hazards

Fire hazards in the proposed expansion project are much less (Fuels-coal, HSD (limited storage only)). However process has fire hazards due to hydrogen.

6.6. Recommendations

Based on the outcome of the risk assessment, following recommendation has been made to avoid any risk associated with the storage and use of hazardousmaterials in the plant:

6.6.1. LDAR program :--

Chemicals are manufactured in multi-stages in batch/continuous mode. In the manufacture of chemicals, various unit processes/operations/equipment are used in industries.

The chemical industries are using pipelines, pumps, valves/ vessels and other fittings in the transfer of materials from reactors and other ancillary facilities to other equipments. To reduce fugitive emissions in the plant, proper Leak Detection &Repair (LDAR) program is required in the industry.

The proposed LDAR program is as follows: --

Identification of sources: Valves, pipes, joints, pump seals, flanges etc.

Monitoring of gases/fluids is to be carried out regularly. Monitoring frequency should be once in a quarter is required.

The industries handling small/large quantities of hazardous chemicals like chlorine, Ammonia, Hydrogen, Carbon Monoxide, SOx/NOx etc. can use simpler methods like gas/vapour sensors.

Focus should be for prevention of fugitive emissions by having preventive maintenance of pumps, valves, pipelines etc. A preventive maintenance schedule should be prepared and it should be strictly adhered to



When monitoring results indicate hazardous gases/vapors/VOC above permissible limit repairing should be done immediately. The repair should be conducted in such a way that there is no fugitive emission from the particular component.

6.6.2. Fugitive Emission Control Guidelines :--

The following guidelines will be strictly followed :--

Fugitive emissions over reactors, formulation areas, rotary machines, chemical loading, transfer areas etc. will be collected through hoods and ducts by induced draft and controlled by scrubber/ dust collector.

Scrubbers installed for channelized emissions are used for fugitive emissions control also and sometimes-dedicated scrubbers will be used.

Hazardous gaseous emissions (toxic and odorous) will be routed to activated carbon beds or to incinerator, and for dust emissions cyclones/bag filters will be provided.

Enclosures to chemical storage area, collection of emissions from loading of raw materials, in particular, solvents through hoods and ducts by induced draft, and control by scrubber/ dust collector will be ensured.

Vapour balancing, nitrogen blanketing, iso tanks etc, will be provided. Special care will be taken for odorous chemicals.

6.6.3. Hazardous Liquids Spillage

Full body protection will be provided to operator.

Caution note and emergency first aid will be displayed

All employees will be trained for use of emergency first aid.

Safety shower and eye wash will be provided in storage tank area and plant area.

Dyke wall will be provided to storage tank

Tanker unloading procedure will be prepared.

SOP will be prepared for Hazardous Liquids handling.

Training programme will be conducted for safe handling and emergency handling of Hazardous Liquids

In Storage Tank Area, reaction with water generating fumes should be displayed and avoided (if applicable)

Suitable extinguishing media-Extinguish with dry powder / sand. Do not use water.

Fire and explosion hazards-Not flammable. May evolve toxic fumes in fire (sulphur oxides/CO).

Personal protective equipment-Fire fighter must use fresh-air helmet and chemical protection suit

Personal protection: complete protective clothing including self-contained breathing apparatus. Do not let this chemical enter the environment.

Evacuate danger area. Do not absorb in saw-dust or other combustible absorbents.

6.7. Occupational Exposure Mitigation Planning



To control any occupational health and safety impact a detailed planning for mitigation measures has been done in the design stage of the project. Apart from the occupational exposure mitigation plans for various activities and work areas of hazards, following administrative control measures will be followed:

All the employees will be trained for EHS policies.

Health check-up for OHS– Yearly

Health check-up for Employees- Yearly

All the OHS peoples have been trained for Basic life support, first aid, Basic fire safety and emergency preparedness.

Ambient air quality monitoring in every month at 3 locations

Monthly monitoring of environmental parameters.

Safety display boards provided throughout the plant.

Monthly fire extinguisher audit.

Work permit system

PPE adherence

Waste management and hazardous waste handling

Safe lifting operation

Industrial hygiene

6.8. Other Recommended Measures for Safe Operation of the Plant

In addition to the specific recommendations made in the above section for storage and handling of hazardous materials within the plant premises, for safe operation of the plant and risk reduction, following suggestions and recommendations are made:

Personnel especially contractor workers at the plant should be made aware about the hazardous substance stored at the plant and risk associated with them.

A written process safety information document may be compiled for general use.

The document compilation should include an assessment of the hazards presented including (i) toxicity information (ii) permissible exposure limits. (iii) Physical data (iv) thermal and chemical stability data (v) reactivity data (vi) corrosivity data (vii) information on process and mechanical design.

The process design information in the process safety information compilation must include P&IDs/PFDs; process chemistry; maximum intended inventory; acceptable upper and lower limits, pressures, flows and compositions and process design and energy balances.

The adequate numbers of heat, smoke detectors may be provided at strategic locations in the plant and indication of detectors/sensors should be provided in main control room.

Predictive and preventive maintenance schedule should be prepared for equipment, piping, pumps, etc. and thickness survey should be done periodically as per standard practices.

Safe work practices should be developed to provide for the control of hazards during operation and maintenance.



Personnel engaged in handling of hazardous chemicals should be trained to respond in an unlikely event of emergencies.

The plant should check and ensure that all instruments provided in the plant are in good condition and documented.

Safety measures in the form of DO and Don’t Do should be displayed at strategic locations especially in Hindi and English language.

6.8.1. Personal Protective Equipment

Personal protective equipment (PPEs) are devices that are fitted and issued to each worker personally for his or her exclusive use. They are intended for temporary use and emergency response action only. If a worker must enter a contaminated area, he must wear adequate protective equipment. Employees should be taught when and how to use respiratory apparatus (SCBA) provided, and how to recognize defects in the equipment. Without SCBA entry into the contaminated area should not be attempted.

Keep personal protective equipment where it can be accessed quickly, outside the hazardous material storage area and away from areas of likely contamination.

Each employee should maintain his personal protective equipment in clean, working condition at all times.

All equipment should be used and maintained in accordance with the manufacturer’s instructions.

Equipment installed for body and eye wash should be checked properly for round the clock operation.

6.8.1.1 Handling of Hazards

Some of the measures employed in handling of hazards:

Personal protective equipment used by the workers during handling of hazardous chemicals, should be replaced after getting defective.

If any spillage of hazardous chemicals, it should be cleaned and disposed as per standard practiced.

Empty drums of hazardous chemicals should neutralize immediate.

Workers engaged in handling of hazardous chemicals should be made aware of properties of hazardous chemicals.

6.8.1.2 General Working Conditions at the Proposed Expansion Plant

House Keeping

The House Keeping practices employed would be:

All the passages, floors and stairways should be maintained in good conditions.

The system should be available to deal with any spillage of dry or liquid chemical at the plant.

Walkways should be always kept free from obstructions.

In the plant, precaution and instructions should be displayed at strategic locations in Hindi and English Languages.

All pits, sumps should be properly covered or securely fenced.

Ventilation



The Ventilation measures that would be employed:

Adequate ventilation would be provided in the work floor environment.

The work environment would be assessed and monitored regularly as local ventilation is most effective method for controlling dust and gaseous emissions at work floor.

Safe Operating Procedures

Other operation procedures followed would be:

Safe operating procedures will be available for mostly all materials, operations and equipment.

The workers will be informed of consequences of failure to observe the safe operating procedures.

Work Permit System

Work permit system will be followed at the plant during maintenance.

Fire Protection

For fire protection the measures taken are:

The fire fighting system and equipment will be tested and maintained as per relevant standards.

Smoke detectors will be provided at the plant and shall be calibrated and maintained properly.

Static Electricity

The general instructions for working with static electric are:

All equipment and storage tanks/containers of flammable chemicals shall be bounded and earthed properly.

Electrical pits shall be maintained clean and covered.

Electrical continuity for earthing circuits shall be maintained.

Periodic inspections shall be done for earth pits and record shall be maintained.

Material Handling

For material handling the regulatory measures that are taken for workers handling various materials would include:

The workers shall be made aware about the hazards associated with manual material handling.

The workers shall be made aware and trained about the use of personal protective equipment (PPE) while handling hazardous chemicals.

Communication System

Communication facilities shall be checked periodically for its proper functioning.

Safety Inspections

The system shall be initiated for checklist based routine safety inspection and internal audit of the plant. Safety inspection team shall be formed from various disciplines and departments.



Predictive and preventive maintenance schedule shall be followed in religious manner.

Electrical Safety

For electric safety provisions to be taken care of are:

Insulation pad at HT panels shall be replaced at regular interval.

Housekeeping in MCC room shall be kept proper for safe working conditions.

Colour Coding System

Colour coding for piping and utility lines shall be followed in accordance with IS: 2379:1990.



CHAPTER 7. ON SITE EMERGENCY PLAN

7.1. Introduction

KFCL fertilizer plant at Panki is in industrial area away from near habited town / city and also from infrastructure facilities normally available there. All necessary facilities are available with KFCL which shall be utilized for proposed expansion project.

Admittedly, the best way of managing an emergency situation lies in its prevention. This is sought to be achieved by good engineering design and construction, use of latest technology and sophisticated equipment, reliable safety systems, careful personnel selection and training. Adequate knowledge of dangers and appropriate safety training ensures that all hazardous situations will be handled without any panic and controlled by rational actions. This is supplemented with repeated practices through real time exercises (mock drills—a copy of mock drill is attached as Annexure V and X and noting the weak spots and taking needful corrective actions). Nevertheless, it is recognized that despite our best efforts, things can go wrong. Therefore, it is essential to plan and develop the support system, required in case an emergency arises. ‘EMP’ guidelines are given below for reviewing the existing EMP.

7.2. Probable Hazards & Risk

From the preliminary risk assessment study presented in Chapter 6 of this report, some of the possible hazards have been identified. The most likely accident scenario identified is given below:

Table 7.1 : Probable Hazards

S. No.

Scenario Vulnerability Zone

Remarks

1 Ammonia Storage Tank heavy spillage

Surrounding Area

Hypothetical worst possible scenario; Approach with gas mask / lifeline; transfer all possible ammonia to adjoining tank; Dissolve in water and store and treat the water gradually.

2 Chlorine Tonner Leakage

Surrounding Area

Isolate the line / area. Approach with gas mask / lifeline. Cover the cylinder with hood, take a vent line from hood to caustic scrubber.

3 NG Line Leakage Area

Near by area Isolate the line / area. Approach with Fire Protection Suit/ gas mask / lifeline.

Above mentioned hazard scenario can further aggravate into a much more serious incident if not attended in time. The vulnerability zone will be considerably enlarged. The vapours of inflammable fluids if carried away by wind above LEL concentrations may further enlarge the vulnerability zone.

7.3. Objectives

The Emergency Management Plan (EMP) is developed to make the best possible use of the resources available at KFCL and the nearby agencies to provide help/assistance in case of an emergency in the plant. The activities will include:

Rescue the victims and give them the necessary medical attention in the shortest possible time.

Safeguard other person (evacuate them to a safer place).



Contain the incident and control it with minimum damage to human and life and property.

Provide necessary information to families/relatives of affected persons, outside agencies including media and statutory bodies.

7.4. Emergency Management Plan

The existing Organization structure of the Facility is depcted in Figure 7.1, which is set up for ensuring safety and health.

Figure 7.1 : Existing Organizational Structure at KFCL Facility



7.5. Responsibilities & Role of Key Personnel

Salient features of existing EMP are as given below. This will be updated as per Mock drills and as per changes in modernization and expansion.

RESPONSIBILITIES ASSIGNED TO PERSONS IN CASE OF AN EMERGENCY: First Hand Information:-

As per the emergency plan, any person at shop floor level/ Operation area who possesses the first information of leakage of Toxic gas or Fire will communicate about the emergency as under:-

By informing to concerned control room / Shift In charge immediately

In Fire Control Room Local telephone nos. 2222 /3555

By shouting and informing to others working in nearby area.

Attempt to control fire / spillage with proper safety precautions, if there is a Fire incident then try to extinguish immediately with available extinguisher in near by area.

Direct rescue team to the site of incident on their arrival

APPOINTMENT OF KEY PERSONNEL: Functions, duties & responsibilities of key persons are given below:

Some of the key persons have to move to ICR or ECR as per their assigned duty. It is expected that all persons should take care of their safety while moving to plant. If it is not safe to move, then they should wait till conditions become favorable for movement.

However Director Incharge/ VP(Production)/ GM (Ammonia),DGM (Urea & off Site) and Sr. Manager (Production) are authorized to use emergency Vehicles to reach plant after wearing Compressed Air Breathing Apparatus (CABA) sets and other required PPEs.

Ambulance will be used as rescue vehicle. It will have Compressed Air Breathing Apparatus (CABA) kept inside in case it is required, before moving into toxic atmosphere.

An Emergency vehicle may also be summoned to use as rescue vehicle. Person using the rescue vehicle must use Compressed Air Breathing Apparatus (CABA) sets and other PPEs as required.

EMERGENCY CONTROLLER: DIRECTOR INCHARGE/DESIGNATED SENIOR MOST PERSON FROM PLANT OPERATION On declaration of the Emergency the Director Incharge shall proceed to ECR and take the charge of the incident. He will be guiding various controllers in carrying out functions effectively for overall control in handling the On-site emergency situation in the factory. He has to liaison with civic authorities in handling Off-site emergency.

In absence of the Emergency Controller, VP (Production) / GM (Ammonia) DGM (Urea & off Site) and Sr. Manager (Production) shall act as Emergency Controller.He will:

Report at the Emergency Control Centre as soon as he gets information about the emergency at site and take overall command of emergency management

Assume overall responsibility of taking decisions and directing actions as necessary for mitigating the situation and managing the emergency effectively



with due consideration and priorities for personnel safety, safety to the Company’s property and the environment

Assess the magnitude of the situation in Coordination with the Works Incident Controller and decide whether major emergency exists or is likely to develop, requiring external assistance. Accordingly he will decide to inform District authorities of Fire, Police and Factory Directorate for help and nature of the help required including assistance from mutual aid members and declare on-site emergency

Ensure that non-essential personnel are safely moved to assembly point

Direct actions for safe shutdown of plant section(s) and evacuation of plant personnel and other necessary actions in consultation with the Works Incident Controller& Unit head of other plant /stream.

Exercise control over areas other than those affected in consultation with the respective Unit head of other plant /stream.

Ensure that casualties are receiving attention and traffic movement within the works is well regulated

Release authorized information to the Press, statement prepared by VP (HR, Commercial)

Arrange for a log of the emergency to be maintained in the Emergency Control Centre

Control rehabilitation of the affected persons and the affected areas after cessation of the emergency.

Instruct for calling the Emergency over.

Order for inquiry into the incidence. On the inquiry report he would authorize the implementation of remedial measures to avoid reoccurrence of such event.

WORKS INCIDENT CONTROLLER: a. VP (Production) b. GM (Ammonia Production) or GM (CPP) or DGM (Urea Production & Offsite) c. Sr. Manager / Manager (Production) d. Shift In-charge

On receiving, the EMERGENCY information the available Works Incident Controller in the above order will be the In-charge of their respective plant (Ammonia/ Urea & Offsite/ CPP) activities.

He will be responsible for handling/ controlling the emergency at their respective plants to bring it under control in minimum time. He will apprise to the Emergency Controller on all aspects of handling the emergency. He will:

Rush to the Incident Control Room /Spot of Incident, keeping himself safe and ascertain all available information regarding the emergency such as:

Location & Wind direction

Nature -Fire, Explosion or Toxic release & Dimensions Casualties

Assess situation and declare “On Site Emergency” as per situation in consultation with Emergency Controller and inform Fire station for sounding siren.

Brief the Emergency Controller and keep him informed about all the development.



Inform Sr. Manager (Safety), Manager Fire to reach to site and also inform Sr. Medical Officer and ask him to be ready for coming to site.

Direct plant operation / shut down operation as required controlling the emergency. Stop all the work nearby, if required.

Ensure the use of Personal Protective Equipment by all concerned.

Ensure that injured persons are removed from the contaminated area and brought to safe area.

Keep contact with the other Controllers and seek necessary assistance wherever required.

Advise Material Controller to arrange & shift any material falling short of the required quantity.

Arrange for chronological recording of the Emergency.

Preserve records and other evidence, which may be required for inquiry.

Make schedule and instruct the persons for continued operation in case of prolonged emergency.

Ensure supply of safe drinking water.

Decide and initiate necessary evacuation measures and ensure evacuation of non-essential workers, visitors and contractors to safe assembly points.

Take action to restore the situation back to normal in consultation with Emergency Controller.

Give instruction for restart up of Plant only after satisfying him self about safety of the plant, personnel and getting clearance from competent authority.

Note: Director In-charge /VP(Production) / GM (Ammonia), DGM (Urea & Off Site) and Sr. Manager (Production) are authorized to use emergency car to reach plant after wearing Compressed Air Breathing Apparatus (CABA) sets and other required PPEs.

After the arrival of Incident Controller the production department staff will work under his guidance.He is authorized to coordinate various activities as per available resources under his control.

SHIFT INCHARGE He is the senior most person available amongst the operation group at site beyond general shift. He will:

Assume the charge of Emergency Controller and the Incident Controller till arrival of senior officials.

Ascertain the available information on emergency and declare On-site Emergency in consultation with Director Incharge / VP (Production) / GM (Ammonia) / respective Section Head.

Alert all sections in the plant on PA system / Telephone.

Ensure that message is sent to Fire Station/Safety Station.

Take action to shut down the plant /section, if required. Close valves and isolate source of flammable /toxic material in the plant and pipelines. Cut off the flow of material from the point of escape.

Inform other Shift Manager / Incharge regarding simultaneous action that are required to be taken in respective Plants.



Direct fire fighting and rescue operations.

Call Medical help/ Ambulance, if necessary.

SECTION MANAGER / INCHARGE Production Manager - Ammonia

Production Manager – Urea & Offsite

Production Manager – CPP

He is the senior most person available amongst the operation group at site in General shift. He will:

Rush to the Incident Control Room and declare Emergency if not declared as yet after assessing the situation in consultation with Director Incharge / VP (Production) / GM (Ammonia)

Take charge of Control Room operation.

Take safe plant shutdown to control hazardous situation.

Makes available necessary safety equipment /rescue apparatus.

Ask field people to assemble at specified area after doing necessary emergency operations in the field.

Give call to Maintenance/ Engineering Managers i.e. VP (Mechanical) / DGM (Mechanical) GM (Instrument), Sr. VP/ GM (Electrical) as per the requirements and inform them about the safe route to reach ICR.

Take roll call. Check that nobody is left behind.

Keep liaison with Sr. Manager (Safety) / Manager (Fire) and Sr. Medical Officer for Rescue and Fire Fighting and Medical Care.

PROCESS OPERATORS /TECHNICIANS In case of fire initiate fires call point/ or call to fire station on internal telephone

– 2222, 3555.

Report matter to the Control Room or Shift In charge or Section Manager in their respective control room.. Give exact location of fire.

In case of gas leak inform Control Room/ Shift In charge/ Shift Manager/ Plant Manager over Tannoy, telephone, pager or in person. Give exact location of leak.

Take action to cut off supply of naphtha/gas to the point of fire/leakage keeping himself safe in consultation with the Shift In charge/ Section Manager.

Wait for instructions from Control Room / Shift In charge. Keep ready for evacuation if needed.

ROLE OF TECHNICAL, SAFETY, FIRE & RESCUE CONTROLLER VP (Technical)

Sr. Manager Safety / Manager Fire

Hearing Emergency siren or on being told of emergency by Incident Controller / Security Incharge, DO the following:

1. Obtain all necessary information regarding the emergency, particularly that pertaining to the Fire Fighting, Safety, Emergency Rescue and Environmental Pollution.

2. Whether the Director Incharge has consented for communication of emergency and its effects on environment to the Pollution Control Board.



3. Contact Sr. Manager Safety / Manager Fire & Safety Engineers and after passing on relevant information instruct them to proceed to site.

4. Contact Pollution Control Board and convey as informed by Main Emergency Controller or HR & Supply Controller Contaminant released. Environment Polluted; Air Or Water Extent of release and the area affected.

5. Go to the site stopping en-route at Canal Pump House for checking safe approach route outside and within factory.

6. Rush to Incident Control Room take necessary information, visit Scene of Incident, and assess situation in consultation with Shift Incharge. Appraise situation to Main Emergency Controller / Incident Controller.

7. Co-ordinate Firefighting and Rescue operation including sending of injured persons to hospitals.

8. Ensure Hot Job and other work in the vicinity of the affected area have been suspended and affected area is cordoned off.

9. Inform Main Emergency Controller the number of persons affected and its likely impact in the surroundings. If situation warrants for evacuating plant persons, advise Main Emergency Controller / Incident Controller for the same.

10. Instruct Lab Manager to be in touch with Incident Controller and do sampling for environment monitoring inside factory premises as asked.

11. Keep liaison with Fire Station of UP Fire Service at Fazal Ganj for the additional help required for fire fighting.

12. Keep liaison with Representatives of neighbouring Industries; who have arrived for help under Mutual Aid Scheme.

13. Ensure that Safety & Fire personnel have supplied required Safety and Firefighting equipment.

14. Assess the situation and advise the Incident Controller and Emergency Controller to evacuate the plant.

15. In consultation with Main Emergency Controller, instruct Lab Manager to collect samples at least in the range of 1 ~ 2km in the wind direction to evaluate concentration of toxic gases, if required.

Sr. Manager Safety: He will be Controller for Safety, Fire Fighting, & Emergency Rescue operations.

Rush to the Incident Control Room/ Scene of Incident on receiving message.

Access the situation in case of gas leakage/ flammable material leakage.

Advise the Emergency Controller to evacuate plant if the situation warrants.

Appraise the situation to the Emergency Controller/ Incident Controller.

Co-ordinate fire fighting and rescue operations in the affected area.

Co-ordinate arrival of ambulance /vehicle to send the injured person to hospital co-ordinate first-aid operation.

Inform to the Emergency Controller the number of persons affected and its likely impact in the surrounding.

Ensure that hot work and other work in nearby areas have been suspended and the affected area is cordoned off with the help of security personnel.

Ensure availability /issuance of safety required for plant Emergency controlling.

Keep liaison with UP Fire Services / Fire station (HQ) Fazalganj for additional help required for fire fighting.

Manager Fire



Rush to the Incident Control Room and then spot of incident.

Assess the situation and inform to the Incident Controller / Emergency Controller.

Ensure availability /issuance of Fire fighting equipments required for plant Emergency controlling.

Co-ordinate rescue and fire fighting operation.

Keep liaison with UP Fire Services/ Fire station (HQ) Fazalganj for additional help required for fire fighting.

Invalidate the Work Permits in the affected and nearby areas.

Get help if needed from Security department/ persons for cordoning off the area and rescue and fire fighting in the plant.

Safety Engineer Rush to the incident control room/ Site of Incident

Work accordingly the instruction given by Sr. Manager- Safety

Help people in wearing of BA set, Canister mask , Fire suit etc

Ensure availability of Personal protective equipments

Arrange to supply extra safety equipment required at site of Emergency

Ensure that hot work has been suspended in affected area.

Provide assistance in fire fighting & rescue operation.

Fire Supervisor / Fire Man See the Fire alarm on the panel / Take proper message.

Direct fire tender immediately to the spot of emergency

Sound the siren of “On site Emergency” depending upon the type of emergency as instructed by Incident Controller.

Inform Manager (Fire), Sr. Manager (Safety) & Security at main gate.

Assess the situation and contact Shift In charge/Manager of the affected plant/area

Keep constant watch on fire brigade personnel so as not to endanger them while rescuing or fire fighting.

Supply additional fire fighting appliance as required.

Keep in contact with Incident Controller and communicate about prevailing situation from time to time.

Render any other help requested by Incident Controller.

MANAGER (LABORATORY) On hearing Emergency siren/ message in office, act as per advice /message from Incident Controller/ Safety, Fire & Rescue Controller.

Alert laboratory staff and ensure their availability for taking emergency samples if required.

Keep in touch with the Incident controller for taking samples and rendering help to plant personnel.

Keep in touch with the Safety, Fire & Rescue Controller for taking samples for analysis outside factory area.



Take samples at least in the range of 1-2 km in the wind direction to evaluate concentration of toxic gases, if required.

Inform concentration of toxic gases to the, Emergency Controller and the Incident Controller/ Safety, Fire & Rescue Controller.

SERVICE CONTROLLER: I. VP (Admin & Civil) II. Addl. GM (Administration)

He will be the Service Controller for Welfare, Transport and Security. Rush to the Emergency Control Room on receiving the message.

Arrange transport/Ambulance to shift injured persons to Hospital.

Alert all staff under his control and make them available at designated assembly points to give welfare assistance.

Arrange for evacuation of the people from the affected area, if required.

Keep close liaison with the Employees Union and Association for getting their full cooperation.

Arrange for External medical treatment through Sr. Medical Officer, if required.

Deal with the queries of Public and Relatives of employees.

Arrange communication with the relative of employees involved in the emergency control operation and those got injured during controlling and combating operation.

Arrange to supply food, drinking water, shelter, clothing etc if required.

Arrange to replenish the stock of food and other essential items in the Canteen store.

Co-ordinate with all the outside agencies i.e. Government Authorities, Civil Defense Officers, Press/ Media etc.

Release written and approved information to those agencies and the statutory bodies in consultation with Emergency Controller.

Make all arrangement to take Press/ Media Persons and Administrative Officers to a safer place close to the scene of emergency in order that the Officers, Media Reporters and Photographers can get accurate information and details.

Prevent panic caused by false information.

PUBLIC RELATION OFFICER I. Sr. Administration Manager II. Administrative Supervisors

On hearing, Emergency siren/ message are available in office and act as per advice/ message from Emergency / Service Controller.

Make all arrangement for mass communication by announcement on a loudspeaker fitted on a mobile van in the areas around factory in consultation with the Service and Emergency Controller.

Prepare press note. Release approved handbills, and gives correct information through Media (TV, AIR) and local area TV Net work in consultation with Service and Emergency Controller.

Make arrangement for communication about the incident for general awareness of the public in consultation with Service and Emergency Controller.



Make arrangement for publication in local Newspaper about the incident for general awareness of the public.

SR. MEDICAL OFFICER Rush to Hospital on getting information.

Depute one of the assistants with Ambulance/ Rescue Van at incident site for first-aid treatment.

Get in touch with the Emergency Controller for the type of medical help required.

Ensure availability of adequate first aid medical help and co-ordinate for further medical help in the Occupational health Centre / Hospitals/Nursing Homes, if required.

Liaison with Supply Manager for the procurement of additional medicines. Make arrangement for treating the affected persons.

In case of permanent, total, or partial disability of an injured person, assess the extent of disability and inform the Head of the Department, Director In charge and Manager (Fire & Safety).

In case Ambulance is required then Sr. Medical Officer will ask the safe route from Incident Controller and instruct Pharmacists/ First aider accordingly.

MECHANICAL CONTROLLER:

I. VP (Mechanical) II. DGM (Mechanical)

III. Manager Workshop He will ensure that maintenance personnel of Mechanical department are in a

position to undertake urgent maintenance jobs.

Rush to the Incident Control Room on receiving message.

Assess the situation from the angle of help that may be needed to tackle the emergency in consultation with Incident and Emergency Controllers.

On specific request from key personnel if required get necessary equipment like Cranes, Forklifts, Dozers, Trucks, Welding and Cutting Sets etc. as needed for tackling the emergency and make available required personnel to operate above facilities.

On specific request from key personnel if required keep workshop & Stores facilities open with necessary personnel throughout emergency to cater any need for repairs or supply of additional equipment.

Keep in constant touch with Emergency/Incident/Rescue/Mechanical Controller for any assistance to them.

ELECTRICAL CONTROLLER: I. Sr. VP (Electrical) II. GM (Electrical)

III. Sr. Manager(Electrical) He will be Controller of all activities pertaining to electricity and communication

system (Telephones).

Rush/ Contact the Emergency Control Room.

Ensure that electricity of the affected area is cut off, if required by the Incident Controller.



Make arrangement for temporary lighting/emergency lighting to affected areas, shelters and other places of assembly.

Arrange for isolation/ restoration of electric supply as necessary.

Ensure that all communication systems are in operation.

Keep in touch with Emergency/ Incident/ Rescue/ Maintenance Controllers.

Keep liaison with UPPCL and P&T Department for ensuring power supply and operation of the communication system.

INSTRUMENT CONTROLLER: I. GM (Inst. & Mat. Insp.) II. Asstt. Chief Engineer (Instrument)

III. Sr. Manager Instrument. He will be Controller of all activities pertaining to instrumentation and

communication system (PA system & Pagers).

Rush/ Contact the Emergency Control Room.

Keep liaison with Emergency, Incident and Mechanical Controller and Coordinate activities required in the field of instrumentation.

Ensure that all communication systems (Tannoy, pager etc) are in operation.

MANAGER- SECURITY & TRANSPORT: Rush/Contact the Emergency Control Room.

Control movement/ entry of persons at main gate.

STOP vehicle movement at main gate, keep gate free from any obstruction for emergency vehicles movement.

Control movement of traffic around the affected area with the help of security staff.

If situation warrant inform Panki Railway Station to stop train movement/ traffic movements on roads keeping in view the wind direction.

If required arrange vehicles from Contractors etc. for evacuation of the people.

ESSENTIAL WORKERS In plant immediately affected or likely to be affected as decided by the Emergency Controller, efforts will be needed to make shutdown and make process units safe. Plant Managers / Shift In charges will carry out this work with the help of operators provided they could do it without exposing themselves to undue risk.

Firemen, Medical & Security Personnel, Process Plant Operators, Riggers, Maintenance Technicians and other persons who are trained in FIRST AID and / or RESCUE operation come under the category of Essential Workers.

On direction from Incident Controller / Emergency Controller the essential workers shall,

Assist at Incident Control Room / Emergency Control Room to handle out-going and incoming calls and to act Messengers in case of communication failure.

Assist at ‘Assembly’ points to record the arrival of evacuated personnel.

Assist in conducting visitors and contractors to a place of safety.

Assist in moving lorries, tankers and other vehicles from the area of risk.



Trained First Aiders will, on hearing the announcement leave their place of work with the permission of their supervisors and reach the location of emergency to deal with affected persons and help in safe transporting them to medical centre.

Trained Rescuers should reach the site of the emergency after informing their supervisor to rescue persons who may be trapped in Fire/Gas fumes etc.

Riggers who may be on site should reach the site of emergency to help in handling heavy equipment and bring needed equipment from other areas of the factory.

Employees trained in the first aid firefighting must reach the place of emergency to help the Fire Fighting Crew in fighting / controlling fire.

The Security personnel will reach the Site of emergency for:

Crowd control purpose

Barricading the area

Traffic diversion/Blocking in the plant area

Manned the entry gate

Control civic authorities inside the plant

Help in evacuation

The Occupational Health Centre Personnel will: Prepare to receive the injured persons and treat them.

Inform the Factory’s Sr. Medical Officer on the situation.

Alert the city hospitals/nursing homes to expect casualties if directed to do so by the Emergency Controller

The Fire Fighting Crew will: Reach the site of emergency to take appropriate actions

Ensure firewater pumps have started

Inform UP Fire Service, Fazalganj Fire Station to send additional help, if directed by the Incident Controller

Inform Manager (Fire), Sr. Manager (Safety & Fire) about emergency.

DUTIES OF NON-ESSENTIAL WORKERS Those workers whose duties/ responsibilities have not been

described/assigned in the On-site emergency organization chart or as above and the contractor workmen, visitors, vendors etc. Come under the category of non-essential workers.

The Non-essential workers should remain at their work place, if it is safe; otherwise as instructed, they should evacuate the area and report to the identified Assembly Point.

If at office/ workroom, they should remain inside the office/ workroom. If in open, they should either move to nearby office/ assembly point which ever is safe.

They should wait for instructions of their HOD, Incident Controller or Emergency Controller for evacuation from the area not immediately affected.



7.6. Outside Organizations if involved in assisting during On-site Emergency

a. Type of accidents The types of accident, where “Onsite Emergency Plan” is to be involved, during the

course of manufacturing of Fertilizer grade Urea with the help of raw material such as Natural gas, Ammonia, Hydrochloric acid, Chlorine & Gas cylinders storage shed may be considered as listed below :

i. Fire ii. Explosion iii. Release of Toxic material like Ammonia / Chlorine iv. Fire in Natural Gas (NG/RLNG) pipeline v. Fire in Process gas (Hydrogen Rich) vessel / line due to leakage. vi. Fire/ Explosion in Gas cylinders storage shed vii. A combination of more than one viii. Sabotage ix. Act of war x. Negligence

However, types of personnel injuries may include burn injury, cut/ blunt injuries, or fracture injuries during the course of industrial activity.

b. Outside organizations (which are involved to get necessary help during ON-Site emergency) & Responsibilities assigned, are as follows:-

At KFCL Panki Unit, regular mocks are being conducted to ensure preparedness for handling emergency.

Besides this following District, Administrative Agencies and organizations shall be involved to perform their respective activities to bring the emergency if the situation seems to beyond the local management control.

a. Police Station i. As soon as they are informed about an emergency, immediately they should

rush to the site with their team. ii. They should cordon off the area to avoid any inflow of nearby population. iii. If there are people in the surrounding area, who are susceptible to any injury,

then to warn them to move away to a safer place & to assist in evacuation. iv. To control traffic movements in the affected area, give priority to the

movements of Fire Brigade. v. To assist fire brigade in fire fighting / emergency operation. vi. To protect life & property. vii. To help the injured people & medical agencies in providing first aid & further

treatment. viii. To deal with the casualties, to assist in their identification, inform media /

relatives of dead or injured people. ix. To take instruction from District Collector, who is the District Emergency

Officer, & to execute them.

b. Fire Brigade i. As soon as they are informed about an emergency, immediately they should

rush to the site with their team & fire fighting / emergency equipments. ii. They should cordon off the area to avoid any inflow of nearby population. iii. If there are people in the surrounding area, who are susceptible to any injury,

then to warn them to move away to a safer place & to assist in evacuation. iv. To carry out fire fighting / emergency operations. v. To provide information about of the chemical & its hazards.



c. Civil Defence

i. To follow instructions from District Collectorate, Police Authorities. ii. To assist fire brigade in fire fighting / emergency operation.

d. District Collectorate

i. District Collector, who is District Emergency Officer, shall supervise & coordinate all the emergency operations.

ii. It is mandatory to conduct Mock Drill based on the OFF-Site emergency plan.

e. Factory Inspectorate i. To provide information about the nature of the chemical & its hazards. ii. To provide technical expertise to carry out the emergency operations. iii. To assist District Collect orates in conducting the Mock Drill based on the Off-

Site Emergency Plan.

f. Voluntary Organizations i. As soon as they are informed about an emergency, immediately they should

rush to the site with their team. ii. They should cordon off the area to avoid any inflow of near by population with

the help of Police. iii. If there are people in the surrounding area, who are susceptible to any injury,

then to warn them to move away to a safer place & to assist in evacuation. iv. To control traffic movements in the affected area, give priority to the

movements of Fire Brigade. v. To assist fire brigade in fire fighting / emergency operation. vi. To protect life & property. vii. To help the injured people & medical agencies in providing first aid & further

treatment with Doctor’s helped. viii. To deal with the casualties, to assist in their identification, inform media /

relatives of dead or injured people. ix. To provide support like arranging first aid center at the site, manpower,

ambulance, doctors, nurses, medicines, blood, snacks/ food, rehabilitation etc.

g. Nearby Industries

i. As soon as they are informed about an emergency, immediately they should rush to the site with their team and fire fighting / emergency equipments.

ii. To carry out fire fighting / emergency operations like leak plugging, safe decanting.

iii. To provide additional fire fighting / emergency equipments.

h. Nearest Hospital & Ambulance Services i. As soon as they are informed about an emergency, immediately they should

rush to the site with their team. ii. To protect life of the injured people by providing first aid & further treatment. iii. To deal with the casualties, to assist in their identification, inform media /

relatives of dead or injured people.

Provide services like arranging first aid center at the site, ambulance, doctors, nurses, medicines, blood etc.



CHAPTER 8. SUMMARY AND CONCLUSIONS

8.1. Prelude

The present study was aimed at identifying the potential environmental impacts due to the various project activities, assessment of impact with and without mitigation measures, and at developing an environmental management and monitoring plans for proper mitigation of any adverse environmental impact. In this study, the various activities likely to take place during the construction and operation phases of the project have been analysed in relation to the baseline condition of different environmental components. The mitigation measures proposed for the contractors and the project proponent have also been reviewed and the potential residual impacts discussed. The key points considered in this study are described in the following sections:

8.2. Regulatory Compliance

The project is yet at its technical investigation stage. Prior to its implementation, it will be necessary to acquire all the necessary clearance from the Government of India, as per the applicable national regulations. Key clearances include obtaining the No Objection Certificate from the UPPCB under The Water (Prevention and Control of Pollution) Act, 1974 and Rules, 1975; The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982; and Environmental Clearance from the MoEF, under the EIA Notification, 2006, The Environment (Protection) Act, 1986 and Rules, 1986. In addition to that Authorization for Hazardous Waste Management will also be required under the Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008 from UPPCB.

8.3. Baseline Conditions

The monitoring of the existing environmental conditions of the proposed expansion project site and of its close vicinity have been established with respect to physical, biological and human environment. The air quality of the project site meets the prescribed National Ambient Air Quality Standards applicable for the industrial, residential and rural Areas for NOx, SOx and NH3. However, the ambient quality of the surrounding area has high PM10 and PM2.5. The background noise levels were also found within the standards.

The water quality also meets all standards for use in domestic and industrial applications. The geology of the project area is of varied nature; however it is not prone to floods. In addition to that there is no sensitive ecosystem in the vicinity. No rehabilitation and resettlement issue is emerging as expansion is proposed within the existing premises of KFCL.

8.4. Environmental Impacts and Mitigation Measures

The project entails various impacts on the study area, some negative and some positive. The impacts will be caused by the construction activities as well as by the other industrial activities during the construction and operation phases, respectively. Various impacts identified during the study have been provided mitigation measures for a better environmental management. In addition to that the roles and responsibilities of the developers have also been given in the Environmental



Monitoring Programme to monitor the implementation of the environmental management plan to ensure the mitigations of adverse impacts.

8.5. Recommendations

Based on the environmental impact assessment conducted, the following recommendations are made:

Systems of periodic auditing and reporting shall be adopted during the construction period to ensure that the contractors adhere to the Environmental Management Plan.

The project proponent and its team of consultants and contractors are urged to develop a strategy for effective communication with local people.

The construction team/ developer should effectively follow the suggestions made in the EMP and/ or any other environmental measures so as not to damage the environment of the project area.

The industry shall have to adhere the conditions stipulated in the environmental clearance as well as in consent/ authorization from UPPCB.

Since regulations are fast changing in India, the project proponent must keep himself or herself updated with respect to applicable laws and take appropriate actions in case the provisions in some regulations undergo change.



CHAPTER 9. DISCLOSURE OF CONSULTANTS ENGAGED

Declaration by Experts Contributing To the EIA/EMP REPORT for proposed Expansion of Ammonia-Urea Fertilizer Plant & CPP at Udyog Nagar Industrial Area, Panki, Kanpur, up by M/s. Kanpur Fertilizers & Cement Limited. I, hereby, certify that I was a part of the EIA team in the following capacity that developed the above EIA.

EIA Coordinator:

Name: P K Srivastava Signature & Date:

Period of involvement June 2014 to finalization of report Contact Information: 011-30003200

Functional Area Experts

Functional Areas Name of the Expert

Involvement (Period and Task**) June 2014 to finalization of report

Signature

Air Pollution Monitoring & Control (AP)

S K Jain Team Member: Om Prakash (AFAE)

Site visit, assistance in selection of monitoring locations, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM)

Air Quality Modeling and Prediction (AQ)

Sanjeev Sharma Team Member : Rajni Oshan

Assistance in air quality modeling and prediction: met file generation and model run

Noise Sanjeev Sharma

Assistance in selection of monitoring locations, checking noise data, evaluation of results

Water Pollution (WP) S K Jain

Site visit, assistance in selection of sampling locations for surface water sampling, water balance for the project and contribution to EIA documentation

Ecology and Bio-diversity Conservation (EB)

Dr. Sunil Bhatt

Site visit, assistance in selection of sampling locations and contribution to EIA documentation

Solid and Hazardous Waste Management (SHW)

S K Jain

Identification of waste generated from the industry, studying adequacy of mitigation



Functional Areas Name of the Expert

Involvement (Period and Task**) June 2014 to finalization of report

Signature

measures for management of hazardous waste

Socio-Economics (SE)

T G Ekande

Site visit, contribution to Baseline environment and contribution to EIA documentation

Risk and Hazards (RH) S K Jain

Site visit, Identification of modeling scenarios, consequence modeling using PHAST, finalization of DMP, contribution to RA / DMP Documentation and contribution to EIA documentation

Declaration by the Head of the Accredited Consultant Organization/authorized person I, S.K.Jain, hereby confirm that the above-mentioned experts the EIA/EMP REPORT for proposed Expansion of Ammonia-Urea Fertilizer Plant & CPP at Udyog Nagar Industrial Area, Panki, Kanpur, up by M/s. Kanpur Fertilizers & Cement Limited. I also confirm that the consultant organization shall be fully accountable for any mis-leading information mentioned in this statement.

Signature:

Name: S.K.Jain Designation: Director, Technical

Name of the EIA Consultant organization EQMS India Pvt. Ltd. NABET Certificate No. and date NABET/EIA/RA11/007, 19th May, 2014

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