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GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED
EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar, Bharuch, Gujarat.
NOVEMBER 2014
Kadam Environmental Consultants www. k a da m e nv i r o . co m
Environment for Deve lopment
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 I
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar, Bharuch, Gujarat © Kadam Environmental Consultants (‘Kadam’), November, 2014
This report is released for the use of the Gujarat Narmada Valley Fertilizers & Chemicals Ltd, Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.
QUALITY CONTROL
Name of Publication
EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar,
Bharuch, Gujarat
Project Number 1211731618 Report No. 1 Version 1 Released November
2014
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However,
it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The
information is not intended to serve as legal advice related to the individual situation.
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL
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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH TABLE OF CONTENT
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 VIII
CONTENTS
0 EXECUTIVE SUMMARY ................................................................................. 1
0.1 PROJECT DESCRIPTION .............................................................................. 1 0.1.1 About the Company and Project Proponent ................................................. 1 0.1.2 About Project ..................................................................................... 1 0.1.3 Regulatory Framework .......................................................................... 1 0.1.4 Location of the Project .......................................................................... 2 0.1.5 Project Cost ....................................................................................... 2 0.1.6 Raw Materials and Source ...................................................................... 2 0.1.7 Utilities ............................................................................................. 2 0.1.8 Description of the Process ...................................................................... 3 0.1.9 Waste Water ...................................................................................... 4 0.1.10 Air Emissions...................................................................................... 4 0.1.11 Hazardous and Other Solid Wastes ........................................................... 4
0.2 DESCRIPTION OF THE ENVIRONMENT ............................................................ 4 0.2.1 Study Period and Area .......................................................................... 4 0.2.2 Land Use of the Study Area .................................................................... 5 0.2.3 Climatology ....................................................................................... 5 0.2.4 Ambient Air Quality .............................................................................. 5 0.2.5 Noise ............................................................................................... 6 0.2.6 Surface Water and Ground Water Quality ................................................... 6 0.2.7 Soil ................................................................................................. 7 0.2.8 Biological Environment .......................................................................... 7 0.2.9 Air Emissions...................................................................................... 8 0.2.10 Waste Water Quality ............................................................................ 8 0.2.11 Solid / Hazardous Waste Management ....................................................... 8
0.3 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES................... 8 0.3.1 Air Environment .................................................................................. 8 0.3.2 Noise Environment ............................................................................... 9 0.3.3 Water and Waste Water ...................................................................... 10 0.3.4 Land Environment ............................................................................. 11 0.3.5 Biological Environment ........................................................................ 12 0.3.6 Socio-Economic Environment ................................................................ 12
0.4 ENVIRONMENTAL MONITORING PROGRAMME ................................................ 12 0.5 ADDITIONAL STUDIES ............................................................................. 13
0.5.1 Public Hearing .................................................................................. 13 0.5.2 Hazard Identification and Consequence Assessment .................................... 13 0.5.3 Onsite and Offsite Emergency Plan ......................................................... 14
0.6 PROJECT BENEFITS ................................................................................. 14 0.7 ENVIRONMENTAL MANAGEMENT PLAN ......................................................... 15 0.8 CONCLUSION ........................................................................................ 17
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1 INTRODUCTION ........................................................................................ 19
1.1 PURPOSE OF THE REPORT ......................................................................... 19 1.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................. 19 1.3 BRIEF DESCRIPTION OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION ....................................................................................................... 21
1.3.1 Brief Description of Project ................................................................... 21 1.3.2 Importance of the Project to Country & Region .......................................... 22
1.4 REGULATORY FRAMEWORK ....................................................................... 22 1.4.1 Environmental Clearance for Proposed Project ........................................... 22 1.4.2 Status of Environmental Clearances & CC&A/CTO for Existing Units .................. 23 1.4.3 Statutory Clearances and Other Permissions .............................................. 23
1.5 SCOPE OF THE STUDY .............................................................................. 25
2 PROJECT DESCRIPTION ............................................................................. 33
2.1 TYPE OF THE PROJECT ............................................................................. 33 2.1.1 Condensed Description of Aspects .......................................................... 33
2.2 NEED FOR THE PROJECT ........................................................................... 33 2.2.1 Ammonia ........................................................................................ 33 2.2.2 Urea .............................................................................................. 33 2.2.3 Aniline............................................................................................ 34 2.2.4 TDI-MDI Blend (TM Blend) ................................................................... 35 2.2.5 Water Soluble Fertilizer (NPK) ............................................................... 35 2.2.6 CPSU ............................................................................................. 35 2.2.7 Condensed Description of Aspects .......................................................... 35
2.3 LOCATION ............................................................................................ 35 2.3.1 General Location of the Site .................................................................. 35 2.3.2 Specific Location of the Site with Project Boundary ...................................... 35 2.3.3 Location of Severely Polluted Area from Site .............................................. 39 2.3.4 Approach to the site ........................................................................... 39 2.3.5 Condensed Description of Aspects .......................................................... 40
2.4 SIZE AND MAGNITUDE OF OPERATION ......................................................... 40 2.4.1 Condensed Description of Aspects .......................................................... 42
2.5 RAW MATERIAL, STORAGE AND MODE OF TRANSPORT ...................................... 42 2.6 LIST OF SOLVENTS AND SOLVENT RECOVERY SYSTEM ...................................... 46
2.6.1 Naphtha ......................................................................................... 46 2.6.2 Methanol ........................................................................................ 46 2.6.3 aMDEA (Activated Methyl Di-Ethanol Amine) .............................................. 46 2.6.4 ODCB (Ortho-Di-Chloro Benzene) ........................................................... 46
2.7 UTILITY REQUIREMENT ............................................................................ 46 2.7.1 Fuel ............................................................................................... 46 2.7.2 Power Consumption ........................................................................... 47 2.7.3 Manpower Requirement ...................................................................... 48 2.7.4 Water ............................................................................................ 48
2.8 PROJECT IMPLEMENTATION SCHEDULE ........................................................ 48
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2.9 TECHNOLOGY AND PROCESS DESCRIPTION ................................................... 49 2.9.1 Ammonia (Proposed) .......................................................................... 49 2.9.2 Urea (Proposed) ................................................................................ 55 2.9.3 Water Soluble Fertilizers (Proposed) ........................................................ 58 2.9.4 Aniline (Proposed) ............................................................................. 60 2.9.5 TDI – MDI (80:20) Blend (Proposed) ....................................................... 64 2.9.6 Cogeneration Power & Steam Unit (CPSU) - 45 MW ..................................... 66
2.10 WATER CONSUMPTION, WASTE WATER GENERATION & DISPOSAL DETAILS ......... 67 2.10.1 Unit-I ............................................................................................. 67 2.10.2 Unit-II ............................................................................................ 87
2.11 AIR EMISSIONS .................................................................................. 108 2.11.1 Point Source Emissions ...................................................................... 108 2.11.2 Area Source Emissions ....................................................................... 118 2.11.3 Line Source Emissions ........................................................................ 119 2.11.4 Fugitive Emissions ............................................................................ 119
2.12 SOLID AND HAZARDOUS WASTE IDENTIFICATION, QUANTIFICATION, STORAGE AND DISPOSAL ................................................................................................... 121
2.12.1 Quantification and Classification of Solid and Hazardous Wastes generated (Unit I) 121 2.12.2 Quantification and Classification of Existing and Proposed Solid and Hazardous Wastes (Unit-II) ......................................................................................... 129 2.12.3 Details of Hazardous Waste Handling, Storage, Utilization and Disposal ............ 139 2.12.4 Other Solids Wastes .......................................................................... 140
2.13 PROJECT DESCRIPTION ........................................................................ 141 2.13.1 Land Distribution at Site ..................................................................... 141 2.13.2 Layout Plans of Proposed Plants............................................................ 146 2.13.3 Mitigation Measures at Design Stage ...................................................... 149
2.14 ASSESSMENT OF NEW AND UNTESTED TECHNOLOGY .................................... 152
3 DESCRIPTION OF THE ENVIRONMENT ........................................................153
3.1 STUDY AREA ........................................................................................... 153 3.2 PERIOD ................................................................................................ 153 3.3 COMPONENTS.......................................................................................... 153 3.4 METHODOLOGY ........................................................................................ 153
3.4.1 Primary data Collection ...................................................................... 153 3.4.2 Secondary Data collection ................................................................... 155
3.5 ESTABLISHMENT OF BASELINE FOR VALUED ENVIRONMENTAL COMPONENTS AND BASE MAPS ....... 155 3.5.1 Long Term Meteorology ..................................................................... 155 3.5.2 Land Use ....................................................................................... 162 3.5.3 Ambient Air Quality ........................................................................... 170 3.5.4 Noise ............................................................................................ 184 3.5.5 Vibration ........................................................................................ 188 3.5.6 Hydrology and Groundwater ................................................................ 189 3.5.7 Geology ......................................................................................... 210
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3.5.8 Soil .............................................................................................. 212 3.5.9 Ecology and Biodiversity ..................................................................... 219 3.5.10 Socio-Economics .............................................................................. 236
4 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES ........244
4.1 INVESTIGATED ENVIRONMENTAL IMPACTS DUE TO THE PROPOSED PROJECT ........ 244 4.1.1 Assessment of Significance of Impacts .................................................... 244
4.2 AIR ENVIRONMENT ................................................................................ 250 4.2.1 Sources of Emissions and Emission rates ................................................. 254 4.2.2 Fugitive Emissions & Control ................................................................ 262 4.2.3 Area Source Emissions ....................................................................... 262 4.2.4 Line Source Emissions ........................................................................ 263
4.3 NOISE ENVIRONMENT............................................................................. 269 4.3.1 Noise Modeling Study ........................................................................ 269 4.3.2 Mitigation Measures to control Noise Emission ........................................... 270
4.4 WATER ENVIRONMENT ........................................................................... 272 4.4.1 Ground Water ................................................................................. 272 4.4.2 Impact on Ground Water .................................................................... 272 4.4.3 Mitigation measure ........................................................................... 272 4.4.4 Surface / River Water ........................................................................ 272 4.4.5 Impact on Surface Water .................................................................... 272 4.4.6 Mitigation measure ........................................................................... 273
4.5 LAND USE AND LAND COVER ..................................................................... 277 4.5.1 Site Preparation ............................................................................... 277 4.5.2 Green Belt Development ..................................................................... 277 4.5.3 Mitigation Measures for Impact on Land Use / Land Cover ............................ 277
4.6 SOIL CONSERVATION ............................................................................. 279 4.6.1 Mitigation Measures for Soil Conservation ................................................ 279
4.7 ECOLOGY AND BIODIVERSITY ................................................................... 283 4.8 SOCIO ECONOMIC ................................................................................. 285 4.9 OCCUPATIONAL HEALTH AND RISK ............................................................. 288
4.9.1 General Safety Measures .................................................................... 288 4.9.2 Mitigation Measures .......................................................................... 288
5 ANALYSIS OF ALTERNATIVES ....................................................................292
5.1 SITE ALTERNATIVE .................................................................................... 292 5.1.1 At Existing Site ................................................................................ 292 5.1.2 At New Site, Dahej............................................................................ 293
5.2 ANALYSIS OF ALTERNATIVE RESOURCES & TECHNOLOGIES ........................................... 293 5.2.1 Ammonia Technologies ...................................................................... 293 5.2.2 Urea Technology .............................................................................. 294 5.2.3 Innovation in Unconventional Technologies in Ammonia production ................. 295
5.3 NOTE ON VIABILITY OF THE PROJECT IN ABSENCE OF AVAILABILITY OF NATURAL GAS .............. 295
6 ENVIRONMENT MONITORING PROGRAM ....................................................297
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6.1 INTRODUCTION .................................................................................... 297 6.2 THE OBJECTIVES OF MONITORING ............................................................. 297 6.3 ENVIRONMENTAL MONITORING PROGRAMS.................................................. 297
6.3.1 Air Environment ............................................................................... 297 6.3.2 Noise Environment ............................................................................ 299 6.3.3 Water Environment ........................................................................... 301 6.3.4 Land Environment ............................................................................ 304 6.3.5 Ecology and Biodiversity ..................................................................... 308
6.4 PROJECTED EXPENDITURE ON ENVIRONMENTAL MATTERS ............................... 310
7 ADDITIONAL STUDIES ..............................................................................313
7.1 PUBLIC CONSULTATION ............................................................................... 313 7.1.1 Notice of Public Hearing ..................................................................... 313 7.1.2 Publicity of Public Hearing ................................................................... 313 7.1.3 Panel ............................................................................................ 314 7.1.4 Proceedings .................................................................................... 314
7.2 QUANTITATIVE RISK ASSESSMENT .................................................................... 319 7.3 OBJECTIVE............................................................................................. 319 7.4 STUDY METHODOLOGY ................................................................................ 319
7.4.1 Plant Data ...................................................................................... 320 7.4.2 Generic Failure Rate Data ................................................................... 320 7.4.3 Population Data ............................................................................... 320 7.4.4 Meteorological Data .......................................................................... 320 7.4.5 Ignition Source Data ......................................................................... 321
7.5 HAZARD (OR FAILURE CASE) IDENTIFICATION ........................................................ 321 7.5.1 Hazard and Damage Assessment .......................................................... 322
7.6 RISK ASSESSMENT / CONSEQUENCE ANALYSIS ........................................................ 324 7.6.1 Selection of Material .......................................................................... 325 7.6.2 Scenarios Considered for Risk Analysis .................................................... 327 7.6.3 Consequence Analysis ........................................................................ 328 7.6.4 Conclusion...................................................................................... 340
7.7 CONSEQUENCE CALCULATIONS ........................................................................ 341 7.8 RISK CALCULATIONS .................................................................................. 341
7.8.1 Risk Presentation .............................................................................. 342 7.8.2 Risk Assessment .............................................................................. 342 7.8.3 Risk Tolerability Criteria ...................................................................... 342 7.8.4 Individual Risk Criteria ....................................................................... 342 7.8.5 Group Risk Criteria – FN Curves ............................................................ 343
7.9 THE APPROACH TO CALCULATE FAILURE FREQUENCY ................................................. 344 7.10 RESULTS ANALYSIS RESULTS ....................................................................... 346
7.10.1 Individual Risk ................................................................................. 346 7.10.1.1 Group Risk-FN Curve....................................................................... 350 7.10.2 Risk Contribution .............................................................................. 353
7.11 CONCLUSIONS ...................................................................................... 353
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7.12 MITIGATIONS ....................................................................................... 354 7.13 ONSITE EMERGENCY PLAN .......................................................................... 355
7.13.1 Emergency Categorized ...................................................................... 355 7.13.1.1 Emergency controllable within the plant / area ....................................... 355 7.13.1.2 Emergency confinable within the Factory premises .................................. 355 7.13.1.3 Likelihood of vapor cloud with formation of toxic / flammable gases drifting and affecting the general public (i.e. outside of plant premises) ..................................... 355 7.13.2 On Site Emergency Plan for GNFC, Bharuch.............................................. 355 GNFC have a detailed On Site Emergency Plan in place covering all the plants for more than 15 years. The Plan is supported by the following: ................................................. 355 7.13.2.1 Mutual Aid Scheme ......................................................................... 356 7.13.2.2 Information on the Preliminary Hazard Analysis ...................................... 356 7.13.2.3 Details about the Site ...................................................................... 357 7.13.2.4 Hazards in Various Plants ................................................................. 358 7.13.2.5 Details Regarding Warning, Alarm, and Safety and Security Systems ............. 359 7.13.2.6 Rescue Tools ................................................................................ 364 7.13.2.7 Detectors .................................................................................... 365 7.13.2.8 Inventory for Fire Protection ............................................................. 366 7.13.2.9 Occupational Health of the Contract and Sub contract Workers .................... 367 7.13.2.10 Antidote and First Aid Box .............................................................. 371
7.14 PRECAUTIONS TAKEN DURING STORAGE AND TRANSPORTATION OF HAZARDOUS CHEMICALS ..... 372
8 PROJECT BENEFITS ..................................................................................378
8.1 TECHNOLOGICAL BENEFITS ............................................................................ 378 8.2 SUBSTANTIAL SOCIO-ECONOMIC BENEFITS ............................................................ 378 8.3 OTHER TANGIBLE BENEFITS ........................................................................... 378
9 ENVIRONMENTAL COST BENEFIT ANALYSIS ................................................379
10 ENVIRONMENTAL MANAGEMENT PLAN ....................................................380
10.1 INTRODUCTION ................................................................................. 380 10.2 PURPOSE OF EMP ................................................................................ 380 10.3 ENVIRONMENTAL MANAGEMENT PLANS .................................................... 380
10.3.1 Air Environment ............................................................................... 380 10.3.2 Water Environment ........................................................................... 380 10.3.3 Land Environment ............................................................................ 382 10.3.4 Socio-Economic Environment ............................................................... 385
10.4 ENVIRONMENT MANAGEMENT CELL ......................................................... 389 10.5 SUMMARY OF EMP ............................................................................... 390
11 SUMMARY AND CONCLUSION .................................................................392
11.1 SUMMARY ......................................................................................... 392 11.2 CONCLUSION ..................................................................................... 392
12 DISCLOSURE OF CONSULTANTS ENGAGED ................................................393
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12.1 BRIEF RESUME AND NATURE OF CONSULTANCY .......................................... 393 12.2 EIA TEAM MEMBERS ............................................................................ 394
13 CERTIFIED COMPLIANCE REPORT OF EC CONDITIONS ...............................399
13.1 COMPLIANCE REPORT FOR EC FROM MOEF (FOR EXPANSION UNITS OF WNA, CAN, METHANOL, ACETIC ACID, FORMIC ACID ETC.) ............................................................................ 399 13.2 COMPLIANCE REPORT FOR EC FROM SEIAA (ETHYL ACETATE) .................................... 410 13.3 NON-COMPLIANCES / PARTLY COMPLIANCES FOR EC FROM MOEF FOR EXPANSION UNITS OF WNA, CAN, METHANOL, ACETIC ACID, FORMIC ACID ETC. ......................................................... 433 13.4 NON-COMPLIANCES / PARTLY COMPLIANCES FOR EC FROM SEIAA FOR ETHYL ACETATE ......... 438
LIST OF ANNEXURES
Annexure 1: The Letter/application for EC ................................................................................... 443
Annexure 2: Document of Notified Industrial Area ....................................................................... 444
Annexure 3: ToR Letter from MoEF, New Delhi ............................................................................ 454
Annexure 4: Corporate Environmental, OH&S and Quality Policy of GNFC ...................................... 458
Annexure 5: ISO 14001:2004 and OSHAS 18001:2007 Certificates ............................................... 459
Annexure 6: Environment Clearance for the Existing Unit Issued by the Ministry ............................ 461
Annexure 7: Copies of Consent to Operate and Authorization Accorded by the GPCB ..................... 481
Annexure 8: ‘Permissions’ for the Drawl of Water ........................................................................ 519
Annexure 9: Inprinciple Approval for additional 24 MLD Water Requirement for Proposed Projects .. 534
Annexure 10: Comfort Letter for Gas Supply from GSPC & MoU with Hazira LNG Pvt. Ltd. .............. 538
Annexure 11: Commitment Regarding No Additional Storage for Ammonia .................................... 547
Annexure 12: CREP Compliance of GNFC .................................................................................... 548
Annexure 13: MSDS of all Chemicals Involved in the Project ......................................................... 551
Annexure 14: Process Description for Existing Products................................................................ 552
Annexure 15: Block Diagram of Existing Central ETP (Unit-I) ........................................................ 566
Annexure 16: Block Diagram Proposed Sewage Treatment Plant (Unit-I) ....................................... 567
Annexure 17: Block Diagram for Effluent Treatment System after Proposed Expansion (Unit-I) ....... 568
Annexure 18: Block Diagram Existing Aniline ETP (Unit-II) ........................................................... 569
Annexure 19: Block Diagram Proposed Aniline ETP (Unit-II) ......................................................... 570
Annexure 20: Details of Online TOC Meter and Ammonical Nitrogen Analyzer ................................ 571
Annexure 21: Membership Certificates for Solid Waste and Hazardous Waste (Existing & Proposed) 574
Annexure 22: Definitions of First and Second Level of Classification .............................................. 584
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Annexure 23: Climatological Data for Broach (Bharuch) District .................................................... 588
Annexure 24: National Ambient Air Quality Standards .................................................................. 590
Annexure 25: Impact Assessment Methodology ........................................................................... 591
Annexure 26: Air Dispersion Modeling Results and Isopleths ........................................................ 600
Annexure 27: Details of Injury to the Contract Workers in the Year 2012 ...................................... 618
Annexure 28: Letter from Regional Officer, MoEF regarding Certification of Compliance ................. 620
Annexure 29: NABET Certificate – Kadam Environmental Consultants (Sr. No. 84 on Nabet’s Website, as on Feb. 5, 2014) ................................................................................................................... 622
Annexure 30: Advertisement for Public Hearing ........................................................................... 625
Annexure 31: Copy of Letters issued by GPCB to Concerned Authorities for PH .............................. 628
Annexure 32: Proof of Executive Summary Distribution in 59 Villages ............................................ 635
LIST OF APPENDIX
Appendix 1: MoM of Public Hearing ............................................................................................ 641
Appendix 2: MSDS of Chemicals used in Unit – 1 ......................................................................... 878
Appendix 3: MSDS of Chemicals used in Unit – 2 ....................................................................... 1165
LIST OF TABLES
Table 1-1: Schedule of Proposed Project ....................................................................................... 19
Table 1-2: GNFC’s Top Management List....................................................................................... 21
Table 1-3: Brief Description of the Proposed Project ...................................................................... 21
Table 1-4: Statutory Clearances and Other Permissions ................................................................. 23
Table 1-5: Compliance with the Terms of Reference ...................................................................... 26
Table 2-1: Projected Demand Supply Gap for Urea (‘000 tonnes of material) ................................... 33
Table 2-2: Aniline Demand Projected by the End of 2015 ............................................................... 34
Table 2-3: Import and Indigenous Production of Aniline ................................................................. 34
Table 2-4: Latitude and Longitude of the Corners of the GNFC Complex .......................................... 36
Table 2-5: Product List with Existing and Proposed Capacity for Unit 1 and Unit 2 ............................ 40
Table 2-6: Details of Raw Material Requirement for Proposed New Plants (Unit-1) ........................... 43
Table 2-7: Details of Raw Material Requirement for Proposed New Plants (Unit-2) ........................... 45
Table 2-8: Fuel Consumption of Unit 1 .......................................................................................... 46
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Table 2-9: Fuel Consumption of Unit 2 .......................................................................................... 47
Table 2-10: Mass Balance for Ammonia (Proposed) ....................................................................... 54
Table 2-11: Mass Balance for Urea (Proposed) .............................................................................. 57
Table 2-12: Mass Balance for Aniline and Nitro Benzene (Proposed) ............................................... 63
Table 2-13: Mass Balance for TDI-MDI Blend (Proposed) ............................................................... 65
Table 2-14: Water Consumption details Existing and after Proposed Expansion (Unit-I) .................... 70
Table 2-15: Wastewater Generation for Existing and Proposed Expansion (Unit-I) ........................... 71
Table 2-16: Design Flow, Outlet Characteristics for the Existing Central ETP (Unit-I) ........................ 76
Table 2-17: Adequacy of Existing Central ETP based on Hydraulic Load (Unit-I) ............................... 79
Table 2-18: Analysis Results for Samples Collected from Existing Central ETP (Unit-I) ...................... 80
Table 2-19: Stage Wise Reduction after each Stage of Treatment of Central Aniline ETP (Unit-I) ...... 81
Table 2-20: Design Flow, Inlet and Outlet Characteristics for the Proposed STP (Unit-I) ................... 83
Table 2-21: Unit Sizes for Proposed Sewage Treatment Plant (Unit-I) ............................................. 86
Table 2-22: Water Consumption Details Existing and after Proposed Expansion (Unit-II) .................. 87
Table 2-23: Waste Water Generation Details Existing and after Proposed Expansion (Unit-II) ........... 88
Table 2-24: Design Flow, Inlet and Outlet Characteristics for the Existing Aniline ETP (Unit-II) ......... 92
Table 2-25: Adequacy of Existing Aniline ETP based on Hydraulic Load (Unit-II) .............................. 97
Table 2-26: Analysis Results for Samples Collected from Existing Aniline ETP (Unit-II) ..................... 99
Table 2-27: Stage Wise Reduction after each Stage of Treatment of Existing Aniline ETP (Unit-II) .... 99
Table 2-28: Design Flow, Inlet and Outlet Characteristics for the Proposed Aniline ETP (Unit-II) ..... 101
Table 2-29: Unit Sizes for Proposed Aniline Effluent Treatment Plant (Unit-II) ............................... 106
Table 2-30: Details of Existing and Proposed Flue Gas Stacks of Unit 1 ......................................... 108
Table 2-31: Details of Existing and Proposed Flare Stacks of Unit 1............................................... 108
Table 2-32: Details of Existing and Proposed Process Vents of Unit 1 ............................................ 109
Table 2-33: Details of Existing and Proposed Stacks of Unit 2 ....................................................... 110
Table 2-34: Details of Air Pollution Control Equipment at Unit-1 .................................................... 110
Table 2-35: Details of Air Pollution Control Equipment at Unit-2 .................................................... 112
Table 2-36: Sizing and Specifications of Ventuary Scrubber attached to Incinerator ....................... 113
Table 2-37: Specifications of Packed Bed Scrubber attached to Incinerator Stack ........................... 113
Table 2-38: Specifications of Air Pollution Control Equipments in Unit 2 ......................................... 117
Table 2-39: Details & Specifications of Proposed Air Pollution Control Equipment at Unit-1 ............. 118
Table 2-40: Details & Specifications of Proposed Air Pollution Control Equipment at Unit-2 ............. 118
Table 2-41: Daily Work Place Monitoring at GNFC ........................................................................ 119
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Table 2-42: Existing Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ........ 121
Table 2-43: Proposed Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ...... 125
Table 2-44: Summary Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ...... 126
Table 2-45: Adequacy of Hazardous Waste Storage Facility (Unit-I) .............................................. 128
Table 2-46: Existing Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ....... 129
Table 2-47 Proposed Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ...... 133
Table 2-48: Summary Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ..... 136
Table 2-49: Adequacy of Hazardous Waste Storage Facility (Unit-II) ............................................. 138
Table 2-50: Proximate Analysis of TDI Tar .................................................................................. 139
Table 2-51: Coordinates of Land Allocated for Proposed Plants ..................................................... 141
Table 2-52: Land Distribution Area Breakup for Proposed Plants (Unitwise) ................................... 145
Table 2-53: Operational Controls at Design Stage ........................................................................ 150
Table 3-1: Predominant Month-wise Wind Directions ................................................................... 155
Table 3-2: Average Meteorological Condition at Bharuch (1961 – 1976) ........................................ 156
Table 3-3: Monitoring Methodology of Meteorological Data .......................................................... 158
Table 3-4: Mean Meteorological Data for Summer Season 2013 .................................................... 159
Table 3-5: Synopsis of Land Use / Landcover Classification used for the Project ............................. 162
Table 3-6: GPS Readings Enumerating Land Features within Study Area ....................................... 164
Table 3-7: Land use / Landcover Pattern of the Study Area .......................................................... 165
Table 3-8: Area Statistic for Land Use / Land Cover Categories in the Study Area .......................... 166
Table 3-9: Important Feature within the Study Area .................................................................... 170
Table 3-10: Ambient Air Quality Monitoring Location Details and Justification ................................ 170
Table 3-11: Methodology of Ambient Air Monitoring..................................................................... 173
Table 3-12: Ambient Air Monitoring Results ................................................................................. 174
Table 3-13: Stack Monitoring Analysis Summary for Unit – 1 ........................................................ 178
Table 3-14: Stack Monitoring Analysis Summary for Unit – 2 ........................................................ 182
Table 3-15: Methodology of Noise Sampling & Monitoring ............................................................ 184
Table 3-16: Sampling Locations for Noise ................................................................................... 184
Table 3-17: Noise Level Readings (Unit – I) ................................................................................ 187
Table 3-18: Noise Level Readings (Unit – II) ............................................................................... 187
Table 3-19: Noise Level Readings (Study Area) ........................................................................... 187
Table 3-20: Ambient Noise Levels as per Noise Regulations.......................................................... 188
Table 3-21: Analysis Methodology of Ground Water and Surface Water ......................................... 189
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Table 3-22: Surface Water Sampling Location (Pond & River) ....................................................... 190
Table 3-23: Analysis Results of Surface Water Samples ................................................................ 194
Table 3-24: Analysis Result of River Water Sample ...................................................................... 196
Table 3-25: Ground Water Sampling Locations ............................................................................ 197
Table 3-26: Analysis Report of Ground Water Samples ................................................................. 199
Table 3-27: Details of Samples Collected to assess impact of GNFC Waste Water Discharge on Water Quality of River ......................................................................................................................... 203
Table 3-28: Analytical Results of Surface Water samples collected along Garamia Nalla to assess impact of GNFC Waste Water Discharge on Water Quality of Nalla as well as Bhukhi River ............. 204
Table 3-29: Analytical results of Water samples Collected at Junction Point of Garamia Nalla & Bhukhi River ........................................................................................................................................ 207
Table 3-30: Comparison of GNFC Outlet with Discharge Norms Specified in Consent ...................... 209
Table 3-31: Geological Succession of Bharuch District .................................................................. 210
Table 3-32: Analysis Methodology of Soil .................................................................................... 214
Table 3-33: Soil Sampling Locations ........................................................................................... 214
Table 3-34: Soil Analysis Result .................................................................................................. 217
Table 3-35: Formulas for Analyzing Phyto-Sociological Characteristics of Vegetation ...................... 221
Table 3-36: Location of Quantitative Study of vegetation ............................................................. 221
Table 3-37: Quantitative Assessment of Vegetation ..................................................................... 224
Table 3-38: List of Flora in the Study Area .................................................................................. 225
Table 3-39: List of Birds with its Distribution and Migratory Status ................................................ 230
Table 3-40: List of Butterflies, Reptiles and Mammals with its Distribution and Migratory Status ...... 232
Table 3-41: Details of Sampling Locations ................................................................................... 234
Table 3-42: Phytoplankton Cell Count (No./Lit.) Across Sampling Locations ................................... 234
Table 3-43: Abundance of Phytoplankton .................................................................................... 234
Table 3-44: Zooplankton Standing Stock (No. /Lit)....................................................................... 235
Table 3-45: Abundance of Zooplankton....................................................................................... 235
Table 3-46: Presenting diversity (Shannon Weaver Index) Across Sampling Locations .................... 235
Table 3-47: List of Villages, Households and Population within the Study Area ............................... 237
Table 3-48: Gender Wise Population and Households Distribution ................................................. 238
Table 3-49: Number of SC/ST Population within the Study Area ................................................... 238
Table 3-50: Number of Villages having Educational Facilities within the Study Area ........................ 239
Table 3-51: Literacy Rate within the Study Area .......................................................................... 240
Table 3-52: Number of Villages having Health Facilities within the Study Area ............................... 240
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Table 3-53: Details of Drinking Water Facilities ............................................................................ 240
Table 3-54: Occupational Status of the Study Area ...................................................................... 242
Table 3-55: Number of Villages having Transportation Facilities within the Study Area ................... 242
Table 3-56: Communication Facilities within the Study Area ......................................................... 243
Table 4-1: Aspect – Impact Identification from Proposed Project .................................................. 245
Table 4-2: Impact Scoring Air Environment ................................................................................. 251
Table 4-3: Proposed Stacks of Unit – 1 ....................................................................................... 254
Table 4-4: Proposed Stacks of Unit – 2 ....................................................................................... 255
Table 4-5: Assumptions for Calculating Emission Estimate for Point Source ................................... 255
Table 4-6: Emission Estimate (Point Source) from Proposed Plants in Unit – 1 ............................... 256
Table 4-7: Emission Estimate (Point Source) from Proposed Plants in Unit – 2 ............................... 256
Table 4-8: Summary of Air Dispersion Modeling for Proposed Stacks ............................................. 258
Table 4-9: 24 Hr Average Incremental Increase in GLC from Proposed Project............................... 258
Table 4-10: Road Transportation Details for Raw Material (In) ..................................................... 263
Table 4-11: Road Transportation Details for Finished Product (Out) .............................................. 263
Table 4-12: Transportation Details for Unit 1 ............................................................................... 264
Table 4-13: Transportation Details for Unit 2 ............................................................................... 264
Table 4-14: Hourly Average Traffic Survey on NH-8 (Mumbai to Delhi) .......................................... 266
Table 4-15: Hourly Average Traffic on NH-8 (Delhi to Mumbai)..................................................... 266
Table 4-16: Hourly Average Traffic Survey on SH-6 (Dahej to Bharuch) ........................................ 266
Table 4-17: Hourly Average Traffic on SH-6 (Bharuch to Dahej) ................................................... 267
Table 4-18: Noise Modelling Calculation & Results for Long Duration Noise Sources ....................... 270
Table 4-19: Impact Scoring Noise Environment ........................................................................... 271
Table 4-20: Impact Scoring for Water Environment ..................................................................... 274
Table 4-21: Impact Scoring Land Use / Land Cover ..................................................................... 278
Table 4-22: Impact Scoring Soil Conservation ............................................................................. 280
Table 4-23: Impact Scoring – Solid Hazardous Waste Generation ................................................. 281
Table 4-24: Impact Scoring Ecology and Biodiversity ................................................................... 284
Table 4-25: Impact Scoring for Socio-Economic Environment ....................................................... 290
Table 4-26: Impact Scoring for Occupational Health and Risk to Surrounding Community ............... 290
Table 6-1: Environmental Monitoring Program for Air Environment ............................................... 298
Table 6-2: Environmental Monitoring Program for Noise Environment ........................................... 300
Table 6-3: Environmental Monitoring Program for Water Quality ................................................... 302
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Table 6-4: Environmental Monitoring and Management Program for Soil Environment .................... 305
Table 6-5: Environmental Monitoring and Management Program for Solid Hazardous Waste Management ............................................................................................................................ 306
Table 6-6: Environmental Management Program for Ecological and Biodiversity Environment ......... 309
Table 6-7: Expenditure on Environmental Matters........................................................................ 310
Table 6-8: Summary of Environmental Monitoring Program .......................................................... 311
Table 7-1: Issues Rose during Public Hearing .............................................................................. 315
Table 7-2: Environment Related Key Issues for Proposed Plants and Commitment by GNFC ........... 316
Table 7-3: Positive Response from Nearby Villages ...................................................................... 317
Table 7-4: Population Data ........................................................................................................ 320
Table 7-5: Weather Condition Selected ....................................................................................... 320
Table 7-6: Event Classification ................................................................................................... 321
Table 7-7: Damage due to Radiation Intensity............................................................................. 323
Table 7-8: Overpressure Damage ............................................................................................... 323
Table 7-9: Chemicals with Storage Capacity, Storage Condition and Bund Dimension ..................... 326
Table 7-10: Radiation Level and Effect Distance due to release of Ammonia .................................. 328
Table 7-11: Overpressure Effect Distance due to the Release of Ammonia..................................... 328
Table 7-12: Effect Distance for Toxic Dose Due to Release of Ammonia ........................................ 329
Table 7-13: Radiation Level and Effect Distance Due to Release of Aniline ..................................... 330
Table 7-14: Overpressure Effect Distance Due to Release of Aniline .............................................. 330
Table 7-15: Radiation Level and Effect Distance Due to Release of Benzene .................................. 332
Table 7-16: Overpressure Effect Distance Due to Release of Benzene ........................................... 332
Table 7-17: Effect Distance for Toxic Dose Due to Release of Benzene .......................................... 332
Table 7-18: Radiation Level and Effect Distance Due to Release of Methanol ................................. 334
Table 7-19: Overpressure Effect Distance Due to Release of Methanol .......................................... 334
Table 7-20: Effect Distance for Toxic Dose Due to Release of Methanol......................................... 334
Table 7-21: Radiation Level and Effect Distance Due to Release of Nitrobenzene ........................... 336
Table 7-22: Overpressure Effect Distance Due to Release of Nitrobenzene .................................... 336
Table 7-23: Radiation Level and Effect Distance Due to Release of Toluene ................................... 337
Table 7-24: Overpressure Effect Distance Due to Release of Toluene ............................................ 337
Table 7-25: Effect Distance for Toxic Dose Due to Release of TDI ................................................ 339
Table 7-26: Conclusion .............................................................................................................. 340
Table 7-27: Failure Cases Input to PHAST Risk ............................................................................ 345
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Table 7-28: Major Risk Contributors ........................................................................................... 353
Table 7-29: Fire Protection Facility at Site ................................................................................... 366
Table 7-30: Details of Checkup based on Exposure ...................................................................... 368
Table 10-1: Available Rainwater (Annual) for Harvesting in Unit-I ................................................. 381
Table 10-2: Available Rainwater (Maximum) for Harvesting in Unit-I ............................................. 381
Table 10-3: Available Rainwater (Annual) for Harvesting in Unit-II ................................................ 382
Table 10-4: Available Rainwater (Maximum) for Harvesting in Unit-II ............................................ 382
Table 10-5: Plant Species used for Landscaping around Offices and Residential Areas .................... 382
Table 10-6: Trees and Shrubs Species Planted in Various Locations of the Project Area .................. 383
Table 10-7: Proposed Plantation Schedule for next Five Years ...................................................... 385
Table 10-8: Allocation of Funds for CSR Activities in Last 5 Years.................................................. 385
Table 10-9: Proposed CSR Activities ........................................................................................... 386
Table 10-10: Traffic Management Plan ....................................................................................... 388
Table 10-11: Summary of EMP ................................................................................................... 390
Table 13-1: Status of Non and Partially compalances (Compliance Report – EC from MoEF-1) ......... 433
Table 13-2: Status of Non and Partially Compalances (Compliance Report – EC from MoEF-2) ........ 435
Table 13-3: Status of Non and Partially compalances (Compliance Report – EC from SEIAA) ........... 438
LIST OF FIGURES
Figure 2-1: Project Implementation Schedule ................................................................................ 48
Figure 2-2: Process Flow Diagram of Ammonia Plant (Proposed) .................................................... 50
Figure 2-3: Process Flow Diagram for Urea Plant (Proposed) .......................................................... 55
Figure 2-4: Process Flow Diagram for Water Soluble Fertilizers ....................................................... 58
Figure 2-5: Process Flow Diagram for Aniline Plant (Proposed) ....................................................... 61
Figure 2-6: Process Flow Diagram for TDI-MDI Blend (Proposed) ................................................... 64
Figure 2-7: Process Flow Diagram for CPSU (Proposed) ................................................................. 66
Figure 2-8: Existing Water Balance Diagram (Unit-I) ...................................................................... 72
Figure 2-9: Water Balance for Proposed Expansion of Ammonia and Urea Plant ............................... 73
Figure 2-10: Water Balance Diagram after Proposed Expansion (Unit-I) with Recycling and Reuse .... 74
Figure 2-11: Existing Water Balance Diagram (Unit-II) ................................................................... 89
Figure 2-12: Water Balance Diagram of Proposed Expansion (Unit-II) ............................................. 90
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Figure 2-13: Water Balance Diagram after Proposed Expansion (Unit-II) ......................................... 91
Figure 2-14: Google Image of Site Showing Land Distribution of Proposed Plants .......................... 142
Figure 2-15: Site Location of Proposed Ammonia – Urea & CPSU Plants ........................................ 143
Figure 2-16: Site Location of Proposed Water Soluble Fertilizers (NPK) Plant ................................. 143
Figure 2-17: Site Location of Proposed Aniline Plant .................................................................... 144
Figure 2-18: Site Location of Propsoed ETP – Unit 2 .................................................................... 144
Figure 2-19: Site Location of Proposed TDI-MDI Blend Plant ........................................................ 145
Figure 2-20: Site Layout Plan for Proposed Ammonia and Urea Plants ........................................... 146
Figure 2-21: Site Layout Plan for Water Soluble Fertilizers (NPK) Plant .......................................... 147
Figure 2-22: Site Layout Plan for Proposed Aniline Plant............................................................... 148
Figure 2-23: Site Layout Plan for Proposed TDI – MDI Blend Plant ................................................ 149
Figure 3-1: Windrose Diagram for Summer Season ...................................................................... 160
Figure 7-1: Approach to QRA ..................................................................................................... 319
Figure 7-2: Late pool fire risk contour due to 50 mm Leak in Ammonia tank at weather 4.0/D ........ 329
Figure 7-3: Concentration risk contour - Catastrophic Rupture of Ammonia Tank at 4.0/D .............. 330
Figure 7-4: Late pool fire risk contour - Catastrophic Rupture in Aniline tank at 4.0/D .................... 331
Figure 7-5: Late Explosion overpressure risk contour catastrophic rupture of Aniline tank at 4.0/D .. 331
Figure 7-6: Late pool fire risk contour - Catastrophic Rupture in Benzene tank at 4.0/D .................. 332
Figure 7-7: Late Explosion overpressure risk contour - catastrophic rupture of Benzene tank at 4.0/D ............................................................................................................................................... 333
Figure 7-8: Concentration risk contour - Catastrophic Rupture of Benzene tank at 4.0/D ................ 333
Figure 7-9: Late pool fire risk contour - Catastrophic Rupture in Methanol tank at 4.0/D ................. 335
Figure 7-10: Late Explosion overpressure risk contour - Catastrophic rupture of Methanol tank at 4.0/D ............................................................................................................................................... 335
Figure 7-11: Late pool fire risk contour - Catastrophic Rupture in Nitrobenzene tank at 4.0/D ......... 336
Figure 7-12: Late Explosion overpressure risk contour - Catastrophic rupture of Nitrobenzene tank at 4.0/D ....................................................................................................................................... 337
Figure 7-13: Late pool fire risk contour - Catastrophic Rupture in Toluene tank at 4.0/D................. 338
Figure 7-14: Late Explosion overpressure risk contour - catastrophic rupture of Toluene tank at 4.0/D ............................................................................................................................................... 338
Figure 7-15: Concentration risk contour - Catastrophic Rupture of Toluene tank at 4.0/D ............... 339
Figure 7-16: Concentration risk contour - Catastrophic Rupture of TDI tank at 4.0/D ..................... 340
Figure 7-17: Criteria for Individual Risk ....................................................................................... 343
Figure 7-18: Criteria for Group Risk ............................................................................................ 344
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Figure 7-19: Iso-risk Contours-Overall Plant Area ........................................................................ 347
Figure 7-20: Iso-Risk Contour Enlarged View............................................................................... 348
Figure 7-21: Individual Risk ....................................................................................................... 349
Figure 7-22: FN Curve of Group Risk (on-site) ............................................................................. 351
Figure 7-23: FN curve of Group Risk (off-site) ............................................................................. 352
Figure 10-1: Hierarchy of Environment Management Cell ............................................................. 389
LIST OF PHOTOGRAPHS
Photograph 2-1: Photos of Central Effluent Treatment Plant (Unit-I) ............................................... 77
Photograph 2-2: ABB Analyzer system – EL3020.......................................................................... 112
Photograph 3-1: Meteorological Station set up at the Site ............................................................ 160
Photograph 3-2: Various Land uses of Study Area ....................................................................... 169
Photograph 3-3: AAQ Sampling Stations ..................................................................................... 171
Photograph 3-4: Noise Level Sampling Locations ......................................................................... 185
Photograph 3-5: Surface Water Sampling Locations ..................................................................... 192
Photograph 3-6: Ground Water Sampling .................................................................................... 198
Photograph 3-7: Photographs of Sampling at Garamia Nalla ......................................................... 210
Photograph 3-8: Soil Sampling Locations .................................................................................... 215
Photograph 3-9: Vegetation Cover and Sampling in Study area .................................................... 223
Photograph 3-10: Method of data collection used within the study area ........................................ 236
Photograph 3-11: Educational Facilities within the Study Area ...................................................... 239
Photograph 3-12: Animal Husbandry within Study Area................................................................ 241
Photograph 3-13: Places of Religious Importance Present within the Study Area ............................ 243
Photograph 7-1: Photographs of Public Hearing Publicity through Auto ......................................... 314
Photograph 7-2: Photographs of Public Hearing........................................................................... 318
Photograph 7-3: Rescue Tools Available ..................................................................................... 365
Photograph 7-4: Leak Detectors installed at Site.......................................................................... 366
Photograph 7-5: Photographs of Occupational Health Centre and Check up ................................... 372
Photograph 10-1: Existing Landscaping and Greenbelt with Project Premise .................................. 384
Photograph 12-1: Photographs showing EIA Team at Project Site and Study Area ......................... 397
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LIST OF MAPS
M- 2-1: Project Location Map ....................................................................................................... 37
M- 2-2: Satellite Image Showing the Project Site with Coordinates .................................................. 38
M- 2-3: Map Indicating Distance of Project site from Severely Polluted Area .................................... 39
M- 3-1: Study Area Map showing Nearby Industries, Habitation and Surface Water Bodies ............. 154
M- 3-2: Sampling Location Map .................................................................................................. 161
M- 3-3: Map Showing Land Use / Land Cover .............................................................................. 168
M- 3-4: Map Showing Extent of Garamia Nalla and Bhukhi River and Sampling Locations for Surface Water Samples collected ............................................................................................................ 208
M- 3-5: Geomorphology of Region .............................................................................................. 211
M- 3-6: Seismic Map of Gujarat State ......................................................................................... 212
M- 3-7: Soil Profile of Bharuch Region ........................................................................................ 213
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ABBREVIATIONS
AAQM : Ambient Air Quality Monitoring
AAS : Atomic Absorption Spectroscopy
AERMIC : American Meteorological Society/Environmental Protection Agency Regulatory Model Improvement Committee
AERMOD : AMS/EPA Regulatory Model
ALARP : As Low As Reasonably Practicable
ANP : Ammonium Nitro Phosphate
APCM : Air Pollution Control Measures
APHA : American Public Health Association
BASF : Badische Anilin- und Soda-Fabrik
BATNEEC : Best Available Technology Not Entailing Excessive Costs
BEIL : Bharuch Enviro Infrastructure Limited
BHEL : Bharat Heavy Electricals Limited
BLEVE : Boiling Liquid Expanding Vapor Explosion
BOD : Biological Organic Demand
BSI : British Standards Institution
BVB : Bhartiya Vidya Bhavan
CAN : Calcium Ammonium Nitrate
CAS : Chemical Abstracts Service
CBM : Coal Bed Methane
CCA : Consolidated Consent and Authorization
CCE : Center for Credentialing and Education
CCTV : Closed Circuit Television
CETP : Central Effluent Treatment Plant
CAN : Concentrated Nitric Acid
CPCB : Central Pollution Control Board
CPSU : Cogeneration Power and Steam Unit
CO : Carbon Monoxide
COD : Chemical Oxygen Demand
CREP : Corporate Responsibility for Environment Protection
CSR : Corporate Social Responsibility
CTO : Consent to Operate
dB : Decibels
DCS : Distributed Control System
DG : Diesel Generator
DGVCL : Dakshin Gujarat Vij Company Limited
DM : De-mineralization
DMIC : Delhi-Mumbai Industrial Corridor
DMP : Disaster Management Plan
DNV : Det Norske Veritas
DPR : Detailed Project Report
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EAC : Expert Appraisal Committee
EC : Environmental Clearance
ECG : Electrocardiogram
EDTA : Ethylene-Diamine-Tetraacetic Acid
EIA : Environmental Impact Assessment
EMP : Environmental Management Plan
EMS : Environmental Management Systems
ERPG : Emergency Response Planning Guideline
ESP : Electro Static Precipitator
ETP : Effluent Treatment Plant
FAE : Functional Area Expert
FLOX : Flameless Oxidation
FRV : Fiber Reinforced Vinylester
GAIL : Gas Authority India Limited
GC : Gas Chromatography
GEPIL : Gujarat Enviro Protection & Infrastructure Limited
GHGs : Green House Gases
GIDC : Gujarat Industrial Development Corporation
GmbH : Gesellschaft mit beschränkter Haftung
GNFC : Gujarat Narmada Valley Fertilizers and Chemicals Limited
GoG : Government of Gujarat
GoI : Government of India
GPCB : Gujarat Pollution Control Board
GPS : Global Positioning System
GSFC : Gujarat State Fertilizers Company Limited
GSI : Geological Survey of India
GSPC : Gujarat State Petroleum Corporation Limited
GSPL : Gujarat State Petronet Limited
HB : Hemoglobin
HCs : Hydro-Carbons
HDPE : High-Density PolyEthylene
HF : Hydrogen Fluoride
HP / MP / LP : High Pressure / Medium Pressure / Low Pressure
HRSG : Heat Recovery Steam Generators
HRT : Hydraulic Retention Time
HSD : High Speed Diesel
HTAS : Haldor Topsoe
Hz : Hertz
IAA : Impact Assessment Authority
IAY : Indra Awas Yojna
IC : Incident Controller
ICDS : Integrated Child Development Services
IDLH : Immediately Dangerous to Life & Health
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IL&FS : Infrastructure Leasing & Financial Services Limited
IMD : India Meteorological Department
INR : Indian Rupees
IPP : Import Party Prices
IRC : Indian Roads Congress
IS : Indian Standards
ISLM : Integrating Sound Level Measurement
ISO : International Organization for Standardization
IUCN : International Union for Conservation of Nature
JV : Joint Venture
KBR : Kellogg Brown and Root
KEC : Kadam Environmental Consultants
KO : Knot Out
kPa : Kilo Pascal
kVA : Kilo Volt Amperes
LAC : Linde Ammonia Concept
LDO : Light Diesel Oil
LDPE : Low-Density PolyEthylene
LNG : Liquefied Natural Gas
LSIR : Location Specific Individual Risk
LSTK : Lump Sum Turn Key
MCAS : Maximum Credible Accident Scenario
MCC : Motor Control Center
MLSS : Mixed Liquor Suspended Solids
MMSCMD : Million Standard Cubic Feet per Day
MNREGS : Mahatma Gandhi National Rural Employment Guarantee Scheme
MTA : Metric Tons Per Annum
MTPD : Metric Tons Per Day
MDI : Methylene Diphenyl Diisocyanate
MoEF : Ministry of Environment & Forest
MSDS : Material Safety Data Sheet
MSU : Methanol Synthesis Unit
MW : Mega Watt
NABET : National Accreditation Board of Education & Training
NARDES : Narmadanagar Rural Development Society
NB : Nitrobenzene
NCPL : Narmada Chematur Petrochemicals Limited
NCSC : Narmada College of Science and Commerce
NEST : Narmada Education & Scientific Research Society
NG : Natural Gas
NH : National Highway
NH3 : Ammonia
NIHL : Noise Induced Hearing Loss
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NIP : New Investment Policy
NITT : National Institute of Technical Training
NOC : No Objection Certificate
NOx : Oxides of Nitrogen
NPK : Nitrogen, Phosphorus & Potassium
NRHM : National Rural Health Mission
NRSA : National Remote Sensing Agency
ODCB : Ortho Di Chloro Benzene
ODS : Oxide Dispersion Stabilized
OHS : Occupational Health & Safety
OM : Office Memorandum
OMIFCO : Oman India Fertilizer Company
OSHAS : Occupation Health and Safety Assessment Series
P&ID : Piping and Instrumentation Diagram
PCM : Pollution Control Measures
PCPIR : Petroleum, Chemicals and Petrochemicals Investment Region
PCU : Passenger Car Unit
PDIL : Projects and Development India Limited
PEL : Permissible Exposure Level
PESO : Petroleum and Explosives Safety Organization
PFD : Process Flow Diagram
PFR : Pre-Feasibility Report
PFT : Pulmonary Function Test
pH : Power of Hydrogen
PHAST : Process Heating Assessment and Survey Tool
PM : Particulate Matter
PP : Polypropylene
PPE : Personal Protective Equipment
ppm : Parts per Million
PSA : Pressure Swing Adsorption
PUCC : Pollution Under Control Certificates
QCI : Quality Council of India
QRA : Quantitative Risk Assessment
GLC : Ground Level Concentration
GNFC : Gujarat Narmada Valley Fertilizers and Chemicals Limited
GSFC : Gujarat State Fertilizers Company Limited
RO : Regional Officer
RO : Reverse Osmosis
RLNG : Regasified Liquefied Natural Gas
RWH : Rain Water Harvesting
SAC : Sulphuric Acid Concentration
SAY : Sardar Awas Yojna
SEIAA : State Environmental Impact Assessment Authority
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH TABLE OF CONTENT
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXIX
SEZ : Special Economic Zone
SGPT : Serum Glutamic Pyruvate Transaminase (Liver Test)
SH : State Highway
SMC : Site Main Controller
SPL : Sound Pressure Level
SS : Suspended Solids
STP : Sewage Treatment Plant
TDI : Toluene Di-Isocyanate
TDS : Total Dissolved Solids
TEC : Toyo Engineering Corporation
TEFR : Techno-Economic Feasibility Report
TM Blend : TDI - MDI Blend
TOC : Total Organic Carbon
ToR : Terms of Reference
TSDF : Treatment, Storage and Disposal Facility
USEPA : United States Environmental Protection Agency
VOCs : Volatile Organic Compounds
VSCC : Vertical Submerged Carbamate Condenser
VTC : Vocational Training Center (VTC)
WNA : Weak Nitric Acid
ZSI : Zoological Survey of India
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH TABLE OF CONTENT
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LIST OF PERSONS AND INSTITUTIONS MET
GNFC Personnel
1 Mr. A. T. Patadia Executive Director
2 Mr. V. S. Sirohi General Manager
3 Mr. V. K. Nema General Manager
4 Mr. S. K. Mehta General Manager
5 Mr. P. G. Dave Additional General Manager
6 Mr. K. N. Jaggi Additional General Manager
7 Mr. V. C. Bhatt Additional General Manager
8 Mr. K. H. Patel Chief Manager
9 Mr. B. T. Golwala Chief Manager
10 Mr. P. K. Purohit Chief Manager
11 Mr. Y. C. Prajapati Sr. Manager
12 Mr. T.S Santa Sr. Manager
13 Mr. D.B. Shah Sr. Manager
14 Mr. V. N. Patel Sr. Manager
15 Dr. A. D. Thakkar Sr. Manager
16 Dr. J. B. Joshi Manager
17 Mr. Y. A. Patel Manager
18 Mr. S. R. Desai Manager
19 Mr. D. K. Patel Sr. Environmental Engineer
20 Mr. Anurag Srivastava NARDES - Manager
Others
1 Shri Jagdishbhai Patel Local Resident (Umraj Village)
2 Shri Madhusudan Patel Sarpanch (Umraj Village)
3 Shri Vasava Taraben Melabhai Sarpanch (Haldarva Village)
4 Shri Raijibhai Narsinhbhai Vasava Local Resident (Chavaj Village)
5 Shri Dahyabhai Premabhai Parmar Local Resident (Vadadla Village)
6 Smt Rashmika Parmar Local Resident (Vadadla Village)
7 Shri Ishwarbhai Ratanbhai Parmar Sarpanch (Vadadla Village)
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 1
0 EXECUTIVE SUMMARY
0.1 PROJECT DESCRIPTION
0.1.1 About the Company and Project Proponent
GNFC is a joint sector enterprise promoted by the Government of Gujarat and the Gujarat State Fertilizer Company Ltd. (GSFC). It was set up in Bharuch, Gujarat in 1976. Located at Bharuch in an extremely prosperous industrial belt, GNFC draws on the resources of the natural wealth of the land as well as the industrially rich reserves of the area. For more than 30 years it is serving nation by making Fertilizers and Chemicals. It is a partner to the Nation's progress, its fertilizers playing a key role in enhancing agricultural output and its chemicals helping the Indian industrial revolution.
GNFC started its manufacturing and marketing operations by setting up in 1982, one of the world's largest single-stream ammonia-urea fertilizer complexes. Over the next few years, GNFC successfully commissioned different projects - in fields as diverse as chemicals, fertilizers and electronics.
GNFC has an enterprising, strategic view towards expansion and diversification. GNFC promoted Narmada Chematur Petrochemicals Limited. Now, it is merged as Unit – 2 in year 2007. As on date, Unit – 1 and Unit – 2 has separate Consent Orders from Gujarat Pollution Control Board (GPCB).
GNFC is run by experienced chairman, managing director, directors and executive directors with well qualified employees. GNFC has won various prestigious National and International awards with its state-of-the-art technology, high quality standards and productivity-conscious work-force. Recent award includes National Energy Conservation Award - 2013 in Fertilizer Sector. The award was bestowed to the MD-GNFC, Dr. Rajiv Kumar Gupta, IAS at the hands of Hon’ble President of India. Also, GNFC has won the prestigious FAI (Fertilizer Association of India) Award for the best production performance in Complex Fertilizer NP/NPK category for the year 2012-13.This award was given based on performance in production, specific energy consumption and P2O5 efficiency.
It intends to expand its manufacturing facilities for fertilizers and chemicals within its existing Fertilizer Complex at Bharuch.
0.1.2 About Project
Proposed project comprises of Brownfield Ammonia (2,800 MTD), Urea (3,850 MTD), various grades of Water Soluble Fertilizers (NPK) (5,000 MTA) and a 45 MW Co-generation Power & Steam Unit (CPSU) for Unit 1, whereas new Aniline (78,000 MTA) and TDI – MDI Blend (7,800 MTA) for Unit 2.
0.1.3 Regulatory Framework
The existing manufacturing facility has received environmental clearances for existing products from MoEF, New Delhi and SEIAA, Gujarat. Conditions as stipulated in valid consents are being complied with. Certification of compliance for environmental clearance conditions by MoEF, Bhopal has been received.
The proposed project is classified as Category “A” Project. Various components of the proposed expansion project lie under the following Project or Activity and Categories as per the schedule in EIA Notification 2006 amended till date:
1. 5(a) for Chemical Fertilizers : Category “A”
M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.
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2. 5(f) for Synthetic Organic Chemicals Industries : Category “B” 3. 1(d) for Thermal Power Plants : Category “B”
Considering that the expansion projects are part of an integrated fertilizers and chemicals complex, these are submitted to the Impact Assessment Authority (IAA), Ministry of Environment and Forests (MoEF), New Delhi for consideration as an integrated project.
0.1.4 Location of the Project
The project site is located at Survey No. 5, 24/1-B, 99/3-A, 127, 38, 15 and 74 in Notified Industrial Area as per gazette notification enacted by Government of Gujarat (Ref. Map, M- 2-1). It is surrounded by Mumbai-Delhi National Highway (NH-8) at a distance of 0.5 km in East Direction and adjacent State Highway (SH – 6) connecting Dahej, a major sea port at approximately 48 km, Bharuch Railway Station is at ~3.9 km distance in SW direction, nearest airport is Surat Airport at a distance of 70.6 kms in SW Direction. The base elevation of site is at 19.2 m above mean sea level.
0.1.5 Project Cost
The estimated project cost INR 4,463 Crore includes environmental management cost ~ INR 153.67 Crore and recurring expenditure ~ INR 6.41 Crore per annum.
GNFC is engaged in the CSR activities like Education,