Environmental Impact Assessment Environmental Management ... · PDF fileEnvironmental Impact...
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Environmental Impact Assessment &
Environmental Management Plan
for
Expansion Project of - Ammonia 2200 MTPD & Urea 3850 MTPD, at Village
Piprola, Distt Shahjahanpur, U.P
Submitted by:
KRIBHCO Shyam Fertilizers Limited
April 2015
Environmental 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]
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. i
Table of Contents
Executive Summary ........................................................................................................................... x Chapter 1. Introduction and Background ...................................................................................... 7
1.1. Preamble ............................................................................................................................ 7 1.2. Importance and Need of an EIA ......................................................................................... 7 1.3. Project & Project Proponent ............................................................................................... 8 1.4. Objectives of the EIA Study .............................................................................................. 10 1.5. Project Site and Regulatory Compliance Status ............................................................... 10 1.6. Scope of Study ................................................................................................................. 12 1.7. Public Hearing .................................................................................................................. 19
Chapter 2. Project Description .................................................................................................... 20 2.1. Introduction ...................................................................................................................... 20 2.2. Existing Status.................................................................................................................. 20 2.3. Proposed Project .............................................................................................................. 21 2.4. Existing Plant and Facilities .............................................................................................. 23
2.4.1. Ammonia Plant ............................................................................................................. 23 2.4.2. Urea Plant .................................................................................................................... 27 2.4.3. Power Plant and Utilities ............................................................................................... 30 2.4.4. Waste Water / Effluent Treatment System in KSFL ...................................................... 31 2.4.5. Solid Waste Disposal System ....................................................................................... 36 2.4.6. Sources of Gaseous Emissions .................................................................................... 36 2.4.7. Noise Environment ....................................................................................................... 38
2.5. Proposed Expansion Project ............................................................................................ 40 2.5.1. Ammonia plant ............................................................................................................. 40 2.5.2. Urea Plant .................................................................................................................... 42 2.5.3. Utilities and Offsite Facilities ......................................................................................... 44 2.5.4. Air Emission ................................................................................................................. 50 2.5.5. Noise Environment ....................................................................................................... 51 2.5.6. Effluent Generation and Control System ....................................................................... 51 2.5.7. Solid Waste Management ............................................................................................. 52
2.6. Green Belt Development .................................................................................................. 52 2.7. Occupational Health and Safety ....................................................................................... 56 2.8. KSFL CSR (Corporate Social Responsibilities) Activities .................................................. 56 2.9. CREP Compliance ........................................................................................................... 58
Chapter 3. Description of the Environment ................................................................................. 62 3.1. Prelude ............................................................................................................................. 62 3.2. Site Location and its surroundings .................................................................................... 63 3.3. Physical Environment ....................................................................................................... 63
3.3.1. Physiographic and Topography .................................................................................... 63 3.4. Geomorphology ................................................................................................................ 66 3.5. Climatology and Meteorology ........................................................................................... 66 3.6. Micro-Meteorology ............................................................................................................ 67 3.7. Baseline Environment....................................................................................................... 69 3.8. Air Environment ................................................................................................................ 72 3.9. Noise Environment ........................................................................................................... 78 3.10. Water Environment ........................................................................................................... 78 3.11. Soil ................................................................................................................................... 82 3.12. Land use .......................................................................................................................... 88 3.13. Biological Environment ..................................................................................................... 90 3.14. Demographic and Socio-Economic Features .................................................................. 100
Chapter 4. Anticipated Environmental Impacts and Mitigation Measures ................................. 114 4.1. Prelude ........................................................................................................................... 114
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. ii
4.2. Air Environment .............................................................................................................. 114 4.3. Noise Environment ......................................................................................................... 131 4.4. Water Environment ......................................................................................................... 132 4.5. Effluent Generation and Discharge ................................................................................. 133 4.6. Land Environment .......................................................................................................... 134 4.7. Biological Environment ................................................................................................... 135 4.8. Socio – Economic Environment ...................................................................................... 136
Chapter 5. Environmental Management Plan ........................................................................... 137 5.1. Prelude ........................................................................................................................... 137 5.2. Objectives of EMP .......................................................................................................... 137 5.3. Components of EMP ...................................................................................................... 137 5.4. Central Pollution Control Board {CPCB} Guidelines for Fertiliser Industry ...................... 138
5.4.2. Air Environment .......................................................................................................... 141 5.4.3. Noise Environment ..................................................................................................... 142 5.4.4. Water Environment ..................................................................................................... 143 5.4.5. Biological Environment ............................................................................................... 143 5.4.6. Land Environment ...................................................................................................... 144 5.4.7. Socio-economic Environment ..................................................................................... 144 5.4.8. Environmental Management Cell ................................................................................ 144 5.4.9. Post – Operational Monitoring Program ...................................................................... 145
Chapter 6. Hazard Evaluation and Risk Analysis...................................................................... 147 6.1. Prelude ........................................................................................................................... 147 6.2. Hazards Survey .............................................................................................................. 147 6.3. Hazard Evaluation .......................................................................................................... 149 6.4. Potential Hazards ........................................................................................................... 150 6.5. Inventory Analysis .......................................................................................................... 151 6.6. Methodology, Approach and Damage Criteria for Risk Assessment ............................... 153 6.7. General Control Measures ............................................................................................. 160
Chapter 7. On Site Emergency Plan......................................................................................... 163 7.1. Introduction .................................................................................................................... 163 7.2. Probable Hazards & Risk ............................................................................................... 163 7.3. Emergency Management Plan ....................................................................................... 165
7.3.13. Role of Head Security / Security Officer / Asst. Security Officer .................................. 171 7.4. Post Emergency Recovery ............................................................................................. 172 7.5. Enclosures ..................................................................................................................... 173
Chapter 8. Disclosure of Consultants ....................................................................................... 177
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. iii
List of Tables
Table 1.1 : Awards & Certifications Received .............................................................................. 10 Table 1.2 TOR Compliance Status............................................................................................... 12 Table 2.1 : Plant and Facilities Required for the Expansion Project ............................................. 22 Table 2.2 Bulk Hazardous Materials Storages (Existing) .............................................................. 31 Table 2.3 Existing Emission Load ................................................................................................ 37 Table 2.4 UPPCB prescribed norms for Prilling Tower at KSFL ................................................... 37 Table 2.5 Noise Survey of KSFL Complex ................................................................................... 38 Table 2.6 Ambient Air Quality Standards with respect to Noise .................................................... 40 Table 2.7 Raw Material ................................................................................................................ 44 Table 2.8 : Estimated Stack Emission Load (Kg / hr.) due to Expansion for KSFL ....................... 50 Table 3.1 Summary of Climatic Condition at the Site ................................................................... 67 Table 3.2 Details of Sampling Locations ...................................................................................... 69 Table 3.3 Ambient Air Quality Data around the various villages of KSFL in 10 km radius ............ 73 Table 3.4 National Ambient Air Quality Standards (CPCB), 2009 ................................................ 74 Table 3.5 Ambient Noise Quality Results ..................................................................................... 78 Table 3.6 Surface Water Analysis at various locations around KSFL ........................................... 79 Table 3.7 Ground Water Analysis around various Location of KSFL ............................................ 81 Table 3.8 Physicochemical Characteristics of Soil ....................................................................... 84 Table 3.9 Land use category in the Study Area ........................................................................... 88 Table 3.10 List of Tree and Shrub Flora Recorded in the Study Area .......................................... 92 Table 3.11 List of Herbs, Climbers and Grasses Recorded in the Study Area .............................. 94 Table 3.12 List of Mammalian Fauna Recorded in the study area ................................................ 96 Table 3.13 List of Avi- Fauna Recorded in the study area ............................................................ 97 Table 3.14 List of Herpetofauna Recorded in the study area ....................................................... 97 Table 3.15 List of Fish Fauna Recorded in the study area ........................................................... 98 Table 3.16 : Village-wise details of population ........................................................................... 100 Table 3.17 Production and Productivity of major crops cultivated .............................................. 107 Table 3.18 Comprehensive List of Infrastructures present in the Study Area ............................. 110 Table 4.1 Stack Parameters and Emission Load (Existing and Proposed Expansion Project).... 116 Table 4.2 Summary of Maximum 24-hour GLC due to the Existing Facility ................................ 117 Table 4.3 Summary of Maximum 24-hour GLC due to the Proposed Expansion ........................ 118 Table 4.4 Summary of Maximum 24-hour GLC due to the Existing Facility and Proposed
Expansion ........................................................................................................................... 118 Table 4.5 Summary of Maximum GLC at Monitoring Locations due to the Existing Facility and
Proposed Expansion ........................................................................................................... 119 Table 5.1 : Action Points ............................................................................................................ 139 Table 5.2 : Environmental Monitoring Program .......................................................................... 146 Table 6.1 : Hazardous Materials Storages ................................................................................. 148 Table 6.2 : Likely Accident Scenario .......................................................................................... 152 Table 6.3 : Effects due to Incident Radiation Intensity ................................................................ 153 Table 6.4 : Thermal Radiation Impact to Human ........................................................................ 154 Table 7.1 : Probable Hazards .................................................................................................... 163
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. iv
List of Figures Figure 1.1 10 Km radius Google Map of the Project ..................................................................... 12 Figure 2.1 Plant Layout Showing Expansion Location ................................................................. 21 Figure 2.2 : Ammonia Plant Process Flow Diagram ..................................................................... 25 Figure 2.3 Flow diagram of the Urea Plant ................................................................................... 28 Figure 2.4 : ETP System in KSFLShahajahanpur (Existing) ......................................................... 40 Figure 2.5 Ammonia Plant Block Flow Diagram ........................................................................... 42 Figure 2.6 Urea Plant Block Flow Diagram .................................................................................. 44 Figure 2.7 : Water Balance in KSFL Shahajahanpur (Existing) .................................................... 48 Figure 2.8 : Water Balance in KSFL Shahajahanpur (Expansion) ................................................ 49 Figure 3.1 Location Map of study Area ........................................................................................ 63 Figure 3.2 Digital Elevation Model (DEM) of the Study Area ........................................................ 65 Figure 3.3 Contour map of the Study Area ................................................................................... 65 Figure 3.4 Geomorphological Map ............................................................................................... 66 Figure 3.5 Wind Rose .................................................................................................................. 68 Figure 3.6 Wind Class Frequency Distribution (Post Monsoon Season) ...................................... 69 Figure 3.7 Sampling Locations in Study Area .............................................................................. 71 Figure 3.8 Statistical Comparison of PM2.5 Concentration (Post Monsoon Season) ................... 76 Figure 3.9 Statistical Comparison of PM10 Concentration (Post Monsoon Season) .................... 76 Figure 3.10 Statistical Comparison of SOx Concentration (Post Monsoon Season) ..................... 77 Figure 3.11 Statistical Comparison of NOx Concentration (Post Monsoon Season) ..................... 77 Figure 3.12 Soil map of Shahjahanpur District ............................................................................. 83 Figure 3.13 Landuse / Land Cover Statistics of the Study Area ................................................... 89 Figure 3.14 Land use map of the Study Area ............................................................................... 89 Figure 3.15 A View of Thick Green Belt around project boundary from Shajahanpur-Farrukhabad
Highway ................................................................................................................................ 99 Figure 3.16 National Parks and Sanctuaries in Uttar Pradesh .................................................... 100 Figure 3.17 Sex wise SC, ST Population in Study Area ............................................................. 103 Figure 3.18 Percentage wise break up of SC, ST and General Population in Study Area .......... 103 Figure 3.19 Gender-wise Distribution of Literate and Illiterate in Study Area .............................. 104 Figure 3.20 Workers Scenario of the Area ................................................................................. 105 Figure 3.21 Distribution of Main Workers ................................................................................... 106 Figure 3.22 Distribution of Marginal Workers ............................................................................. 107 Figure 4.1 Isopleth for NOx GLC due to operation of Existing Facility ........................................ 121 Figure 4.2 Isopleth for SPM GLC due to operation of Existing Facility ....................................... 122 Figure 4.3 : Isopleth for NH3 GLC due to operation of Existing Facility ...................................... 123 Figure 4.4 Isopleth for SOx GLC due to Proposed Expansion .................................................... 124 Figure 4.5 : Isopleth for NOx GLC due to Proposed Expansion ................................................. 125 Figure 4.6 : Isopleth for SPM GLC due to Proposed Expansion ................................................. 126 Figure 4.7 Isopleth for NH3 GLC due to Proposed Expansion ................................................... 127 Figure 4.8 : Isopleth for SOX GLC due to Existing Facility and Proposed Expansion ................. 128 Figure 4.9 Isopleth for NOX GLC due to Existing Facility and Proposed Expansion ................... 129 Figure 4.10 Isopleth for SPM GLC due to Existing Facility and Proposed Expansion ................. 130 Figure 4.11 : Isopleth for NH3 GLC due to Existing Facility and Proposed Expansion ............... 131 Figure 6.1 :Rupture in NG Line .................................................................................................. 155 Figure 6.2 Failure in Ammonia Line ........................................................................................... 157 Figure 6.3 Ammonia Tank Heavy Leakage Stability Class “F” .................................................... 158 Figure 6.4 Ammonia Tank Heavy Leakage Stability Class “D” ................................................... 159 Figure 6.5 Chlorine Cylinder Leakage ........................................................................................ 160 Figure 7.1 : KSFL’s Internal Emergency Communication Network ............................................. 166
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. v
Abbreviation
AAQ Ambient Air Quality
AAQMS Ambient Air Quality Monitoring Station
ADM Additional District Magistrate
AFFF Aqueous Film Forming Foam
APC Ammonia Process Condensate
APTI Air Pollution Tolerance Index
Asstt. Assistant
BA Breathing Apparatus
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
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EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. vi
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
KSFL Kribhco Shyam Fertilizers Limited
KBR Kellogg Brown & Root
KVA Kilovolt-Ampere
LDPE Low Density Polyethylene
LTS Low Temperature Shift Converter
MAGP Modern Agro Growth Programme
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. vii
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 Metric Tonsper 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
REIA Rapid Environmental Impact Assessment
RO Reverse Osmosis
RSPM Respiratory Suspended Particulate Matter
SBU Strategic Business Unit
SG Stream Generation
SGP Steam Generation Plant
SGWA State Ground Water Authority
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EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
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EQMS INDIA PVT. LTD. viii
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
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. ix
Annexure
Annexure I : KSFL Environment Policy
Annexure II : Environmental Clearances/ NOC of existing Plant
Annexure III : Ramky Certificate for Hazardous Wastes
Annexure IV : Ambient Noise Standards
Annexure V : Ground Water Approval
Annexure VI : UPSIDC Industrial Area Documents
Annexure VII : Land allotment documents
Annexure VIII : Environmental Cell set
Annexure IX : KSFL DMP
Annexure X : Ambient Air Quality Monitoring Results
Annexure XI : Compliance of Environmental Conditions
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. x
EXECUTIVE SUMMARY
Introduction and Background Project Highlight
KRIBHCO Shyam Fertilizers Limited (KSFL) was incorporated on December 8, 2005 pursuant to a
joint venture agreement between KRIBHCO and Shyam Group to acquire the urea manufacturing
facilities at Shahjahanpur in the state of Uttar Pradesh in India from Oswal Chemicals & Fertilizers
Ltd. in the shareholding ratio of 60:40. Effective March 30, 2009 the shareholding ratio of KRIBHCO
and Shyam group is 85:15.
KRIBHCO was incorporated on April 17, 1980 as National Level Multistate Cooperative Society and
is governed by Multistate Cooperative Society Act, 2002. KRIBHCO’s paid up capital as on March
31, 2013 is Rs. 390.18 crore.
KRIBHCO has state-of-the art Fertilizer Complex based on natural gas at Hazira, District Surat,
Gujarat consisting of two streams of Ammonia Plant and four streams of Urea Plant with annual
capacity of 1.00 Million MT and 1.73 Million MT respectively. KRIBHCO is in advanced stage of
implementing revamp of its Fertilizer Complex which will increase the annual capacity of ammonia&
Urea Plants to 1.25 Million MT and 2.19 Million MT respectively. KRIBHCO is also producing Argon
Gas from its Fertilizer Complex at Hazira.
The management control of the Company rests with KRIBHCO, a cooperative society engaged in
manufacturing nitrogenous and bio-fertilizers since 1980. KRIBHCO’s long and valuable experience
in fertilizer sector provides the Company the advantage of their management expertise and
business know-how. The Company leverages on the extensive marketing and distribution network
of KRIBHCO, under which our products are marketed. The Company also has access to ’, ‘
’ brand, which is a well-established and respected brand amongst farmers and co-operative
societies across India.
KSFL manufactures nitrogenous fertilizer viz. urea through our integrated urea and ammonia
manufacturing facility at Shahjahanpur. The Plant is the latest Greenfield Urea Plant in India-
commissioned in November 1995 and is strategically located in North India, right in the middle of a
high urea consumption belt and based on Natural Gas as feedstock supplied through the Hazira-
Vijaypur-Jagdishpur ("HVJ") gas pipeline.
The Plant has an installed capacity of 864,600 MTPA (2 x 1310 MTPD) of urea and 501,600 MTPA
(1 x 1520 MTPD) of ammonia. The Plant is operating at more than 100% capacity utilisation since
acquisition.
The plant is ISO 9001:2008, ISO-18001(OHSAS) and ISO 14001:2004 certified by BSI Group India
Pvt. Ltd. The marketing of Urea and surplus ammonia produced by the Company is undertaken by
KRIBHCO, one of the promoters Company
The total land acquired at Shahjahanpur is about 780.75 acres (including township). About 33% of
the land is under green cover.
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. xi
KRIBHCO Shyam Fertilisers Limited (KSFL), Ammonia – Urea complex is located in the Village
Piprola Distt Shahjahanpur in Uttar Pradesh, 12 km from the district town of Shahjahanpur and 80
km from Bareilly town. The plant is well connected by rail and road. The nearest airport is at New
Amausi (~180 km from site). The total land available under KSFL / Township is around 780.75
acres. About 33% of the land is under green cover. Balance land is outside the industrial complex.
The site is well connected with road and rail network.
The power requirement for both existing plant is met by Gas Turbines of 2X25 MW capacities. In
addition there is provision of emergency power supply from 2000KVA DG sets.
Existing facilities also comply with the conditions made by the Ministry of Environment and Forest,
Government of India, Central Pollution Control Board and UP State Pollution Control Board.
As a forward looking company KRIBHCO Shyam (KSFL) considered the future demand of fertiliser
in the country and initiated for expansion of Shahjahanpur unit by proposing to set up a grass root
Natural Gas /RLNG based Ammonia plant of 2200 MTPD single stream and Prilled Urea plant of
3850 MTPD with provision for augmentation of utilities and other off-site facilities considering
available infrastructure. The new expansion project will be located within the existing complex
where adequate land is available.
The key facilities for the proposed expansion project shall be as below:
Sl. No. Plants & Facilities Provisions
1. Ammonia Plant 2200 MTPD 2. Urea Plant 3850 MTPD 3. Main Raw Material --NG/LNG
Transportation & Metering Station
By GAIL Pipeline and metering station provided
4. Product Storage & Handling Facilities
a] **Ammonia Storage Tank b] Silo c] Empty Bag Storage d] Bagging Plant
5000 MT at -330C and atmospheric pressure 30000 MT - (6+2) Slats each of 60 TPH (design capacity)
5. Cooling Tower a] Ammonia Plant
b] Urea Plant 24000 m3/hr. each 21000 m3/hr. each
6. Power Generation & Supply a] Power Generation (GTG)
b] Substation for receiving power from State Grid Emergency DG Set
1X25 MW 1X2000 kVA
7. Steam Generation Facilities
HRSG (GT set) 100 MT/hr
8. Water Supply Treatment & Distribution
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
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EQMS INDIA PVT. LTD. xii
Estimated Capital cost of the proposed expansion of Fertilizer plant is estimated as Rs. 4132 crores
including foreign component of Rs.1319 crores.
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.
(**, installation of new 5000 MT Ammonia Storage tank shall be taken up in first stage of
implementation of project , which will also be used for inspection of existing Ammonia Storage tank
for ensuring safety of the tank.
In second stage of the project, proposed new ammonia & Urea Plant shall be commissioned and
after that existing as well as new proposed Ammonia Storage Tanks will be used for the storage
purpose of surplus ammonia generated from existing & proposed ammonia plants.)
The main suppliers of ammonia technology are:
HaldorTopsoe (HTAS), Denmark
a) Raw Water Supply System b) DM Water Plant c) Cond. Polishing Unit
Bore wells (2+1)×150 m3/hr. (2+1)×200 m3/hr.
9. Yard Piping Provided as per requirement
10. Instrument Air Facilities a] Compressor b] Drying Unit c] Receiver
(1+1)×3000 Nm3/hr. (1+1)×3000 Nm3/hr.
11. Inert Gas Generation 600 Nm3/hr. Of N2; Liquid N2 Storage: 30 m3 with vaporizer
12. Safety & Fire Fighting System including fire water ring with Hydrant System
For the proposed expansion project, existing firewater rings and other facilities shall be augmented as per requirement.
13. Auxiliary services, workshop equipment, laboratory equipment, weighbridge, fire engine, continuous monitoring system, NDT equipment, telephone& telecommunication, Public Address System, etc.
Extra telephone exchange facilities and additional lab and NDT equipment considered
14. General & Welfare Facilities Existing facilities will be augmented as per requirement.
15.
Transport Facilities a] Locomotive b] Railway Siding and lead line c] Road Transport
1X1200 HP To be developed
16. Construction equipment By construction contractor
17. Township &Public Building Existing facilities will be augmented as per requirement.
18. Non-plant Building Existing facilities will be augmented as per requirement.
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. xiii
Kellogg Brown & Root (KBR), USA
Uhde, Germany
The main processes used today in the production of urea are the stripping processes offered by:
Stamicarbon, Netherlands
Snamprogetti (Now Saipem), Italy
Toyo Engineering Corporation (TEC), Japan
**Additional Ammonia Storage Tank: The capacity of ammonia storage tank shall be 5,000 MT. The
ammonia storage tanks will be of double wall double integrity type and provided with suspended
deck. The liquid ammonia produced in the ammonia plant shall be stored at atmospheric pressure
and at a temperature of –33oC. The facilities include one no. double walled insulated atmospheric
storage tank, ammonia boil off compressor, ammonia flare stack and ammonia transfer pumps etc.
for safe operation of the system.
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 2200 MTPD ammonia and
3850 MTPD urea plants are summarized in Table below:
Sl. No.
Raw Material/Utilities Unit Requirement
1.0 Natural Gas (through GAIL) Sm3/hr. 99035
2.0 Water (Bore well) m3/hr. 1122
Pollutants Generation, Treatment and Disposal
Gaseous Emissions
The KSFL plants will have seven continuous sources of emission after expansion
In Proposed Expansion:
The three continuous sources of emission shall be, namely
Reformer flue gas stacks in ammonia plant.
Urea Prilling tower
Power Plant (GTG / HRSG)
The emission from stacks will be well within the stipulated norms. Urea Prilling tower shall be a
natural draft circular tower with ~ 26 m diameter and 102 m height. The tower is so designed that
exhaust gases contain less than 50 mg/Nm3 of urea dust. Emissions from process section of the
plant are controlled through the use of eco-friendly fuel (NG and in case of its shortage, naphtha is
used to a limited extent during short supply of NG only) and high stacks (more height than required
as per norms).
KRIBHCO Shyam Fertilizers Limited
EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt
Shahjahanpur, U.P
EQMS INDIA PVT. LTD. xiv
Fugitive emission occurs in the bagging plant where large quantity of urea is handled. In order to
control the dust, the plant has been provided with de-dusting system. Dust from various points is
collected & sent to Urea plant where it is dissolved in urea solutions and reprocessed in urea plant.
In Existing Plant:
The gaseous emission of the KSFL existing plant is through four number of main stack viz. Service
boiler stack, GTG I&II stack, Ammonia reformer stack, prilling tower There are number of other
stacks viz. Vent stack Ist and IInd, Blow down stack, CO2 compressor vent (2 no.), main flare stack,
ammonia flare stack, ETP Stripper, CO2 vent. These stacks are not continuous and operate only
during abnormality in plant. The emission from continuous stacks is well within the stipulated
norms. Urea Prilling tower is a natural draft circular tower with ~ 26 m diameter and 102 m height.
The tower is so designed that exhaust gases do not contain more than 50 mg/Nm3 of urea dust.
Liquid Effluents
KSFL has followed the policy of “at source treatment of effluents and recycling of treated effluents
back into the process”. The major potential liquid pollutants emanating from the KSFL complex are
from the Ammonia and Urea process plants, Demineralization plant regeneration waste water,
cooling tower blow down, boiler blow down etc. Various categories of effluents generated in the
complex and their treatment philosophy is as given below:
Effluents treated in the individual plant battery limits
Ammonia plant process Condensate is treated in the ammonia plant, recycled to DM plant
and after polishing used as boiler feed water.
Urea plant process condensate treated in urea plant, recycled to DM plant and after
polishing used as boiler feed water.
Turbine steam condensate treated in DM plant (polishing unit) and recycled back as BFW.
Demineralization water plant effluent, neutralized before sending to Guard pond via settling
chamber.
Effluents treated outside the main process plant
Domestic waste water from the plant and township area is treated in Sewage treatment
plant.
Ammonia and Urea process Condensate at ETP in case of upsets.
Floor washings / process drains from ammonia and urea plants at ETP in case of non-
confirming quality.
Oily waters if any generated from various sections of Urea and Ammonia plants is collected
in oily water pit provided in the respective plant. The water is pumped to oily water pit at
ETP.
Sanitary waste water from township & factory in Sewage treatment plants.
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Contaminated pond having capacity of 5000 m3 is provided for collecting floor washing of
urea and ammonia plants and also the condensates of ammonia and urea plants during
any emergencies for further treatment before discharge.
A balance pond having capacity of 30,000m3 is provided for balancing and equalizing the
effluent coming from DM plant, cooling tower and stripper outlet.
The balance pond water overflows to guard pond-having capacity of 5000m3. Treated
effluent from guard pond is pumped to stabilization pond for final discharge/ green belt
irrigation within project premises.
Proposed Expansion Project:
KSFL is in the field of fertilizer production having its production facilities at Shahjahanpur (U.P.) and
produces prilled urea. In the process of urea production from natural gas, ammonia is also
produced as intermediate product which is consumed for urea production. There is also some
surplus generation of ammonia because of the feed quality and quantity of surplus ammonia
depends on Carbon/Hydrogen ratio of Gas (feed). In its existing plant some treated effluent water,
confirming to PCB norms, is disposed off to water bodies. KSFL proposes to implement its
Brownfield Expansion Project for production of ammonia (2200 MTPD) & urea (3850 MTPD).
Solid Waste
KSFL being an environmentally conscious organization has always stresses on pollution prevention
rather than 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. Basically the following types
of solid wastes are generated at KSFL:
Biodegradable wastes
Non-biodegradable waste
Township Waste and
Hazardous wastes
Following wastes are generated at KSFL as per Hazardous Waste (Management, Handling &Trans
boundary Movement) Rules, 2008
Spent catalyst (Nickel, Chromium & Copper based)
Spent / used oil
Wastes are disposed off as per rules.
Green Belt:
A thick green belt has been provided almost all around the plant. The tree plantation is an on-going
process & KSFL is planting number of trees every year to fill up extra land available with them.
KSFL has developed a thick green cover in and around the plant complex including township. The
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tree cover is sparse in the immediate vicinity of the Plant, which includes township area, market
places, office complexes, residential areas etc.
Environmental Status of Plant Site and Study Area
Site Characteristics
KSFL fertilizer complex is located at a distance of 12 km from Shahjahanpur town near village
Piprola on the State Highway No.29 to Farrukhabad and lies close to the broad gauge railway line
from Lucknow to Moradabad and the National Highway No. 24. The nearest airport is in Amausi
(Lucknow), at a distance of 150 km.
KSFL plant is located in the state of Uttar Pradesh. Uttar Pradesh stretches into two of India’s major
physiographic divisions, namely the Great Plains of North India and the Peninsular Plateau. Almost
90% of the total area in Uttar Pradesh is Under Great Plains of North India, while the Southern part
of the state belongs to the Peninsular Plateau. Both of these major divisions in U.P. are marked by
a variety of physiographic and relief features.
District Shahjahanpur is situated in South East of Rohilkhand Division. It was established in
1813.Before its creation it was a part of district Bareilly. It Consists of 4 Tehsils, 15 Blocks, 922
Gram Panchayats, 1 Constituency and 6 Assembly Areas.
Land of district Shahjahanpur is plains and fertile. Land of district Shahjahanpur on the side of the
river bank is low and other side it is comparatively high side of land is called Bangar and low side is
called 4 khadar. The north side land of tehsil Puvayan as is domat land. Land in the west side of the
district is comparatively very low due to land erosion of the rivers. Due to this reason at the time of
rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat and
matiyar. In the district water level is 20’ to 25’ below GL. The area is located in the Doab of upper
Ganga, the main drainage feature of the area. The next important drainage channel is Mahuwa,
flowing along the left terrace of the Ganga.
Soil
The soils of Shahajahanpur are complex, highly variable, reflecting a variety of parent materials,
physiographic land features, range of distribution of rainfall, and its effects etc. As such different
soils create different types of habitat for plant growth, therefore, the true choice and afforestation
patterns on such kind of soils vary greatly. Soils are thus, variable in their soil-water-plant
relationship, conservation needs and production potentials.
The mantle of alluvium in this area is confined to the North Eastern sector. It is then on Sandstone
plateaus, where over large spread of bare rock is there. Usually it is light loam, sandier over
sandstone tracts, and more clayey upon the shale.
The fertility of soils of the study area is medium and is known to be good for cultivation.
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Water Resources and Water Quality
The annual rainfall data from meteorological department in the district is 907 mm. The winter rains
are uncertain. Light showers may occur during December and January.
The primary drains comprise the river Ganges. It flows in a wide and sandy bed and changes its
channel year to year. The river is perennial and shows effluent behaviour throughout the stretch of
the study area. The banks of the river are alternatively sloping and steeper cliffs, a cliff on one side
being usually faces by a slope on the other.
Ground water is important source of drinking water. In larger part of the area the aquifer is
unconfined at shallow depths depending upon the thickness of overlying clay horizon. Estimation of
ground water resources of Shahjahanpur has been carried out based on the methodology
recommended by the Ground Water Estimation Committee (GEC’97). The net ground water
availability of the District is 140974.03 Ham and gross ground water draft is 83111.52 Ham. Thus
the level of development is 58.96. District Shahjahanpur come under Safe Category.
Surface and ground water samples were collected and analysed for suitability as drinking water (IS
10500).Surface water samples analysis indicates that water from all the location meet the ‘desirable
limits’ of drinking water. Total Dissolved Solids levels are high in almost all the samples. Ground
water analysis indicates that all the ground water samples have high magnesium content (even
crossing permissible limits in the absence of alternate source). Other parameters though do not
meet the ‘desirable limits’ of drinking water and in but are within the ‘permissible limit in the
absence of alternate source’
Meteorology
Uttar Pradesh climate greatly varies according to the variation in the topography of the region. The
climate of the state is tropical, but variations exist because of difference in altitudes. The Himalayan
region is cold. The average temperature varies in the plains from 3 to 4 °C in January to 43 to 45°C
in May and June. There are three distinct seasons - winter from October to February, summer from
March to mid-June, and the rainy season from June to September. The landlocked state is devoid
of moderating influence of the sea.
Summer: The month of April marks the start of summers in Shahjahanpur and it lasts till June.
Temperature ranges between 22°C to 48°C during these months.
Monsoon: Shahjahanpur experiences the monsoon season from July till October. The city remains
drenched during these months. Average annual rainfall is 907 mm.
Winter: Winters in Shahjahanpur start in the month of November and last till February. The weather
is pleasant during these months and the temperature ranges between a comfortable 2°C to 23°C.
This is the apt time for visiting the city.
A metrological station was set up inside the plant and temperature, wind velocity and direction,
humidity and rainfall were recorded for the winter season (three months). Maximum and minimum
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(mean) temperature recorded was 34 and 90C.Highest relative humidity during the study period is
observed as 94% and lowest as 8 %. The predominant wind directions are North West and West.
Air Quality
National AAQ norms for residential areas are always met for NH3, SOX and NOX. For SPM /RSPM
they could not be met due to local phenomenon.
Noise
Ambient standards both Ld and Ln with respect to noise applicable for residential area during day
time {55 dB (A)} and night time Ln {45 dB (A)} are mostly met except near commercial areas.
Environmental Impact Assessment
Topography and Soils
The proposed KSFL plant 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, three new sources of gaseous
emission are added. The existing sources of emission i.e. Reformers in Ammonia Plant, auxiliary
Boiler, Gas Turbine and Prilling Tower in Urea Plant will be emitting NOx (from Reformer, boilers
and Gas Turbine), SPM and NH3 (from Prilling Tower). The summary of GLC at monitoring station
due to the existing facility and proposed expansion marked in below Table.
Incremental increase in ground level concentration due to 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 due to the Existing Facility and Proposed Expansion
Location Rise in GLC
Max. Background
Concentration
Impact from Project
NAAQS
(µg/m3) (µg/m3) (µg/m3) (µg/m3)
Project Site
SOX 0.0017 6.04 6.042 80
NOX 0.0861 11.78 11.87 80
SPM 0.0046 153.18 153.184 200
NH3 0.0058 22.54 22.55 400
Sahjana
SOX 0.13 5.55 5.68 80
NOX 6.51 9.8 16.31 80
SPM 1.30 139.97 141.27 200
NH3 1.31 20.83 22.14 400
Sikarpur SOX 0.07 5.99 6.06 80
NOX 3.08 11.6 14.68 80
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Location Rise in GLC
Max. Background
Concentration
Impact from Project
NAAQS
(µg/m3) (µg/m3) (µg/m3) (µg/m3)
SPM 0.83 146.81 147.64 200
NH3 0.70 20.79 21.49 400
Akhtyarpur
SOX 0.10 5.86 5.96 80
NOX 4.40 10.92 15.32 80
SPM 1.00 149.24 150.24 200
NH3 0.98 21.33 22.31 400
Lalpur
SOX 0.002 5.87 5.87 80
NOX 0.05 10.86 10.91 80
SPM 0.02 147.2 147.22 200
NH3 0.02 20.79 20.81 400
Khalauli
SOX 0.01 5.37 5.38 80
NOX 0.30 10.72 11.02 80
SPM 0.07 138.47 138.54 200
NH3 0.06 19.63 19.69 400
SOX: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum SOx concentration of 6.06 µg/m3 at Sikarpur village with project
impacts of 0.07 µg/m3and baseline contribution of 5.99 µg/m3.The total impact from the project of
6.06 µg/m3 is well within the stipulated standard of 80 µg/m3for industrial as well as residential
areas.
NOx: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum NOx concentration of 16.31 µg/m3 at Sahjana village with project
impacts of 6.51 µg/m3 and baseline contribution of 9.80 µg/m3.The total impact from the project of
16.31 µg/m3 is well within the stipulated standard of 80 µg/m3for industrial as well as residential
areas.
SPM: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum SPM concentration of 153.18 µg/m3 at project site with project
impacts of 0.0046 µg/m3 and baseline contribution of 153.18 µg/m3.The total impact from the
project of 153.184 µg/m3 is well within the stipulated standard of 200 µg/m3for industrial as well as
residential areas.
NH3: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum NH3 concentration of 22.55 µg/m3 at project site with project
impacts of 0.0058 µg/m3 and baseline contribution of 22.54 µg/m3.The total impact from the project
of 22.55 µg/m3 is well within the stipulated standard of 400 µg/m3for industrial as well as residential
areas.
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Noise
The operation of expanded capacity of KSFL 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.
A critical review of noise monitoring shows that:
Within the plant area noise level was more near synthesis compressor in ammonia (~73 -
74 dB (A)) and near Prilling Tower (~72 dB (A) etc. However the noise level along the plant
boundary gets reduced to considerable extent as monitored at main security gate (~49 dB
(A)), and Technical Building (~49 dB (A)).
In township the noise level was measured in public places like Temple and guest house. It
was 42 to 60 dB (A).
Employees working near turbines, blowers, compressors or gas turbines are exposed to slightly
high decibels noise (+ 80 dBA). Very few employees work in such areas and have been provided
cabins with acoustic protection and have also been provided with ear plugs etc.
Water Resources and Water Quality
Water Resources
Water requirement for existing plant (after debottlenecking) is around ~878 m3 / hr. (~ 21072
m3/day) including 2184 m3/day for domestic purpose (both plant and township). The water
consumption in proposed expansion project will be ~1122 m3 / hr. (26928 m3/day). The water will
be drawn from existing as well as from additional tube wells. Necessary approval / clearance from
Central Ground Water Authority/ Board are being taken.
Industrial wastewater after it is discharged into surface water body should not produce significant
deterioration in its water quality. The effects on surface water depend on wastewater characteristics
and quantity. The impact on surface water depends on the characteristics and also on quantity of
water in the receiving water body.
KSFL is consuming water for their process below the specified value i.e. < 7.8 m3/t of urea against
the CPCB (Probe 97/2002-03) Norms 8.0 m3/t of urea
The operation of the expansion plants will have no adverse impact on ground water resources
although there will be some increase in treated effluents quantum. The effluents from the expansion
plant will be recycled or reused in green belt development.
The treated effluent use for irrigation / development of green belt will not have any adverse impact
on ground water quality as the treated effluents are well within the norms laid down by the UP
Pollution Control
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Water Quality
The process effluents from the proposed expansion unit shall be treated in the existing effluent
treatment system (after augmentation) i.e.
APC (Ammonia Process condensate) treated in in Ammonia plant, UPC (Urea Process
condensate) treated in in Urea plant and along with turbine condensate shall be recycled as
BFW after polishing in DM plant.
Acidic & alkaline effluents from DM plant &Waste water from laboratory are mutually
neutralized in Neutralisation pits in DM Plant and then sent to ETP for further treatment.
Oily water from plant goes to Oily water treatment plant and after treatment, treated water
go to ETP.
The treated effluents will go to balance pond and then to guard pond. The effluents meeting
the norms will be discharged to Garrai Nala.
Domestic wastewater will be treated in oxidation ponds and the treated effluents are utilized
for irrigation in KSFL green belt / horticulture.
As such the expansion project will not have any impact on water (ground or surface water
resources) sources.
Climatology and Meteorology
The little construction activities and operation of the proposed KSFL 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. KSFL 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 KSFL 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
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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.
OHS System
Health hazards associated with the occupation are called occupational hazards. In chemical
industry due to handling of toxic and hazardous chemicals there are possibilities of developing
occupational diseases. KSFL currently employs various measures with respect to occupational
health and safety (more details in Chapter 2).
Risk Assessment
KSFL fertilizer plant uses a number of hazardous chemicals, namely NG, Naphtha, NH3, Acids,
fuels etc. The use of these chemicals is inevitable. KSFL has MSDS and understands the risks
associated with these chemicals. Adequate control measures have been taken by the KSFL to
prevent any dangerous incident.
KSFL 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. KSFL has provided PPE to operating personnel (as per requirement) for carrying
hazardous activities.
All the employees are being retrained through refresher in Fire & Safety training once 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:
The control measures through proper upkeep; preventive maintenance and good
housekeeping will considerably reduce the fugitive emission.
Monitoring of fugitive emission should be continued at human receptive points as per
existing practice.
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Existing schedule monitoring system under ISO-14001 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
KSFL has gradually reduced its water consumption/ effluent generation and energy consumption.
The treatment philosophy adopted by KSFL has given 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 now 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. Monitoring of underground
water level in pre and post monsoon should be started.
Awareness program should be continued to increase the interest among employees for
conservation of water.
Water harvesting schemes should be taken up (use of ground water) where ever possible.
Climatology and Meteorology
The construction and operation of the proposed expansion of KSFL plant will not affect meteorology
and Climatology of the study area and as such no management plan will be required.
Green Belt
KSFL has developed green belt all around it and also along roads, as groves of fruit trees, as forest
blocks, lawns and ornamental / flowering bushes. Mostly the trees have been planted in blocks of
one particular plant-Acacia Arabica, Alibizzia lebbeck, Alibizzia procera, Alstonia scholaris,
Anthocephalus cadamba, Ficus religiosa etc.
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 an 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.
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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.
Public Hearing
The proposed project site is situated at notified UPSIDC Industrial Area, village & Post Piprola /
Kanth Tehsil Sadar, District Shahjahanpur, Uttar Pradesh.
As per Office Memorandum dated 10th December, 2014 viz. Exemption from public Consultation
for the projects/ activities located within the Industrial Estates/ Parks, the proposed project is
exempted from public hearing since the proposed project is located in notified industrial area.
Hence, no public hearing was conducted for the proposed project.
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CHAPTER 1. INTRODUCTION AND BACKGROUND
1.1. Preamble
The Ammonia-Urea Complex of M/S KRIBHCO Shyam Fertilisers Limited located at Village
Piprola about 12 km in south west direction of Shahjahanpur city is one of the six Urea
producing fertilizer plant based on Natural Gas as feed stock available from Mumbai High Sea.
The other fertilizer plants based on same feed stocks are namely:
NFL Vijaipur (M.P)
IFFCO, Aonla (U.P)
Indogulf Fertilisers Ltd (U.P)
Chambal Fertilisers & Chemicals Ltd, Kota (Raj)
Tata Chemicals Ltd, Babrala (U.P)
The sixth and last fertilizer plant of this series M/S KRIBHCO Shyam Fertilisers Limited
(Formerly Oswal Chemicals and Fertilisers Ltd.) Shahjahanpur was commissioned in November
1995 having rated production capacity for 8,64,600 MT per annum Urea and 5,02,000 MT per
annum Ammonia along with necessary utilities and in house auxiliary facilities.
KSFL plant is based on the technology and processes know how as below:
For Ammonia - M/s Haldor Topsoe, Denmark
For Urea - M/s Snamprogetti, Italy
The detailed engineering of entire complex including preparation of plant lay out, offsite, effluent
treatment and environmental protection measures etc. was executed by M/s Projects and
Development India Ltd (PDIL) a renowned Govt. of India Undertaking.
1.2. Importance and Need of an EIA
Government of India, as per its policy has given emphasis on Sustainable Development. While it
is supporting the industrial growth, the environmental protection has been made the integrated
criteria for this support. In line with this policy, Ministry of Environment & Forests has defined
elaborated ‘Environment Clearance (EC)’ framework under The Environmental (Protection) Act,
1986 (Environmental Impact Assessment Notification, 2006) for establishing/expanding an
industry/development project. The EC process takes into consideration local conditions, public
concerns, effectiveness of impact assessment and proposed mitigation measures in sustaining
environmental equilibrium. The base documentation/ study report, called Environmental Impact
Assessment (EIA) detailing baseline conditions, environmental impacts, mitigation measures
and management plan is required to be prepared for start of EC process. Prior Environmental
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Clearance is required from concerned authorities for all projects detailed in the ‘Schedule’ as
given in the ‘Notification dated 14th September, 2006’. The projects listed as category ‘A’ under
EIA notification and require EIA report for appraisal by expert committee prior to EC. As per this
category all fertiliser projects require environmental clearance. Since EIA preparation and
compliance to EC requirement is time consuming, MoEF has started accepting one season
based EIA study to reduce the overall clearance cycle time.
The remarkable progress achieved in fertilizer consumption, during last 4-5 decades, has been
possible mainly because of fertilizer was available to the millions of farming community spread
over more than 6 lakhs villages. This task has been achieved by: Continuous building up of
fertilizer capacity in the Country;
Equitable distribution of the available fertilizers in all parts of the Country by evolving coordinated
supply plan under the Essential Commodity Act (ECA) and; however there is huge gap in the
demand and indigenous supply of urea fertiliser. Arranging imports as indigenous production
capacity has been inadequate to meet the ever-increasing demand for fertilizers.
In order to close this gap in demand and supply of urea fertiliser Kribhco Shyam Fertilisers
Limited (KSFL), has planned expansion of its fertilizer manufacturing facilities at Shahjahanpur,
UP by installing an Ammonia Plant Capacity –2200 MTPD, Urea Plant Capacity –3850 MTPD
other associated facilities including ammonia storage tank of capacity 5000 MT to be used for
existing (for inspection of installed ammonia storage tank) as well as expansion project and
upgrading some existing utilities and other off site facilities for the proposed expansion project.
The estimated cost of the proposed expansion project is Rs 4132 crores including foreign
component of Rs 1319 crores.
1.3. Project & Project Proponent
Kribhco Shyam Fertilizers Limited (KSFL) was incorporated on December 8, 2005 pursuant to a
joint venture agreement between KRIBHCO and Shyam Group to acquire the urea
manufacturing facilities at Shahjahanpur in the state of Uttar Pradesh in India from Oswal
Chemicals & Fertilizers Ltd. in the shareholding ratio of 60:40. Effective March 30, 2009 the
shareholding ratio of KRIBHCO and Shyam group is 85:15.
KRIBHCO was incorporated on April 17, 1980 as National Level Multistate Cooperative Society
and is governed by Multistate Cooperative Society Act, 2002. KRIBHCO’s paid up capital as on
March 31, 2013 is Rs. 390.18 crore.
KRIBHCO has state-of-the art Fertilizer Complex based on natural gas at Hazira, District Surat,
Gujarat consisting of two streams of Ammonia Plant and four streams of Urea Plant with annual
capacity of 1.00 Million MT and 1.73 Million MT respectively. KRIBHCO is in advanced stage of
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EQMS INDIA PVT. LTD. 9
implementing revamp of its Fertilizer Complex which will increase the annual capacity of
ammonia & Urea Plants to 1.25 Million MT and 2.19 Million MT respectively. KRIBHCO is also
producing Argon Gas from its Fertilizer Complex at Hazira.
The Shyam Group is an integrated player in telecom industry with interests in basic and satellite
telephony, ISP and VSAT services, manufacture of a wide range of telecom equipment and agri-
business initiatives such as contract farming and fertilizers. The Group was promoted by Mr.
Rajiv Mehrotra, Mr. Ajay Khanna and Mr.Alok Tandon, who are also directors on the Board of
various group companies. Shyam Basic Infrastructure Projects Private Limited (“SBIPPL”) was
incorporated in 1996 and part of the Shyam Group.
The management control of the Company rests with KRIBHCO, a cooperative society engaged
in manufacturing nitrogenous and bio-fertilizers since 1980. KRIBHCO’s long and valuable
experience in fertilizer sector provides the Company the advantage of their management
expertise and business know-how. The Company leverages on the extensive marketing and
distribution network of KRIBHCO, under which our products are marketed. The Company also
has access to ’, ‘ ’ brand, which is a well-established and respected brand amongst
farmers and co-operative societies across India.
KSFL manufactures nitrogenous fertilizer viz. urea through our integrated urea and ammonia
manufacturing facility at Shahjahanpur. The Plant is the latest Greenfield Urea Plant in India-
commissioned in November 1995 and is strategically located in North India, right in the middle of
a high urea consumption belt and based on Natural Gas as feedstock supplied through the
Hazira-Vijaypur-Jagdishpur ("HVJ") gas pipeline.
The Plant has an installed capacity of 864,600 MTPA (2 x 1310 MTPD) of urea and 501,600
MTPA (1 x 1520 MTPD) of ammonia. The Plant is operating at more than 100% capacity
utilisation since acquisition.
The plant is ISO 9001:2008, ISO 18001 (OHSAS) and ISO 14001:2004 certified by BSI Group
India Pvt. Ltd. The marketing of Urea and surplus ammonia produced by the Company is
undertaken by KRIBHCO, one of the promoters Company. KSFL has well laid down environment
policy duly signed by Managing Director (Annexure I). The Environment Policy provides and
guides all concerned about the KSFL commitment for environment.
The total land acquired at Shahjahanpur is about 780.75 acres (including township). About 33%
of the land is under green cover.
The power requirement for both existing plant is met by Gas Turbines of 2X25 MW capacities
operating on Natural Gas/Naphtha. In addition there is provision of emergency power unit of
2000 KVA.
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Existing facilities also comply with the conditions made by the Ministry of Environment and
Forest, Government of India, Central Pollution Control Board and UP State Pollution Control
Board.
The proposed expansion project will augment the urea manufacturing facilities of KSFL and
meet the soaring demand of urea in the country.
KSFL plants are very well operated, maintained that have been acknowledged and praised time
to time by various national & international institutes as mentioned below:
Table 1.1 : Awards & Certifications Received
Sl. No.
Year Name of Award Presentation Institute
1 2010-2011 National Energy Conservation Award-2011
[“Certificate of Merit” in Fertilizer Sector]
Ministry of Power (Bureau of Energy Efficiency), New
Delhi.
2 2010-2011
Improvement in Company’s Overall
Performance
[First Prize in the Fertilizer (Ammonia & Urea) Plant]
The Fertilizer Association of India, New Delhi.
3 2011-2012
Improvement in Company’s Overall
Performance
[Joint Runner-up in the Fertilizer (Ammonia & Urea) Plant]
The Fertilizer Association of India, New Delhi.
1.4. Objectives of the EIA Study
The objectives of the present EIA are to:
Assess the impacts on various environmental components viz water, air, soil, flora
fauna, noise, land use, resource use due to proposed Expansion of urea production
Capacity of KSFL.
Suggest appropriate Impact Mitigation Measures and Environmental Management Plan
to ensure that the adverse impacts if any are eliminated or minimized.
1.5. Project Site and Regulatory Compliance Status
The proposed project is located at Village & Post Piprola, close to the town of Shahjahanpur of
District Shahjahanpur in Uttar Pradesh at approximately 790 50’ E longitudes and 270 50’ N
latitude. The location map for the plant is presented in Figure 1.1. The plant is located on a plot
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of about 780.75 acres. KSFL site is approximately 12 km in south west direction of
Shahjahanpur town near village Piprola. Bareily is about 80 km and state capital Lucknow is
~180 km from site. State highway 29 to Farrukabad and National Highway NH 24 are close by.
Shahjahanpur is the nearest railway station (~ 15 km) located on Lucknow - Moradabad BG
railway line. Shahjahanpur has got all weather approach road from Delhi, Aligarh, Badaun and
Moradabad.
KRIBHCO Shyam Fertilizers Limited (KSFL) unit was set up after obtaining Environmental
Clearance from Ministry of Environment & Forests (MoEF), Govt. of India vide their letter No.J-
11011/15/90-IA (II) dated 1st March 1993. The company has enhanced the production upto
Ammonia 1800 MTPD and Urea 3000 MTPD through revamp by utilizing the in built margins
provided in the design of various equipments / machineries of the plant.
As per the ‘Notification dated 14th September, 2006’ KSFL had also obtained the environmental
clearance vide letter no. F. No. J-11011/53/2008-IA-II(I) Dated : June 11, 2008 for the production
of Ammonia 1800 MTPD & Urea 3000 MTPD and also for the proposed enhancement in the
capacity upto Ammonia 1950 MTPD & Urea 3130 MTPD through debottlenecking. However
KSFL has not implemented the debottlenecking scheme due to techno-economic reasons.
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 & Transboundary Movement) Rules, 2008; 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, KSFL 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.
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Figure 1.1 10 Km radius Google Map of the Project
(Source: Google Earth)
1.6. Scope of Study
The scope of study is as based on as per the proposed TOR (Terms of Reference) for the REIA
study submitted to MoEF. The EIA report has been prepared based on the same:
1.6.1. Terms of Reference
The Ministry of Environment & Forests (MoEF), New Delhi vide dated 22nd November 2013 has
prescribed the following terms of reference (Point wise compliance of the TORs including index).
Table 1.2 TOR Compliance Status
Sr. No.
Terms of Reference Status
1. A separate chapter on status of compliance of Environmental Conditions granted by State/Centre to be provided. As per
Annexure XI
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Sr. No.
Terms of Reference Status
circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA/EMP report.
2. Executive summary of the project Attached
3. Justification of the project. Chapter 1, Section 1.2
4. Promoters and their back ground. Chapter 1, Section 1.3
5. Regulatory framework. Chapter 1, Section 1.5
6. Environment clearance for the existing unit issued by the Ministry (reasons, if not obtained), Consent to Operate and Authorization accorded by the UPPCB.
Environment clearance for the existing unit
issued by the Ministry, Consent to Operate and Authorization accorded by the UPPCB is given
vide
Annexure II
7. Compliance to the conditions stipulated in the Environmental Clearance / NOC granted by the SPCB.
Compliance to the conditions stipulated in
the Environmental Clearance/ NOC
granted by the UPPCB is given vide Annexure II
8. 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
9. 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 2.4.4; 2.4.5 and 2.4.6
10. Project location and plant layout. Plant location in Section 3.2, Figures 3.1 and Plant layout Figure 2.1
11. Details of the existing fertilizer plant. Existing status of fertilizer plant is given in
Section 2.4
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Sr. No.
Terms of Reference Status
12. Infrastructure facilities including power sources for the proposed expansion.
Plant facilities required for expansion of project
given in Table 2.1/ Section 2.5
13. Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures
Estimated Capital cost of the proposed modernization &
expansion of Fertilizer plant is estimated as Rs.
4182 crores.
Recurring Cost ~ Rs 21 crore per annum.
14. Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests etc.
Project Site location Figure 3.1
15. Present land use based on satellite imagery for the study area of 10 km radius.
Section 3.12 and figure 3.14
16. Location of National Park/Wild life sanctuary/Reserve Forest within 10 km radius of the project.
There is no National Park or Wildlife
Sanctuary within 10 km radius of the site
boundary. Details are provided in Section 3.13
17. Details of the total land and break-up of the land use for green belt and other uses.
Land use detail of the study area given in
Section2.1
18. List of products along with the production capacities. List of products is given vide Table 2.1
19. Manufacturing process details along with the chemical reactions and process flow chart.
Manufacturing process details along with the
chemical reactions and process flow chart is
given vide Section 2.4
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Sr. No.
Terms of Reference Status
20. Detailed list of raw material required and source, mode of storage and transportation.
Detailed list of raw materials are given vide Section 2.5.3 & Table
2.2 & 2.7 21. Ammonia storage tank shall not exceed 5000 T. Maximum Capacity of
new storage tank shall be 5000 T
22. A note on the long term strategy for the gas availability. Alternative, if the gas is not available
Chapter 2, Section 2.5.3.1
23. A note on the viability of the project in absence of non-availability of gas.
Chapter 2 Section 2.5.3.1
24. Action plan for the transportation of raw materials and products. Chapter 2 ; Raw Material- Section 2.5.3.1 Product- Section 2.5.3.7
25. 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) and VOCs for all the stacks for the existing fertilizer plant.
Ambient Air Quality Monitoring: Chapter-3
Section 3.8.2 and Table 3.3; Stack Emission
Data: Chapter 2: Table 2.3
26. Data for surface and ground water, treated effluent quality data, noise pollution and solid waste management for the existing plant should also be included.
Chapter 3; Section 3.10 Surface water details
analysis given in Table 3.6 and ground water
detailed analysis given in Table 3.7; Table 2.2
(Solid & Hazardous Wastes)
27. Air pollution control measures proposed for the effective control of gaseous emissions within permissible limits.
Chapter 2; Section 2.5.4
28. Plant-wise air pollution control measures proposed for the control of emissions from all the sources particularly uncontrolled NOx emission and method to control NOx.
Chapter 2; Section 2.5.4
29. Name of all the solvents to be used in the process and details of solvent recovery system.
Not applicable
30. Details of water and air pollution and its mitigation plan. Section 2.5.4 and 2.5.6; Sections 4.2 & Section
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Sr. No.
Terms of Reference Status
4.4; Sections 5.4.2 and 5.4.4
31. Action plan to control ambient air quality as per NAAQMS Standards notified by the Ministry on 16th September, 2009
Chapter 5; Section 5.4.2
32. An action plan to control and monitor secondary fugitive emissions from all the sources.
Chapter 2; Section 2.4.6
33. 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
Air quality modeling for proposed plant, the
isoplethe for existing, increase in GLC after
expansion shown in Fig. 4.1 to Fig. 4.11
34. Details of water requirement for existing and proposed expansion. Water balance chart for existing and proposed expansion including water intake, effluent generated, recycled and reused and discharged is to be provided.
Chapter 2; Figures 2.7 and 2.8; Section 2.5.6
35. Action plan to reduce fresh water requirement. Methods adopted/to be adopted for the water conservation should be included.
Chapter 5; Section 5.4.4
36. Layout plan indicating surface water collection. Internal water supply arrangement to be submitted.
Sections 2.5.3.2; Figures 2.7 and 2.8
37. ‘Permission’ for the drawl of existing and proposed water
requirement from the Competent Authority. Attached as Annexure V
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
Chapter 2; Section 2.4.4
39. Action plan for ‘Zero’ discharge of effluent should be included. Section-2.5.6
40. Ground water monitoring minimum at 6 locations should be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic).
Ground water monitoring minimum at
6 locations given in section 3.10.3 and
Table 3.7
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Sr. No.
Terms of Reference Status
41. Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management
Ground water monitoring minimum at
6 locations given in section 3.10.3 and
Table 3.7
42. 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
Chapter 2; Section 2.5.7/ Table 2.2
43. Precautions to be taken during storage and transportation of hazardous chemicals should be clearly mentioned and incorporated
Chapter 6; Section 6.7
44. Plan for the implementation of the recommendations made for the fertilizer plants in the CREP guidelines must be prepared and included.
Chapter 2; Section 2.9
45. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.
Attached as
Annexure III
46. An action plan to develop green belt in 33 % area. Layout map for existing and proposed Greenbelt
The total land acquired at Shahjahanpur is about 780.75 acre
(including township) about 33% (296 acres)
of the land is under green cover
47. 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.
Chapter 5; Section 5.4.4.
48. Details of occupational health program.
i) To which chemicals, workers are exposed directly or indirectly.
ii) Whether these chemicals are within Threshold Limit Values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation.
iii) What measures company have taken to keep these chemicals within PEL/TLV?
iv) How the workers are evaluated concerning their
Section – 2.7
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Sr. No.
Terms of Reference Status
exposure to chemicals during pre-placement and periodical medical monitoring.
v) What are onsite and offsite emergency plan during chemical disaster.
vi) Liver function tests (LFT) during pre-placement and periodical examination.
vii) Details of occupational health surveillance programme.
49. Socio-economic development activities should be in place. Chapter 2; Section 2.8
50. Detailed Environment management Plan (EMP) with specific 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.
Chapter 5
51. EMP should include the concept of waste-minimization, recycle / reuse / recover techniques, Energy conservation, and natural resource conservation.
Energy trend in KSFL given in Section 4.5
52. Corporate Environmental Responsibility
(a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.
(b) Does the Environmental Policy prescribe for standard operating process /procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms/ conditions? If so, it may be detailed in the EIA report.
(c) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions? Details of this system may be given.
(d) Does the company have a system of reporting of non-compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report
Approved Policy is attached as Annexure I.
Please describe accordingly.
Environment management Cell
structure is attached as Annexure VIII.
53. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof
Nil
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Sr. No.
Terms of Reference Status
54. Public hearing issues 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
Chapter 1, Section 1.7
1.7. Public Hearing
The proposed project site is situated at notified UPSIDC Industrial Area, village & Post Piprola /
Kanth Tehsil Sadar, District Shahjahanpur, Uttar Pradesh.
As per Office Memorandum dated 10th December, 2014 viz. Exemption from public Consultation
for the projects/ activities located within the Industrial Estates/ Parks, the proposed project is
exempted from public hearing since the proposed project is located in notified industrial area.
Hence, no public hearing was conducted for the proposed project.
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CHAPTER 2. PROJECT DESCRIPTION
2.1. Introduction
KRIBHCO Shyam Fertilisers Limited (KSFL), Ammonia – Urea complex is located in the Village
Piprola Distt Shahjahanpur in Uttar Pradesh, 12 km from the district town of Shahjahanpur and 80
km from Bareilly town. The plant is well connected by rail and road. The nearest airport is at New
Amausi (~180 km from site). The total land available under KSFL/ Township is around
780.75acres .The present land use is Industrial complex including residential area:
Total Area: 780.75 acres
About 33% (296 acres) of the land is under green cover. Balance land is outside the industrial
complex. The site is well connected with road and rail network.
KSFL plant started the commercial production in 1995 and soon stabilized and achieved rated
capacity. The plant was based on NG as feed stock (main raw material) supplied through GAIL
HVJ pipe line network. But due to shortage of NG KSFL has developed facilities to handle,
storage, feeding and processing of Naphtha for use as fuel for steam generation, power
generation and also in Ammonia plant.
2.2. Existing Status
Each section of KSFL complex has been performing very well right from the inception.
Considering the consistent good performance of the plant & in order to improve further, KSFL
Ammonia and Urea complex plant capacity has been revised / enhanced (through revamping) as
given below:
Name Plate rated capacity was Ammonia-1350 MTPD and Urea-2250 MTPD. (Ministry of
Environment & Forests (MoEF), Govt. of India vide their letter No.J-11011/15/90-IA(II)
dated 1st March 1993
Capacity reassessed by Dept. of Fertiliser – ammonia- 1520 MTPD and Urea- 2620
MTPD Capacity enhancement through optimization (obtained NOC from UPPCB – letter
no. 09865/191.5/NOC-104/2006/6 dated 14 – 12 2006) Ammonia – 1800 MTPD and
Urea 3000 MTPD, through revamp by utilizing the in built margins provided in the design
of various equipment / machineries of the plant.
As per the ‘Notification dated 14th September, 2006’ KSFL had also obtained the
environmental clearance vide letter no. F. No. J-11011/53/2008-IA-II(I) Dated : June 11,
2008 for the production of Ammonia 1800 MTPD & Urea 3000 MTPD and also for the
proposed enhancement in the capacity up to Ammonia 1950 MTPD & Urea 3130 MTPD
through debottlenecking. However KSFL has not implemented the debottlenecking
scheme due to techno-economic reasons.
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Figure 2.1 Plant Layout Showing Expansion Location
(Source: KSFL)
2.3. Proposed Project
As a forward looking company KRIBHCO Shyam (KSFL) considered the future demand of
fertiliser in the country and initiated for expansion of Shahjahanpur unit by proposing to set up an
grass root Natural Gas /RLNG based Ammonia plant of 2200 MTPD single stream and Prilled
Urea plant of 3850 MTPD with provision for augmentation of utilities and other off-site facilities
considering available infrastructure. The new expansion project will be somewhere within the
existing complex where adequate land exists. The rationale behind the proposed expansion
project is:
Availability of existing infrastructure facilities.
Lower capital cost compared to a grass root project resulting in lower cost of production
and retention price and consequently lower incidence of subsidy.
To meet the gap in demand and supply of urea in the country.
The project would essentially consist of new ammonia and urea plants and related offsite and
utility facilities considering utilisation of the existing facilities to the maximum extent possible. The
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broad provision of plants and facilities to be made for proposed project has been presented in
following:
Table 2.1 1: Plant and Facilities Required for the Expansion Project
1** installation of new 5000 MT Ammonia Storage tank shall be taken up in first stage of implementation of project, which will also be used for inspection of existing Ammonia Storage tank for ensuring safety of the tank In second stage of the project, proposed new ammonia & Urea Plant shall be commissioned and after that existing as well as new proposed Ammonia Storage Tanks will be used for the storage purpose of surplus ammonia generated from existing & proposed ammonia plants.
Sl. No. Plants & Facilities Provisions
1. Ammonia Plant 2200 MTPD 2. Urea Plant 3850 MTPD 3. Main Raw Material --NG/LNG
Transportation & Metering Station
By GAIL Pipeline and metering station provided
4. Product Storage & Handling Facilities
a] **Ammonia Storage Tank b] Silo c] Empty Bag Storage d] Bagging Plant
5000 MT at -330C and atmospheric pressure 30000 MT - (6+2) Slats each of 60 TPH (design capacity)
5. Cooling Tower a] Ammonia Plant
b] Urea Plant 24000 m3/hr. each 21000 m3/hr. each
6. Power Generation & Supply a] Power Generation (GTG)
b] Substation for receiving power from State Grid Emergency DG Set
1X25 MW 1X2000 kVA
7. Steam Generation Facilities
HRSG (GT set) 100 MT/hr
8. Water Supply Treatment & Distribution
d) Raw Water Supply System e) DM Water Plant f) Cond. Polishing Unit
Bore wells (2+1)×150 m3/hr. (2+1)×200 m3/hr.
9. Yard Piping Provided as per requirement
10. Instrument Air Facilities a] Compressor b] Drying Unit c] Receiver
(1+1)×3000 Nm3/hr. (1+1)×3000 Nm3/hr.
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2.4. Existing Plant and Facilities
2.4.1. Ammonia Plant Ammonia Plants is based on HaldorTopsoe technology and is using Natural Gas as feedstock.
Following process steps are involved in the manufacturing of liquid ammonia:
De-sulphurization of Feedstock
Steam Reforming
Gas Purification (Shift Conversion and CO2 Removal)
Ammonia Synthesis & Refrigeration
Ammonia Absorption and Condensate Recovery
Flow diagram of the Ammonia Plant is given in Figure 2.2.
2.4.1.1 Desulphurisation of Feed Stock
Natural Gas is fed to De-sulphurisation unit where the sulfur present in Natural Gas is converted
into Hydrogen Sulfide in presence of hydrogen rich gas & hydrogen sulfide formed is absorbed by
zinc oxide in ZnO Absorber as per the following reaction. The final De-sulphurised feedstock
contains less than 0.1-ppm sulphur:
11. Inert Gas Generation 600 N m3/hr of N2; Liquid N2 Storage: 30 m3 with vaporizer
12. Safety & Fire Fighting System including fire water ring with Hydrant System
For the proposed expansion project, existing firewater rings and other facilities shall be augmented as per requirement.
13. Auxiliary services, workshop equipment, laboratory equipment, weighbridge, fire engine, continuous monitoring system, NDT equipment, telephone& telecommunication, Public Address System, etc.
Extra telephone exchange facilities and additional lab and NDT equipment considered
14. General & Welfare Facilities Existing facilities will be augmented as per requirement.
15.
Transport Facilities a] Locomotive b] Railway Siding and lead line c] Road Transport
1X1200 HP To be developed
16. Construction equipment By construction contractor
17. Township &Public Building Existing facilities will be augmented as per requirement.
18. Non-plant Building Existing facilities will be augmented as per requirement.
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RSH + H2 RH + H2S
C4H4S + 4H2 C4H10 + H2S
ZnO + H2S ZnS + H2O
2.4.1.2 Steam Reforming
The Desulphurised feed gas is mixed with Process Steam to achieve steam to carbon ratio (3.2 in
Phase-I) and heated in the convection section of Primary Reformer. The mixture then passes
through vertical Primary Reformer tubes containing nickel-based catalyst. Since the reforming
reaction is endothermic, the furnace provides necessary heat is provided in the furnace by
burning fuel. The Primary Reformer furnace is designed to achieve maximum thermal efficiency
and uniform heat distribution. Maximum heat is recovered from the flue gases in the convection
section of Primary Reformer to pre-heat mixed feed (gas/steam mixture), Process air for
Secondary Reformer, Combustion air and to superheat the High Pressure steam. Primary
Reformer reforming reaction is given below:
C2H2n+2 + 2H2O Cn-1H2n + CO2 + 3H2 – HEAT
CH4 + H2O CO + 3 H2 - HEAT
CO + H2O CO2 + H2 - HEAT
CH4 + 2H2O CO2 + 4H2 - HEAT
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Figure 2.2 : Ammonia Plant Process Flow Diagram
(Source: KSFL)
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The partially reformed gas from Primary Reformer is mixed with Process air and the mixture flows
through a bed of nickel based catalyst in the Secondary Reformer. Process Air Compressor
supplies process Air to Secondary Reformer. The quantity of air is controlled to provide nitrogen
in the required proportion for the formation of ammonia. The process gas from the Secondary
Reformer is routed to a Waste Heat Boiler to generate high-pressure steam.
2.4.1.3 CO Shift Conversion
Gas leaving the Waste Heat Boiler system enters the High Temperature CO Shift converter
(HTS) charged with Iron-oxide catalyst. Here the CO content is converted to CO2. Since the
reaction is exothermic, the outlet temperature rises. This gas is then cooled down in another
Waste Heat Boiler by producing HP Steam. Finally the gas is cooled in BFW Pre-heater before
entering Low Temperature CO Shift Converter (LTS). In LTS Converter, CO is further converted
to CO2 by reaction over a Copper based Catalyst. This reaction is also exothermic, which is
given below:
CO + H2O CO2 + H2 + HEAT
Gas is then further cooled in two BFW Pre-heaters. Then it enters the Re-boiler of CO2 removal
system after the removal of process condensate in a separator. This process condensate is sent
to Process Condensate treatment section.
2.4.1.4 CO2 Removal
GV is the Process Licensor of CO2 Removal Process in Ammonia. Carbon Dioxide is removed by
absorption in Hot Potassium Carbonate solution.
The process gas from the Re-boiler is cooled after exchanging heat in a BFW Pre-heater enters
the CO2 Absorber where its CO2 content is brought down. The absorber is a packed column. The
Hot Potash solution is introduced into the Absorber at two places, the lean solution is at the top
bed and the semi-lean at the middle-bed. The CO2 rich solution from the Absorber bottom is
depressurized through a Hydraulic Turbine with a steam recovery system, before it is discharged
to the top of the Regenerator, where the CO2 flashes off. The heat for regeneration is supplied to
the regenerator partly from the Re-boiler and partly from flashed steam/live steam. The
regenerated solution is then pumped to the Absorber by Lean & Semi-lean solution circulation
pump. CO2 is sent to Urea Plant.
2.4.1.5 Methanation
The gas from Absorber is pre-heated by heat exchange with the outlet gas from the Methanator in
a Gas/Gas exchanger. The small quantities of CO and CO2 in the gas are converted to methane
by reaction with hydrogen over a nickel-based catalyst. This reaction, which is given below is
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exothermic and the heat is used for heating the feed gas. The gas from Gas/ Gas Exchanger
outlet is cooled in a final gas cooler and sent to the suction of Synthesis Gas Compressor:
CO2 + 4H2 CH4 + 2H2O + HEAT
CO + 3H2 CH4 + H2O + HEAT
2.4.1.6 Ammonia Synthesis & Refrigeration
The synthesis gas, which has hydrogen & nitrogen in a volumetric ratio of 3:1 and some inert, is
compressed to synthesis loop pressure by Synthesis Gas Compressor and is introduced into the
synthesis loop from where it goes to the series of Ammonia Converters (two radial converters) to
get maximum ammonia conversion along with the re-circulating gas. Ammonia Converter
synthesis reaction is given below:
N2 + 3H2 2 NH3 + HEAT
The converter effluent gas is cooled in a Waste Heat Boilers after both the converters for
generating HP Steam. This is further cooled in a BFW pre-heater and then in a hot heat
exchanger. It is then cooled in water cooler & chillers. The condensed ammonia is separated
from the circulating gas in Ammonia Separator. From this Ammonia Separator, separated hot
ammonia is sent directly to Urea Plant and cold ammonia can be sent to Atmospheric Ammonia
Storage tank.
Ammonia Refrigeration system consists of centrifugal Refrigeration compressor along with
condenser.
2.4.1.7 Ammonia Absorption and Condensate Recovery
In Ammonia, purge gases from the synthesis loop are fed to PGRU for hydrogen recovery. Let-
down & inert gases from the Synthesis loop are fed to an Absorber where ammonia is absorbed
in the circulating water. The ammonia free gas is then sent to fuel system. The Ammonical water
is treated in a distillation Column to strip out free ammonia, which is condensed and sent to
ammonia accumulator in the refrigeration system. The process condensate and CO2 absorption
section condensate are treated in a high-pressure process condensate stripper to remove
ammonia, CO2 and methanol etc. The treated condensate is sent to off sites and Utility facility for
reuse as Boiler Feed water after polishing
2.4.2. Urea Plant Urea plant is based on Snamprogetti, Italy process and having two streams with common Prilling
Tower and Process Condensate Treatment Sections.
The Urea production process involves the following steps:
Urea Synthesis
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Urea Purification
Urea concentration
Urea Prilling
Process Condensate Treatment
Flow diagram of the Urea Plant is given in Figure 2.3.
Figure 2.3 Flow diagram of the Urea Plant
(Source: KSFL)
2.4.2.2 Urea Synthesis
Synthesis of Urea is carried out at high pressure of 156 Kg/Cm²g and temperature of about
190°C in a carbon steel Rector with SS 316 L modified liner. The liquid ammonia coming directly
from the Ammonia Plant is collected in the Ammonia Receiver. From the receiver, it is pumped
by means of a pump and fed to the Urea Reactor. The carbon dioxide is also compressed to
Synthesis pressure by a centrifugal compressor and fed to the Reactor. The small quantity of air
is added into carbon dioxide for Passivation of the stainless steel surfaces and thus protects the
equipment form corrosion.
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Exothermic reaction between Liquid ammonia & gaseous carbon dioxide in Urea Reactor is given
below:
Carbonate Formation
2 NH3 + CO2 NH2 COO NH4 + HEAT
Dehydration
NH2 COO NH4 NH2 CO NH2 + H2O - HEAT
The reaction products from the Reactor flow to the steam heated falling film type Stripper
operating at Synthesis pressure. The mixture is heated as it flows down and the carbonate is
decomposed by the stripping action. The carbonate decomposition heat is supplied by steam on
the shell side. The overhead gases from the stripper flow to the carbamate condenser along with
recycle carbamate solution from downstream, where these are condensed and recycled back to
Reactor. Condensing the gases at high-pressure results in low-pressure steam generation in
carbamate condenser, which is utilized in the process.
2.4.2.3 Urea Purification
Urea purification takes place in two pressure stages i.e. MP pre-decomposition (proposed to be
installed in revamp case) and MP Decomposition at operating pressure of 17 Kg/Cm²g and LP
Decomposition at operating pressure of 3 Kg/Cm²g. When solution is let down from high pressure
to lower pressure, gaseous ammonia & carbon dioxide are generated. These gaseous mixtures
are condensed/absorbed at respective pressures and recovered Carbamate solution is recycled
back to the Reactor.
2.4.2.4 Urea Concentration Section
Urea solution leaving the LP decomposer shall be sent to first vacuum concentrator operating at
0.3 Kg/Cm²A pressure.
The gases leaving from pre-concentrator & Ist vacuum separator are removed first vacuum
system. Final concentration of 99.7 % is achieved in the second vacuum concentrator operating
at 0.03 Kg/Cm²A pressure. The gases leaving the top separator are removed by the second
vacuum system. Water vapours from the concentration section are condensed in cooling water
Surface Condensers and recovered condensate, which contains urea mist, CO2 and Ammonia is
sent to Process Condensate treatment section.
Urea Pre-Concentrator shall also to be installed under energy saving scheme before Ist vacuum
separator.
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2.4.2.5 Urea Prilling
The molten Urea solution after final concentration in vacuum section is fed to the Prilling bucket
by means of a Urea Melt pump. The urea coming out from the rotating prill bucket encounters
cold airflow in a natural draft Prilling tower, which causes its solidification. The product urea prills
falling to the bottom of the Prilling tower are collected through a rotary scrapper and are sent to
Bagging Plant.
2.4.2.6 Process Condensate Treatment
The process condensate containing small amount of CO2, Ammonia and Urea coming out of
vacuum condensers is collected in a buffer tank. The solution from this tank is fed to Process
Condensate Stripper to strip ammonia and CO2. The solution drawn from an intermediate tray of
this column is sent to a Hydrolyser. In the Hydrolyser Urea is hydrolysed to ammonia and carbon
dioxide. Hydrolyser vapours are recycled to the stripper for further stripping of ammonia & CO2.
The treated condensate is sent to off sites and Utility facility for reuse as Boiler Feed water after
polishing.
2.4.3. Power Plant and Utilities 2.4.3.1 Raw Materials
Natural gas is the main raw material and fuelling KSFL. It is supplied by GAIL through HBJ pipe
line. However KSFL has taken approval for using Naphtha as feed stock and fuel in the plant.
Naphtha is used only when there is acute shortage of NG.
2.4.3.2 Water Treatment System
Fresh water for the existing plant is drawn from the bore wells. The total requirement is (878)
m3/hr. KSFL has permission from U. P. ground water Board to draw 2000 m3 /hr. Water is treated
in DM plant for supplying as Boiler feed water to SG plant. In DM plant mixed bed units are there
to polish treated condensate from ammonia and urea plant.
2.4.3.3 Steam Generation System
KSFL has two numbers of gas fired boilers each of 100 tph capacity and two numbers of HRSG
each capacity 100 tph. The total requirement of steam for the existing operation is ~ 4080 MTPD
is met from the existing facilities.
2.4.3.4 Power Generation Plant
Presently, Power requirement is met through the existing two gas turbines have 25 MW
capacities each.
In addition there is provision of emergency power supply from 2000 KVA DG Set.
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2.4.3.5 Other Facilities
The other facilities like liquid ammonia storage facilities, bagging plant {seven lines}, fire fighting
system, storages etc. are adequate for the existing capacity of the plant. There are existing bulk
storages for Liquid Ammonia and other materials as given in Table-2.2.
Table 2.2 Bulk Hazardous Materials Storages (Existing)
S.
No.
Hazardous chemicals
handled
Quantity Handled
/ In process Type of Storage
1
Naphtha 4600 KL
1350 KL
600 KL
3 nos. MS Tanks
2 Main Raw Material-
Natural Gas
--- Supply from GAIL through HVJ gas
line
3 Ammonia 1 X 5000 MT Double walled, double integrity,
Atmospheric Tank
4 Chlorine Gas 0.9X12.0 MT Tonnage Cylinders
5 Sulphuric Acid 35 MT, 30.5 MT 2 XMS storage tanks
6 Hydrochloric acid 3X 60 MT (each) MSRL (Mild Steel Rubber Lined)
storage tank.
7 Caustic Lye (Sodium
Hydroxide)
2 X 44 MT (each) MSRL (Mild Steel Rubber Lined)
storage tank
8 Liquid Nitrogen 2 X 25 KL (each) Double Wall Storage Tank
9 Diesel 3 X 12 KL (each) 3 tanks
2.4.4. Waste Water / Effluent Treatment System in KSFL 2.4.4.1 Sources of liquid Effluent and Treatment system
Process Condensate from Ammonia Plant In the primary reformer excess steam is feed along with natural gas due to process requirements.
After reforming and shift reactions are completed, the excess steam in process gas along with the
methanol, ammonia and water formed during the methanation is separated by the cooling the
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process gas. The condensate coming out after cooling the process gas contains impurities
namely Ammonia 500ppm and methanol 200 ppm.
Treatment at source The condensate is feed to CO2 stripper and then to steam stripper (F-1321) for the treatment of
ammonia and methanol. The treated effluent contains 5 ppm of NH3, 10ppm of CO2 and 5ppm of
methanol.
Treatment at ETP In case the quantity of condensate is not good enough to be sent to DM plant for polishing due to
temporary process disturbance, it is sent to ETP, where it is stripped in steam stripper at ETP.
The stripped condensate is then pumped to balance pond. The balance pond water overflows to
guard pond. From guard pond it is pumped to stabilization pond for final discharge.
Floor washings/ process drains: All the process drains and floor washings from ammonia plant have an average flow of 1.0m3/hr.
(range, 0.5-3m3/hr.) and the following characteristics-
NH3 500ppm Methanol 20ppm
This effluent is pumped to ETP. After steam stripping at ETP, stripped effluent is sent to the
balance pond. Balance pond water overflows to guard pond. From guard pond it is pumped to
stabilization pond for final discharge.
Oil Leakage/ Spillage from Ammonia plant The runoff water from the compressor house, pump house, inters stage separators of
compressors are normally polluted with oily water along with the oil spillage from the refrigeration
system. Waste water containing oil with an average flow of 1 m3/hr. (range 0-2 m3/hr.) having
TSS as 200 ppm and oil as 1000 ppm is collected separately in a pit in ammonia plant. Then it is
pumped to oil separator at ETP. The clear water containing less than 10 ppm of oil is further
treated in the stream stripper at ETP for removal of contaminants like ammonia, if any, and is
pumped to balance pond.
Process condensate from Urea plant Total process condensate coming from the urea plant ranges between 45-60 m3/hr. with an
average of 55 m3/hr. it contains various impurities like,
NH3-5.0% CO2-1.50% Urea-0.9%
2.4.4.2 Treatment at source
Waste water containing ammonia, CO2 and urea coming out from 1st and 2nd vacuum system is
collected in tanks, from where it is feed in the distillation tower through centrifugal pumps. Before
feeding it to the distillation tower, solution is preheated by means of bottom outlet product heat
exchange. From middle of the distillation column, solution is feed to urea hydrolyses, where urea
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is decomposed it CO2 and ammonia. Solution free from urea is again feed to distillation tower to
remove ammonia and CO2 present in the solution. In the distillation column, ammonia and CO2 by
means of 3.5 atmospheres saturated stream. The vapours coming from the top of the tower is
condensed in overhead condenser and collected in a Carbonate solution accumulator. A part of
the solution is recycle back to the top of distillation tower as reflux and thus remaining is sent to
the urea plant. The bottom product coming out of the distillation tower contains a max. Of 5 ppm
of ammonia and urea each. This condensate is sent to the DM plant for polishing to make it
suitable for boiler feed.
2.4.4.3 Treatment at ETP
In case of quality of condensate is not good enough for sending it to demineralisation plant for
polishing due to temporary process disturbance, it is sent to ETP, where it is stripped in steam
stripper. The stripped condensate is then pumped to balance pond.
Floor washings/ process drain All the floor washing/ process drains form the urea plant having an average flow of 1.5m3/hr. with
ammonia concentration as 200 ppm and traces of urea is collected in a pit and then pumped to
contaminated pond at ETP. After being stripped in stream stripper at ETP, the stripped effluent is
sent to the balance pond.
Oil leakage/ spillage form the Urea plant Waste water containing TSS as 200 ppm and oil and grease as 1000 ppm is collected separately
in a pit in the urea plant and pumped to oil separator at ETP. The clear water containing less than
10 ppm of oil is further treated in stream stripper in ETP for removal of contaminants like
ammonia, if any and is finally pumped to the balance pond. Oil and grease are always not
traceable in the stabilization pond’s sample.
Turbine Steam Condensate Condensate produced by condensing of the steam in condensing turbine is normally 30m3/hr.
having TDS as 1-5 ppm and traces of ammonia. It is sent to demineralisation plant for polishing
and then recycled back as boiler feed water.
Urea Stream Condensate Condensate produced by condensing heating steam in various heat exchangers in urea plant
varies from 45-60 m3/hr. This condensate also has traces of ammonia with TDS as 1-5 ppm and
traces of TSS. It is sent to mixed bed units in DM plant for polishing and then used as boiler feed
water.
Boiler Blow down Water Its average flow ranges from 0-2 m3/hr. with TDS as 50 ppm and phosphate as 6-10 ppm. This
blow down water is sent to ammonia cooling tower and used as a makeup.
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Demineralisation Plant Waste water In the demineralisation plant, mixed bed units consist of 3 numbers each of strong anion-cation
exchanger I & II in series, weak base anion exchanger and strong base anion exchanger in series
and mixed bed units. The anions and cation are regenerated in through fare manner, i.e.
regenerate consumption and produces weak acidic and weak alkaline effluents. These effluents
are segregated and collected into separate pits. These acidic and alkaline effluents are
proportionately mixed and neutralized in a neutral effluent pit. These acidic and alkaline effluents
are proportionately mixed and neutralized in a neutral effluent pit. After proper neutralization i.e.
pH between 6.5 to 8.0,average flows is measured as ranging between 9-15 m3/hr. Its TDS is as
high as 1500-2100 ppm this neutralized effluent is sent to balance pond.
Cooling Tower Waste Water The treatment made for circulating closed loop cooling water system is non-chromate based.
Cooling tower wastewater comprises of blow down flow ranges and filters back wash. Cooling
tower blow down average flow ranges between 10-20 m3/hr. and that of filter back wash water is
25-30 m3/hr., both having the TDS as 1500-2100 ppm, Zn 2ppm and a max. Of 2-8 ppm of
phosphate as per the requirements of cooling water treatment. Biocides and dispersants are
added in cooling tower, and these are non-toxic and biodegradable. Treated effluent from this
section is partly sent to the fire water pond as a makeup and rest is sent to balance pond. The
balance pond water overflows to guard pond. From guard pond it is pumped to stabilization pond
for final discharge.
2.4.4.4 Effluent Treatment Facilities
The details of equipment/ vessels at ETP and their functions as follows:
Ammonia Steam Stripper Ammonia steam stripper in ETP is designed to strip the incoming floor washing effluents from
Ammonia and Urea plants and also the upsets condensates discharged during any emergencies
in Ammonia and Urea plants. The stripped effluent is discharged to balance pond. The balance
pond water overflows to guard pond. From guard pond it is pumped to stabilization pond for final
discharge. The steam stripper is in two sections. The bottom horizontal cylindrical vessel receives
the effluent where it is heated with steam. Above this, in the vertical section there are two packed
beds of pall rings. This heat exchanger is used for exchange of heat between bottom product
from stripper and feed to stripper. In this way, the feed entering the stripper is getting heated and
bottom product from the stripper is getting cooled. This saves energy in terms of steam used for
stripping.
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Contaminated Pond Contaminated pond having capacity of 5000 m3 is provided for collecting floor washing of urea
and ammonia plants and also the condensates of ammonia and urea plants during any
emergencies for further treatment before discharge.
Balance pond A balance pond having capacity of 30,000m3 is provided for balancing and equalizing the effluent
coming from DM plant, cooling tower and stripper outlet.
Guard pond The balance pond water overflows to guard pond-having capacity of 5000m3. Treated effluent
from guard pond is pumped to stabilization pond for final discharge.
Disc Oil Separator Oily waters if any generated from various sections of Urea and Ammonia plants is collected in oily
water pit provided in the respective plant. The water is pumped to oily water pit at ETP.
2.4.4.5 The Effluent Treatment Plant (ETP)
Effluent treatment system in KSFL is described as follows. The following effluents from fertilizer
complex have been considered.
Cooling tower blow down Cooling water system based on non-chromate treatment system has been adopted. The cooling
tower blow down and the filter backwash water containing non-toxic chemicals and suspended
solids within the limit laid down for discharge are sent to the balance pond for further dilution and
stabilization before being discharged outside.
Effluent from ammonia plant Process condensate from ammonia plant and GV section are treated in condensate stripping unit
and sent to the DM plant for further treatment for making boiler feed water. In the case of
emergency and during start-up, the condensate containing little ammonia is sent to the
contaminated effluent pond and then treated through stripper to strip off whatever little ammonia
present and taken to the balance pond from where discharged outside complex through
stabilization pond.
Process condensate from urea plant Process condensates from urea plant are treated in hydrolyser and stripper system where
ammonia is recovered. The treated condensate is sent to the DM plant for making boiler feed
water. In case of emergency and during start up, the urea plant waste water containing ammonia,
urea and CO2 is sent to the contaminated effluent pond where it is stripped off. This treated
effluent is sent to the balance pond where it gets further diluted and stabilized then discharged
through stabilization pond.
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Treated Oily Waste Water Oily waste water from urea and ammonia plant is pumped to the oily waste water pit in ETP and
the oil is separated by discoil unit. The disc oil collects the floating oil in water and the
accumulated oil is stored in drums. The clear water after oil separation with oil content 10 mg/l is
pumped to the contaminated pond and after stripping it goes to balance pond and discharged
finally through stabilization pond.
Floor washing Floor washing drains from urea plant is received in RCC pit in urea plant and pumped to the
Effluent treatment section of effluent collection tank before treatment. The above effluent is
treated through sand filter, steam stripper etc. and then treated effluent is collected in balance
pond.
Guard pond and stabilization pond The overflow of balance pond comes to the guard pond to give more retention time. The water
from guard pond is pumped to a very large stabilization pond having capacity of 1, 20,000m3.
Finally the treated effluent from this pond is discharged to Garrai nallah after meeting all the
required environmental standards through a closed conduit.
2.4.4.6 Sewage Treatment Plant
Domestic waste water from the plant and township area is treated in Sewage treatment plant.
When it passes through screen chambers the grits are screened and separated from the sewage
water and then allowed to flow under gravity to the Aeration tank. In the aeration tank, the waste
water is subjected to vigorous aeration and the sludge is allowed to settle in sludge settling tanks.
The supernatant water is collected in effluent pit and discharged. The remaining sludge is
collected in sludge drying beds for use as manure. The discharged water flows out with the BOD
of less than 30 mg/l and used for green belt development / discharged in Garrai Nallah.
2.4.5. Solid Waste Disposal System Catalysts after their expected life in the form of spent catalyst are sold to authorized vendors for
its metal value. The other solid wastes are segregated and stored in the separate storage space
and finally sold to the authorized vendors time to time.
2.4.6. Sources of Gaseous Emissions The gaseous emission of the KSFL is through five number of main stack viz. Service boiler stack,
GTG-1 stack, GTG-II stack, Ammonia reformer stack, prilling tower There are number of other
stacks viz. Vent stack Ist and IInd, Blow down stack, CO2 compressor vent (2 no.), main flare
stack, ammonia flare stack, ETP Stripper, CO2 vent. These stacks are not continuous and
operate only during abnormality in plant. The continuous stacks attached to different facilities are
as given below:
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Table 2.3 Existing Emission Load
Stack Stack(m) SOx
ppm
NOx
ppm
SPM
mg/Nm3
NH3
ppm
Remark
Height Dia. Temp0C
Primary
Reformer
32 3.0 160 NT 100 NT NT Fuel:
NG/Naphtha;
Avg gas Velocity:
14 m/sec
Service Boilers
I &II
30 3.2 150 NT 65 NT NT Fuel:
NG/Naphtha;
Avg gas Velocity:
7.7 m/sec
GTG I &II(20
MW)
30 3.2 170 NT 60 NT NT Fuel:
NG/Naphtha;
Avg gas Velocity:
15.5 m/sec
Prilling Tower 102 26 57 NT NT 36 46 Avg gas Velocity:
0.7 m/sec
Source: KSFL
Table 2.4 UPPCB prescribed norms for Prilling Tower at KSFL
Pollutants Ammonia
ppm
Urea Dust
mg / Nm3
Emission norms 100 50
Fugitive Emission Fugitive emission occurs in the bagging plant where large quantity of urea is handled. In order to
control the dust the plant has been provided with wet dedusting system. Centrifugal fans sucks
the urea dust laden air from various dust emission points and delivers to the venturi scrubbers.
The scrubber liquor which is under circulation dissolves most of the dust and clean air leaves the
stack. The solution at intervals is sent for urea recovery in urea plant. Cyclone separators have
been provided at transfer points during conveying for controlling urea dust. Dust thus collected at
these points is further dissolved in urea solution for reprocessing in Urea plant. The system is
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effective in controlling air pollution at work place and creates a dust free atmosphere for better
working conditions and to increase ultimate plant efficiency.
2.4.7. Noise Environment The fertilizer complex has large machines as well as other sources of noise like boiler and other
high pressure vent valves. In addition there is movement of vehicles and railway wagons. There
are provisions and attempt to reduce the noise levels at the source itself and in specific areas
where it cannot be further reduced, plant personnel have been provided with ear protective
appliances. The noise survey of the KSFL plant and township was carried out and the results are
given in Table - 2.5. The Ambient air Quality standards with respect to noise are given in Table -
2.6.
Table 2.5 Noise Survey of KSFL Complex
A: - Ambient Noise
S No. Location Noise dB (A)
Day Night
1 Main Gate Factory 48 39
2 Town Ship Gate 49 40
3 Guest House 49 39
4 B-Type Quarter 49 40
5 A1-A2 Type Quarter 48 39
6 A- Type Quarter 48 39
7 Near Temple 49 40
8 Piprola Village Kesorai Side 49 39
9 Labor Colony -LDPE Gate Side 49 40
10 Kesorai Village 49 39
11 Boundary Wall N.E. Side 48 40
12 Near Gail Metering 49 39
B: - Work Place Noise
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S No Plant Location Noise dB (A)
1 Ammonia Process Air Compressor 74
Refrigeration Compressor 73
Syn. Gas Compressor 73
I. D. Fan 74
Control Room 51
Operator Cabin 61
2 Urea CO2 Compressor 11- Unit 74
CO2 Compressor 21- Unit 74
Near Prilling Tower 72
Control Room 52
Operator Cabin 11-Unit 60
Operator Cabin 21- Unit 61
3 Off-Site HRSG 74
Service Boiler 73
DM Plant Control Room 54
Cooling Tower-Ammonia 73
Cooling Tower-Urea 73
Control Room 52
Operator Cabin 61
4 E & QC Central lab 57
5 Bagging Near Machine 71
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Table 2.6 Ambient Air Quality Standards with respect to Noise
Category of Area Limits Leq, dB(A)
Day Time Night Time
Industrial 75 70
Commercial 65 55
Residential 55 45
Silence 50 40
Figure 2.4 : ETP System in KSFLShahajahanpur (Existing)
(Source: KSFL) To Fire Water Pond
2.5. Proposed Expansion Project
2.5.1. Ammonia plant Ammonia is produced commercially from non-renewable hydrocarbon sources like coal, fuel oil,
naphtha, coke oven gas, refinery gas, natural/associated gas etc. Among the various feedstocks,
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natural gas is the most preferred feedstock for ammonia production because of simpler process
sequence and low capital requirement as compared to other feedstock. The basic steps of
producing ammonia from natural gas are same:
Hydrogen production (usually by reforming of natural gas or partial oxidation of heavier
hydrocarbon feedstock including coal)
Synthesis gas purification (including CO2 removal)
Ammonia synthesis and purging of inert
Air is the ultimate source of nitrogen, and methane or heavier hydrocarbons are usually the main
source of hydrogen. Of the hydrogen feedstock sources - natural gas, coal, and petroleum
fractions – natural gas is the most often employed in commercial ammonia plants, with coal
derived synthesis gas making up the majority of the remainder.
A typical ammonia system will consist of the following steps:
Desulphurization – Natural gas contains large percentage of methane along with ethane,
propane, butane, pentane, carbon-di-oxide, and nitrogen sulphur compounds. Small quantities of
sulphur compounds in the gas are removed by passing the gas through desulphurization unit.
Reforming – Sulphur free gas is then mixed with steam and sent to Primary Reformer where
reforming reaction takes place in the presence of catalyst & produces a gaseous mixture of
hydrogen, carbon monoxide & carbon-di-oxide. Further reforming takes place in the Secondary
Reformer where air is added to furnish the nitrogen required for Ammonia synthesis.
Shift Conversion – Hot reformed gases from Secondary Reformer are cooled by heat recovery in
waste heat boiler and introduced in the shift converters where most of carbon monoxide gets
converted to carbon-di-oxide.
CO2 Removal - Carbon-di-oxide from the gaseous mixture is separated in the CO2 Absorber
using 2- stage efficient absorbing chemicals media and sent to Urea Plant.
Methanation - Residual oxides of carbon in the synthesis gas leaving Absorber are converted to
methane in the Methanator.
Ammonia Synthesis –. Pure synthesis gas from Methanator is compressed and sent to Ammonia
convertors where Ammonia is formed. Ammonia product obtained is sent to urea plant for the
production of Urea.
The main suppliers of ammonia technology are:
HaldorTopsoe (HTAS), Denmark
Kellogg Brown & Root (KBR), USA
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Uhde, Germany
To achieve zero effluent from the plant, the following inbuilt facilities have been considered:
Process condensate stripper to strip off dissolved gases from process condensate with
steam. After stripping the condensate is sent to DM plant for further treatment to convert
it to the Demineralized Water
Turbine condensate is sent to DM plant for polishing and used as boiler feed water
Boiler blow down is used as cooling tower make up.
Ammonia Process Flow Block Diagram (HaldorTopsoe Process) is given Figure 2.5
KSFL is considering various options for finally selecting the technology, the prime
consideration being the energy consumption and eco-friendly nature (least pollution).
Figure 2.5 Ammonia Plant Block Flow Diagram
(Source: KSFL)
2.5.2. Urea Plant
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Urea manufacturing technology has more or less been perfected. All technology suppliers have
been concentrating on:
Specific consumption of Ammonia and Steam
Specific consumption of other utilities power and CW
Least pollution potential i.e. release of ammonia and urea (dust) to environment.
The Ammonia and carbon dioxide produced in Ammonia Plant are again made to react to form
first Ammonium carbonate and then to Urea. The concentration of urea is progressively increased
by the decomposition and separation of Ammonium carbonate the melt urea of 99.8%
concentration is sprayed in a prilling tower through revolving bucket. The solid particles of prilled
urea are packed in 50 kg polythene lined urea bags.
The process steps are:
CO2 Compression
Urea Synthesis
High Pressure Recovery
Medium Pressure Recovery
Low Pressure Recovery
Urea Purification
Urea Prilling
Waste Water Treatment
The main processes used today in the production of urea are the stripping processes offered by:
Stamicarbon, Netherlands
Snamprogetti (Now Saipem), Italy
Toyo Engineering Corporation (TEC), Japan
Stamicarbon and Saipem have been market leaders in terms of installed capacity with
approximately 90 per cent of the total.
Urea Process Flow Block Diagram (Saipem Process) is given in Figure 2.6.
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Figure 2.6 Urea Plant Block Flow Diagram
KSFL is studying the salient features of technologies and weighing various options before arriving
at the final decisions. Energy and environmental are the main considerations.
2.5.3. Utilities and Offsite Facilities The layout of the plant has been shown in Figure 2.1 detailing the different plant facilities.
2.5.3.1 Raw material
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 2200 MTPD ammonia
and 3850 MTPD urea plants are summarized in Table below:
Table 2.7 Raw Material
Sl. No. Raw Material/Utilities Unit Requirement
1.0 Natural Gas Sm3/hr. 99035
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Sl. No. Raw Material/Utilities Unit Requirement
2.0 Water m3/hr. 1122
Natural Gas
Natural Gas / RLNG are considered to be available through HVJ pipeline in the plant battery limit.
The material and energy balance for the project has been developed based on the representative
analysis of the gas. The total requirement of natural gas at rated capacity operation of the plants
is estimated at about 99035 Sm3/hr. (LHV 8200 Kcal/Sm3).
2.5.3.2 Raw water Treatment Plant
Water is considered to be available through bore wells. Water requirement for the proposed
project is approximately 1122 m3/hr. Water is used after treatment. The requirement of treated
water is mainly for cooling water make up. Other requirement of process water is as make up
water to DM water plant
Domestic water supply is presently catered by the bore wells in the factory & township.
2.5.3.3 Steam and Power Generation
The normal power requirement for the proposed project is envisaged to be met by new captive
power plant. Natural gas based turbo generator of 25 MW along with HRSG of 100 MTPH will be
installed. The exhaust gas from the gas turbine (GT) shall be utilised for generating HP steam
required in urea plant. No additional service/auxiliary boiler has been provided for the complex.
The requirement of steam for Urea Plant and other facilities would be met by surplus steam
available from ammonia plant and HRSG boiler of Gas Turbines of CPP. In Gas Turbines of
Captive power plant, provision has been made for supplementary and additional firing and also
HRSG can be operated independently even if Gas Turbines are not in operation. Hence, no
additional boiler has been considered for the project to raise the steam for start-up purpose.
2.5.3.4 Cooling Tower
Latest design induced draft type cooling towers separately for ammonia and urea plants along
with pumps, side stream filters etc. would be provided for expansion plants. The capacity of each
cell shall be 3000 m3/hr. for both ammonia and urea to minimise the spare needed for cooling
Towers. The number of cell in ammonia CT and urea CT shall be (7+1) and (7+1) respectively
and both the cooling Tower units will be interconnected. The sump and deck of both the cooling
towers shall be covered to prevent the external material from falling into the system. Return
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headers of CW shall be located at ground floor instead of located at deck in existing system. All
the cooling water pumps shall be motor driven.
2.5.3.5 Proposed Ammonia Storage and Handling
In first step of project, there is a provision for the installation of new 5000 MT Ammonia Storage
tank, which will be used for inspection of existing Ammonia Storage tank to ensure safety of the
tank. In second stage of the project, proposed new ammonia & Urea Plant. Shall be
commissioned and after that existing as well as new proposed Ammonia StorageTanks will be
used for the storage purpose of surplus ammonia generated from existing& proposed ammonia
plants.
The liquid ammonia produced in the ammonia plant shall be stored at atmospheric pressure and
at a temperature of –33oC. The capacity of this proposed ammonia storage tank shall be 5,000
MT. The ammonia storage tank will be of double wall double integrity type and provided with
suspended deck. The facilities include one no. double walled insulated atmospheric storage tank,
ammonia boil off compressor, ammonia flare stack and ammonia transfer pumps etc. for safe
operation of the system.
2.5.3.6 Instrument Air Facilities
The normal instrument air requirement for the plant will be met from the Process Air Compressor.
However, as instrument air is very vital for process control instruments, (1+1) Centrifugal Air
Compressors each having a capacity of 3000 Nm3/hr. along with air dryer and receiver units have
been provided for the Project. This arrangement will add to the fail-safe system of instrument
control.
2.5.3.7 Urea Storage and Bagging Plant
For the proposed project, one silo of 30,000 MT capacities has been envisaged. Provision of
automatic bagging (6+2) bagging streams, each of 60 TPH, have also been considered. Modern
and automatic system has been considered for bagging and loading of product into railway
wagons/trucks. The system broadly consists of lifting of empty bags from the sack magazine,
placement of empty bags on the bag holder, stitching of filled bags and flattening of filled bags on
subsequent flat belt conveyor; loading of filled bags into rail wagons/trucks shall be completely
automatic involving very little manual labour. Product shall be transported through strengthen the
existing road transportation system, moreover, railway siding is considered to be developed by
KRIBHCO Infrastructure Limited (KRIL) and integrated with Indian Railway system
2.5.3.8 Inert Gas Generation
Provision has been made for one unit of Inert Gas Generation of 600 Nm3/hr. of Gaseous N2 or
100 Nm3/hr. equivalent liquid N2. Requirement of inert gas nitrogen is mainly arises during start-
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up and shutdown and that shall be met from the centralized inert gas supply system. Provision of
one storage tank of 30 m3 capacity with vaporizer has also been made.
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Figure 2.7 : Water Balance in KSFL Shahajahanpur (Existing)
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Figure 2.8 : Water Balance in KSFL Shahajahanpur (Expansion)
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2.5.3.9 Pollution Sources and Control Measures- After Expansion
KSFL is well conversant with the stringent regulations of State as well as Central Pollution
Control Boards. The company will take necessary steps towards getting all statutory clearances
and approvals from the concerned agencies. The sources of pollution in the KSFL plant after
expansion will increase but the types of pollution will not change (since the coming units are
similar to existing one).
2.5.4. Air Emission Main sources for the air emissions will be the stacks in Ammonia, Power plant (GT/HRSG) and
Prilling tower System in Urea plant. The suitable stack height will be considered to take care of
proper dispersion of pollutants and based on suitable dispersion modelling. Quality of
emissions will be monitored and ensured to confirm the stipulated standards.
The three continuous sources of emission shall be, namely
Reformer flue gas stacks in ammonia plant.
Urea Prilling tower
Power Plant (GTG /HRSG)
The emission from stacks will be well within the stipulated norms. Urea Prilling tower shall be a
natural draft circular tower with ~ 26 m diameter and 102 m height. The tower is so designed
that exhaust gases contain less than 50 mg/Nm3 of urea dust.
2.5.4.1 Emission Load
Expected emission load in terms of relevant pollutants from new stacks in the KSFL fertilizer
complex is given in the Table – 2.8. The expected emission load for SPM, ammonia and NOx
works out to be as below:
Table 2.8 : Estimated Stack Emission Load (Kg / hr.) due to Expansion for KSFL
Stack Stack(m) SPM NOx SOX NH3 Remark
Hei
ght
Dia
me
ter
Tem
p0 C
mg/
Nm
3
Kgm
/ h
r.
pp
m
Kgm
/ h
r.
pp
m
Kgm
/ h
r.
mg/
Nm
3
Kgm
/ h
r.
Primary
Reformer
30 3.0 160 <5.0 1.5 ≤400
Mg/NM3
as
76.19 <5.0 2.7 CO-
<100ppm
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NO2at
3%O2
HC<50
ppm
3,02,117
m3/h
GT/HRSG 30 3.2 200 <5.0 1.9 <100 47.5 <5.0 3.3 CO-
<100ppm
HC<50
ppm
3,80,000
m3/h
Prilling
Tower
102 26 75 <50 53.3 <100
ppm
80.9 13,60,000
m3/h
2.5.5. Noise Environment KSFL fertilizer complex expansion to increase the plant capacity to by 3850 MTPD of urea will
require installations of number of new equipment and machines which will generate noise.
However the quality and technology of these equipment and machines will ensure that noise
generation will be minimum. The additional noise will not disturb the neighbourhood due to
extensive thick green belt all around which will attenuate the same. There can be some
additional vehicles and railway wagons load due to increased plant capacity.
2.5.6. Effluent Generation and Control System 2.5.6.1 Proposed Zero Liquid Discharge (ZLD)
The final treated effluent from effluent treatment plant will have a very good quality for the use
of green belt irrigation. KSFL has developed a thick green cover in and around the plant
complex, including township. The tree plantation is an on-going process & KSFL is planting
number of trees every year to fill up extra land available within its premises. For maintaining &
development of green belt areas at KSFL, an appreciable quantity of water is required for
irrigation purpose on regular basis.
By extending the irrigation pipe line network in leftover greenbelt areas, within total land
acquired area, KSFL will make efforts to utilise the final treated effluent, to maximum possible
extent, for the purpose of irrigation or developing green belts, to achieve Zero discharge,
except rainy season.
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Sewage
Presently domestic wastewater from the plant and township area is treated in Sewage
Treatment Plant (STP). In STP, after passing through screen chambers the grits are
screened and separated from the sewage water and then the sewage water is allowed
to flow under gravity to the Aeration Tank. In the Aeration Tank, the wastewater is
subjected to vigorous aeration and the sludge is allowed to settle down in sludge
settling tanks. The overflowing water, meeting with all required environmental
standards, is collected in effluent pit from where it is discharged to Garrai Nallah or
used for the irrigation of greenbelt. The remaining sludge is collected in sludge drying
beds and used as manure.
Additional sewage water generated from the proposed fertilizer complex has been
considered to be treated by using existing sewage treatment facilities after necessary
augmentation or a new unit shall be set up.
2.5.7. Solid Waste Management The solid waste generation from the ammonia plant, urea and bagging plants will remain similar
in nature. There will be some increase in solid waste generation from the expansion units. Solid
and other hazardous wastes generated in the process plants will be properly stored and
disposed of as per the prevailing environmental regulations. All hazardous wastes will be
handled, stored, and disposed off as per the prevailing Hazardous waste (management,
handling and Trans boundary movement), Rules 2008.
2.6. Green Belt Development
A green belt of thickness 50 -to-100 meters is provided almost all around the plant. The tree
plantation is an on-going process &KSFL is planting number of trees every year to fill up extra
land available with them. KSFL has developed a thick green cover in and around the plant
complex including township. The tree cover is sparse in the immediate vicinity of the Plant,
which includes township area, market places, office complexes, residential areas etc. Beyond
this zone, the tree cover is considerably high, which can be further improved by extensive
plantation in residential areas, school complexes, parks etc. Other areas where there is still
scope for increasing the plant cover are:
In the residential and private settlement areas
In the unused areas,
Along the roadsides, outer zone of the plant area.
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Factory and Township: A green belt of 100 m width in the half the periphery of the actual
factory area and of 50 m width in the remaining periphery area has been developed. The total
green belt area is about 296 acres of the total land in possession of KSFL.
Plan for further Greenbelt development: Considering the present status of the greenery in and
around the Plant complex and keeping in view the proposed expansion program, the following
plan is recommended for greenbelt development.
A. SELECTION OF PLANT TYPES
The following evergreen trees and shrubs are recommended for greenbelt development and for
improvement of the existing green cover in and around the Plant. These plants are selected on
the basis of their growth find morphological characteristics (height, crown cover, and
ornamental values) and on their performance in adverse environmental conditions in urban
areas.
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Eucalyptus
Sheeshum
Arjun
Neem
Jamun
Sirsa
Babool
Kangi
Teak
Jungle
Jalebi
Gold mohr
pakar
ashok
Peepal
phycus
molshree
bottle brush, silver oak
ornamental trees
B. LOCATIONS FOR GREEN BELT DEVELOPMENT
Inside the Plant Area, there is dense green belt is surrounding the periphery of the plant.
However; the degree of tree cover may be increased by carefully selecting locations in between
units, on both sides of internal roads and near the boundary wall. Taking into account the security
and other aspects, only small-sized evergreen trees may be selected for this area and the
following species may be chosen for plantation:
Careya arboreal,
Holarrhena antidysenterica,
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Mallotus philippinensis,
Murraya exotica,
Randia dumetorum,
Wrightia tomentosa,
Zizyphus mauritiana
The outer zone of the Plant: Though there is not much open space available for development of
a proper greenbelt zone, there is scope for intensifying the existing tree plantation; in the
residential areas, the public places and on the roadside. The plants recommended for this zone
are:
Adhatoda sp.,
Callicarpa macrophylla,
Carissa opaca,
Clerodendron viscosum,
Colebrookia oppositifolia,
Euphorbia royleana,
Ixora sp.,
Murraya sp.,
Woodfordia sr.
Zizyphus sr.
The above trees should be planted with a regular distribution depending on the availability of
space. Where there is limitation of space, trees with smaller crown cover may be preferred (e.g.
Wrightia tomentosa Zizyphus mauritiana]
Wild Animals: Although there is no ecological sensitive area (like biosphere reserve, national
park, sanctuary, or water body/lake etc.) within 25 km of KSFL complex, Open scrub Jhau and
Sarkanda bushes of this area inhabits Nilgai, deer, rabbits etc. Nilgai are observed throughout the
year but deers are seen during the rainy season.
Natural / Birds: There is no Zoo or animal or bird sanctuary in the study area. common birds or
animals, based on the observations by the field team or information collected locally exist in the
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study area Migratory Birds area within the plant (near natural ponds). After October when Indian
climate starts getting cooler some migratory birds are observed:
TadomaFerruginea Surkhab/Brahmany duck
Sarkidiomismelanotos Comb ducks/Nakhta ‘Pinant’
Grus Antigone Saras Crane
Greyleg Goose Kalhansa
Greater Flamingo Hansavar
Painted Stork Bugla
2.7. Occupational Health and Safety
Health hazards associated with the occupation are called occupational hazards. In chemical
industry due to handling of toxic and hazardous chemicals there are possibilities of developing
occupational diseases. KSFL currently employees the following measures with respect to
occupational health and safety:
1. A fully fledged occupational health centre exists at site having adequate infrastructure and
under the supervision of the qualified medical practitioner.
2. On-site 24 x 7 ambulance support.
3. Pre - employment medical check-up at the time of employment.
4. Annual medical check-up for all employees.
5. Yearly and monthly check up for employees working in hazardous process.
6. monitoring of occupational hazards like noise and chemical exposure (of working areas) at
regular intervals and record the data,
7. Engineering controls, wherever possible, to reduce workplace hazards.
8. Training to employees on personal hygiene, health, personnel protective equipment & first aid.
2.8. KSFL CSR (Corporate Social Responsibilities) Activities
WELFARE MEASURES HAVE BEEN TAKEN BY THE COMPANY IN THE SURROUNDING
VILLAGES
1. KSFL have adopted a residential girls college named as Kasturba Gandhi Aavasiya
Balika Vidhyalaya of Jalalbad, Distt. Shahjahanpur, for improvement in facilities for
education of poor girls.
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2. KSFL is providing assistance to Samvardhan Society for upliftment of children suffering
from malnutrition and for their health & cleanliness. The society has been formed by
District Administration.
3. Hand pumps installed in Piprola village to provide the neat & clean drinking water for
villagers.
4. Primary School building constructed in Kesorai village for welfare of children.
5. A road has been constructed to connect the Kesorai village from State Highway,
supported for fund mobilization from Govt agency.
6. Public toilets have constructed in Kesorai and in Piprola village for the use of villagers.
7. To help the poor workers at Bareilly, KSFL distributed hand Rickshaws by the Chief
Minister of Utter Pradesh,
8. To prevent the villagers of Piprola from water born disease due to stagnation of rainy
water, a cemented channel with culvert has been constructed from Piprola village to
Garrai Nallah.
9. An earthen road in Piprola village has been constructed to make better connectivity
among villagers.
10. To make connectivity between Piprola & Kishurhai village one pucca road has been
made.
11. A Temple has been constructed by the KSFL for worship by the people of surrounding
areas.
12. A branch of Oriental Bank of Commerce has been opened in our township land with the
ATM facility, which is being utilized by our employees as well as nearby villagers.
13. A good shopping complex has been established where all items of day to day use and
medicines are available and is being used by our employee as well as nearby villagers.
14. A very good English Medium school up to 10+2 level affiliated with C.B.S.E. Board has
been opened in township for the welfare of the wards of employees and also for the
children of surrounding areas.
Continuous activities-
1. To empower the widow women in nearby villages, KSFL is providing pensions to widows
under its widow pension scheme for the residents of villages like Piprola, Kant, Kesorai,
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Kamalanpur, Jamaur, and Mutihasa & Chakmamrejpur. Pensions to each widow are
being credited in their saving bank account directly.
2. Weekly medical check-up is being carried out by company’s Doctor in the surrounding
villages and the lifesaving drugs is also being distributed to them free of cost. Beyond this
the facility of free consultation to the villagers by our Company’s Doctors in all week days
is also being provided at KSFL Health Centre.
3. “Krashak Gosthi” is being organized from time to time for the villagers of the surrounding
areas for upgrading their knowledge about optimum use of fertilizers, use of bio-fertilisers
& other good farming practices.
4. Constructed boundary wall of nearby temple to increase the safety of pilgrims.
5. Repairing of earthen road in Piprola village being done time to time.
6. Cleaning of pucca channel in Piprola village has been done to avoid water born disease
due to stagnation of water.
7. As per request of District Administration Shahjahanpur, KSFL is providing Rs 15000/- per
month for the development of Shaheed Udyan Park, at Shahjahanpur.
8. With the help of Gramin Vikas Trust the KSFL has started to train the farmers of nearby
area for up-gradation the farming practices to get good quality and high yield of crops.
2.9. CREP Compliance
KSFL is complying all the applicable norms on CREP as given below:
Status of Implementation of the action points in charter on corporate responsibility for
Environment Protection
No. Waste Water Management
Efforts will be made for conservation of water ,particularly
with a target to have consumption less than 8, 12 & 15
m3/tone 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/tone will be achieved. An action plan for this will be
submitted by June 03 and targets will be achieved by March
Through various efforts for water
conservation, we have achieved
water consumption less than 8
m3/tone of urea. (Annually)
1.
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04.
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.
a) We do not have Arsenic based CO2 absorber in Ammonia Plant.
b) 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, there is no need for
chromate removal system.
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, fluoride.
Ground water monitoring is being
done for pH& Fluoride on regular
basis.
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.
No effluent is allowed to go to
storm water drain. However,
monitoring of storm water is
being done 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.
No waste water/effluent flow
through the storm water drain. A
provision has been made to divert
storm water to Effluent Treatment
Plant.
1
Air Pollution Management
All the upcoming urea plants will have urea prilling towers
based on natural draft so as to minimize urea dust emissions
We have natural draft based urea
prillling tower
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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.
Not Applicable.
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/tone 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/tone 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 controls systems will be installed by Jun-2004to
achieve the norms on total fluoride emissions (25mg/nm3).
Not Applicable
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
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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 this type of plant.
1
Solid Waste Management
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
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CHAPTER 3. DESCRIPTION OF THE ENVIRONMENT
3.1. Prelude
The 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 type of process
(Physical, Chemical, fuel combustion etc.) involved in the project, processing capacity (scale/
Size of the project), type and extent of pollution control measures, project location, surrounding
geomorphology etc. To assess environmental impacts from proposed project at a specific
location, it is essential to monitor the environmental quality prevailing in the surrounding area
prior to implementation of the proposed 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 impact from an existing industrial project on its surrounding environment are mainly regulated
by the nature of pollutants, their quantities discharged to the environment, existing environment
quality, assimilative capacity of the surrounding environment and topography and terrain of the
project site (its location) as well as the surrounding area.
In other to identified and establish the extent of likely impact, it is essential to assess existing
environmental parameters with regards to various components of the environment namely:
3.1.1. Physical Environment
Topography and physiographic
Climatology and Meteorology
Air Environment
Noise Environment
Water Environment
Soils
Land use Pattern
3.1.2. Biological Environment
Terrestrial Ecology
Terrestrial Wild Life
Aquatic Ecology
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3.1.3. Socio-Economic Environment
Demography & Socio-Economic Features
3.2. Site Location and its surroundings
KSFL fertilizer complex is located at a distance of 12 km from Shahjahanpur town near village
Piprola on the State Highway No.29 to Farrukhabad and lies close to the broad gauge railway line
from Lucknow to Moradabad and the National Highway No. 24. The nearest airport is in Amausi
(Lucknow), at a distance of 150 km.
Figure 3.1 Location Map of study Area
(Source: Google Earth)
3.3. Physical Environment
3.3.1. Physiographic and Topography
KSFL fertilizer complex is located at a distance of 12 km from the district headquarter
Shahjahanpur town near village Piprola on the State Highway No.29 to Farrukhabad and lies
close to the broad gauge railway line from Lucknow to Moradabad and the National Highway No.
24. India, the major portion of the Indian subcontinent, lying atop the Indian tectonic plate, a minor
plate within the Indo-Australian Plate. Uttar Pradesh is India's fifth largest and most populous
state, located in the north-central part of the country. It spreads over a large area, and the plains
of the state are quite distinctly different from the high mountains in the north. Uttar Pradesh
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stretches into two of India’s major physiographic divisions, namely the Great Plains of North India
and the peninsular Plateau. Almost 90% of the total area in Uttar Pradesh is under Great Plains
of North India, while the Southern part of the state belongs to the Peninsular Plateau. Both of
these major divisions in U.P. are marked by a variety of physiographic and relief features.
District Shahjahanpur is situated in South East of Rohilkhand Division. It was established in
1813.Before its creation it was a part of district Bareilly. It Consists of 4 Tehsils, 15 Blocks, 922
Gram Panchayats, 1 Constituency and 6 Assembly Areas.
Land of district Shahjahanpur is plains and fertile. Land of district Shahjahanpur on the side of the
river bank is low and other side it is comparatively high side of land is called Bangar and low side
is called 4 khadar. The north side land of tehsil Puvayan as is domat land. Land in the west side
of the district is comparatively very low due to land erosion of the rivers. Due to this reason at the
time of rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat
and matiyar. In the district water level is 20’ to 25’ below.
A digital elevation model (DEM) is a digital representation of ground surface topography or
terrain. It is also widely known as a digital terrain model (DTM). A DEM can be represented as a
raster (a grid of squares, also known as a height map when representing elevation) or as a
triangular irregular network. The proposed plant location is shown in that Relief map.
For the relief study of the area very higher quality ASTER (Advanced Space borne Thermal
Emission and Reflection Radiometer) DEM is downloaded. These DEMs of the Terra satellite is
freely available for 99% of the globe, and represents elevation at a 30 meter resolution. After
downloading the DEMs the farther processing is done using the ARC GIS 9.2 version.30 m
interval contours are generated using the 3 D Analyst -Surface analysis – Contour option. Then
the TIN model is generated using the height source of these contours in the 3 D Analyst
environment.
The digital elevation model of the project site is shown in the Figure 3.2 with the height range.
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Figure 3.2 Digital Elevation Model (DEM) of the Study Area
(Source: SRTM DEM)
Figure 3.3 Contour map of the Study Area
(Source: SRTM DEM)
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3.4. Geomorphology
Located in the south-east of Bareilly Division, Shahjahanpur is an agriculture-based district of
Uttar Pradesh. As per government notification it was established in the year 1813. Before its
creation it was a part of Bareilly district. Geographically, it is situated at 27.35 N Latitude and
79.37 E longitude. It has an average elevation of 194 metres (600 feet) from sea level. It is
bounded on North Wet by Bareilly district, on north by Pilibhit district, in the east district Kheri, in
the south district Hardoi, in the south west district Farrukhabad and in the west district Badaun.
The total geographical area of the district is 4575Km2.This is Agriculture based District of Uttar
Pradesh.Ramganga, Garrah & Gomti are the main rivers of district.Kathana, Jhukma & Mensiare
are the attached rivers of Gomti. Garrah is the main river. Khannaut, Suketa and Kai are the
attached rivers of Garrah.Flood - mostly effects Jalalabad Tehsil.Major crops of the district are
Wheat, Gram, Millet & Potato.
There exists an army cantonment, and a major clothing factory for defence forces called
Ordnance Clothing Factory. Shahjahanpur Club is a famous club of the district, whose
membership was once regarded as very exclusive.
Figure 3.4 Geomorphological Map
3.5. Climatology and Meteorology
Metrological plays vital role in affecting the dispersion of pollutants into the environment after their
discharge into the atmosphere. Uttar Pradesh climate greatly varies according to the vacation in
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the topography of the region. The climate of the state is tropical, but variations exist because of
difference in altitudes. The Himalayan region is cold. The (extreme) temperature varies in the
plains from 3 to 40C in January to 43 to 450C in May and June. There are three district seasons-
winter from November to February, summer from April to June and the monsoon season from
July to October.
Summer Season
The month of April marks the start of summers in Shahjahanpur and it lasts till June. Temperature
ranges between 22°C to 48°C during these months.
Monsoon Season
Shahjahanpur experiences the monsoon season from July till October. The city remains drenched
during these months. Average annual rainfall is 907 mm.
Winter Season
Winters in Shahjahanpur start in the month of November and last till February. The weather is
pleasant during these months and the temperature ranges between a comfortable 2 °C to 23°C.
This is the apt time for visiting the city.
3.6. 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; 2013.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 3.1.
Table 3.1 Summary of Climatic Condition at the Site
Month Parameters Temp (Deg C) RH (%)
October Max 34.0 94.0
Min 20.0 0.0
Mean 26.3 44.2
November Max 29.0 88.0
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Month Parameters Temp (Deg C) RH (%)
Min 14.0 8.0
Mean 20.8 59.3
December Max 25.0 95.0
Min 9.0 23.0
Mean 16.4 69.1
(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 NE and W with wind frequencies of 3.85% and 3.13%, respectively. Calm conditions
were prevailed for 82.92% of the total time. Average wind speed was observed as 0.19m/s during
the study period.
Figure 3.5 Wind Rose
(Source: Interpretation of Meteorological Data)
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Figure 3.6 Wind Class Frequency Distribution (Post Monsoon Season)
(Source: Interpretation of Meteorological Data)
3.7. Baseline Environment
Sampling Location:
Monitoring of Baseline Environmental Quality of the Study Area has been done during Post
Monsoon Season (October’13 to December’13). Table 3.2 Shows the Sampling location which
are also depicted in Figure 3.7
Table 3.2 Details of Sampling Locations
Code Location Distance from the Site Direction Ambient Air Sampling Locations
AQ1 Project site - - AQ2 Sahjana 2.66 Km E AQ3 Sikarpur 5.33 Km SE
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Code Location Distance from the Site Direction AQ4 Akhtyarpur 2.70 Km N AQ5 Lalpur 4.70 Km ENE AQ 6 Khalauli 4.73 Km S
Noise Sampling Locations NQ1 Nearest Road NQ2 Project site - - NQ3 Sahjana 2.66 Km E NQ4 Sikarpur 5.33 Km SE NQ5 Akhtyarpur 2.70 Km N NQ6 Lalpur 4.70 Km ENE NQ7 Khalauli 4.73 Km S
Ground Water Sampling Locations GW1 Project site - - GW2 Sahjana 2.66 Km E GW3 Sikarpur 5.33 Km SE GW4 Akhtyarpur 2.70 Km N GW5 Lalpur 4.70 Km ENE GW6 Khalauli 4.73 Km S
Surface Water Sampling Location SW1 Near Pirola Village 1.16 Km S SW2 Garrah Nallah 6.10 Km E
Soil Sampling Locations SQ1 Project site - - SQ2 Sahjana 2.66 Km E SQ3 Sikarpur 5.33 Km SE SQ4 Akhtyarpur 2.70 Km N SQ5 Lalpur 4.70 Km ENE SQ6 Khalauli 4.73 Km S
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Figure 3.7 Sampling Locations in Study Area
(Source: Google Earth)
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3.8. Air Environment
Prevailing air environment i.e. baseline conditions in an area is primarily governed by the different
activities going on in that area including industrial, agricultural, domestic and commercial
activities. The pollutant concentrations in the atmosphere is also governed by the meteorology,
topography, natural settings in terms of plantation, forest cover, vegetation etc. as these factors in
combination with each other are responsible for dispersion, diffusion, transportation and
assimilation of pollutants in the local air shed.
3.8.1. Reconnaissance Survey
The prime objective of the AAQ survey within the study area around the fertilizer plant was to
establish the existing background levels for various air pollutants e.g. PM10, PM2.5, SO2, NOx,
CO, NH3, HC (Methane and Non-methane), and VOCs.
3.8.2. Ambient Air Quality (AAQ) Monitoring
In order to establish existing status of atmospheric conditions of study area in terms relevant
pollutants namely particulate matter (PM10, PM2.5), sulphur dioxide, nitrogen oxides and
ammonia, AAQ monitoring was carried out for the Post Monsoon season a network of six
numbers of AAQ stations were set up to establish the base line conditions of air environment in
the study area. The AQ stations locations were selected keeping in mind the findings of the
reconnaissance survey, major settlements, micrometeorology and topography of the study area.
The locations and bearing of the AAQ stations have been projected in Table 3.2 and Figure
3.7.The respirable dust sampler and PM2.5 sampler along with the analytical methods prescribed
by CPCB were used for carrying out air quality monitoring. The data on pollutants concentrations
were processed for different statistical parameters like arithmetic mean, minimum and maximum
concentration and 90 percentile value.
3.8.3. Baseline Status
The ambient air quality levels at all the sampling locations were within the limits as specified by
CPCB for industrial/ mixed use and residential/ rural use. The existing PM10, PM2.5, SO2, NOx,
CO, NH3, HC and VOCs concentrations (average of the three months) in the above sites
described are given in Table 3.3 and National Ambient Air Quality Standards (NAAQS) are given
in Table 3.4. Detailed ambient air quality monitoring results have been presented in Annexure-X
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Table 3.3 Ambient Air Quality Data around the various villages of KSFL in 10 km radius
Location Parameter
PM2.5 (µg/m³)
PM10 (µg/m³)
SO2
(µg/m³) NOx
(µg/m³) NH3
(µg/m³) HC
(µg/m³) VOCs
(µg/m³) CO(µg/
m³)
Project site Max 55 76 6.8 13 27 <0.1 <0.1 <1.0 Min 40 60 5.1 10.1 18 <0.1 <0.1 <1.0
Avg 47.5 68.1 6.0 11.8 22.5 <0.1 <0.1 <1.0
98 percentile
55 75.5 6.8 13.0 27 <0.1 <0.1 <1.0
Sahjana Max 53 73 6.5 10.9 25 <0.1 <0.1 <1.0
Min 32 51 4.4 8.2 17 <0.1 <0.1 <1.0
Avg 42.6 62.2 5.6 9.8 20.8 <0.1 <0.1 <1.0
98 percentile
53 72.5 6.4 10.9 24.5 <0.1 <0.1 <1.0
Sikarpur Max 55 75 6.8 13.1 25 <0.1 <0.1 <1.0
Min 33 52 5.2 9.3 16 <0.1 <0.1 <1.0
Avg 45.4 65.3 6.0 11.6 20.8 <0.1 <0.1 <1.0
98 percentile
55 75 6.8 13.0 25 <0.1 <0.1 <1.0
Akhtyarpur Max 52 75 7.1 12.7 25 <0.1 <0.1 <1.0
Min 34 56 5.2 8.3 17 <0.1 <0.1 <1.0
Avg 43.96 66.33 5.86 10.92 21.33 <0.1 <0.1 <1.0
98 percentile
52 74.1 6.9 12.7 24.5 <0.1 <0.1 <1.0
Lalpur Max 56 74 6.5 12.7 25 <0.1 <0.1 <1.0
Min 35 51 4.5 9.3 16 <0.1 <0.1 <1.0
Avg 46.08 65.42 5.87 10.86 20.79 <0.1 <0.1 <1.0
98 percentile
55.5 74 6.5 12.6 25 <0.1 <0.1 <1.0
Khalauli Max 54 74 6.9 13.5 24 <0.1 <0.1 <1.0
Min 30 51 4.1 9.2 15 <0.1 <0.1 <1.0
Avg 41.13 61.54 5.37 10.72 19.63 <0.1 <0.1 <1.0
98 percentile
53.5 73.5 6.6 13.2 24 <0.1 <0.1 <1.0
(Source: ITL, Patila)
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Table 3.4 National Ambient Air Quality Standards (CPCB), 2009
S. No.
Pollutant Time 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
Geake
•Ultraviolet
fluorescence
24 hours** 80 80
2 Nitrogen Dioxide
(NO2),μg/m3
Annual* 40 30 •Modified Jacob &
Hochheiser (Na-Arsenite)
•Chemiluminescence
24 hours** 80 80
3 Particulate Matter (size less than 10
μm) or
PM10μg/m3
Annual* 60 60 •Gravimetric
•TOEM
•Beta attenuation
24 hours** 100 100
4 Particulate Matter (size less than 2.5 microns) or
PM2.5μg/m3
Annual* 40 40 •Gravimetric
•TOEM
•Beta attenuation
24 hours** 60 60
5 Ozone (O3) μg/m3
8 hours ** 100 100 •UV photometric
•Chemiluminescence
•Chemical method
1 hour ** 180 180
6 Lead (Pb) μg/m3
Annual* 0.5 0.5 •ASS / ICP method
after sampling on EPM 2000 or equivalent filter paper
•ED – XRF using Teflon filter
24 hours** 1.0 1.0
7 Carbon 8 hours** 2 2 Non Dispersive Infra-
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S. No.
Pollutant Time Weighted average
Concentration in Ambient Air
Industrial, Residential, Rural and Other Area
Ecologically sensitive area (notified by Central Govt.)
Methods of Measurement
Monoxide (CO) mg/m3
1 hour** 4 4 RED (NDIR) Spectroscopy
8 Ammonia (NH3) μg/m3
Annual* 100 100 •Chemiluminescence
•Indophenol blue
method
24 hours** 400 400
9 Benzene (C6H6) μg/m3
Annual* 5 5 •Gas
chromatography based continuous analyser
•Adsorption and
desorption followed by GC analysis
10 Benzo (a) Pyrene (BaP) – particulate phase only ng/m3
Annual* 1 1 Solvent extraction followed by HPLC / GC analysis
11 Arsenic (As) ng/m3
Annual* 6 6 AAS / ICP method after sampling on EPM 2000 or equivalent filter paper
12 Nickel (Ni) ng/m3
Annual* 20 20 AAS / ICP method after sampling on EPM 2000 or equivalent filter paper
* 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.
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3.8.4. Interpretation of result
PM2.5 (Post Monsoon): The highest PM2.5 level was observed Lalpur (56 µg/m3), while the
lowest level was observed at Village Akhtyarpur (52 µg/m3). The Average PM2.5 levels are within
the NAAQS levels for Industrial, Residential, Rural and Other Areas (60 µg/m3).
Figure 3.8 Statistical Comparison of PM2.5 Concentration (Post Monsoon Season)
(Source: EQMS)
PM10 (Post Monsoon):PM10 levels were found ranging from 73 to 76 µg/m3. The highest PM10
levels were found at Project Site (76 µg/m3) while the lowest levels was found at Village Sahjana
(73 µg/m3). The PM10 in the study area is contributed mainly by industrial emissions, vehicular
emissions, re-suspended 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
Figure 3.9 Statistical Comparison of PM10 Concentration (Post Monsoon Season)
(Source: EQMS)
0
10
20
30
40
50
60
Max
Min
Average
98 Percentile
01020304050607080
Max
Min
Average
98 percentile
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Sulphur Dioxide (Post Monsoon): The highest level of SO2 was found at the Village Akhtyarpur
(7.1 µg/m3) whereas lowest level was found at Village Sahjana and Lalpur (6.5µg/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 SOx Concentration (Post Monsoon Season)
(Source: EQMS)
Oxides of Nitrogen (Post Monsoon): The highest level of NOx was found at the Village Khalauli
itself (13.5 µg/m3) whereas lowest level was found at Village Sahjana (10.9 µg/m3). The NOx
level of the Study area is well under the NAAQS Standard of 80 µg/m3. The main source of NOx
emission is industrial & vehicular.
Figure 3.11 Statistical Comparison of NOx Concentration (Post Monsoon Season)
(Source: EQMS)
0
1
2
3
4
5
6
7
8
Max
Min
Average
98 Percentile
0
2
4
6
8
10
12
14
16
Max
Min
Average
98 percentile
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3.9. Noise Environment
Noise can be defined as an unwanted sound. Noise beyond a certain level has an adverse impact
on human beings and their environment. If intense enough it can damage hearing or is otherwise
annoying.
Noise monitoring was carried out at 7 locations that are described in Table 3.2. 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.
The results of the monitoring are provided in Table 3.5. Monitored levels were compared against
Ambient Noise Standards prescribed under Gazette Notification 643 of Ministry of Environment
and Forests (Ref. Annexure IV), Government of India. The noise levels at all the 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.
Table 3.5 Ambient Noise Quality Results
S NO. Location Noise level in dB (A) Day Time
Noise level in dB (A) Night Time
1 Nearest Road 57.6 41.9
2 Project Site 52.3 42.1
3 Sahjana 48.5 39.5
4 Sikarpur 50.6 39.5
5 Akhtyarpur 48.5 39.6
6 Lalpur 47.9 39.5
7 Khalauli 47.6 39.8
(Source: ITL, Patiala)
3.10. Water Environment
Water environment of an area is broadly classified into the following categories
Surface water: Rivers, drains, canal, ponds etc.
Ground water: Water seepage and accumulations in deeper strata of ground.
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The only source of recharging for both surface and ground water source is from precipitation
(rainfall). The annual rainfall in 907 mm. The winter rains are uncertain. Light showers may occur
during December and January. Shahjahanpur is situated on a strip of alluvial plain extending
north of the Ganga River.
3.10.1. Surface Water Quality
Surface water samples were collected from 2 locations during the study period and analysed for a
number of physico-chemical parameters. The results of the physico-chemical analysis of Surface
water are given in Table 3.6.
Table 3.6 Surface Water Analysis at various locations around KSFL
S.No. Parameters Unit SITE SPECIFIC (Near Piprola
Village)
GARRAH Nallah
1 pH - 8.44 8.00
2 Turbidity NTU <5 <5
3 EC µMho/cm 512 422
4 TSS mg/L 26 18
5 TDS mg/L 314 274
6 Total Alkalinity as CaCO3
mg/L 198 164
7 Chloride as Cl- mg/L 21 12
8 Sulphate as SO42- mg/L 39 31
9 Nitrate as NO3 mg/L 5 2
10 Phosphate as PO4 mg/L 5 6
11 Total Hardness as CaCO3
mg/L 171 122
12 Calcium as Ca mg/L 89 70
13 Magnesium as Mg mg/L 82 52
14 Sodium as Na mg/L 34 36
15 Potassium as K mg/L <10 <10
16 Flouride as F- mg/L 1.6 1
17 Iron as Fe mg/L 0.6 0.2
18 Phenolic Compounds
mg/L 0.001 0.001
19 Cyanide as CN- mg/L 0.01 0.01
20 Residual Chlorine as Cl-
mg/L 0.01 0.01
21 Cadmium as Cd mg/L 0.001 0.001
22 Total Chromium as Cr
mg/L 0.01 0.01
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S.No. Parameters Unit SITE SPECIFIC (Near Piprola
Village)
GARRAH Nallah
23 Lead as Pb mg/L 0.01 0.01
24 Zinc as Zn mg/L 0.01 0.01
25 Manganese as Mn mg/L 0.01 0.01
26 Copper as Cu mg/L 0.01 0.01
27 Nickel as Ni mg/L 0.01 0.01
28 Total Coliforms MPN/ 100 ml 900 90
29 E-coli Absent/ml present present
30 Insecticides mg/L <0.002 <0.002
31 Dissolved oxygen mg/L 4.5 7.1 32 BOD (3 days at
27˚C) mg/L 34 14
33 Arsenic as As mg/L 0.01 0.01
34 Selenium as Se mg/L 0.01 0.01
35 Oil and grease mg/L 0.01 0.01
36 Mercury as Hg mg/L 0.01 0.01
37 Aluminum as Al mg/L 0.01 0.01
38 Anionic detergents as MBAS
mg/L 0.1 0.1
(Source: ITL, Patiala)
3.10.2. Ground water availability
Ground water is a dependable resource that is contained and transmitted through the interstices
in rock materials below the earth surface. It is considered and rather used to be a cheap and
easily extractable commodity. However, with a rapid growth of population and all around
development, there is incessant pressure on the ground water withdrawal resulting compulsive
awakening in terms of both the quality and quantity. Estimation of ground water resources of
Shahjahanpur has been carried out based on the methodology recommended by the Ground
Water Estimation Committee (GEC’97). The net ground water availability of the District is
140974.03 Ham and gross ground water draft is 83111.52 Ham. Thus the level of development is
58.96. District Shahjahanpur come under Safe Category.
3.10.3. Ground Water Quality
Ground water samples were collected from 6 locations during the study period and analysed for a
number of physico-chemical parameters. Sampling Locations are detailed in Table 3.2 and Figure
3.7. The results of the physico-chemical analysis of ground water are given in Table 3.7.
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Table 3.7 Ground Water Analysis around various Location of KSFL
SN PARAMETERS
UNIT PROJECT SITE
SAHJANA
VILLAGE
SIKARPUR
VILLAGE
AKHTYARPUR VILLAGE
LALPUR VILLAGE
KHALAULI VILLAGE
1 pH - 7.54 7.76 8.06 7.64 7.82 8.02 2 Turbidity NTU <5 <5 <5 <5 <5 <5
3 EC µMho/cm 554 447 492 689 567 420 4 TDS mg/L 341 291 320 448 369 270 5 Total Alkalinity
as CaCO3 mg/L 177 106 164 128 141 165
6 Chloride as Cl- mg/L 16 8 13 50 16 12 7 Sulphate as
SO42-
mg/L 31 18 26 38 14 26
8 Nitrate as NO3 mg/L 8 6 5 3 5 6 9 Phosphate as
PO4 mg/L 2.1 2.2 2.4 6.5 1.5 2.1
10 Total Hardness as CaCO3
mg/L 151 101 134 114 125 146
11 Calcium as Ca mg/L 78 64 84 69 76 84 12 Magnesium as
Mg mg/L 73 37 50 45 49 62
13 Sodium as Na mg/L 41 35 24 31 18 34 14 Potassium as
K mg/L < 10 < 10 < 10 < 10 < 10 < 10
15 Fluoride as F- mg/L 1.1 0.5 1.4 0.5 0.4 0.5 16 Iron as Fe mg/L 0.5 0.8 1.2 0.1 0.2 0.4 17 Phenolic
Compounds mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001
18 Cyanide as CN-
mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
19 Cadmium as Cd
mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001
20 Total Chromium as Cr
mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001
21 Lead as Pb mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 22 Zinc as Zn mg/L 2.1 1.6 0.6 2.1 1.2 0.8
23 Manganese as Mn
mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
24 Copper as Cu mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 25 Nickel as Ni mg/L <0.02 <0.02 <0.02 <0.02 <0.02 <0.02
26 Total coliforms MPN/ 100 ml
Absent Absent Absent Absent Absent Absent
27 E-coli Absent/ml Absent Absent Absent Absent Absent Absent 28 Arsenic as As mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
29 Mercury as Hg mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001
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(Source: ITL, Patiala)
Discussion
The ground water quality in the region has been compared with respect to the Drinking Water
Quality Standards as per IS 10500:1991. It was observed that ground water samples on all six
locations were in the norms “Desirable Limits” of TDS, Turbidity, EC, Total Alkalinity, Chlorides,
Sulphate, Nitrate, Phosphate & Total Hardness while Calcium, Magnesium, Sodium & Potassium
comes under the norms “Permissible Limits.” It is observed that ground water sample of Village
Sikarpur contain iron (1.2 mg/l) which is more than permissible limit.
Surface water in the region has been compared with respect to the Water Quality Standards as
per IS 2296:1992.
Study shows the water quality comes under designed Class-C (Drinking Water Sources with
Conventional Treatment followed by Disinfection) of IS 2296:1982 and can be used for
domestic/Drinking use after conventional treatment and disinfection.
3.11. Soil
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
colour 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.
For general characterization of soil a few random samples from the study area to the depth of
about 15-cm may sufficient. Deeper soil samples may be needed only for the study of soil profile.
3.11.1. Study Area Soil Characteristics
Land of district Shahjahanpur is plains and fertile. Land of district on the side of the river bank is
low and other side it is comparatively high side of land is called Bangar and low side is called
Khadar. The north side land of tehsil Puvayan as is domat (Loam) land. Land in the west side of
the district is comparatively very low due to land erosion of the rivers. Due to this reason at the
time of rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat
(loam) and matiyar (clay).
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Most of the soil are sandy, clay loam and loam in the district. Sandy soils are found with 50%
sand in rain fed farming areas of the district. Loam& Clay Loam textured soil are found in Irrigated
areas & most of the crops are grown in these soils. Paddy, wheat and other oil seed & pulse
crops are grown in loam soils of the district. Soil map of Shahjahanpur district is shown as Figure
3.12.
Figure 3.12 Soil map of Shahjahanpur District
3.11.2. 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 labelled in the field with location, number
and sent to the laboratory for the analysis of physicochemical parameters.
3.11.3. Selection of Sampling Locations
Six (06) soil sampling locations were selected based on the local land use conditions and the
agricultural practices.
3.11.4. Soil sampling locations
Soil sampling was conducted once during the study period of Post-monsoon season. Six (06) soil
samples were collected from selected locations in the vicinity of the proposed project. 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 analysed for physicochemical characteristics. Soil
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sampling locations with their distance & directions with respect to the project site, are presented
in Table 3.2 & shown in Figure 3.7.
3.11.5. 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: 3.8 given as
follows;
Table 3.8 Physicochemical Characteristics of Soil
S. No.
Parameters UNIT (S-1) (S-2) (S-3) (S-4) (S-5) (S-6)
Physical Characteristics 1 Texture - Sand
y Loam
Sandy Loam
Sandy Loam
Clay Loam
Sandy Loam
Sandy Loam
2 Porosity % 42 36 46 43 49 40 3 Bulk Density (BD) gm/cc 1.41 1.38 1.48 1.29 1.37 1.41 4 Water Holding
Capacity(WHC) % 36 32 42 38 46 35
5 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
Chemical Characteristics 6 pH (20%Slurry) 8.42 8.31 8.14 8.22 8.35 7.98 7 Conductivity µmhos/cm 544 428 487 524 434 511 8 Sodium Absorption
Ratio(SAR) %
0.458 0.612 0.584 0.574 0.647 0.612
9 Zinc as Zn meq/100gm <0.1 <0.1 0.2 <0.1 <0.1 0.2 10 Manganese as Mn meq/100gm <0.1 0.2 <0.1 <0.1 0.2 <0.1 11 Organic Carbon % 0.5 0.4 0.4 0.8 0.6 0.4 12 Boron as B meq/100gm <0.1 0.2 0.3 <0.1 0.2 0.4 13 Nitrogen as N mg/Kg 14 23 22 18 25 28 14 Phosphorus as P mg/Kg 12 16 14 11 18 16 15 Potassium as K mg/Kg 48 52 46 42 46 44 16 NPK index - 21 21 18 26 24 23 17 Exchangeable Ca meq/100gm 2.2 0.4 1.6 1.4 0.8 1.2 18 Exchangeable Mg meq/100gm 0.6 0.2 0.6 0.2 0.3 0.6 19 Exchangeable Na meq/100gm <0.1 0.2 <0.1 <0.1 0.2 <0.1 20 Fluoride meq/mg <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
(Source: ITL, Patiala)
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3.11.6. Physico-Chemical Characteristics of Soil
Interpretation of Soil Characteristic has been dwelled in following sub-sections;
Physical characteristics of soil
Physical characteristics of soil greatly influence its use and behaviour towards plant growth.
3.11.6.1 Soil Texture
Texturally the soils of study area are observed as Sandy Loam, & Clay Loam Soils.
3.11.6.2 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
1.29 to 1.48-gm/cm3.
3.11.6.3 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 32 to 46%.
3.11.6.4 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 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).
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3.11.6.5 Soil Reaction
Soil pH is an important soil property, which affects the availability of several plant nutrients. It is a
measure of acidity and alkalinity and reflects the status of base saturation. The soil pH ranges
from 7.98 to 8.42, thereby indicating the soils are moderately alkaline.
3.11.6.6 Organic Carbon
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
0.4 to 0.8%, thereby implying that soils are low to medium in organic content.
3.11.6.7 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.
3.11.6.8 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 content in the surface soils
ranges between 14.0 and 28.0-mg/kg (30.0 & 60.0-kg/ha) thereby indicating that soils are low in
available nitrogen content.
3.11.6.9 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
aluminium and iron and in alkaline condition with calcium. Available phosphorus content ranges
between 11.0 & 18.0-mg/kg (21.0 & 37.0-kg/ha) thereby indicating that soils are having medium
to high available phosphorus.
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3.11.6.10 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 content in these soils
ranges between 42.0 and 52.0-mg/kg (81.0 & 108.0-kg/ha) thereby is indicating that the soils are
low to medium in potassium content.
3.11.6.11 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.
3.11.6.12 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.
3.11.6.13 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 ranges between <0.1 and 0.2-mg kg-1. As per the critical
limit of available zinc (>0.5-mg/kg-1), most of the study area soils are sufficient in available zinc in
the vicinity of existing / proposed project.
3.11.6.14 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 ranges from <0.1and 0.4-mg/kg-1. The critical limit for
deficiency of the available boron is <0.5-mg/ kg-1.
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3.12. Land use
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.
Data Used in the land use map preparation is the satellite Imagery of Indian Remote Sensing
Satellite (IRS- ID, sensor P6, LISS III) of 23.5 m resolution. The Swath of the imagery is 141 Km
x 141 Km. LANDSAT imagery of 30 meter resolution and 185 x 185 km swath is also used for the
comparative and overall analysis of the area. LISS III imagery and LANDSAT imagery of 30
meter resolution were used for the complete coverage of the study area. (Software used- Arc GIS
9.3 & Erdas Imagine 9.1)
The area contains different types of land cover and land use:-
Agriculture land
Human settlements
Open lands-like Agricultural Fallow and other fallow areas
Water Bodies
Some shrub vegetation areas are also there in the study area
Barren land
Land use / land cover map of 10 km study area has been show in Figure 3.14 The agricultural
area and Agri fallow land represents around 59 % and 27 % of the whole land cover. Vegetation
covers about 6 % of the area. Table 3.9 & Figure 3.13 shows the land use categories with the
respective percentages in the study area.
Table 3.9 Land use category in the Study Area
Class Area(Sq km) Agricultural land 186.03 Agri. fallow land 84.74
Water body 5.59 Settlement 14.42
Vegetation/shrubs 18.64 Barren land 5.07
Total 314.49
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Figure 3.13 Landuse / Land Cover Statistics of the Study Area
(Source: EQMS)
Figure 3.14 Land use map of the Study Area
(Source: glovis.usgs.gov)
59% 27%
2% 4%
6%
2%
Land Cover Statistics
Agricultural land
Agri. fallow land
Water body
Settlement
Vegetation/shrubs
Barren land
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3.13. Biological Environment
Nature supports a great variety of living beings under a structural and functional unit called
ecosystem. In any natural ecosystem, there are several components which exist in harmony and
survive only by interdependence. These components may be either biotic or abiotic.
Developmental activities often have great impacts on the biodiversity both ecosystems as well as
species level. Present study has been carried out to inventories the biodiversity exist 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.
Forest and Forest Types
The extent of Natural forests in Uttar Pradesh is very low and a total of 16583 km2 forest area
recorded in the State which is about 6.88 % 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 Shahajahanpur district which accounts for a geographical area of 4575 km2 having 122 km2
forest cover which is about 2.67% of the district’s geographical area. The forests of the district
support a variety of flora and fauna.
The baseline ecological surveys were carried out, based on various secondary sources (Forest
Department Data, Scientific Studies etc.) which further validated from various primary surveys,
and also through interviewing local people. Present biological studies were carried out in two
zones: core zone [Expansion Area of project- 60 Acre] and buffer zone (10 km surrounding the
core area). The area to be used for expansion project is open and very few shrubs and grasses
have been recorded in that area. Good greenery in the form of greenbelt and roadside plantation
already exist within the project area. There is no reserve forest area falls in the study area and
the natural vegetation of the area is assumed under anthropogenic pressure. The present primary
survey was carried out in following sampling locations:
Expansion Area (Core Area) S-I
Near Kanth (Surrounding Area) S-II
Near Shahajahanpur City (Surrounding Area) S-III
Flora
The present baseline floristic study has been carried out to inventories floral composition in the
study area. Three sampling locations; one in expansion area (core zone) and two in outer area
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within the 10 km of core zone (Buffer zone) were selected for carrying out vegetation survey and
in addition an inventory of various floral species was also prepared for each sampling locations.
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.
The vegetation of the district belongs to moist deciduous forest and presents very open form so
that the trees and shrubs are widely spaced. The vegetation of study area generally divided into:
Vegetation of ruderal and waste lands, aquatic vegetation near water sources and weeds of
cultivation. Sharma and Dhakre (1993)2 reported a total number of 654 species of angiosperms
which belong to 116 families from Shahajahanpur district. They reported Cyprus, Euphorbia,
Ipomoea, Ficus, and Cassia as leading genera. In the present primary study, a total of 28 trees,
16 shrubs, 19 herbs, 4 climbers and 5 grasses were recorded in both core and buffer areas of
study. (Table 3.13 & 3.14)
Core Area (project expansion area)
In the project expansion area, few shrubs’ individuals like Calotropis procera, Cassia tora and
Cassia occidentalis are recorded. Ground vegetation of the area comprised with some herb
species (Parthenium hysterophorus, Argemone Mexicana, Oxalis corniculata, Cannabis sativa,
Ageratum conyzoides) along with seasonal grasses dominated with Cynodon dactylon. The list of
trees, shrubs, herbs, climbers and grasses found in the core zone area listed in Table 3.13 &
3.14.
Buffer Area (10 Km surrounding of core area)
In the buffer area of the project, main tree species recorded during field study were Kanju
(Holoptelea integrifolia), Pankar (Ficus sp), Neem (Azadirachta indica), Aam (Mangifera indica),
Shahtoot (Morus alba), Shisham (Dalbergia sissoo), Imli (Tamarindus indica), Jamun (Syzium
cumini), Pipal (Ficus religiosa), Mahuwa (Madhuca indica), Eucalyptus (Eucalyptus sp), Khajura
(Phoenix sylvestris) etc. Shrubby vegetation of this zone includes Aak (Calotropis procera),
Cassia tora, Cassia auriculata, Cassia occidentalis and Lantana camara. In the herbaceous flora,
Parthenium hysterophorus, Cynodon dactylon, Argemone Mexicana, Cannabis sativa,
Polygonum sp and Euphorbia hirta were found dominated along some grass species. The list of
floral species recorded in buffer zone is presented in Table 3.10 & 3.11
2Sharma and Dhakre (1993).Flora of Shahajahanpur District, Uttar Pradesh: An Enumeration of Flowering Plants, Vegetos 6 (182):
15-30
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Table 3.10 List of Tree and Shrub Flora Recorded in the Study Area
Sl. No.
Name Scientific Name Family Core Zone
(Expansion Site)
Surrounding Area
Trees S-I S-II S-III
1 Aam Mangifera indica Anacardiaceae *
2 Amaltas Cassia fistula Fabaceae *
3 Kanju Holoptelea integrifolia
Ulmaceae *
4 Asina Terminalia tomentosa
Combretaceae *
5 Ashoka Polyalthia longifolia Annonaceae *
6 Gulmohar Delonix regia Caesalpiniaceae *
7 Bargad Ficus bengalensis Moraceae * *
8 Bel Aegle marmelos Rutaceae *
9 Ber Zyzyphus jujube Rhamnaceae * *
10 Ehretia laeves Boraginaceae *
11 Eucalyptus Eucalyptus sp Myrtaceae *
12 Goolar Ficus glomerata Moraceae * *
13 Imli Tamarindus indica Fabaceae *
14 Jamun Syzygium cumini Myrtaceae *
15 Kachnar Bauhinia variegata Fabaceae * *
16 Semal Bombax ceiba Malvaceae *
17 Khajura Phoenix sylvestris Arecaceae * *
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Sl. No.
Name Scientific Name Family Core Zone
(Expansion Site)
Surrounding Area
18 Mahua Madhuca indica Sapotaceae *
19 Neem Azadirachta indica Meliaceae * *
20 Ailanthus excelsa Simaroubaceae *
21 Peepal Ficus religiosa Moraceae * *
22 Ratanjot Jatropha curcas Euphorbiaceae *
23 Reetha Sapindus mukorossi
Sapindaceae *
24 Sahtoot Morus alba Moraceae *
25 Shisham Dalbergia sissoo Fabaceae * *
26 Siris Albizia lebbeck Fabaceae * *
27 Subabool Leucaena leucocephala
Fabaceae *
28 Pankar Ficus spp Moraceae *
Shrubs
1 Karipatta Murraya sp Rutaceae *
2 Aak Calotropis procera Apocynaceae * * *
3 Karvanda Carissa congesta Apocynaceae * *
4 Cassia tora Caesalpinioideae * * *
5 Tarvad Cassia auriculata Caesalpinioideae
*
6 Lantana Lantana camara Verbenaceae * * *
7 Capparis sepiaria Capparaceae * *
8 Facourtia indica Salicaceae *
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Sl. No.
Name Scientific Name Family Core Zone
(Expansion Site)
Surrounding Area
9 Clerodendrum aculeatum
Verbenaceae *
10 Croton bonplandianum
Euphorbiaceae * *
11 Cassia occidentalis Caesalpiniaceae * *
12 Pisola Artemisia nilagirica Asteraceae *
13 Adhatoda zeylanica Acanthaceae *
14 Clerodendrum viscosum
Lamiaceae * *
15 Ipomoea sp Convolvulaceae *
16 Datura sp Solanaceae *
*Present
(Source: EQMS Field Study)
Table 3.11 List of Herbs, Climbers and Grasses Recorded in the Study Area
Sl. No. Name Scientific Name Family Core Zone (Expension
Site)
Surrounding Area
Herbs
1 Gazar ghass Parthenium hysterophorus Asteraceae * * *
2 Doob Cynodon dactylon Poaceae * * *
3 Argemone Mexicana Papaveraceae * * *
4 Dudhee Euphorbia hirta Euphorbiaceae * * *
5 Baraira Sida acuta Malvaceae *
6 Melochia corchorifolia Malvaceae * *
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Sl. No. Name Scientific Name Family Core Zone (Expension
Site)
Surrounding Area
7 Ambushi Oxalis corniculata Oxalidaceae * *
8 Desmodium triflorum Fabaceae * *
9 Ageratum conyzoides Asteraceae * *
10 Barleria cristata Acanthaceae *
11 Tridax procumbens Asteraceae *
12 Oldenlandia corymbosa Rubiaceae *
13 Polygonum sp Polygonaceae *
14 Cannabis sativa Cannabaceae * * *
15 Solanum nigrum Solanaceae * *
16 Leucas sp Lamiaceae *
17 Pogostemon bengalensis Lamiaceae * *
18 Colocasia sp Araceae *
19 Corchorus aestuans Tiliaceae * *
Climbers
1 Cocculus villosus Menispermaceae * *
2 Abrus precatorius Fabaceae *
3 Ichnocarpus frutescens Apocyanaceae * *
4 Smilax ocreata Liliaceae *
Grasses
1 Bothriochloa pertusa Poaceae * *
2 Dichanthium annulatum Poaceae * *
3 Dactyloctenium aegyptium Poaceae * *
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Sl. No. Name Scientific Name Family Core Zone (Expension
Site)
Surrounding Area
4 Setaria glauca Poaceae * *
5 Tetrapogon tenellus Poaceae * *
*Present
(Source: EQMS Field Study)
Fauna
In order to study the wild mammals, avifauna, heretofauna 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.
Forest Department reported 19 big animals from the study area. (Forest Working plan)In the
present study, a total of 5 mammalian species were sighted from the study area which is listed in
Table 3.12
Table 3.12 List of Mammalian Fauna Recorded in the study area
S. No.
Scientific Name Order Family Schedule CS
1 Boselaphus tragocamelus
Artiodactyla Bovidae IV LC
2 Canis lupus Carnivora Canidae II LC
3 Vulpes bengalensis Carnivora Canidae II LC
4 Sus scrofa Artiodactyla Suidae IV LC
5 Funambulus palmarum Rodentia Sciuridae IV LC
(Source: EQMS Field Study)
Forest Department also reported 47 bird species in the study area. During the primary study a
total of 12 bird species has been recorded. The common birds recorded from the study area are:
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Common Pigeon (Columba livia), Common Peafowl (Pavo cristatus), Common Myna
(Acridotheres tristis) and Common Myna (Acridotheres tristis). The list of avifauna and birds
recorded in the study area is listed in Table 3.13.
Table 3.13 List of Avi- Fauna Recorded in the study area
S. No.
Name Scientific Name Order Habit
1 Bank Myna Acridotheres ginginianus Passeriformes R
2 Black Drongo Dicrurus macrocercus Passeriformes R
3 Common Myna Acridotheres tristis Passeriformes R
4 Common Peafowl Pavo cristatus Galliformes R
5 Common Pigeon Columba livia Columbiformes R
6 House Crow Corvus splendens Passeriformes R
7 House Sparrow Passer domesticus Passeriformes R
8 Indian Pond Heron Ardeola grayii Pelecaniformes R
9 Jungle Bablar Turdoides striata Passeriformes R
10 Pied Kingfisher Halcyon rudis Coraciiformes R
11 Spotted Dove Stigmatopelia chinensis Columbiformes R
12 White-throated Kingfisher
Halcyon smyrnensis Coraciiformes R
(Source: EQMS Field Study)
Four species of lizards were sighted during the primary survey along with rat snake. (Table 3.14)
Table 3.14 List of Herpetofauna Recorded in the study area
S. No.
Name Scientific Name Order Family
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1 Common House Gecko Hemidactylus frenatus Squamata Gekkonidae
2 Leopard gecko Eublepharis macularius Squamata Gekkonidae
3 Common garden lizard Calotes versicolor Squamata Agamidae
4 Indian chameleon Chamaeleo zeylanicus Squamata Chamaeleonidae
5 Oriental rat snake Ptyas mucosus Squamata Colubridae
(Source: EQMS Field Study)
Aquatic Ecology
Garrha River is the potential aquatic body present in the study zone along with Garai Nala. Some
birds like Pied Kingfisher and Cattle Egret has been sighted near river course. Fishing has not
been carried out under this survey and fish fauna was recorded from secondary information’s.
Forest working Plan reported 10 fish species from the study area in which following species were
confirmed under present survey:
Table 3.15 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 Lanchi Wallago attu Siluriformes Siluridae NT
3 Singhi Heteropneustes fossilis
Siluriformes Heteropneustidae LC
4 Catla Catla catla Cypriniformes Cyprinidae LC
(Source: EQMS Field Study)
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Bank Myna Pied Kingfisher
Black Drongo Cattle Egret
Ageratum conyzoides Cannabis sativa
Figure 3.15 A View of Thick Green Belt around project boundary from Shajahanpur-Farrukhabad Highway
National Parks/wildlife Sanctuary / Reserve Forest
There are no National Parks/wildlife sanctuaries in the 10 km radius of the study area.
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(Source: http://www.mapsofindia.com/maps/wildlife/wildlife-uttarpradesh.htm)
Figure 3.16 National Parks and Sanctuaries in Uttar Pradesh
3.14. Demographic and Socio-Economic Features
Demographic Profile of Study Area
The Study Area of 10 km radial Zone mainly falls in the Shahjahanpur district in Uttar Pradesh.
There are total 77 Rural Villages and 1 urban town in Study Area.
Population
Total Population of the Study area as per Census of India, 2011, is 158454 .The total number of
Households are 27660. The total Male and Female population of the Study area is 84152 and
74302 respectively. The Village-wise demographic details are given in Table 3.16
Table 3.16 : Village-wise details of population
District Village No. of
Household
Total Populatio
n
Male Populatio
n
Female Populatio
n
Shahjahanpur
Kishurhai 221 1025 542 483
Jamaur 569 3342 1750 1592
Piprola Ahmedpur 1009 5000 2660 2340
Abhain 404 2312 1253 1059
Barua Bujurg 108 680 352 328
Rawatpur 591 3592 1940 1652
Mohammedpur Azmabad 189 908 501 407
Mutiyasa 125 742 407 335
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Chandgoi 377 2114 1132 982
Mathurapur 119 736 410 326
Aliyapur 191 994 544 450
Jajalpur 251 1344 727 617
Pandaincha 217 1151 616 535
Kurseli 67 401 212 189
Kailha Elaqa Sisnai 248 1211 646 565
Khijerpur 66 375 207 168
Baberpur 118 616 323 293
Bhudia 179 1135 588 547
Bhanpur 193 1196 650 546
Umraha 378 2229 1193 1036
Misripur 1619 9328 4912 4416
Rausar 279 1551 817 734
Bijlapur 121 727 379 348
Shahwazpur Daniapur 163 987 513 474
Sujatpur 303 1953 1035 918
Utaha 168 964 516 448
Chauthera 1703 10007 5419 4588
Bawakkarpur 196 996 542 454
Nagerpal 491 2595 1421 1174
Akrra Rasoolpur 471 2622 1395 1227
Dadroul 236 1310 687 623
Paintapur 60 394 225 169
Midi Gawan 338 1791 951 840
Bakian 275 1511 770 741
Panchouli 89 524 270 254
Chandapur Barkatpur 399 2181 1174 1007
Sisnai 356 1940 1018 922
Kari Makuapur 228 1242 655 587
Kalyanpur Nawadia 65 389 189 200
Nagaria Talluqa Gopalpur 246 1349 717 632
Rai Khurd 170 919 471 448
Shahbaz Nagar 2485 14044 7375 6669
Bamiahar 86 552 288 264
Bhedpur 186 998 527 471 Rahman Nagar Uaf Raikhera 326 1859 982 877
Lalpur 313 1806 938 868
Mauzampur 597 3500 1846 1654
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Mudiya Narain 117 662 346 316
Harnokha 191 1242 664 578
Dhakaurdharanpur 158 874 458 416
Bhursandi 271 1719 915 804
Mirpur Mafi 95 578 319 259
Khamriya 76 453 248 205
Hasanpur Raskoopa 213 1273 691 582
Parwatpur 201 1140 611 529
Gandhar 359 2004 1038 966
Bahadurpur Bishunipatti 108 548 283 265
Koelha Patti 123 588 314 274
Gulam Khera 370 1973 999 974 Akhtiyar Nagar Urf Eknaura 626 3394 1772 1622
Bawakkerpur Sarawar 191 1137 604 533
Ladpur Sarai 42 212 121 91
Jahangeerpur 60 370 178 192
Hari Pura 115 596 326 270
Endeypur 208 1319 720 599
Mitya Poufi 148 1057 582 475
Ptiyari 159 861 467 394
Mohanpur Mamraijpur 216 1219 632 587
Rajpur Gumtani 63 342 181 161
Mohddinpur 168 737 367 370
Kattupur 10 46 22 24
Dilawarpur 310 1703 877 826
Digurpur 232 1554 834 720
Hatipur Kurria 299 1594 864 730
Walipur 155 982 535 447
Mahanpur 158 942 529 413
Jarawan 169 1056 575 481
Kanth (NP) 4460 27137 14395 12742
Total 27660 158454 84152 74302
Sex Ratio
The Sex ratio of the Study area is 883 Females / 1000 Males and the child sex ratio (0-6 years) is
896 Females /1000 Males.
SC / ST Population
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A considerable population (13%) in the Study Area is constituted by SC/ST of which the former
population constitutes 13 % and the latter 0% of the total population of the study area. A graphical
presentation of SC/ST Population in Study Area with sex wise breakup is given in Figure 3.17 and
3.18 respectively.
Figure 3.17 Sex wise SC, ST Population in Study Area
(Source: EQMS)
Figure 3.18 Percentage wise break up of SC, ST and General Population in Study Area
Male, Total 158454, 84152
Male, SC 20961, 11188
Male, ST 7, 3
Female, Total 158454, 74302
Female, SC 20961, 9773
Female, ST 7, 4
Male Female
General Population,
137486, 87%
SC Population, 20961, 13%
ST Population, 7, 0%
SC/ST/General Population
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(Source: EQMS)
Literacy Rate
The Literacy Rate of the study area is 47.2% of which male and female literate are 54.6% and
38.7% respectively. The illiterates 52.8% of the total population of which female illiterates are
61.3%. The graphical presentation of both sexes of literates and illiterates in study area is given
in Figure 3.19
Figure 3.19 Gender-wise Distribution of Literate and Illiterate in Study Area
(Source: EQMS)
Employment Scenario
Workers Participation Ratio of the Area is 29%.Among this 23% is the Main workers and 6% are
the marginal Workers.
Total Population, Population,
158454
Total Population, Male, 84152
Total Population, Female, 74302
Literates Population,
Population, 74712
Literates Population, Male,
45976
Literates Population,
Female, 28736
Illiterates Population,
Population, 83742
Illiterates Population, Male,
38176
Illiterates Population,
Female, 45566
Total Population Literates Population Illiterates Population
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Figure 3.20 Workers Scenario of the Area
(Source: EQMS)
Main Workers
A considerable percentage (23%) of Main workers in the Study area belongs to Casual Labours
38%, Agricultural 32%, Household workers constitutes 3% and other workers 27% respectively.
Main Workers,
36675, 23%
Marginal Workers, 9879,
6%
Non Workers, 111900, 71%
Workers Scenario
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Figure 3.21 Distribution of Main Workers
(Source: EQMS)
Marginal Workers
A considerable percentage (6%) of Main workers in the Study area belongs to Casual Labours
12%, Agricultural 50%, Household workers constitutes 4% and other workers 34% respectively
Casual Workers
14134 38%
Agricltural Workers
11579 32%
Household Workers
947 3%
Others Workers
10015 27%
Main Workers
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Figure 3.22 Distribution of Marginal Workers
(Source: EQMS)
Cropping Pattern
Major Farming Systems/ Enterprises of district are as follows;
Crop production system
Crop production and livestock production system
Fruits/ vegetable/ floriculture/ farming
Fisheries, Poultry, Mushroom production and Goatary
Area, Production and Productivity of major crops cultivated in the district are listed below;
Table 3.17 Production and Productivity of major crops cultivated
S.N. Crop Area (ha) Production (Qtl) Productivity (Qtl/ha)
1 Rice 204615 459829000 22.44
2 Maize 297 5610000 18.87
3 Jowar 1553 1592000 10.25
4 Bajra 4666 5291000 10.25
Casual Workers, 1208, 12%
Agricltural Workers, 4888,
50%
Household Workers, 391,
4%
Others Workers, 3392,
34%
Marginal Workers
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5 Pulses (Kharif) 8483 5455000 -
6 Ground Nut 6101 6278000 10.29
7 Seasmum 4765 548000 1.15
8 Soybean 56 55000 9.76
9 Wheat 247112 864892000 35.00
10 Barley 574 1169000 20.36
11 Gram 543 483000 8.89
12 Pea 1600 1872000 11.70
13 Lentil 5412 3969000 7.33
14 Linseed 289 119000 4.13
15 Mustard 7677 7351000 9.58
16 Toria 12000 9608000 8.00
Infrastructure
Education facilities
There are 75 Primary School, 14 Middle School, 2 Secondary Schools and 1 Senior Secondary
Schools in 77 villages in study area. Higher education facilities are available in district
headquarters Shahjahanpur District.
Health facilities
There are 2 allopathic and 4 ayurvedic hospital in the study area villages and addition there are 2
ayurvedic, 9 homeopathic dispensary, 3 Primary Health Centre and 1 Primary Health Sub-
centres in the study Area. However, several private medical practitioner and community health
workers are also available.
Drinking Water facilities
Villagers mostly depend on groundwater resource for drinking/domestic water by various means
such as hand pumps (75 villages), well (61 villages) and Tap water facilities by the state
department has been provided in 47 villages.
Communication Facilities
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In the study area there are 11 post offices. There are 45 villages approach by paved road and
bus services are available for 2 (Dadraul and Gulam Khera) villages only. No of telephonic
connections are 88.
Banking Facilities
5 Banks and 7 Credit Societies operates in the study area.
Electricity
37 villages are electrified out of 77 villages in the study area. Comprehensive List of
Infrastructures presents in the Study Area as per Census records 2001 is given in Table
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Table 3.18 Comprehensive List of Infrastructures present in the Study Area
Village: Number of
primary
schools
Number of middl
e schoo
ls
Number of
secondary
schools
Number of
senior second
ary schools
Number of
colleges
Hospital
Dispensary
PHC
PHSC
Number of post
office
No. of telepho
nic connecti
on
Bank
Credit societi
es
Drinking water
facilities
Communication
facilities (Bus
services)
Approach
paved roads
Power
supply
facilities
Kishurhai 3 0 0 0 0 0 0 0 0 0 0
0 0 HP N I A A
Jamaur 1 0 0 0 0 0 0 0 0 1 5
0 0 WW, HP N I NA A
Piprola Ahmedpur 1 0 0 0 0 0 0 0 0 1 1
1 0 TW, WW,
HP N I A A
Abhain 1 0 0 0 0 0 0 0 0 0 1
0 0 TW, WW,
HP N I A A
Barua Bujurg 1 0 0 0 0 0 0 0 0 0 0
0 0 TW,HP N I NA NA
Rawatpur 1 1 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
Mohammedpur Azmabad 1 0 0 0 0 0 0 0 0 1
11 0 0 HP N I A NA
Mutiyasa 1 0 0 0 0 0 0 0 0 0 1
0 0 TW, WW,
HP N I A NA
Chandgoi 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA A
Mathurapur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Aliyapur 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Jajalpur 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Pandaincha 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I A NA
Kurseli 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Kailha Elaqa Sisnai 0 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I A A
Khijerpur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Baberpur 1 0 0 0 0 0 0 0 0 0 0
0 0 TW,HP N I NA NA
Bhudia 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
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Bhanpur 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
Umraha 1 0 0 0 0 1 AY 0 0 0 1 0
0 0 HP N I A A
Misripur 3 1 0 0 0 0 0 0 0 0 1
1 0 TW, WW,
HP N I A A
Rausar 0 0 0 0 0 0 1 HM 1 0 0 1
0 0 WW, HP N I A A
Bijlapur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Shahwazpur Daniapur 1 0 0 0 0 0 0 0 0 0
0 0 0 WW, HP N I NA NA
Sujatpur 1 1 0 0 0 0 0 0 0 0 0
0 0 HP N I A NA
Utaha 1 1 0 0 0 0 0 0 0 0 0
0 0 TW,HP N I A A
Chauthera 6 3 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I A A
Bawakkarpur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Nagerpal 1 0 0 0 0 0 1 AY, 1
HM 0 0 0 0
0 0 TW, WW,
HP N I A A
Akrra Rasoolpur 1 0 0 0 0 0 1 AY, 1
HM 0 0 0 0
0 0 TW, WW,
HP N I A A
Dadroul 1 1 0 0 0 1 AL, 1
AY 1 HM 0 1 1 0
1 2 WW, HP A A A
Paintapur 0 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I A A
Midi Gawan 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA A
Bakian 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Panchouli 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I A NA
Chandapur Barkatpur 1 1 1 1 0 1 AY 1 HM 0 0 1
0 0 2
TW, WW, HP N I A A
Sisnai 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Kari Makuapur 2 0 0 0 0 0 0 0 0 0 1
0 0 WW, HP N I A NA
Kalyanpur Nawadia 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Nagaria Talluqa Gopalpur 0 0 0 0 0 0 0 0 0 0
0 0 0 HP N I NA NA
Rai Khurd 1 0 0 0 0 0 0 0 0 0 0
0 0 TW N I A NA
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Shahbaz Nagar 3 2 0 0 0 1 AY 1 HM 0 0 1 50
1 0 WW, HP N I A A
Bamiahar 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Bhedpur 0 0 0 0 0 0 0 0 0 0 0
0 0 HP N I A NA
Rahman Nagar Uaf Raikhera 1 0 0 0 0 0 1 HM 0 0 1
0 0 1 TW,HP N I NA A
Lalpur 1 0 0 0 0 0 0 0 0 0 1
0 0 WW, HP N I A A
Mauzampur 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
Mudiya Narain 0 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Harnokha 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Dhakaurdharanpur 1 1 0 0 0 0 0 1 0 0 5
0 1 WW, HP N I A NA
Bhursandi 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Mirpur Mafi 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Khamriya 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Hasanpur Raskoopa 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Parwatpur 1 0 0 0 0 0 0 0 0 0 0
0 0 WW, HP N I NA NA
Gandhar 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA A
Bahadurpur Bishunipatti 1 1 0 0 0 0 0 0 0 0
2 0 0 WW, HP N I NA A
Koelha Patti 1 0 0 0 0 0 0 0 0 0 4
0 0 TW, WW,
HP N I A NA
Gulam Khera 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP A A A
Akhtiyar Nagar Urf Eknaura 1 0 0 0 0 0 0 0 0 0
0 0 0
TW, WW, HP N I NA A
Bawakkerpur Sarawar 1 0 0 0 0 0 0 0 0 0
0 0 0
TW, WW, HP N I NA NA
Ladpur Sarai 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Jahangeerpur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW,HP N I NA NA
Hari Pura 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
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Endeypur 1 0 0 0 0 0 0 0 0 1 0
0 0 TW,HP N I NA NA
Mitya Poufi 1 0 0 0 0 0 0 0 0 0 1
0 0 TW, WW,
HP N I A A
Ptiyari 1 0 0 0 0 0 0 0 0 0 0
0 0 TW,HP N I NA A
Mohanpur Mamraijpur 1 0 0 0 0 0 1 HM 0 0 1
1 1 1
TW, WW, HP N I A A
Rajpur Gumtani 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I NA NA
Mohddinpur 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A NA
Kattupur 0 0 0 0 0 0 0 0 0 0 0
0 0 - N I NA NA
Dilawarpur 1 0 0 0 0 0 0 0 0 1 1
0 0 TW, WW,
HP N I A A
Digurpur 2 1 1 0 0 0 0 1 0 0 1
0 0 TW, WW,
HP N I A NA
Hatipur Kurria 1 0 0 0 0 1 AL 1 HM 0 0 0 0
0 0 TW, WW,
HP N I A A
Walipur 0 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
Mahanpur 1 0 0 0 0 0 0 0 0 0 0
0 0 HP N I NA A
Jarawan 1 0 0 0 0 0 0 0 0 0 0
0 0 TW, WW,
HP N I A A
Total 75 14 2 1 0 2 AL, 4
AY 2 AY, 9
HM 3 1 11 88
5 7 - - - -
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CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
4.1. Prelude
The possible impact on various components of environment due to the proposed expansion of
KSFL 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 analysed on the 10 km radius
study area around the proposed plant site for each environmental parameter. Impact assessment
study for the existing KSFL 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. Air Environment
The pre-project (baseline) ambient air quality status in the study area indicates that all the criteria
pollutants are well within the prescribed National Ambient Air Quality Standards (NAAQS) for
industrial, residential, rural and other areas.
The ambient air quality with respect to air pollutants will change during the operation phase of the
proposed project. However, adequate stack height will be provided for better dispersion of flue
gas as per the guidelines of UPPCB. In addition to that adequate greenbelt will be developed for
further control of air pollution.
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Compliance with the existing ambient air quality standards will be achieved by implementation of
the measures as outlined in EMP. This needs to be coupled with the continuous monitoring of air
pollutants within and around the project site as well as in adjoining areas.
To assess the impact of air emissions from various continuous point sources, air dispersion
modelling study has been conducted with the help of ISCST3 View 6.2 model of Lakes
Environmental. Detailed description has been given in the following sub-sections:
4.2.1. Model Brief
Air dispersion modelling can be used to predict atmospheric concentrations of pollutants at
specific locations (receptors) over specific averaging times (i.e. annual, daily, and hourly). An
atmospheric dispersion model accounts for the emissions from a source; estimates how high into
the atmosphere they will go, how widely they will spread and how far they will travel based on
temporal meteorological data; and outputs the pattern of concentrations that will occur for various
exposure periods, thereby providing the exposure risks for different receptors.
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 predictions for air quality during operation phase were carried out for suspended particulate
matter (SPM), oxides of sulphur (SOx) and oxides of Nitrogen (NOx), 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
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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 centre
of the proposed project. In addition to that, receptors were also placed at the sampling
locations.
Emissions
The main sources of air pollution due to the operation of the plant are the existing boiler, service
boiler I and II, GTG I and II (20 MW), Primary reformer and prilling tower. With the proposed
expansion, the main sources of air pollution will be primary reformer, GT/HRSG and another
prilling tower. SPM, SOX, NOx and NH3 are the main air pollutants generated from the proposed
project. The emission rates and stack parameters of the sources are listed in Table 4.1.
Table 4.1 Stack Parameters and Emission Load (Existing and Proposed Expansion Project)
S.
No. Stack
Stack
Height
(m)
Stack
Diameter
(m)
Stack Exit
Velocity
(m/s)
Stack
Temperature
(K)
Emission Rates (g/sec)
SOX NOx SPM NH3
Existing Facility
1 Primary
Reformer 32 3.0 14.00
443.15 - 18.60 - -
2 Service Boilers I
& II 30 3.2 7.70
423.15 - 7.56 - -
3 GTG I & II (20
MW) 30 3.2 15.50
443.15 - 4.48 - -
4 Prilling Tower 102 26.0 0.70 330.15 - - 13.37 11.88
Proposed Expansion
5 Primary
Reformer 30 3.0 11.87 443.15 0.75 21.16 0.42 -
6 GT/HRSG 30 3.2 13.13 448.15 0.92 13.19 0.53 -
7 Prilling Tower 102 26.0 0.71 348.15 - - 14.81 22.47
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4.2.2. Meteorological Data
The meteorological data consists of wind speed, direction, temperature, humidity, solar radiation,
cloud cover and rainfall recorded during the months of October through December, 2013, 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.
4.2.3. Receptor Locations
A total of about 366 receptors – 360 receptors of which were generated with a polar grid from the
centre of the proposed project and extended to 10 km. Apart from these receptors, the sampling
locations were also taken into account to assess the incremental load on the baseline
environmental scenario.
4.2.4. Summary of Predicted GLC’s
The summary of maximum ground level concentrations (GLC) for the existing facility, proposed
expansion and the combined impact of the existing facility, proposed expansion and the
combined impact of the existing facility and proposed expansion are listed in Table 4.2, 4.3 & 4.4
respectively.
Table 4.2 Summary of Maximum 24-hour GLC due to the Existing Facility
Description Concentration (g/m3)
SOx NOx SPM NH3
Maximum Rise in GLC - 7.62 3.23 2.87
Distance of occurrence (km) - 5.13 4.07 4.06
Direction of Occurrence - SW SW SW
Maximum Baseline Concentration
reported
6.04 11.78 153.18 22.54
Total Concentration 6.04 19.40 156.41 25.41
Prescribed Standards 80 80 200 400
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Table 4.3 Summary of Maximum 24-hour GLC due to the Proposed Expansion
Description Concentration (g/m3)
SOx NOx SPM NH3
Maximum Rise in GLC 0.42 8.78 2.43 3.34
Distance of occurrence (km) 5.02 5.13 6.06 6.10
Direction of Occurrence SW SW SW SW
Maximum Baseline Concentration
reported
6.04 11.78 153.18 22.54
Total Concentration 6.46 20.56 155.61 25.88
Prescribed Standards 80 80 200 400
Table 4.4 Summary of Maximum 24-hour GLC due to the Existing Facility and Proposed Expansion
Description Concentration (g/m3)
SOx NOx SPM NH3
Maximum Rise in GLC 0.42 16.39 5.59 6.13
Distance of occurrence (km) 5.02 5.13 5.10 5.09
Direction of Occurrence SW SW SW SW
Maximum Baseline Concentration
reported
6.04 11.78 153.18 22.54
Total Concentration 6.46 28.17 158.77 28.67
Prescribed Standards 80 80 200 400
The above tables show that in the worst case scenario, the maximum ground level concentration
due to the existing facility and proposed project will be in the predominant SW direction. In the
post-project scenario, the 24-hour average concentration for all the criteria pollutants are well
within the ambient air quality standards for industrial, residential, rural and other areas in the
worst case. The isopleths of the pollutant concentration due to the impacts associated with the
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operation of the existing facility are shown in Figures 4.1 through 4.3 for NOx, SPM andNH3
respectively. The isopleths of the pollutant concentration due to the impacts associated with the
operation of the proposed expansion are shown in Figures 4.4 through 4.7 for SOX, NOx, SPM
and NH3respectively.The isopleths of the pollutant concentration due to the impacts associated
with the combined operation of the existing facility and proposed expansion are shown in Figures
4.8 through 4.11 for SO2, NOx, SPM and NH3 respectively.
Additionally, the cumulative impact of the proposed project at the monitoring locations within 10
km radius is provided in Table 4.5.
Table 4.5 Summary of Maximum GLC at Monitoring Locations due to the Existing Facility and Proposed Expansion
Location
Rise in GLC Max. Background
Concentration
Impact from
Project NAAQS
(g/m3) (g/m
3) (g/m
3) (g/m
3)
Project Site
SOX 0.0017 6.04 6.042 80
NOX 0.0861 11.78 11.87 80
SPM 0.0046 153.18 153.184 200
NH3 0.0058 22.54 22.55 400
Sahjana
SOX 0.13 5.55 5.68 80
NOX 6.51 9.8 16.31 80
SPM 1.30 139.97 141.27 200
NH3 1.31 20.83 22.14 400
Sikarpur
SOX 0.07 5.99 6.06 80
NOX 3.08 11.6 14.68 80
SPM 0.83 146.81 147.64 200
NH3 0.70 20.79 21.49 400
Akhtyarpur SOX 0.10 5.86 5.96 80
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Location
Rise in GLC Max. Background
Concentration
Impact from
Project NAAQS
(g/m3) (g/m
3) (g/m
3) (g/m
3)
NOX 4.40 10.92 15.32 80
SPM 1.00 149.24 150.24 200
NH3 0.98 21.33 22.31 400
Lalpur
SOX 0.002 5.87 5.87 80
NOX 0.05 10.86 10.91 80
SPM 0.02 147.2 147.22 200
NH3 0.02 20.79 20.81 400
Khalauli
SOX 0.01 5.37 5.38 80
NOX 0.30 10.72 11.02 80
SPM 0.07 138.47 138.54 200
NH3 0.06 19.63 19.69 400
As is evident from the Tables above, there will be no adverse impacts on the surrounding area.
Highly efficient air pollution control systems will be adopted to mitigate particulate matter as well
as gaseous emissions in the ambient environment.
Discussion of the Cumulative Impacts at monitoring locations:
SOX: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum Sox concentration of 6.06 µg/m3 at Sikarpur village with project
impacts of 0.07µg/m3and baseline contribution of 5.99µg/m3.The total impact from the project of
6.06µg/m3 is well within the stipulated standard of 80µg/m3for industrial as well as residential
areas.
NOx: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum NOx concentration of 16.31 µg/m3 at Sahjana village with project
impacts of 6.51µg/m3 and baseline contribution of 9.80µg/m3.The total impact from the project of
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16.31µg/m3 is well within the stipulated standard of 80µg/m3for industrial as well as residential
areas.
SPM: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum SPM concentration of 153.18 µg/m3 at project site with project
impacts of 0.0046µg/m3 and baseline contribution of 153.18µg/m3.The total impact from the
project of 153.184µg/m3 is well within the stipulated standard of 200 µg/m3for industrial as well
as residential areas.
NH3: The total impacts from the project (existing facility, proposed expansion and baseline
contribution) indicate maximum NH3concentration of 22.55 µg/m3 at project site with project
impacts of 0.0058µg/m3 and baseline contribution of 22.54µg/m3.The total impact from the
project of 22.55µg/m3 is well within the stipulated standard of 400 µg/m3for industrial as well as
residential areas.
As is evident from the tables and discussion above, there will be no adverse impacts on the
surrounding area. Highly efficient air pollution control systems will be adopted to mitigate
particulate matter as well as gaseous emissions in the ambient environment.
Figure 4.1 Isopleth for NOx GLC due to operation of Existing Facility
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Figure 4.2 Isopleth for SPM GLC due to operation of Existing Facility
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Figure 4.3 : Isopleth for NH3 GLC due to operation of Existing Facility
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Figure 4.4 Isopleth for SOx GLC due to Proposed Expansion
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Figure 4.5 : Isopleth for NOx GLC due to Proposed Expansion
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Figure 4.6 : Isopleth for SPM GLC due to Proposed Expansion
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Figure 4.7 Isopleth for NH3 GLC due to Proposed Expansion
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Figure 4.8 : Isopleth for SOX GLC due to Existing Facility and Proposed Expansion
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Figure 4.9 Isopleth for NOX GLC due to Existing Facility and Proposed Expansion
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Figure 4.10 Isopleth for SPM GLC due to Existing Facility and Proposed Expansion
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Figure 4.11 : Isopleth for NH3 GLC due to Existing Facility and Proposed Expansion
4.3. Noise Environment
The sources of noise during the operational phase of the plant are mainly turbines compressors,
blowers, pumps and furnaces. The other sources of noise are the movement of vehicles along the
road. The noise survey of the plant was carried out and the noise level at various locations is
given in Table - 2.6(in Chapter-II). The proposed expansion project will be similar but will have
advanced technology and improved equipment both in terms of energy efficiency and less noisy.
A critical review of Table – 2.6(in Chapter-II) shows that:
Within the plant area noise level was more near process air /synthesis compressors in ammonia
(~73 - 74 dB (A)) and near Prilling Tower (~72dB (A) etc. However the noise level along the plant
boundary gets reduced to considerable extent as monitored at main security gate (~49 dB (A)),
and Gas metering station (~49 dB (A)).
In township the noise level was measured in public places like Temple and guest house. It was
49 dB (A).
4.3.1. Impacts due to Transportation
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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 fertilisers through
road transport. The large quantity of fertilisers shall be dispatched through railway rakes also.
4.3.2. Impact on Community
Equivalent sound levels are often used to describe community exposures to noise. Noise survey
was also carried out at 7 locations outside the plant but within the study area. Equivalent noise
levels were measured for residential area both in KSFL Township as well as 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) except at near road where it was observed to be 57.6 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 KSFL proposed expansion project will have the noise level not exceeding the
present 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 attenuators.
4.4. Water Environment
Impact on water environment due to KSFL proposed expansion project scheme will be in terms of
additional water consumption {water demand} and waste water / effluent generation and
discharge to environment.
4.4.1. Water Demand
4.4.1.1 Construction Phase
Since the KSFL expansion project will have water requirement both during construction period as
well as during operation. The requirement during construction period will be much less as
compared to that during operation and will be met with the withdrawal from existing tube wells. As
such then there will not be any additional water requirements for construction.
4.4.1.2 Operational Phase
Water during operational phase is normally required for:
Cooling Water
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Boiler Feed Water
Process Water
Domestic and Green Belt
Water requirement for existing plant (after debottlenecking) is around ~878 m3 / hr. (~ 21072
m3/day ) including 2184 m3/day for domestic purpose (both plant and township) as given in
“Water Balance {Existing Status}” in Figure 2.7.The water consumption in proposed expansion
project will be ~1122 m3 / hr. (26928 m3/day). The water will be drawn from existing as well as
from additional tube wells. Necessary approval / clearance from Central Ground Water Authority/
Board are being taken.
4.5. Effluent Generation and Discharge
Industrial wastewater after it is discharged into surface water body should not produce significant
deterioration in its water quality. The effects on surface water depend on wastewater
characteristics and quantity. The impact on surface water depends on the characteristics and also
on quantity of water in the receiving water body. KSFL has gradually reduced its water
consumption/ effluent generation and energy consumption as given below:
KSFL is consuming water for their process below the specified value i.e. < 7.8 m3/t of urea
against the CPCB (Probe 97/2002-03) Norms 8.0 m3/t of urea.
Energy Trend in KSFL Complex (in Gcal /MT of Urea)
2011 -12 5.5886
2012 – 13 5.5758
2013 – 14 5.5762
The treatment philosophy (treatment at source details in chapter – 2 adopted by KSFL) has given
very good results. The treated effluent quality has also considerably improved. Various measures
adopted are:
Awareness programs on EMS.
Arresting leaky points of TAN at source itself. And
Mapping of TAN generation points & countermeasures.
The sump pit and the guard ponds have got sufficient capacity to hold the effluents even during
emergency. The sump pits are lined with impervious lining to prevent seepage to ground water.
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The plant is operating since more than 18 years and no complaint of ground water contamination
has been received from neighbouring villages.
As a result the quality of treated effluents has considerably improved and most of the effluent is
being utilised for horticulture purposes except in rainy season when water requirement for
irrigation is nil or very less.
The existing philosophy of treating the effluents in the plant and recycling the same in the process
{process condensates} or send these to sump pits - guard ponds and after equalisation /
treatment use for irrigation of green belt or discharge to Garrah Nallah shall be followed. For
expansion project it is proposed to augment the existing Effluent Treatment Plant as per
requirement to accommodate the additional effluent.
The expected characteristics of treated effluents shall be maintained as today or shall be
improved further.
4.6. 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.
4.6.1. Land Diversion
KSFL 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 KSFL expansion project, no soil
erosion or diversion of land is involved.
4.6.2. 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. The soil analysis shows that existing operations and urea emissions have
not caused any deterioration to nearby land in the study area. There can be slight increase in
nitrogen content of the soil and this elevated nitrogen content will have positive impact on the
plant growing in the area. Plant Proposed expansion project will improve the urea availability in
the area and consequently better crop yield.
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The healthy growth of trees and other plants both in factory as well as in township shows that
there is no deterioration of soil and land due to KSFL plant. This was also noted during the site
survey of limited villages in the study area.
The solid wastes generated in the plant are having intrinsic values and are sold to interested
parties. The plant operations after KSFL expansion 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 KSFL expansion project.
4.7. Biological Environment
4.7.1. Flora
The quality of soils in the premises of the KSFL {factory and township} shows that there is no
adverse effect of air, water and solid effluents on the soil system. A special thrust has been given
right from the beginning to develop the premises into a live green belt. Green belt has been
developed in an area of >33% within the premises with more than 100 species of trees thus the
plant has a significant positive impact on flora and fauna. The treated effluent is used for the
irrigation purposes to the maximum extent within the KSFL premises. This is confirmed by the
healthy growth and development of green belt consisting of variety of trees, plants and lawns
within and near the factory area.
The development of green belt provides habitat, food and breeding areas to birds, small animals
and insects. No rare or endangered species of fauna are reported to exist in the area. Thus, no
impacts on rare / endangered species are envisaged due to normal operations. The groves of
Neem, Kadamb, Kanchan, bottle bush, Bougainvillea sp., Nerium, Tabernaemontana Siris, Rain
tree, Queen’s flower, Queen of the Night, Scarlet Cordia, Tulip tree, Gul Mohar, growing within
the plant showed no adverse effect. The lawns and other plants after watering with treated
effluents continued their healthy growth. The leaf and flowers are all healthy and flowering pattern
has not changed. The KSFL expansion project would not affect the soil and so the plant growth in
the study area.
4.7.2. Fauna
The cattle and birds living in and around in KSFL factory area did not show any harmful
symptoms due to grazing or other soil contamination. The survey team carried out investigation
by checking with villagers in the study area and also discussed with doctors in state veterinary
centre. Thelarge numbers of birds were seen during the site visit. There is no Zoo or animal or
bird sanctuary in the study area. common birds or animals, based on the observations by the field
team or information collected locally exist in the study area Migratory Birds area within the plant
(near natural ponds). After October when Indian climate starts getting cooler some migratory
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birds are observed. Although there is no ecological sensitive area (like biosphere reserve,
national park, sanctuary, or water body/lake etc.) within 25 km of KSFL complex, open scrub
Jhau and Sarkanda bushes of this area inhabits Nilgai, deer, rabbits etc. Nilgai are observed
throughout the year but deers are seen during the rainy season.
4.8. Socio – Economic Environment
KSFL fertiliser plant was commissioned in November 1995 and during it’s more than 18 years of
operation it has spurred a lot of growth in the area. KSFL has carried out lots of social work (as a
part of its ‘CSR’ objectives).KSFL has undertaken a number of projects (CSR activities in brief are
given in Chapter 2).
In addition KSFL as good corporate citizen is carrying out a lot of social work (continuous
activities) as detailed in Chapter 2 section “WELFARE MEASURES HAVE BEEN TAKEN BY
THE COMPANY IN THE SURROUNDING VILLAGES”.
KSFL expansion project will have some impacts also on socio – economic environment of the
study area- some are as given below:
4.8.1. 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.
KSFL expansion project would increase requirement from ancillary and auxiliary
industries in the vicinity e.g. bagging units.
With more load on infrastructure facilities – roads and rails; these facilities would be
improved.
More income to Government through more taxes on higher amount of production.
4.8.2. 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.
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CHAPTER 5. ENVIRONMENTAL MANAGEMENT PLAN
5.1. Prelude
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.
KSFL by way of EIA study proposes 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 where a similar unit is already operating efficiently with little
pollution. 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. Objectives of EMP
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.
5.3. Components of EMP
EMP for KSFL to enhance the production capacity through expansion project (new Ammonia /
Urea / power complex) considers the following aspects:
Description of mitigation measures
Description of monitoring program
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Institutional arrangements
Implementation schedule and reporting procedures
Institutional framework includes the responsibilities for environmental management as
well as responsibilities for implementing environmental measures.
5.4. Central Pollution Control Board {CPCB} Guidelines for Fertiliser Industry
CPCB in its publication “Probe/97/2002 - 03”- ‘Environmental Management in Selected Industrial
Sectors Status / Needs’, which also includes fertilizer sector, has brought out suggestions /
recommendations and norms for fertilizer units. The suggestions / recommendations and norms
as applicable to KSFL and their compliance status are detailed below:
5.4.1. Emission and Effluent Standards
5.4.1.1 Emission
Emission from Prilling Tower:
o For units commissioned after January 01, 1986: 50 mg/Nm3 or 0.5 kg/t of
product;
KSFL Emission from Prilling Tower of Existing Unit:
o <40 mg/Nm3.
5.4.1.2 Water Consumption
For Straight Nitrogenous Fertilizer units 8 m3 / t of urea or equivalent
Existing Unit Water consumption rate < 8 m3 / t of urea
Waste Water Generation Rate 5 m3 / t of urea
Existing Unit wastewater generation <5 m3 / t of urea.
5.4.1.3 Energy Consumption
Energy consumption is also an indicator plant efficient running. KSFL energy consumption trend
is as follows.
2011 - 12 5.5886 Gcal/MT urea
2012 - 13 5.5758 Gcal/MT urea
2013 - 14 5.5762 Gcal/MT urea
2014-15 5.5341 Gcal/MT urea
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Table 5.1 : Action Points
Sr. No.
Action Points Status at KSFL
1. Purge gas recovery unit (PGRU) should be
installed by all ammonia plants for
recovery of gases.
KSFL has installed PGRU to recover
hydrogen.
2. All the plants should recover ammonia as
well as bottom water from condensate
arising from ammonia plant by installing
steam-stripping system.
KSFL has installed ‘Steam Stripping
System ’ in Ammonia plant to recover
condensate, Expansion project will also
have similar system
3. All the operating urea plants should install
deep hydrolyser – stripper as a facility for
treatment of condensate arising from urea
plant and to recycle ammonia and use
bottom water.
KSFL has installed deep hydrolyser –
stripping system for recovery of ammonia
and use of bottom condensate. Expansion
project will also have similar system
4. As far as possible, the treatment units
should be provided at the end of the
processing plant for specific pollutants
such as oil removal system at the place of
oil handling, phosphate and fluoride
removal system after phosphate and
fluoride bearing effluents, ammonia
removal system for ammonia bearing
effluents, chromium removal system for
CW blow down where chromate based
chemicals are used.
KSFL has followed this practice of treating
pollutants at the place of generation {
ammonia, acidic etc.} and will continue the
practice for Expansion project
5. Residual pollutants can be removed in a
centralized biological treatment plant,
where necessary by providing nitrification
and de -nitrification system. It must be
ensured that performance of de -
nitrification process is complete.
KSFL plant effluents are already meeting
the desired norms. Biological treatment of
effluents is not required.
6. The industries should install holding ponds KSFL have centralized treatment system
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Sr. No.
Action Points Status at KSFL
for storing occasional, accidental and
unforeseen effluents, which can disturb the
performance of effluent treatment system.
Such holding ponds should have an
arrangement to pump the effluents to ETP
at regulated rate.
and holding ponds {Sump pits with
treatment facilities and one Guard and one
Stabilization Pond.}.
7. Water Conservation: Industry should
consider and attempt dry floor cleaning so
as to minimize use of water for floor
washing. No process water is to be used
for floor washing.
KSFL follows this and will continue to do
so.
8. The leakages, overflows and spillages
taking place in distribution system should
be checked and controlled to avoid
wastage of water.
KSFL follows this and will continue to do
so.
9. For development of green belt treated
wastewater may be used instead of fresh
water.
KSFL follows this to full extent {as seen in
water balance diagram} and will continue
to do so.
10. Spillage urea around prilling tower should
be recovered by dissolving in urea
dissolving tank followed by recycle in the
process. At the bagging plant also spilled
urea and the de-dusting scrubber liquor
are to be collected and recycled in the
process plant through urea dissolving unit.
KSFL follows this and will continue to do
so.
11. Hazardous chemicals are to be adequately
stored and marked.
KSFL follows all norms as applicable
(hazardous chemicals-inflammable,
explosives and toxic) and will continue to
do so.
12. Solid Waste Management: Catalysts are KSFL follows – selling the solid waste
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Sr. No.
Action Points Status at KSFL
charged or made up based on loss of
activity after use for some time. The waste
catalysts are to be disposed. Disposal
should be done with appropriate and
organised manner – secured land fill,
returning to the supplier with special
contract at the time of purchasing, selling
for metal recovery.
(Catalysts) to authorized re-processors or
recyclers and will continue to do so.
13. Monitoring: AAQ monitoring at appropriate
locations.
Ambient Air Quality Monitoring at all the
four monitoring stations and at one place
outside the factory are being carried out as
per the standard procedures on bi-weekly
basis and data regularly submitted to
UPPCB.
14. Ground water monitoring around the
storage facilities and also beyond the
factory premises are to be carried out .at
the regular interval – particularly for the
parameters nitrate, fluoride, pH etc. The
records of sampling, Depth and locations
are to be maintained. The locations of
sampling stations should be indicted in a
map showing the contours of the area.
Monitoring of ground quality is being
carried out for pH, Nitrate, Fluoride, Ca &
Mg Hardness, Iron, Na, K etc. on monthly
basis and reports are being sent regularly
to UPPCB.
15. Environment Management Cell headed by
an experienced technologist and provided
with facilities like laboratory, library and
sufficient manpower.
KSFL has an Environment Management
cell headed by a senior executive and the
same system will continue.
5.4.2. Air Environment The emission from KSFL expansion project shall be mainly from the three stacks (Reformer,
HRSG/GT, PT), very limited fugitive emissions while handling product (as KSFL has urea dust
collection and recovery system in bagging plant). In order to mitigate the adverse environmental
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impact due to the operation at expanded / increased capacities following measures are
recommended:
The control measures (through proper upkeep / maintenance) and good housekeeping
will considerably reduce the fugitive emission.
Existing monitoring system of air pollutants SOx, NOx, ammonia and SPM should be
continued.
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.
5.4.3. 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 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 and township 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.
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5.4.4. Water Environment KSFL plant has taken ample precautions to reduce water consumptions and tackle effluents
problem. The philosophy of segregation of effluent streams and treatment near the source and
recycle back to the system has helped in reducing the water consumptions and effluent
generation considerably. These efforts should continue and now efforts should be directed to:
Increased use of treated effluents in horticulture and green belt developments.
Recycle of treated effluents in the system as far as possible.
The treated sewage should be effectively utilized in the plant after treating it (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.
Water is a precious commodity and it should be conserved.
KSFL is having 03 No of Rainwater harvesting ponds and they are considered in Ground
Water Survey Report.
5.4.5. Biological Environment KSFL has developed green belt all around it and also along roads, as groves of fruit trees, as
forest blocks, lawns and ornamental / flowering bushes. Mostly the trees have been planted in
blocks of one particular plant – Albezzia Lebbecks, Dalbergia Sissoo, Pinnata, Termenalia Arjuna
etc.
Block plantation of same species of trees is not a healthy practice KSFL should plant different
species of trees
The trees, which have attained their age, should be cut and new trees should be planted.
Proper maintenance is required for the avenue trees. Avenue trees should not block the
view of road or building. This is necessary from safety and security point of view.
The proper distance of avenue trees should be maintained.
The road curbs should not have trees rather shrubs.
The prevailing wind direction at KSFL rotates from NW to WNW (Post Monsoon Season).
Although wind rotates at all angles, the green belt is developed all around the industrial unit but
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the same is more critical towards the windward side and residential areas (villages / township).
The pollutants emitting from KSFL plant falls beyond 300 – 400 m from the source. Considering
this the green belt of width 200 – 300 m in the windward direction is enough to attenuate
pollutants. The scattered and fugitive emissions can be taken care by the plantation inside the
plant complex.
Some of the cautions and guidelines for green belt at KSFL complex area:
The high trees should have ground vegetation in between shrubs to give good coverage
and more attenuation area.
The trees around the boundary walls of township and plant should be fast growing and
perennial trees.
Block plantation should be restricted. Mixed plantations are good for the plant growth. In
the plant area more shrubs are needed close to the fugitive pollution sites.
To maintain healthy life of the plant, diseased plants (herbs, shrubs, trees) should be
removed.
5.4.6. Land Environment The expansion project will generate the solid wastes similar (in quality as well as increase in
quantity) to the existing system and the existing handling system for the same is to continue. No
additional measures are required.
5.4.7. Socio-economic Environment KSFL is carrying out various welfare programs in adjoining areas. The other agriculture
related programs like horticulture, bio fertilizers, compost from agriculture and domestic
wastes through worm , bio-pesticides etc. should be actively initiated with related
agencies.
As a good corporate citizen and major industry KSFL may consider adopting few more
selected villages in developing them as model villages (with educational facilities for
children, medical facilities, infrastructure as roads, sanitation facilities (more specifically
for ladies), improved agriculture techniques etc.).
More awareness program are to be initiated in immediate neighbouring villages about
KSFL plant activities and the various EHS measures undertaken to make the plant safe
and environment friendly.
5.4.8. Environmental Management Cell
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KSFL has an environment management cell headed by a senior executive and supported by
other supporting staff. It reports to Sr Vice President. The environment set up and guide lines are
given in Annexure VIII.
The Environment Management Cell is formed keeping the following objectives in view:
To update the Environmental Protection Measures.
Efficient control of Environmental degradation.
Conservation of Natural resources. To achieves the better productivity through the
Environmental Management.
Continuous monitoring of the Quality of liquid effluent, stack emissions and ambient air
quality.
Minimization of leakage of any toxic gases. Recycling and reuse of effluent.
EMC consists of various qualified experts of different discipline. Our targets are to keep clean
environment free from all pollutants and comply all the conditions laid down by UPPCB and MoEF
The plant also has well equipped quality and environmental control laboratory having
sophisticated instruments including:
Gas Chromatograph
Microscope,PM2.5 & PM 10 samplers , Gaseous Pollutants sampler, Handy samplers
Colony Counter
Spectrophotometer
Naphalometer
Stack Monitoring Kits.
Drager Pumps and tube kits
pH Meter
Gas Chromatograph for NG etc
A team of well trained and experienced staff carries out tests in the laboratory.
5.4.9. Post – Operational Monitoring Program KSFL is carrying out environment monitoring and has necessary equipment and associated
facilities. However monitoring plan proposed is as follows:
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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, NO2and NH3
Twice a week Shall be complied
Stack Emission
All continuous
stacks
NOx & SO2 in Primary Reformer, GT/HRSG stacks and NH3 & PM in Prilling Tower
Fortnightly
Shall be complied
Effluents
Final effluents discharge point
pH, Free NH3, TAN; TKN;NO3;TSS; PO4as P, Oil-grease; COD; BOD
pH,& TAN -As & when discharge or utilized for irrigation& rest on weekly basis
Shall be complied
Sanitary TSS; BOD Weekly Shall be complied
Ground Water Quality
{Wells / Hand pumps}
pH, NO3, Floride & NH3
Monthly Shall be complied
Surface Water Quality (Upstream & Downstream) of Garrai Nallah
Two (100 mt up & 100 mt down from discharge point)
pH, Free NH3, TAN; TKN;NO3;TSS; PO4 as P, Oil-grease; COD; BOD
pH,& TAN -As & when final effluent discharged & rest on weekly basis
Shall be complied
Noise Plant area &neighboring villages
Day & Night time noise level
Monthly
Shall be complied
Health Check Up
All Plant Personnel
Occupational Health diseases
Annually Shall be complied
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CHAPTER 6. HAZARD EVALUATION AND RISK ANALYSIS
6.1. Prelude
Industrial plants deal with materials, which are generally hazardous in nature by virtue of their
intrinsic chemical properties or their operating temperatures or pressures or a combination of
these. Fire, explosion, toxic release or combinations of these are the hazards associated with
industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated
methods of Safety Engineering, such as, Hazard Analysis and Risk Assessment have now been
developed to improve upon the integrity, reliability and safety of industrial plants.
The primary emphasis in safety engineering is to reduce risk to human life, property and
environment. Some of the more important methods used to achieve this are:
Risk Analysis: Provides a relative measure of the likelihood and severity of various
possible hazardous events by critically examining the plant process and design.
Work Safety Analysis: The technique discerns whether the plant layout and operating
procedures in practice have any inherent infirmities.
Safety Audit: Takes a careful look at plant operating conditions, work practices and work
environments to detect unsafe conditions.
Together, these three broad tools attempt to minimize the chances of accidents occurring. Yet,
there always exists, no matter how remote, probability of occurrence of a major accident. If the
accident involves highly hazardous chemicals in sufficiently large quantities, the consequences
may be serious to the plant, to surrounding areas and the populations residing therein.
To meet emergencies caused by such major accidents, planning response strategies are termed
as On-site Emergency Plan /Disaster Management Plan (DMP).
DMP cannot be considered in isolation or act as a substitute for maintaining good safety
standards in a plant. The best way to protect against a major accident occurrence is by
maintaining very high levels of safety standards.
6.2. Hazards Survey
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Hazard identification and risk assessment studies can be performed at any stage, that is, at initial
design stage or as on-going operation in the system. Hazard survey is a formal systematized
approach employed for hazard identification.
Appraisal of material characteristics from Material Safety Data Sheet for various materials and
chemicals used or produced in the fertilizer plant of Kribhco Shyam Fertilizer Limited (KSFL)
indicates that some of the materials are highly inflammable/explosive (Natural Gas/Naphtha) and
some are toxic (Ammonia / Chlorine etc.). In addition some of the intermediate materials
produced in the process (hydrogen and carbon monoxide) are extremely dangerous considering
the process conditions.
All process materials which are capable of producing accidents/hazards owing to their physical
and chemical properties are identified and on the basis of material movement, hold ups are
calculated. Quantities in the pipelines are also taken in to account. Large and sub-sequential
inventories in storage or process are indicative of the potential hazards to the plant and its
surroundings. Flammability and toxicity factors of these inventories can lead to the unpredictable
incidents.
KSFL is producing urea for agriculture use. The major raw materials and other consumable used
are given in Table 6.1. Most of the materials consumed (except Naphtha, Ammonia, and
Chlorine) are non-hazardous in nature. However, the materials in the process i.e. NG, hydrogen,
carbon monoxide and ammonia are highly hazardous. The consequence of hazards is enhanced
considering the process conditions (high temperature and pressure). These materials need to be
handled very carefully to ensure safety.
Table 6.1 : Hazardous Materials Storages
S. No.
Hazardous Chemicals Handled
Quantity Handled /In
Process
Type of Storage
1 Naphtha 3 [4600;1350;
600] KL
MS Tanks (Main tanks 4600 KL & 1350 KL are having floating roof while day tank -600KL has fixed roof tank with N2 blanketing)
2 Main Raw Material-Natural Gas
--- Supply from GAIL through HBJ gas line
3 Ammonia 2X 5000 MT Double walled, double integrity Atmospheric Tanks
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S. No.
Hazardous Chemicals Handled
Quantity Handled /In
Process
Type of Storage
(0ne existing and in proposed expansion project).
4 Chlorine Gas 0.9X12 MT Tonnage Cylinders
5 Sulphuric Acid
2
[35;30.5] MT
MS Storage Tank
6 Hydrochloric acid
3
[60;60;60] MT
MSRL Storage Tank
7 Caustic Lye(Sodium Hydroxide)
2
[44;44] MT
MSRL Storage Tank
8 Diesel 3
[12;12;12] KL
MS Storage Tank
9 Liquid Nitrogen
2
[25;25] KL
Double Wall Storage Tank
6.3. Hazard Evaluation
The evaluation phase determines the extent and degree of employee’s exposure to toxicants and
other physical hazards in the work place environment. In the case of major accident/breakdown
occurrences, hazards exposure may cross plant boundary limit and persons/properties in the
neighbouring areas may be exposed. During the evaluation study, the likelihood of large and
small leaks is also considered. Hazardous substances may be released as a result of leaks or
catastrophic failures causing possible damage to the surrounding areas. The extent of damage
will depend upon the nature of release. The release of flammable and toxic materials and
subsequent ignition results in heat radiation, pressure wave or vapour cloud depending upon the
flammability, toxicity and its physical state.
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Sudden exposure to high concentrations of toxic chemicals via leaks or operational upsets (relief
valve pop up) may lead to acute effects, such as, unconsciousness, burning eyes, fits of
coughing, etc.
Chronic effect, however, arises by repeated exposure to toxic chemical concentrations mostly by
small leak. Many fine toxic dusts or vapours are invisible, colourless and odourless (CO). Small
leaks of these substances might not become obvious for months or even years.
6.4. Potential Hazards
Accidental release of flammable or toxic vapours can result in severe consequences. Delayed
ignition of flammable vapours can result in blast overpressures covering large areas. This may
lead to extensive loss of life and property. Toxic clouds may cover yet larger distances due to
lower threshold values in relation to those in case of explosive clouds (the lower explosive
limits).In contrast fires have localized consequences. Fires can be put out or contained in most
cases; there are few mitigating actions one can take once vapour clouds get released. Therefore,
major accident hazards occur upon release of flammable or toxic vapours or BLEVE in case of
pressurized flammable liquefied gases.
6.4.1. Toxic Release
In KSFL complex toxic hazards are mainly due to Ammonia (produced and stored in large
quantity) and chlorine.
Ammonia is a colourless with extremely pungent odour toxic and explosive gas (BP – 33.4C).
Ammonia is highly soluble in water (which can to an extent save an individual from its hazards).
Ammonia exposure limits are –TWA – IND 25 ppm; TWA – ACGIH 25 ppm; STEL- ACGIH 35
ppm. Ammonia is severe irritant respiratory tract. Some hazards arise due to production, transfer,
storage, handling and processing of liquefied ammonia. In case of fully refrigerated liquid
ammonia release, instantaneous flash due to adiabatic expansion is negligibly small. Evaporation
due to aerosol formation also does not occur. Release of liquid ammonia at pressure (in ammonia
plant synthesis section), gives rise to flash evaporation equivalent of the initial flash due to
adiabatic expansion. In case of HP ammonia stored at near ambient temperature liquid released
would completely vaporize with no pool formation. Ejection of high pressure ammonia appears to
entrain 10 to 15 times of its own weight of air enough to evaporate nearly all the liquid. Thus if an
HP release occurs unimpeded the ammonia entrains sufficient air to evaporate all the droplets
carried out with flash.
Chlorine is a toxic gas (B. P. is -34oC). In liquefied form chlorine is a clear amber dense liquid.
The gas is greenish-yellow, about 2.5 times as dense as air, and non-flammable. Liquid chlorine
causes severe irritation and blistering of skin. The gas has a pungent suffocating odour and is
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irritant to the nose and throat. It is an extremely powerful vesicant and respiratory irritant.
Typically, exposure to chlorine concentrations of 3 - 6 ppm results in a stinging and burning
sensation in the eyes. Exposures for 0.5 -1 hour to concentrations of 14 - 21 ppm cause
pulmonary oedema, pneumonitis emphysema and bronchitis. This is usually associated with
marked bronchospasm, muscular soreness and headache. Whilst there is inevitably a variation in
individual susceptibility, typically 4 ppm is the maximum concentration that can be breathed for
one hour without any damage, 40-60 ppm is dangerous for a 30-minute exposure and a
concentration of 1000 ppm is likely to be fatal after a few breaths. IDLH (immediately Dangerous
to Life and Health) value for chlorine is 30 ppm. Permissible limit in exposure of chlorine in work
environment under Factories Act, 1948 is 1 ppm Time Weighted Average (TWA) Concentration (8
hours).
6.4.2. Flammable Release
The flammable materials used at KSFL, involve natural gas used as feedstock, fuel gas and
synthesis gas produced in ammonia plant upstream of Synthesis converter, and naphtha. In
certain section of the plant the operating temperature itself exceeds the auto-ignition temperature
of hydrogen and carbon monoxide. In all such cases due to immediate ignition, a jet flame will
result.
6.4.3. Jet Release
Generally when a gas flows out of an opening at high velocity a turbulent free jet invariably
results. The out-flowing gas entrains a large quantity of the ambient air. The net results being the
jet getting diluted to LEL within the short distance from the release point. If ignited the jet flame
results, but if the released material does not get ignited immediately then the possibility of vapour
cloud explosion or delayed ignition is very remote because by this time free jet has lost its
momentum and the mass can begin to disperse due to environmental forces {the concentration of
flammable material has already fallen below the LEL}.
No vapour cloud explosion has therefore been considered. Jet flames due to impingement on the
adjoining important installations can lead to secondary effects (domino effect). In certain cases
the domino effects could lead/ result in loss of containment of ammonia with serious
consequences. The toxic effect of carbon -monoxide has also not been considered since any
such release due to high system operating pressure (and consequent high momentum) will either
get diluted to low concentrations within short distance from the source due to air entrainment or
will get ignited and hence the consequence distance will be rather small.
6.5. Inventory Analysis
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Inventory plays an important part in regard to the potential hazard. Larger the inventory of the
vessel or a system, larger would be the quantity of potential release. A practice commonly used
to generate an incident list is to consider the potential leaks and major releases from fractures of
pipelines and vessels containing sizable inventories. The potential vapour release (source
strength) depends upon the quantity of liquid release, the property of the materials and the
operating conditions (pressure). These when combined into matrix and vapour source strength
computed for each release case, a ranking should become a credible exercise. Plant inventory
can get discharged to environment due to loss of containment.
From the preliminary risk assessment study carried out for each participating unit, some of the
possible hazards have been identified. The likely accident scenarios considered are given in
Table 6.2:
Table 6.2 : Likely Accident Scenario
S. 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. Hole in Naphtha
line / tank
Area adjoining
leak / tank farm
Isolate the line / area; Cover the spillage with
foam / reclaim if possible to prevent ignition.
3. 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.
4 Ammonia Tank
Heavy Leakage
Surrounding
Area
Try to reclaim Ammonia in other Tank/
Approach with gas mask / lifeline. Dissolve in
water and store and treat the water gradually.
5. 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.
The above mentioned hazards scenarios can further aggravate into much more serious incidents
if not intercepted in time. The fire in one tank of tank farm can spread to adjoining tanks and may
result in explosions. The vulnerability zone will be considerably enlarged. The vapours of toxic
fluids/dust if carried away by wind above TLV concentrations may further enlarge the vulnerability
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zone. Similarly, toxic fluid spillage and all wastes leaving the live processing zone if not
decontaminated properly can cause serious health hazard to plant personnel and persons in
nearby area.
6.6. 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.
6.6.1. 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.
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Incident Radiation kW/m2
Damage Type
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
6.6.2. Selected Failure Cases
Few accidental scenarios have been considered and subjected to consequence analysis /
damage zone.
6.6.2.1 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
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Figure 6.1 :Rupture in NG Line
Threat Zone: Threat is modelled 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)
6.6.2.2 Hole in Naphtha Line/ Tank
Naphtha is used only in case NG shortage from GAIL. The two large and one small day naphtha
storage tanks and transfer lines are the likely sources of leakages. The leaked naphtha will form a
pool and in case of the naphtha catching fire, the radiation intensity / thermal load on the
adjoining area / material has been assessed as below.
Ambient Temperature : 30C Leaked Naphtha Pool Diameter : 20 m Intensity of Radiation : 71.6 kW / m2
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Thermal Load kW/m2
Distance from edge of the pool (m)
Remarks
25.8 1
17.0 4
9.0 10
4.0 21 1st degree burn
2.0 31
1.1 40
6.6.2.3 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 one large ammonia atmospheric storage tank of capacity- 5,000 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:
o Puddle Diameter : 20 m o Puddle Volume : 100 m3 o Total Amount Released : 10,531 kg o 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)
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Figure 6.2 Failure in Ammonia Line
6.6.2.4 Ammonia Tank Failure
Heavy Ammonia Leakage – Puddle Volume 4000 m3. Ammonia evaporates and spreads all
around. Try to reclaim Ammonia to other tank. Ammonia has got odour and any leakage can be
immediately noticed and calls for an action taken.
Ambient Temperature :15C Stability Class- “F” Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3 Source Strength:
o Puddle Volume : 4000 m3 Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:
Red : 1.3 kilometers --- (1100 ppm = AEGL-3 (60 min))
Orange: 3.1 kilometers --- (300 ppm = IDLH)
Yellow: 4.9 kilometers --- (160 ppm = AEGL-2 (60 min))
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Figure 6.3 Ammonia Tank Heavy Leakage Stability Class “F”
Ambient Temperature :35C Stability Class- “D” Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3 Source Strength:
o Puddle Volume : 4000 m3 Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:
Red : 440 meters --- (1100 ppm = AEGL-3 (60 min))
Orange: 939 meters --- (300 ppm = IDLH)
Yellow: 1.4 kilometers --- (160 ppm = AEGL-2 (60 min))
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Figure 6.4 Ammonia Tank Heavy Leakage Stability Class “D”
6.6.2.5 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 modelling 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)3 Orange : 226 m --- (10 ppm = IDLH) Yellow : 526 m --- (2 ppm = AEGL-2 (60 min))
3AEGL – Acute Exposure Guideline Level
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Figure 6.5 Chlorine Cylinder Leakage
6.7. General Control Measures
Since some of the substances in use at KSFL 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:
6.7.1. Flammable Gas Fires
Fire control generally consists of directing, diluting and dispersing the inflammable gas/vapour 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
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monitor nozzles or by fixed water spray system may act as a good carrier fluid for inflammable vapours/gases.
6.7.2. Protection against BLEVE
A basic BLEVE safeguard is to reduce the chance of the thermal (fire) exposure to the container. During a fire exposure the application of water is a basic safeguard to prevent a BLEVE or a compressed gas container failure. Automatic sprinkler protection can greatly limit pressure rise from heat and high metal temperatures from fire exposures.
All pressure vessels and tanks should be periodically inspected for leakage from vessels and its appurtenances. Gas detection instruments/ acoustic gas leak detectors are invaluable help in detecting the leakages.
Over pressure protection devices, namely, relief valves, rupture discs, alarms, etc. are to be regularly checked and calibrated if required.
6.7.3. Commonly Recommended Control Measures
A number of preventive control measures for hazardous occurrences have been analysed and discussed above. Some more salient points are enumerated below:
All storage tanks in the tank farm should be dyked and those storing volatile material may be provided with non-combustible insulation within aluminium’s protection jacket. The tanks should have water deluge system.
Ammonia has got odour. Always look for wind direction while moving in ammonia prone area. Move / approach across or up wind direction. Ammonia is highly soluble in water. A wet handkerchief / cloth are helpful in such a case. While planning a job in such area keep breathing apparatus / gas mask/ water hose ready for emergency.
Concentration detectors for hazardous chemical vapours fire Smoke / heat detectors and fire alarm should be installed at all strategic locations in the plant.
A schedule for preventive maintenance including health survey of all plant equipment should be adhered to as far as possible.
Ensure the absence of ignition sources in Naphtha / HSD / Ammonia storage area. Ensure placement of fire fighting facilities, such as, carbon dioxide, dry chemical powder
and foam type fire extinguishers in addition to fire hydrant system, at strategic locations. Spill control measures, such as, removal of all ignition sources from the spill area and ventilating the area as well as soaking the spilled material with paper, towel or mud and letting the volatile substance evaporate slowly in a safe area.
Compulsory use of protective clothing, non-sparking tools and warning signs during critical operations and maintenance.
Training / refresher courses on safety information’s / norms. Eyewash and showers should be put up at strategic places for use during emergencies.
A group of plant personnel should be trained in first aid, rescue, fire fighting and emergency control measures. These personnel will form core group/emergency squad who will fight the emergency and also act as rescue and first aid team.
In order to ensure communication from isolated places/locations Walkie-Talkie be made available to persons working in these areas. This will considerably improve the effectiveness of emergency management.
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There is no substitute for training-mock drills and these must be held at regular interval keeping the following objectives in mind:
Real time mock-drill should be carried out for probable/likely hazardous situation. Target to be set up for various tasks and events during an emergency. Weak links should be marked and corrective action taken to improve effectiveness during
emergency. KSFL has already implemented many of the measures.
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CHAPTER 7. ON SITE EMERGENCY PLAN
7.1. Introduction
Kribhco Shyam Fertiliser Limited (KSFL) fertilizer plant at Shahajahanpur was commissioned in November, 1995. Subsequently a number of safety studies including Risk Analysis, Safety audits etc. have been carried out by various consultants. In addition KSFL also has an ‘On Site
Emergency Management Plan’ and have submitted the same to Director of Factories. KSFL
carries “mock drills” on a regular basis and observations are recorded & corrective actions are
taken immediately.
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) 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.
7.2. Probable Hazards & Risk
Fertiliser plants have a number of unit processes and unit operations involving hazardous chemicals, consequently there are possibilities various incidents or accidents both minor and major. From the preliminary risk assessment study presented in Chapter 6 of this report, some of the possible major hazards have been identified. The most likely accident scenario identified is given below:
Table 7.1 : Probable Hazards
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. Hole in Naphtha line / tank
Area adjoining leak / tank farm
Isolate the line / area; Cover the spillage with foam / reclaim if possible to prevent ignition.
3. Ammonia line leakage and spillage
Surrounding Area Isolate the line / area. Approach with gas mask / lifeline. Reclaim if possible or dissolve in water and store and treat the water gradually.
4. 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.
Above mentioned hazard scenario can further aggravate into a much more serious incident if not attended in time. The fire in one of the tank of tank farm can spread to adjoining tanks and may result in explosion. The vulnerability zone will be considerably enlarged. The vapours of
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inflammable fluids if carried away by wind above LEL concentrations may further enlarge the vulnerability zone.
7.2.2. Objectives
The Emergency Management Plan is developed to make the best possible use of the resources available at KSFL and the nearby agencies to provide help/assistance in case of an emergency in the plant. The activities will include:
Identify and assess the emergency and its potential. Categorize the emergency as per laid down procedure.
Try to control and confine the emergency (prevent it from spreading). 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.
7.2.3. Assessing the Emergency / Emergency Control Centre
Levels of Emergency can be classified in three categories:
Level – 1 (L1): The leakage of hazardous gas or spillage, or fire or explosion of a minor nature that can be contained within the plant premises. L1-Emergency may be due to:
o Small spot fire in the plant. o Low level Toxic gas release for short duration. o Collapse of small equipment.
Level – 2 (L2): The moderate leakage of hazardous gas / flammable liquid / fire / explosion which is confinable within the factory premises. L2 - Emergency may be due to:
o Fire in the flammable liquid. o Medium scale explosion. o Heavy leakage of toxic gas for short duration.
Level – 3 (L3): Likely hood of cloud formation of a Toxic and / or Flammable gases and drifting of such cloud affecting the general public. L3-Emergency may be due to:
o Explosion in the vessel / pipe line containing Toxic / Flammable material. o Heavy leakage of Toxic / flammable / material for a long duration from pipe line
or storage tanks. The emergencies are handled / resources are deployed, external assistance is called as per the ‘level’ of emergency defined.
L1 - EMERGENCY: May be handled with the resources available within the section of the plant.
L2 –EMERGENCY: On-Site Emergency plan shall be activated. L3 –EMERGENCY: Inform immediately to the local and District Administration. Action to
be taken to activate the Off-Site Emergency Plan with the help of District authorities and local administration.
7.2.4. Emergency Siren
KSFL have two type of Siren one is emergency type wailing sound (15 – 5) for three minutes and other is All Clear continuous Siren for 1 minute.
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Every individual in the plant shall always be on lookout for any abnormal situation or observation. As soon as any such happening is noticed he should immediately notify Shift-In-Charge / Fire (in case of fire or likely fire). Specific type of emergency siren will be activated as per the situation / emergency.
7.2.4.1 On Hearing Emergency Siren
Non-essential personnel (other than production & maintenance employees of KSFL) shall follow safe route for evacuation.
Key personnel shall report to respective control room or emergency control room.
7.2.5. Escape Route and Assembly Points
Every individual inside the plant on hearing the emergency siren will contact the shift in charge and inform him and wait for his instruction. Non plant personnel on getting instruction will proceed towards assembly points. Plant areas have been divided in four zones as the nature of hazards. There are ten locations marked as assembly points (Annexure IX of KSFL’s DMP) and two
escape routes (as per wind direction).
7.3. Emergency Management Plan
Sr. Vice President (Works) may appoint any executive as the Main Emergency Controller (MEC) and he shall be the main guiding person directing the emergency operations. He shall be assisted by a number of executives.
The organizational set-up necessary for chain of commands during emergency situation is shown / briefly described below
7.3.1. KSFL’s Internal Emergency Communication Network
Accidents /emergencies do not give second chance. Even a small incident if ignored or taken lightly can develop in major one. Emergencies are to be dealt as team efforts with all resources. Communication is an important component / strength of team. KSFL has got a very well developed communication network.
7.3.2. Main Emergency Controller (MEC)
The MEC shall have overall responsibility for directing operations and calling outside help. The emergency control centre will be the main operation area.
A group of Sr. personnel shall assist MEC. They will report to MEC as soon as emergency (L2 or L3) is declared.
Look for wind direction & appropriate assembly point in case of gas leakage
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Figure 7.1 : KSFL’s Internal Emergency Communication Network
7.3.3. Some of the key functions of MEC are:
Ensure that Key-Personnel are called-in - All HOD's and medical officer. Direct all Emergency Operations within the approved area with the following priorities:
o Personnel Safety. o Plant, Property and Environment Safety. o Minimum loss of production.
Continuously review & assess possible developments to determine most probable cause of events.
Direct the safe shut down of plants in consultation with the Incident Controller and Key-Personnel if necessary.
MEC- Sr. V.P
(W). (WORKS)
ALTERNATE
CONTROLLER J.
G.M.
SERVICE S
COORDINATOR HEAD
(P&IR)
INCIDENT
CONTROLLER HEAD
(PROD.)
MAINTENANCE
COORDINATOR
HEAD (MAINT.)
MATERIAL
COORDINATOR
ENV. & QUALITY
COORDINATOR
HEADS (E & QC.)
HEAD
(SECURITY)
HEAD
(AMMONIA)
HEAD (ELECT) HEAD
(STORES)
HEAD
(PERSNL)
HEAD
(MEDICAL
HEAD
(ADMIN)
HEAD
(I.R.)
HEAD
(OFFSITES)
HEAD
(UREA)
HEAD
(BAGGING)
HEAD (INSTR)
HEAD
(CIVIIL)
HEAD
(MECH)
HEAD
(F&S)
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Check that all non-essential workers, visitors and contractors are evacuated to assembly points and shifted to safe place / shelter if required.
Give instructions to the Fire Fighting and rescue team and call second line of defence personnel.
If necessary arrange for evacuation and rescue of the neighbouring population. Ensure that search for casualties within the affected area has been carried out & arrange
for hospitalization of victims and additional help if required like shelter, catering etc. Ensure that Manager (Admn.) liaise with out-side agencies such as Police, District
Emergency Authorities, DM, ADM and Director of Factories / Dy. Director of Factories / Asstt. Director of Factories. Provide advice on possible effects to the areas out-side the factory.
Arrange for up-to-date recording of Emergencies. Do not restart the plant unless it is declared safe to start by competent authority. Give clear instructions to assisting staff to do the particular job. Ensure compliance of Checklist of MEC. (given in the end)
7.3.4. Role of Head – Production
In case of emergency in plant, the primary duty of Head – Production is to reach at the site as early as possible. His other responsibilities are as under:
He will direct and assist the Incident controller to take decision of stopping the Plant production / activities.
He will direct the manager of unaffected plant to take action to control the process parameter as per requirement of affected plant.
Remain in direct contact with MEC. Co-ordinate with Head Maintenance in decision making and ask for specific equipment
for maintenance / salvage. Arrange to ensure the evacuation process. Arrange to ensure the preservation of facts and clues for incident. Arrange for start-up of plant after consultation of MEC. Ensure the compliance of Departmental On – Site Emergency Plan
The departments shall need to follow the respective Department Emergency Plan in case of emergency
7.3.5. Role of Incident Controller [Manager / Plant In charge / Asst. Manager of Affected Plant]
Incident Controller’s (Head of affected plant) “Primary Duty” is to take charge of the scene of Incident. His other responsibilities / duties are as under:
By taking into the wide network of process units in SPN site the incident controllers of various units are identified to control the situation.
Incident Controllers of various areas are:-
Ammonia Storage, Chlorine and Naphtha Storage - HOD off-site Ammonia Plant - HOD Ammonia Urea Plant - HOD Urea Bagging Plant - HOD Bagging
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In any emergency Head (Prod) (main controller), Head (M)(Alternate controller), Head (P&A),Head (E), Head (E & QC), Head (Inst), Head (TS), Head(Civil) shall immediately move towards emergency control centre on hearing the emergency siren and report to Main Emergency controller. Head of plant O/S, Ammonia Urea, and Bagging shall move towards their respective plant.
HOD of Fire & Safety shall move towards incident site immediately.
Responsibilities of Incident controller
Following priorities are to be remembered while directing all operations.
Safety of the personnel. Minimum damage to plant, property and environment. Minimum loss of material. Advice fire fighting, rescue and other emergency services. Direct the search of casualties. Evacuate non-essential workers to assembly points. Brief, Main emergency controller about the developments. Preserve evidence for subsequent inquiry into the cause of emergency. Direct evacuation of the plant and areas likely to be affected by the emergency. Takes technical decision to control the incident and decides to continue or stop the
process plant. Ensures that the Main Emergency controller is informed.
Role of Incident Controller.
On reaching the site, he will take charge from the first responder and assess the gravity of the situation and do the following:
Declaration of major Emergency & inform F&S control room to activate the emergency Siren.
Direct the emergency control activities in consultation with the Main Emergency controller and safe shutdown of plant as the situation demands under intimation to Main emergency controller.
7.3.6. Direct emergency activities as mentioned in responsibilities mentioned in above. Role of Deputy Incident Controller (Asst. Manager / Shift Engineer)
7.3.6.1 Shift Engineer
Dy. Incident Controller (Shift Engr. In charge) is available in each of the respective plant. Dy. Incident Controller will assist the Incident Controller in handling the emergency.
In absence or till arrival of incident controller he will take the charge of incident controller and work as incident controller.
Help in plant shut down (if required) and evacuation of non-essential workers. Direct non-essential workers to take a safe route to the assembly points. Arrange to call for essential staff. Call the fire brigade. Call the security to control the traffic. Arrange to send the affected persons to the hospital.
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Up to date information to MEC.
7.3.6.2 Plant Operator (Affected Plant)
Try to control the emergency in safe manner using appropriate PPE. Inform shift Engineer about the emergency situation and follow the instruction given by
shift engineer. Assist in evacuation of non-essential workers. First - Aid and medical help to the affected person
7.3.7. Role of Manager / Plant In Charge / Asst. Manager (Other than Affected Plant)
All other plants personnel (other than the affected plant) are to safeguard their plant, assist the affected plant (through release of second line of defence personnel who are on duty) as per MEC instructions. Specific roles of personnel are briefly given below:
7.3.7.1 Manager
Take action to control the process parameters as per the requirement of affected plant. Remain in direct contact with Main Emergency Controller. Arrange to release second line of defence team members who are on duty.
7.3.7.2 Asstt. Manager
Inform the plant Manager about the incident and work as per instruction till his arrival. Put all field operators on alert. Take action to control the plant parameters.
7.3.7.3 Operator of Respective Plant
Inform shift Engineer about the incident. Stop all maintenance jobs. Work under the direction of the Shift Engineer. Direct all non-essential workers to take a safe route to assembly points.
7.3.8. Role of Manager / Asst. Manager (Fire & safety)
Some important roles / duties of fire and safety manager / Asst. Manager are as follows:
On receipt of information from the Shift In charge of the affected plant
Deputes one person to main Control room. Immediately reach the scene of incident with fire tender and crew. Position the fire tender depending on the wind direction. Reports to the shift in charge (first responder/ Incident controller) decide & start the
course of action to extinguish the fire or assist in controlling the gas leak. 7.3.8.1 Control Room (Fire Station)
Inform Head (F&S) and other officers (F&S). Ensures that the pressure in the fire hydrant system is maintained. Attend the telephone. Keep the fire station store open and ensure supplies to the incident site. On receipt of the information from incident controller, activate the “EMERGENCY SIREN”.
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7.3.8.2 Head (F&S)/ Officers (F&S)
On arrival head (F&S)/ Officers (F&S) at site, assume the charge of firefighting activities. On assessing the severity of the incident , report to the Main Controller. Inform to Main controller about the additional requirement of the fire tenders,
Extinguishing media, firefighting equipment’s and reinforcement. Organize the rescue activities. Coordinate with city fire service at incident site. If situation warrants advise the main controller to Evacuation of plant personnel.
7.3.8.3 Fire Crew Members
On hearing Fire alarm/Emergency siren they shall immediately proceed to the scene of emergency and work as per the direction of Shift-in-charge.
7.3.9. Role of Head (E& QC)
The duties and responsibilities of Head E & QC are briefly described below:
7.3.9.1 Head E & QC / Asstt. Manager-E & QC
Rush to the Emergency Control Centre and report to the Main Controller. Arrange complete laboratory staff and ensure availability of equipment’s
for sampling/analysis. Keep in touch with incident controller for taking samples. Keep in touch with services coordinator for taking samples and analysis
outside the 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, contact officials of U.P.P.C.B
7.3.9.2 Lab Analyst
Work under the guidance of Head (E& QC) / Asstt. Manager –E & QC
7.3.10. Role of Medical Department (Sr. MO / MO / Other medical Staff)
After receiving the information about the emergency he will immediately contact main controller and compounders in first aid center.
He will render necessary treatment at First Aid center and township hospital. He will arrange hospitalization and treatment at outside hospitals if required. He will mobilize extra medical assistances from outside, if necessary
7.3.11. RESPONSIBILITIES OF MAINTENANCE COORDINATORS – HEADS OF MAINTENANCE
The maintenance head shall reach Emergency Control Centre. They will take instructions from Main Controller and shall arrange the following as per requirement in their respective field:
Mobilize maintenance staff for arranging necessary equipment’s like crane, hydra, forklift, welding and cutting sets etc.
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Ensure arrangement of extra lighting, electrical isolation of the affected areas, if required. Make sufficient nos. of contractors, workers available to do civil jobs like filling sand bags,
making bunds, closing drains, excavation work as required for emergency. Keep workshop facilities open with necessary personnel.
7.3.12. Keep in constant touch with Main Controller for any assistance to him. Role of Head (Administration)
Head (Administration) and his team will provide all support related to transportation and other logistics. Some of the duties are as given below: Proceed immediately to the Emergency Control Centre and act as per the directions of the Main Controller.
Also work as a liaison officer during the emergency. Ensure that casualties receive adequate and immediate attention. Inform the relatives of
casualties, if necessary. Control traffic into the premises; ensure availability of alternate transport and free access
for temporary casualties. Arrange for canteen services for personnel on duty as well as in affected areas. Arrange security personnel to cordon off the affected area and helping fire & safety
personnel in fire and rescue operations. Arrange to close the school and shift the children and staff to the safest place, if required. Arrange the cash required for handling critical situations during the emergency. Co-ordinate to avail services from external agencies like police, fire brigade, hospitals
etc., if called for, following the declaration of emergency. Liaison with fire and police officials, safety officials, pollution control boards and other
statutory bodies. If required, issue authorized statement of press release to the media. If required, arrange for evacuation of adjoining areas and villages.
7.3.13. Role of Head Security / Security Officer / Asst. Security Officer
Security is one of the key parts of the organization at all times i.e. before, during and after the emergency. However it is all the more important and sensitive part during emergencies.
7.3.13.1 Head Security
Informs the location of fire/gas leak to the essential staff coming to the Plant. Deputes Security guards for manning the scene of fire/gas leak. Cordon off the area and control the public rushing to the incident site. Control unauthorized entry at the factory main gate. Mobilizes Additional security force for help. Directs the Ambulance and emergency service vehicles to the scene of incident by taking
wind direction into consideration. Operate P.A, system for alerting the employees/casual workers in the factory for safe
evacuation. Assists in shifting of the casualties’ to First aid post/Hospital.
7.3.13.2 Security Guards
Coordinates with Incident Controller and assists in searching for missing persons. Security Guards
On hearing the Emergency Siren, contact Security Officer and work under his directions.
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7.3.14. Role of Manager / Asst. Manager (HR)
Manager (HR) and his team will provide all support related to liason and other logistics. Some of the duties are as given below:
7.3.14.1 Role of Manager - HR / Asstt. Manager (HR)
He will report immediately to Main Emergency Controller. Coordinate to inform relatives of affected persons. Arrange for round the clock persons at the Hospitals to look after the need of the affected
personnel. Prepare record of affected personnel with local and permanent address. Arrange for tea, coffee, milk / snacks / food as required. Inform Director of Factories / Dy. Director of Factories / Asstt Director of Factories about
the incident. Remain in contact with MEC
7.3.14.2 Manning Assembly Points
He will be the overall in charge of Assembly Point No. 1, 2, 3 & 4. Depute one person at each of assembly points to record all personnel arriving there &
pass information to the Main Emergency Controller. Arrange to record the names and Departments of persons assembled there and transfer
them to other places / shelters as instructed by the Main Emergency Controller. Ensure the availability of oxygen and emergency medicine in sufficient quantity in the
hospital.
7.3.15. Role of Bagging
Product Packaging Plant's Control Room is an alternate Emergency Control Centre. It may require establishing if wind direction affects the emergency control centre at the safety office. Manager and Asstt. Manager shall keep their all resources ready to provide assistance to affected plant and other departments as directed by MEC. Some of their functions are:
Leave all labour to assemble at assembly point no. - 4, if wind direction is appropriate. Stop loading / bagging operation. Report immediately to MEC. Request MEC if any help required.
7.3.16. Role of Head (Materials)
Head (materials) and his team will provide all support related to material replenishment or arranging new materials and other logistics. Some of the duties are as given below:
7.3.16.1 Role of Head/ Dy. Manager/ Asstt. Manager (Materials)
Arrange additional man-power for handling store items etc., if required. Arrange to issue items / equipment required during emergency. Take immediate action of emergency procurements & arrange additional man- power for
local purchases etc., if required. Co-ordinate with Manager (Accounts) for financial requirements. Instruct all non-essential personnel to assemble at assembly points. Contract MEC for any help required.
7.4. Post Emergency Recovery
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The post-emergency procedures discussed briefly below are designed to successfully manage the damage / losses of an emergency event. The focus of these procedures is to move the plant back into normal operating mode as quickly and efficiently as possible.
Immediately after the “ALL CLEAR” an emergency meeting will be held in emergency control
centre to assess the loss both for men& materials, where in MEC, all managers and other executives will be present with attendance records, details of injured, outside situation and preparation of press release (if felt necessary)
7.4.1. Accident Investigation
a. As soon as possible after the emergency is over and plant operation has become normal, the investigation and analysis is to be carried out to determine the cause of the event.
b. Representatives from various disciplines will be members of the investigation and analysis team.
c. The areas of the events are to be sealed off so that tempering or alterations of the physical evidence are not likely to occur.
d. Key components are to be photographed and logged with time, place, direction etc.
e. Statements are to be taken from those who were involved with the operation or who witnessed the event.
7.4.2. Damage Assessment
This phase of recovery establishes the quantum of replacement machinery considered necessary for bringing back plant to normal operation; property and personnel losses accounted and culminates in a list of necessary repair, replacement and construction work.
Insurance companies will be informed of the damage and requested to pay the compensation as per claim.
7.4.3. Clean-up and Restoration
This phase will only begin once the investigation is complete. Reporting documentations are to be prepared and forwarded to appropriate authorities. Repair, clean up and restoration work to begin.
7.5. Enclosures
7.5.1. ‘MEC’s Check List
Is means of communication provided to you - walkie - talkie / phone and working satisfactorily?
Have the group paging done to inform the key personnel? Are assistants to MEC arrived? Do you want to call more no. of assistant?
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Are you getting message from incident site as well as from fire station? Have you got the message of Level of Emergency? Have you given clear instruction (fire / gas release) to fire station to blow the siren? Have off - duty fire crew been called? Have they blown the siren? Have you received environmental details - wind direction, speed? Do you have informed the affected assembly points - not to assemble as per prevailing
wind direction? Have key personnel arrived? Has second line of defence team reported? Have medical staffs reached at site? Have first aider reported to MEC? Has incident controller reported you about the root cause of incident? Have you assessed the situation and risk due to this incident? Have you given clear instruction for taking emergency steps to control the emergency? Is plant shut down necessary? Have you informed to railway authority of Shahajahanpur. Do want external help from nearby industries (if any). Have you ensured that HR Dept. communicated with local Govt. Official - SDM / CO -
Police / SHO? Have you received message from assembly points? Have you evaluated the requirement of transport? Is evacuation in township / villages’ necessary? In case of L3. Have non- - essential personnel / vendor / supplier been shifted to safe place? Have you instructed fire station to blow the all clear siren? Have you visited the site? Have you arranged emergency meeting to find out the root cause? Have you reviewed the methods / measures taken to handle the emergency?
7.5.2. PPE Availability& Location
Location
PPE
CCR Ammonia
Plant Urea 11
Urea 21
P.T. Lift
Amm. Storage/
ETP
CT/ DMP
Bagging Plant
Control Room
ECC Fire
Tender Fire
Station
B. A. Set (45 min)
2 2 1 1 2 1 1 - 2 4 12
B. A. Set (30 min)
- - - - - - - - - 2
B. A. Set (15 min)
Airline Respirator
- - - - - - - - - - 10
Airline Trolley
1 - 1 - - - - - -
Amm. Canister
- - 2 - 7
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Location
PPE
CCR Ammonia
Plant Urea 11
Urea 21
P.T. Lift
Amm. Storage/
ETP
CT/ DMP
Bagging Plant
Control Room
ECC Fire
Tender Fire
Station
Mask CO Canister
- - - - - - - - - -
Chlorine Canister
- - - - - - - - 5
Fire Entry Suit
- - - - - - - - - - 2
Gas Tight Suit
- - - - - - - - - - 6
Fire Proximity Suit
- - - - - - - - - - 4
AFFF - - - - - - - - -
3000 Ltrs.
180 Ltrs.
Rescue Tools
- - - - - - - - - - 1 Set
Chlorine Handling Kit
- - - - - - - - - - 2 Sets
HAZMAT Compound
-
- - - - - - - - -
7.5.3. Important Telephone Numbers (External)
IMPORTANT EXTERNAL AGENCIES/ OFFICERS
S.N. OFFICERS/AGENCY PHONE NO OFFICE
PHONENO RESIDENCE
MOBILE NUMBER
1 DISTRICT MAGISTRATE 222540 222221 9454417527
2 SUPRINTENDENT OF POLICE SHAHJAHANPUR
222553 222415 9454400306
3
ADDITIONAL SUPRINTENDENT OF POLICE (RURAL AREA) ADDL.S.P. (R.A.)
222553 223159 9454401114
4 SUB DIVISIONAL MAGISTRATE [SADAR]
222582 223094 9454415878
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IMPORTANT EXTERNAL AGENCIES/ OFFICERS
S.N. OFFICERS/AGENCY PHONE NO OFFICE
PHONENO RESIDENCE
MOBILE NUMBER
5 CHIEF MEDICAL OFFICER 222273 222587 9648935888
6 CIRCLE OFFICER (CITY) POLICE
223109 225862 9454401336
7 DISTT. CONTROL ROOM [POLICE LINES]
223133 -----
8 CITY CONTROL ROOM [SADAR] POLICE
223164/100 -----
9 DISTRICT FIRE OFFICER / STATION
223690/101 ----- 9412657983
10 U.P.POLLUTION CONTROL BOARD BAREILLY [Regional Office]
2585299 ----- 9415805240
11 U.P.POLLUTION CONTROL BOARD LUCKNOW [Head Office]
2720681 -----
12 MINISTRY OF ENVIRONMENT & FORESTS, Regional Office -Lucknow
2763147/ 2763248
-----
13 CITY MAGISTRATE 222582 222178 9454415888
14 CIRCLE OFFICER (SADAR) POLICE
223109 223277 9454401337
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CHAPTER 8. DISCLOSURE OF CONSULTANTS Declaration by Experts Contributing to this Report
Declaration by Experts Contributing to the Environmental impact assessment and Risk assessment for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD at village & Post Piprola, Shahjahanpur Industrial Area, District Shahjahanpur, Uttar Pradesh
I, hereby, certify that I was a part of the EIA team in the following capacity that developed the above EIA.
EIA Coordinator
Name: Prabhat Kumar Srivastava
Signature & Date:
Period of involvement ….. 2014 to finalization of report
Contact Information: 011-30003200
Functional Area Experts
Functional Areas Name of the Expert Involvement
(Period and Task**) Signature
Air Pollution
Monitoring & Control
(AP)
S K Jain
Astha Bishnoi (Team
Member)
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
Rajni Oshan (Team
Member)
Assistance in air quality
modeling and prediction:
met file generation and
model run
Landuse (LU) Anil kumar
Development of land use
maps of study area using
GIS / related tools, site
visit for ground truth
survey, finalization of
land use maps
Noise (NV) Sanjeev Sharma Assistance in selection of
monitoring locations,
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Functional Areas Name of the Expert Involvement
(Period and Task**) Signature
checking noise data,
evaluation of results
Water Pollution (WP)
S K Jain
Astha Bishnoi (Team
Member)
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
measures for
management of
hazardous waste
Socio-Economics (SE) Anil Kumar
Site visit, contribution to
Baseline environment and
contribution to EIA
documentation
Risk and Hazards (RH) Prabhat Kumar
Srivastava
Site visit, Identification of
modeling scenarios,
consequence modeling
using PHAST, finalization
of DMP, contribution to
RA / DMP Documentation
and contribution to EIA
documentation
Soil Conservation (SC) Manoj Sharma
Site visit, assistance in
selection of sampling
locations and contribution
to EIA documentation