Presentation On Environmental Management At Iit Roorkee

130

Transcript of Presentation On Environmental Management At Iit Roorkee

Page 1: Presentation On Environmental Management At Iit Roorkee
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WELCOME

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WELCOME

IFFCO AONLA UNIT, BAREILLY (U.P.)

HONOURABLE CPCB

OFFICIALS,ENGINEERS

& DELEGATES

AT

IIT-ROORKEE

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ENVIRONMENTAL MANGEMENT

AT

IFFCO AONLA UNIT, BAREILLY (U.P.)

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IFFCO - In Brief

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IFFCO’S PLANTS

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IFFCO PLANTS

KALOL UNIT

Year of Commissioning - 1975

Annual Ammonia Capacity - 363000 MT

Annual Urea Capacity - 544500 MT

Year of Commissioning - 1975

Annual P2O5 Capacity - 910000 MT

Annual N Capacity - 351540 MT

KANDLA UNIT

PHULPUR UNIT

Year of Commissioning - 1981

Annual Ammonia Capacity - 824000 MT

Annual Urea Capacity - 1415700 MT

Year of Commissioning - 1988

Annual Ammonia Capacity - 1003200 MT

Annual Urea Capacity - 1729200 MTYear of Acquire - SEP-2005

Annual Capacity -2000000

MT

(DAP + COMPLEX)

AONLA UNIT

CORPORATE OFFICE

NEW DELHI

PARADEEP UNIT

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KALOL UNIT

GUJRAT

YEAR OF COMMISSIONING : 1975INVESTMENT : Rs. 71.23 Cr.YEAR OF EXPANSION : 1997INVESTMENT : Rs. 149.70

Cr.PRODUCT CAPACITY

TPD TPAAMMONIA 1100 3,63,000UREA 1650 5,44,500 „N‟ 759 2,50,470

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KANDLA UNITGUJRAT

YEAR OF COMMISSIONING : 1975INVESTMENT : Rs. 24.26 Cr.YEAR OF FIRST EXPANSION : 1981INVESTMENT : Rs. 28.60 Cr.YEAR OF SECOND EXPANSION : 1999INVESTMENT : Rs. 205.30 Cr.PRODUCT CAPACITY

TPD TPA„ P2O5 2890 9,10,100„N‟ 1115 3,51,540

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AONLA UNIT

UTTAR PRADESH

YEAR OF COMMISSIONING : 1988

INVESTMENT : Rs. 651.6 Cr. AONLA- I

YEAR OF EXPANSION : 1996

INVESTMENT : Rs. 954.7 Cr. AONLA- II

PRODUCT CAPACITY

TPD TPA

AMMONIA 3040 10,03,200

UREA 5240 17,29,200

„N‟ 2410 7,95,430

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PHULPUR UNIT

UTTAR PRADESH

YEAR OF COMMISSIONING : 1981

INVESTMENT : Rs. 205.2 Cr.

Phulpur - 1

YEAR OF EXPANSION : 1997

INVESTMENT - Phulpur-II : Rs.1190 Cr.

PRODUCT CAPACITY

TPD TPA

AMMONIA 2497 8,24,000

UREA 4290 14,15,700

„N‟ 1973 6,51,222

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PARADEEP UNIT

ORISSA

COST OF ACQUISITION Rs. 2589.88 Crore

(September 2005)

PRODUCT CAPACITY

TPD TPA

PHOS. ACID 2650 8,75,000

SULPHURIC ACID 6970 23,00,000

P2O5 2650 8,75,000

N 1006 3,32,000

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IFFCO - AN ORGANISATION

FOR THE FARMERS

OF THE FARMERS

BY THE FARMERS

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IFFCO was established on 3rd

Nov.,67 as a co-operative of

farmers to produce & market

fertilisers.

Origin of IFFCO

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Leading producer of fertilisers in India

No. of plant locations - Five

Installed Annual Capacity

Urea : 3.69 Million Tonne

NPK/DAP : 4.42 Million tonne

IFFCO – In Brief

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Contributes 18.3% to the total”N” and

50% to the total “P2O5” produced in

the country.

Fertiliser marketed through around

37,500 cooperative societies and 158

Farmers Service Centres

Service to the farmers through a

variety of programmes

IFFCO – In Brief

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Vision & Mission

Honorable Managing Director

Shri U.S.Awasthi

Under the dynamic leadership of our

Honorable Managing Director

Shri U. S. Awasthi IFFCO has drawn out

plans to grow manifold in fertiliser

sector as well as in allied areas.

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Recently Implemented

Projects

AONLA EXPANSION PROJECT

PHULPUR EXPANSION PROJECT

KALOL EXPANSION PROJECT

KANDLA EXPANSION PROJECT

ACCUISITION OF OSWAL

FERTILISERS(Phosphatic)

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Joint Ventures

JV FOR PHOS. ACID IN SENEGAL

DIVERSIFICATION IN INSURANCE

OMAN GRASSROOT PROJECT

IFFCO-AIR TEL FOR RURAL

COMMUNICATION

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Vision-2010

Power

Bio Fuels

Renewable

Energy

Banking

New Fertiliser

units

Targets have been set to achieve group

turnover of Rs 15000 crore and annual

profit of Rs 1500 crore. Areas

contemplated for future growth include :

Phos. Acid

Agri Business &

Exports

Petroleum & Natural

Gas

Petrochemicals

Telecommunications

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Vision-2010 (contd…)

De-bottlenecking of existing plants for

Capacity enhancement.

Mining project & Phosphoric acid plant at

Egypt and Jordan

Acquisition of DAP & NPK facilities at

Paradeep in Orissa

1000 MW Power project in State of

Chattisgarh

Investment plan for expansion in Fertiliser

sector and diversification into Power

sector at an estimated outlay of Rs 9000

crore :

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IFFCO

AONLA UNIT

ISO-9001, ISO-14001 & OHSAS-18001

CERTIFIED

ENERGY EFFICIENT

COST- CONSCIOUS

ECO-FRIENDLY & SAFETY CONSCIOUS

HARMONIOUS INDUSTRIAL ENV.

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IFFCO Aonla Unit

…at a Glance

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HBJ Gas

Pipeline

Network

EX HAZIRA CONSUMERS - KRIBHCO, RPL, ESSAR, HWP, GGCL

HAZIRA CS

VAGHODIA CS

JHABUA CS (10 NOS COMPRESSORS)

VIJAIPUR CS (8 NOS COMPRESSORS)

AURAIYA CS

(5 NOS COMPRESSORS)

36” (149 KM)

36” (150 KM)

36” (340 KM)

18” (3.6 KM)

12” (14 KM)

18” (110 KM)

12” (32 KM)

SAMCOR

ANTA

BORARI

LPG

LPG

18” (32 KM)

18” (1.1 KM)

12” (8 KM)

DPD

IOC, IPCL

KAWAS

30” (321 KM)

12” (2 KM)

36” (505 KM)

24” (143 KM)

18” (217 KM)

24” (90 KM)

24” (82 KM)

24” (104 KM)18” (47 KM)12” (35 KM)

6” (52 KM)

6” (20 KM)

MARUTI

BAHADURGARH

SONIPAT

DESU

SAHIBABAD

S‟

BADMATHURA

14” (13 KM)

DADARI

TCL

OCFL

CFCL

NFL

GSFC

IGCL

Jagdishpur

NTPC

Aonla Unit based on

HBJ pipeline

1225 Km from Hazira

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Ammonia Plant-IProduction started on : 15.5.1988

Capacity : 1520 MTPD

Ammonia Plant-II

Capacity : 1520 MTPD

Production started on : 13.12.1996

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Urea Plant-I Urea Plant-II

Capacity : 2620 MTPD

Production started on :26.11.1996Production started on :18.5.1988

Capacity : 2620 MTPD

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Product Handling Plant

Capacity : 2x8 Bagging

Stations (Slat) @ 60 MTPH

Silo - I & IISilo-I : 45000 MT

Silo-II : 30000 MT

Capacity -

9.38 KM Railway Siding on 110 Acres land

In-plant yard comprising of 12 lines

Naphtha / Fuel oil 4 lines on RCC apron

Railway Siding

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Power Plant

Capacity :

Steam generation

plant : 150 MT/Hr

Power generation

Plant :

GTG : 2X18 MW/Hr

HRSG : 2X80 MT/Hr

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Cooling Towers

Urea Plant : 5 nos. each for Urea- I & II

Ammonia Plant :6 nos. each for Ammonia-I & II

Number of cells -

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Ammonia Storage Tanks

Capacity : 2x10,000 MT

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Capacity : 2 x 85000 M3

Lagoons

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Birds in Lagoon

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Fire & Safety

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IFFCO Aonla Unit was set up at Aonla,

Bareilly in the year 1988 to increase the

fertiliser production in the country under

the overall national planning for utilisation

of natural gas available from Bombay

High.

In the year 1996 the production capacity

was doubled with the commissioning of

Aonla-II.

IFFCO Aonla Unit

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Main Plants & Auxilliary Facilities

Ammonia Plant 1520 MTPD 1520 MTPD

(1740 MTPD) (1740 MTPD)

Urea Plant 2620 MTPD 2620 MTPD

(3030 MTPD) (3030 MTPD)

S.G. facilities (116 Kg/Cm2, 515 Deg C)

• Service Boiler 150 MTPH

• Heat Recovery Unit 80 MTPH (80+120) MTPH

Gas Turbine 25 MW 25 MW

Generator (ISO)

Aonla-I Aonla-II

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Instrument / Plant 6 X 1200 NM3/Hr

Air Compressor 1X5000 NM3/Hr

Water Treatment Plant 6 x 140 M3/HR

Inert Gas (N2) Generation 600 NM3 /HR

Ammonia Storage Tank 2 x 10,000 MT

Air & Steam Stripping Unit Of (60+45) M3/Hr

Ammonia Bearing Waste

Main Plants & Auxilliary Facilities(Contd…)

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(Contd…)

UREA BAGGING PLANT 2X8 Bagging

Stations

@ 250 MTPH

FUEL OIL / NAPHTHA STORAGE

Fuel Oil Storage 2 x 3650 M3

Naphtha Storage 2 x 6000 M3

1 x 10000 M3

UREA SILO Aonla-I 45000 MT

Aonla-II 30000 MT

Main Plants & Auxilliary Facilities

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IFFCO-AONLA UNIT GOT SEVERAL AWARDS AND CERTIFICATES FROM VARIOUS

AGENCIES ,FOUNDATIONS, GOVERNMENT BODIES AND INSTITUTES

SHE RELATED AWARDS RECENTLY WON BY IFFCO AONLA UNIT

CII AWARD FOR ENERGY FOR EXCELLENCE IN ENERGY MANAGEMENT 21&22,AUG,2006

“RUNNER UP” IN NATIONAL SAFETY AWARDS-2times

NSCI AWARDS-2004&2006 “PRASHANSHA PATRA”

“GOLDEN PEACOCK” SPECIAL COMMENDATION OF

ENVIRONMENT MANAGEMENT AWARD-2005

“CERTIFICATE OF PARTICIPATION” CORPORATE

ENVIRONMENTAL AWARDS-2002/03

NSCI AWARDS 2000 &-2002 “PRASANSHA PATRA”

“CERTIFICATE OF MERIT” NATIONAL ENERGY

CONSERVATION AWARD-2003

“CERTIFICATE OF MERIT” NATIONAL ENERGY

CONSERVATION AWARD-2002

FAI AWARD FOR EXCELLENCE IN SAFETY2001-02,2005-06

Ministry of labour & employment ,

Govt. of India 07-09-2005,sept2007

National Safety

Council of India

AWARD RECEIVED IN

APRIL,2006&jan 2007

World environment Foundation 11-06-2005

TERI Corporate Environmental Awards

05-06-2004

27-12-2003,10-12-2002National Safety

Council of India

National Energy Conservation in

Fertiliser Sector by Ministry of Power,

Govt. of India 14-12-2003

National Energy Conservation in

Fertiliser Sector by Ministry of Power,

Govt. of India 14-12-2002

FAI, ,05-12-2007 & 16-12-2002

NATIONAL ENERGY CONSERVATION AWARD-2006 (2Nd) 14TH DEC,2006, BY MIN OF POWER

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Awards

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THE FERTILISER ASSOCIATION OF INDIA‟s AWARD FOR

EXCELLENCE IN SAFETY

Awards (Contd…)

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Awards (Contd…)

NATIONAL ENERGY CONSERVATION AWARD, 2002 FROM

MINISTRY OF POWER

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Awards (contd…)

NATIONAL SAFETY COUNCIL OF INDIA

SAFETY AWARDS-2000

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Awards (Contd…)

THE FERTILISER ASSOCIATION OF INDIA‟s AWARD FOR

BEST ARTICLE

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IFFCO-Aonla unit has bagged National Energy

Conservation Award-2003 : Certificate of merit

Awards (contd…)

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IFFCO-Aonla unit has won the NSCI Safety Award

(Prashansa Patra) for the year 2002

Awards (contd…)

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GOLDEN PEACOCK ENVIRONMENT MANAGEMENT

AWARD-2005 (CERTIFICATE OF COMMENDATION)

Awards

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NATIONAL SAFETY AWARD -2004 (RUNNER UP UNDER SCHEME-II)

Award was presented by Sh K M Sahani, Hon‟ble Secretary,

Ministry of Labour & Employment for outstanding

performance in industrial safety during the year 2004

based on longest accident free year

Awards(Contd)

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RAJIV RATNA NATIONAL AWARD-2005 : BEST EXECUTIVE

GOLD AWARD FOR SH H C DAVE, EXECUTIVE DIRECTOR

Awards (contd…)

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PRASHANSHA PATRA

FOR THE YEAR 2004&06 FROM

NATIONAL SAFETY COUNCIL

FOR DEVELOPING AND

IMPLEMENTING OCCUPATIONAL

SAFETY & HEALTH MANAGEMENT

SYSTEMS & PROCEDURES

Awards (contd…)

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NSCI AWARD-2004

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ICQESMS-2005 &2007 EXCELLENCE

AWARD

FOR PAPER PRESENTED IN

4TH INDIAN CONGRESS ON

QUALITY, ENVIRONMENT, ENERGY AND

SAFETY MANAGEMENT SYSTEM-BY

CBWE & JADHAVPUR UNIVERSITY

Awards (contd…)

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ENERGY AWARD

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CII AWARD

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NSA AWARD-2006

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FAI AWARD –SAFETY 2007

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Production

Performance

- A Brief Overview

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Annual Capacity v/s Actual Production (Lakh MT)

8.65

8.14

8.65 8.65 8.65 8.65 8.65 8.65 8.65 8.65

7.8

7.9

8

8.1

8.2

8.3

8.4

8.5

8.6

8.7

Pro

du

cti

on

( la

kh

MT

)

2000-01 2003-04 2004-05 2005-06 2006-07

Capacity Actual Production

UREA PLANT-I

Production Performance

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0

1

2

3

4

5

6

7

8

9

2000-01 2001-02 2002-03 2003-04 2004-05

8.65 8.658.65 8.65 8.65

8.588.64 8.65 8.65

8.65

Pro

du

cti

on

( l

ak

h M

T )

Capacity Actual Production

UREA PLANT-II

Production Performance(Contd.)

Annual Capacity v/s Actual Production (Lakh MT)

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Energy

Conservation -A major concern

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OVERALL ENERGY OF THE COMPLEX

(GCAL/TE UREA)

5.9303

5.8657

5.7998

5.6705

0.25980.13050.0646

5.6243

0.3060 0.2901

5.6402

Reduction In Overall Specific Energy

Consumption (Aonla-I+II)

0.2893

5.6410

5.5733

0.3570

2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-20061998-1999 1999-2000

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Environment Management

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Environment Management

Bagged Indo-German Greentech Environmental

Excellence Award for 2 consecutive years (in 1999-

2000 and 2000-2001).

Bagged Corporate Environment Award 2002-03

(certification of participation) from TERI in recognition

of the efforts made towards Environment

Management and sustainable initiatives.

Bagged Golden Peacock Environment Management

Award-2005 (Certificate of Commendation).

Achieved ISO 14001 certification for Plant and

Township.

Achieved OHSAS-18001 certification.

Awards & Certifications

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Green Belt Development

The project site was completely barren with

high soil alkalinity.

Developed 80-M WIDE GREEN BELT around plant

and township.

Aforestation with about 1,70,000 TREE

PLANTATION.

Soil Treatment by using pyrite alongwith

Gypsum, sweet soil topping up and cow-dung.

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Technology Selection on Zero - effluent concept

based on Recycle and Reuse of Waste Water.

Maximum reuse of treated water in the irrigation

of green belt and lawns in the plant and township.

Developed 80 to 250 meter wide green belt in &

around the plant and township.

Education and training of employees and

awareness to residents of nearby areas regarding

environmental issues

Environment Management

Approach

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Environmental laboratory with pH meter,

conductivity meter, SOx / NOx analyser, High

Volume Sampler and Spectrophotometer etc.

Continuous monitoring of quality of Ground water,

Effluent, Stack emissions and Ambient Air.

Environmental Management Cell for day to day

monitoring , control , Environmental Auditing,

Setting goals i.e Objectives & Targets for reduction

of wastages in all forms.

Environment Management

Approach (contd…)

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Process Condensate

Contaminated Process Condensate

undergoes stripping process in

CONDENSATE STRIPPER with the help of

steam . In this process impurities like CO2 ,

NH3 and CH3OH are stripped off. It is then

treated in Polishing Unit and recycled as

Boiler Feed Water.

Ammonia Plants

Pollution Abatement Facilities

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Purge Gas Recovery Unit to recover Hydrogen

from Purge gas.

Total Recycle of Turbine Condensate.

Reuse of Boiler Blow Down For cooling Tower

Make-Up.

Separation and Collection of Oil from Oily Water

by means of Disc Oil Separator.

Separation & Collection Of Occasional

Ammonical effluents for treatment in ETP.

Ammonia Plants (Contd…)

Pollution Abatement Facilities (Contd…)

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Segregation,collection & Total Recycle of urea

bearing waste after processing in Deep

Hydrolyser and using the treated effluent as BFW

make up after polishing. Ammonia & CO2 are

recycled back to the process.

Collection of occasional spill for treatment at

Centralised Effluent Treatment Plant.

Separation and collection of oil From oily water

by means of Disc Oil Separator.

Urea Prilling Towers (96 m & 104 m)

Urea Plants

Pollution Abatement Facilities

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Polishing Unit for the treatment of

process/steam/ turbine condensates from

the plants.

Segregation, Collection & Neutralisation of

Acidic and Alkaline Effluents.

Utilisation of Acidic & Alkaline effluent for

pH control.

Absorption of Acid vapor fumes by water

spraying.

D M / Water Treatment Plant

Pollution Abatement Facilities (Contd…)

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Dust collection and it‟s

reprocessing

Collection of swept urea and

it‟s reprocessing

Product Handling plant

Pollution Abatement Facilities (Contd…)

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Treats ammonia bearing occasional waste water from urea

and ammonia plants with Air/Steam Strippers.

Stores treated effluent in LDPE lined lagoons for green belt

irrigation and functions as a buffer. These lagoons attract

large number of migratory birds in winter months.

Plant is having facilities for removal of Vanadium

(occasional discharge) from GV system by precipitation

and storage in secured lined pit.

Centralised Effluent Treatment Plant

Pollution Abatement Facilities (Contd…)

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OILY

EFFLUENT

AMMONICAL

EFFLUENT

OCCASIONAL

EFFLUENT

FROM UREA

C.T

BLOWDOWN

ACIDIC

ALKALINE

EFFLUENT

DISC OIL

SEPARATOR

NEUTRALI-

SATION PIT

OILY

WATER

ACIDIC AND ALKALINE EFFLUENT

OVER FLOW

GUARD

PONDS

2X85000

M3

TREES

ACIDIC

ALKALINE

NEUTRALISATION

PIT

LIME

HOLDING

PIT

AIR & STEAM

STRIPPERS

AND V2O5

REMOVAL

HOLDING

PIT

TO ARIL

RIVER

TREES

EFFLUENT FLOW SCHEMATIC DIAGRAM

FOR

IRRIGATION

OF GREEN

BELT

ACID AND ALKALY

DOSING FOR PH

CORRECTION

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Online SO2, NO2, O2 Analysers in Ammonia and

Power Plants.

On line pH meters, conductivity meters and silica

analysers in DM Plant, Ammonia , Urea and Power

Plants.

On line pH meter and Ammonia analyser on factory

discharge.

Ammonia analysers in Ammonia storage area.

On Line Monitoring of Stack Emissions & Liquid

Effluents

Pollution Abatement Facilities (Contd…)

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ISO 14001 certified township.

Irrigation of green belt and lawns by treated

effluent , thus saving natural resources like

water.

Safe collection and disposal of township as

well as Plant canteen solid waste.

Conversion of township/plant solid garbage

into Vermi-compost

Township

Pollution Abatement Facilities (Contd…)

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Obtaining and renewal of Water/ Air Consent every

year and implemented it‟s conditions continuously.

Obtaining and renewal of Hazardous waste/Bio-

medical Wastes Authorisation and implemented

it‟sconditions.

Implemented CREP recommendation.

Safe Storage & disposal of Hazardous Wastes (spent

catalyst and spent oil) as per CPCB guidelines.

Submission of Annual Environmental statement.

Environment & Pollution Control Cell

Pollution Abatement Facilities (Contd…)

Page 78: Presentation On Environmental Management At Iit Roorkee

• In Aonla Unit, Lean NG is being supplied by

GAIL through HBJ pipeline which results in CO2

shortage for conversion of full Ammonia

production to Urea leading to Ammonia stock

buildup in the plant.

• CO2 recovery has been installed to meet the

shortfall of CO2.

• CO2 recovery Plant is recovering 450 MTPD of

CO2 from the Primary Reformer flue gases of

Ammonia-I (A CDM Project).

CO2 Recovery From Flue Gas:

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ID Fan

Flue gases from Primary

Reformer (CO2 : 10-

12%dry basis)

Flue gases

to

atmosphere

CO2 to Urea plant

(CO2 : 99%min. dry

basis)

Rich solution

Lean solution

Flue gases to

atmosphere

Absorption Regeneration

LP Steam

CDR UnitCDR Unit

Flue gas

Blower

CO2

Blower

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Consumption Pattern 2005-06

2006-07

Plant 240 250

Cooling Tower 940 830

Domestic&Miscellaneous 160 130

Total water consumption 1340 1210

Water Consumption (m3/hr)

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Consumption Pattern 2005-06) 2006-07

Total water consumption 10660053 9551476

Urea Production 1737580 1770103

Water Consumption/MT of Urea

6.135 5.396

Water Consumption (yearly)

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Plant Qty. (m3/hour)

Ammonia (Occasional waste)

6

Urea(Occasional waste) 12

Cooling Tower 180

DM Plant 40

Total 238

For Irrigation Purposes 128

Discharge to Aril River 110

Liquid Effluent Generation

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Sr.No Descripn.

Amm-1

Amm-2

1 Installed Capacity MTPD

1520 1520

2 Type of Fuel

NG NG

3 Height of Stack(M)

30 30

4 Flue gas flow rate NM

3 /hr.

2,25,000 1,90,000

Details of Primary Reformer Stack of both

Ammonia Plants

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Details of Primary Reformer Stack of both

Ammonia Plants (contd…)

Sr.No.

Particulars Amm-1

Amm-2

5. Flue gas Temp.0C

160 139

6. Eflux Velocity,m/sec.

9.4 7.9

7. SO2 Conc. (ppm)

Traces Traces

8. Nox Conc. (ppm)

<70 <70

Page 85: Presentation On Environmental Management At Iit Roorkee

Details of Prill Towers

Sr. No.

Particulars Urea-1

Urea-2

1. Installed capacity (MTPD)

2600 2600

2. Height of Prill Tower (m).

104 96

3. Air Flow (nm

3/hr.)

1.06X106 1.27X10

6

4. Exhaust air Temp. (

0C)

53 50

5. Ambient Air Temp. at Ground Level (0C)

22 22

Page 86: Presentation On Environmental Management At Iit Roorkee

Effluent Analysis

(Factory Discharge)

Sr. No.

Parameter Unit Standard Avg Value

(2004-05)

Avg Value

(2005-06)

Avg Value

(2006-07)

1. pH ---- 6.5 – 8.0 7.40 7.52 7.7

2. Ammonical Nitrogen

PPM 50 9.87 11.98 11.92

3. Free-Ammonia

PPM 5 1.60 00.53 0.53

4. Total Kjeldahl Nitrogen

PPM 100 33.70 18.27 24.99

Page 87: Presentation On Environmental Management At Iit Roorkee

Pollutants unit Standard of

UPPCB

Annual

Average

concentration

of Pollutants

% Increase

/Decrease

(+)/(-) of

Pollutants

pH

Cr+6*

Total Cr*

Oil/ Grease

Ammoniacal

Nitrogen as N

T.K.N.

T.S. S

Free NH3

B.O.D

C.O.D

Phosphate as

PO 4

-

mg/L

mg/L

mg/L

mg/L

mg/L

mg/L

mg/L

mg/L

mg/L

mg/L

5.5-9.0

0.1

0.5

10

100

150

100

5.0

30.0

250.0

5.0

7.70

NT

NT

NT

11.92

24.99

33.33

0.53

15.82

39.24

0.65

---

---

---

---

(-)88

(-)83.6

(-)66.67

(-)89.4

(-)42.6

(-)84.3

(-)87

Page 88: Presentation On Environmental Management At Iit Roorkee

ANALYSIS OF STACK EMISSIONS

(AMMONIA PLANTS)

Plant parameter Unit Standards Avg Value

(2004-05)

Avg Value

(2005-06)

Avg Value

(2006-07)

Ammonia-I

SPM Mg/Nm3 500 NT NT NT

SOX PPM 100 Traces Traces Traces

NOX PPM 100 74 72 70

Ammonia-II SPM Mg/Nm3 500 NT NT NT

SOX PPM 100 3.14 Traces Traces

NOX PPM 100 58 42 32

PPM

Page 89: Presentation On Environmental Management At Iit Roorkee

ANALYSIS OF STACK EMISSIONS

( PRILL TOWER UREA DUST EMISSION)

Plant Urea I

Parameter Unit Standard Avg Value

(2004-05)

Avg Value (2005-06)

Avg Value (2006-07)

SPM Urea Dust

Mg/nm3 50 26.90 40 38.59

Ammonia PPM 50 30.48 30 30

Urea II SPM Urea Dust

Mg/nm3 50 27.64 38 35.85

Ammonia PPM 50 36.54 36 36

Page 90: Presentation On Environmental Management At Iit Roorkee

ANALYSIS OF STACK EMISSIONS

(STEAM & POWER GENERATION PLANT)

Plant Parameter Unit Standards Avg Value

(2004-05)

Avg Value

(2005-06)

Avg Value

(2006-07)

Steam & Power Generation Plant

SPM Mg/Nm3 500 Traces Traces Traces

SOX PPM 500 Traces Traces Traces

NOX PPM 100 34 39.19 32

Page 91: Presentation On Environmental Management At Iit Roorkee

ANALYSIS OF STACK EMISSIONS

(HRSG OF POWER PLANT)

Plant Parameter Unit Standards Avg Value

(2004-05)

Avg Value

(2005-06)

Avg Value

(2006-07)

Heat Recovery Steam Generation Plant (HRSG)

SPM Mg/Nm3 500 Traces Traces Traces

SOX PPM 100 Traces Traces Traces

NOX PPM 100 48 34.49 32

Page 92: Presentation On Environmental Management At Iit Roorkee

AMBIENT AIR QUALITY

Location SPM NH3

SO2 NO2

Unit Microgm/nm

3 Microgm/n

m3

Microgm/nm

3

Microgm/nm

3

Standards(UPPCB) 500 100 120 120

NAAQS 360 100 80 80

Ammonia Storage Area (Plant)

182 40 1.84 5.83

Guest House (surrounding area of plant)

176 32 2.00 4.52

GET Hostel (surrounding area of plant)

181 31 2.19 4.99

Transport Office (surrounding area of plant)

203 42 1.48 4.11

Page 93: Presentation On Environmental Management At Iit Roorkee

Ground Water Monitoring

Parameters Unit Standard Annual

Average

Analysis

Nitrate as NO3 PPM 10 1.49

Chromium PPM 0.1 NT

Page 94: Presentation On Environmental Management At Iit Roorkee

Hazardous Waste

Hazardous Waste Financial Year-2005-06 Financial Year-2006-07

a)From Process

Spent Oil(Reclaimed &

Reused /sold)

•Spent Catalyst

b)From Pollution

Control

Facilities

•Acidic and Alkaline

effluents Neutralized

(Quantity)

20 m3

ZNO:22.93 MT

Ni-Catalyst:3.81 MT

35-40 m3/hr (Annual

Average)

21 m3

NIL

35-40m3/hr(Annual

Average)

21

21 m3 spent oil sold to m/s Friends Petro chemical Industires,Panipat

having authorisation from CPCB

Page 95: Presentation On Environmental Management At Iit Roorkee

SOLID WASTES

Hazardous Waste Financial Year(2005-

06)

Financial Year(2006-

07)

Chromate sludge

containing

Hydroxides of Fe, Al,

Cr, Zn & Calcium

•Quantity reused

Use of Cr+6

compounds has been

discontinued since

march 1999,Hence

there is no chromate

sludge formation

NIL

Use of Cr+6

compounds has been

discontinued since

march 1999,Hence

there is no chromate

sludge formation

NIL

Page 96: Presentation On Environmental Management At Iit Roorkee

LIQUID WASTES

(A)COOLING TOWER BLOW DOWN (125 M3/Hr.per plant)

(B) OIL CONTAINING WATER (5 TO 10 M3/Hr):

(C) ACIDIC AND ALKALINE WASTE (Avg. 35 – 40M3/Hr)

COST OF POLLUTION CONTROL MEASURES AGAINST PER

MT OF UREA PRODUCTION DURING 2006-07.

Rs. 25.80 (Approx )

Page 97: Presentation On Environmental Management At Iit Roorkee

ACTIVITIES FOR ENVIRONMENTAL PROTECTION WHICH IS

RELATED TO POLLUTION CONTROL

•Plantation of approx. 8,000 trees in year 2007-08 for gap filling

and replenishment of dead wood trees in factory and township

area.

Pre/Post monsoon “Monitoring of Underground Water” at different

locations as per CPCB guidelines.

Utilisation of more “Treated waste water in Green Belt”.

Consumption of “Natural Resources more economically”.

Safe Disposal of “Solid Waste.”

Implementation of Carbon Dioxide Recovery Unit (CDR)

A carbon Dioxide Recovery (CDR) unit has been installed in the

Capacity Enhancement / debottlenecking of the IFFCO Aonla Unit

, for which environmental clearance from U.P.Pollution Control

Board and Ministry of Environment & Forest have been obtained.

In this unit, a total of 450 MTPD of CO2 is recovered from the

stack flue gas of Primary Reformer of Ammonia –I . This quantum

of CO2 is utilised for the full conversion of ammonia to urea.

Page 98: Presentation On Environmental Management At Iit Roorkee

MEASURES TAKEN FOR ENVIRONMENTAL PROTECTION AND POLLUTION

CONTROL IN IFFCO AONLA UNIT

The environmental management at our unit aims for the abatement of pollution at the

source of generated itself. The following measures are being taken regularly for the

control of pollution and protection of environment :-

•Zero effluent technology, based on recycling and reuse of waste generated in the main

plants.

•Utilization of resources prudently so that waste generation is minimized.

•Treatment of waste water containing Ammonia & Urea through Deep Urea Hydroliser in

both the Urea Plant separately and reusing it as Boiler Feed Water.

•Treatment of Process Condensate by Process Condensate Stripper in both the

Ammonia Plant and reusing it as Boiler Feed Water.

•Treatment and polishing of Turbine Condensates from ammonia and urea plants in DM

Plant and reusing it as Boiler Feed Water.

Collection of Oil containing water and spilled oil from the compressor houses of all the

plants separately in oil collection pit. The oil is separated through “Disc Oil Separator”.

The reclaimed oil is either reused or sold to vendors having authorisation from CPCB

and the waste water is being sent to ETP for further treatment.

Neutralisation of Acidic and Alkaline waste generated due to the regeneration of

exhausted cation and anion resins in DM Plant.

Use of Eco-friendly, Non-chromate based corrosion inhibitor in cooling water

treatment. Thus avoiding the generation of hazardous Chromate sludge .

Treatment of occasional waste water containing ammonia generated during upset and

startup/shutdown condition of the plants in Effluent Treatment Plant through Air/Steam

stripping.

Page 99: Presentation On Environmental Management At Iit Roorkee

•The treated waste water is collected in two nos. of LDPE lined lagoons (Guard-Ponds)

of capacity 85,000 m3 each at the terminal end of ETP. 60-70% of this treated effluentis being used in the irrigation of green belt in and around the plant.

•Continuous monitoring of quality of liquid effluent, storm drain water, ground water,stack flue gases, urea prill tower dust emission, ambient air by IFFCO’s own

Environmental Laboratory and also by an accredited third party U.P. Pollution ControlBoard, Bareilly.

•All pollution control devices in the plants are maintained in perfect good condition andtheir performances are monitored regularly by our laboratory.

•Built in safety logic’s and guards in the plant operations and safe shut down/starts ups.

•Education and training of employees regarding environmental issues.

•Generating awareness for Environment Protection in surrounding villages.

•The safe disposal of wastes of township households , plant canteen and Horticulture

and it’s conversion into manure by “VERMI-COMPOSTING PLANT”.

.The spent oil and spent catalysts (as and when discarded or exchanged) are

stored in factory premises in sealed covered drums on pucca plateform under a shed

and sold to vendors as per CPCB guidelines .

GREEN BELT DEVELOPMENT

Green belt has been developed all along the factory and township. The width of green

belt various from 80 M to 250 M as per the condition of environmental clearance.

Moreover additional afforestation is being carried out every year to fill up left out area

and replacement of dead wood trees in factory and township.

Page 100: Presentation On Environmental Management At Iit Roorkee

EMS IMPLEMENTATION :

IFFCO Aonla fertilizer complex (Plant & township) was accredited for ISO:14001: 1996

certificate by M/s BVQI in 12.08.2000. It was further recertified in January,2003 for 3

years. The ISO:14001:1996 was upgraded as ISO:14001:2004. Environment

Management systems of IFFCO Aonla Unit was also updated as per revised

ISO:14001:2004 standards and got certified by M/s BVQI in April,2006.

Now, the Environment Management System of IFFCO Aonla Unit is accredited by M/s

NQA-QSR and the certificate of ISO:14001:2004 is valid upto 15th May,2010.

OHSAS Accreditation:

The Occupational Health & Safety Management Systems of IFFCO Aonla Unit was

assessed by M/s NQAQSR and found to conform to the “Occupational Health & Safety

Systems Specification” i.e. OHSAS 18001:1999 – Amendment 1:2002 and awarded

IFFCO Aonla Unit with OHSAS:18001:1999 Certificate. The certificate is valid up to

08/12/2010.

AWARDS:

•INDO GERMAN GREENTECH ENVIRONMENT EXCELLENCE AWARD 1999-2000 &

2000-2001

IFFCO Aonla Unit has been assessed and awarded 1st and 2nd position for its

outstanding achievements in the field of environmental protection by Indo-Greentech

Foundation for two successive years i.e. 1999-2000 & 2000-2001 respectively.

Page 101: Presentation On Environmental Management At Iit Roorkee

•TERI CORPORATE ENVIRONMENTAL AWARDS 2002/03IFFCO Aonla Unit has been awarded by “TERI” CORPORATE ENVIRONMENTAL

AWARD 2002/03 (CERTIFICATE OF PARTICIPATION) in recognition of it’s leadership

efforts towards environmental management and sustainable initiatives amongstcorporates with turnover above 500 crore rupees.

•GOLDEN PEACOCK ENVIRONMENT MANAGEMENT AWARD 2005

The Environmental Management Systems and techniques adopted in IFFCO Aonla Unitwere adjudged by a jury of World Environment Foundation and awarded “GOLDEN

PEACOCK AWARD - SPECIAL COMMENDATION” of Environment Management

Award-2005 in June, 2005.

Page 102: Presentation On Environmental Management At Iit Roorkee

ENVIRONMENTAL STATEMENT

•No adverse environmental impact observed in Eco-system due to plant

operation.

•All the pollution Control devices in plants are being kept in perfect

working condition and their performance is being monitored regularly.

•Network of irrigation piping has been laid down in plant and township to

utilise treated waste water/effluent . Approx. 60 to 70% of it is being

used in irrigation of green belt in and around the factory and township.

•Ammonia and Hydrogen monitoring system has been installed in the

plants for early leak detection of leakage’s, if any.

•Series of lectures are being taken regularly on environmental

awareness for the employees, contractors staff etc.

• Eco-friendly , Non-chromate corrosion inhibitors are being used in

cooling water treatment. Thus avoiding generation of hazardous waste

chromate sludge.

Page 103: Presentation On Environmental Management At Iit Roorkee

POLLUTION CONTROL IN UREA PROCESS

Page 104: Presentation On Environmental Management At Iit Roorkee
Page 105: Presentation On Environmental Management At Iit Roorkee

BLOCK DIAGRAM OF EMISSION SOURCES

Page 106: Presentation On Environmental Management At Iit Roorkee

Urea Process generates process water containing NH3-6%,CO2-2% &

Urea-1.0% by weight.

The principal source of this water is the synthesis reaction whwre 0.3 tonnes of

water is formed per ton of Urea.

2NH3+CO2→CO(NH2)2+H2O

The other sources of water are ejector steam,flush and seal water and steam used

in the waste water section.

The principal sources of urea ,NH3 and CO2 in the process water are:-

a)Presence of Ammonia in the urea solution feed to the evaporator

b)The formation of Biuret and the hydrolysis of urea in the evaporators,both

liberating NH3

2CO(NH2)2 →H2NCONHCONH2+NH3

CO(NH2)2+H2O →2NH3+CO2

c)Direct carry over of Urea from the evaporator separators to the

condensers(Physical entraiment)

d)The formation of NH3 from the decomposition of Urea ti Isocyanic Acid

CO(NH2)2 →HNCO+NH3

The reverse reaction occurs on cooling the products in the condensers.

(e) Off-gases from the recovery/recirculation stage absorbed in the process water.

(f) Off-gases from the synthesis section absorbed in the process water.

(g) Flush and purge water from pumps.

(h) Liquid drains from the recovery section.

Page 107: Presentation On Environmental Management At Iit Roorkee

Treated water : Urea-5 ppm,Ammonia-30 ppm

The purpose of the water teatment is to remove Ammonia,CO2,and Urea from the

process water and recycle the gases to the synthesis.This ensures raw material

utilisation is optimised and effluent is minimised.

Prill Tower Emissions

The prill tower is a major source of emission in urea plants. The large volumes of

discharged untreated cooling air contain particulate urea dust (1-2kg/t) as well as

NH3 (0.7-1.0kg/t).

Causes of dust formation

Page 108: Presentation On Environmental Management At Iit Roorkee

Cause Particle Size

Range

Dust %of

Total

Condensation products of urea vapours/aerosols 0.5-2.0µm 50

Reaction product of NH3 and isocyanic acid

(HNCO) to form Urea

0.1-3.0µm 20

Prill satellites and undersize prills 10-100µm 5

Crushing, abrasion and attrition on the tower floor 1-100µm 5

Seeding dust 1-20µm 20

Towers with natural draft cooling are reported to have less dust emission than

towers with forced/induced draft air cooling.

The lower air velocity and product mass per m 3 of tower volume reduces attrition and carryover in the natural draft towers.

Operation and maintenance items significantly affecting dust formation

•Fouling of the prilling device causing wider spread in prill granulometry.

•High melt feed temperature causing increased evaporation.

•High prill temperature at the tower base. The largest prills may not have solidified sufficiently and will fracture on impact.

•Dust emission is approximately proportional to prilling tower capacity.

•High air velocities and the air velocity distribution cause coarse dust to be entrained.

•Weather conditions e.g. relative humidity, temperature can affect the air quality/quantity.

•Unequal pressure in the prilling device causing a broad spread of prill size.

Page 109: Presentation On Environmental Management At Iit Roorkee

Prill Tower (Not Scrubbed) Urea Dust NH3

mg/Nm3 kg/t Mg/Nm3 kg/t

35-125 0.5-2.2 35-245 0.5-2.7

Prill tower emission abatement

Selection of the appropriate equipment for existing plants can be a complex issue.

Dry dust collectors, irrigated electrostatic

precipitators and irrigated dust scrubbers have been considered for dust

abatement but few have been commercially proven

. Wet scrubbers seem to be more attractive than dry dust collectors. Recovery of

the NH3 from the emission (for example by

aqueous scrubbing) is very inefficient due to the low partial pressure of the gas in the discharged air.

Existing prilling plant performance

Causes of dust formation

The following reflects some speculations about the causes of dust formation .

•Urea vapour formation during hot spraying of the urea melt and its subsequent

condensation/solidification into small

•(0.5-3.0mm) particles. The vaporisation becomes negligible when the melt concentration is reduced to 95%.

•Reaction product of NH3 with isocyanic acid to form Urea.

•Entrainment of fine dust in the air.

Page 110: Presentation On Environmental Management At Iit Roorkee

•Solidification of sprayed molten urea droplets prior to coating due to excessive• air flow.

•High vapour pressure of sprayed molten urea.

•High or low temperature, producing soft or brittle granules.

•Inter-granular friction causing surface abrasion

Feasible and Available Emission Abatement Techniques

Gaseous emissions

•Scrubbing of off-gases with process condensate prior to venting inerts toAtmosphere.

•Wet scrubbing of prill tower and granulation air to recover urea and NH3.

•Connection of ammonia pump safety relief valves/seals to a flare; connection of

• tank vents to the plant main stack• or other safe location.

•Impact of granules with the metal surface of the drum.

•Dust reduction by producing granular rather than prilled product.

•Bag filtration of dust laden air from transfer points, screens, bagging

machines, etc. coupled with a dissolving system for recycle to the process.

•Flash melting of solid urea over-size product for recycle to the process.

•Collection of solid urea spillages on a dry basis

Liquid emissions

Treatment of process waste water for recovery of urea, NH3 and CO2.

Improved evaporation separator design to minimize urea entrainment.

Provision of adequate storage capacity for inventory to cater for process upset

and shut-down conditions.

Page 111: Presentation On Environmental Management At Iit Roorkee

•Provision of submerged tanks to collect plant washings, etc. from drains for recycle to the waste water treatment section.

•Use of mechanical seals instead of gland packing for pumps.

•Use of closed circuit gland cooling water system for reciprocating pumps.

•Replacement of reciprocating machinery with centrifugal type.

Solid waste

In the modern urea processes although the sophisticated handling of product

urea has reduced the chances of spillage,

still the formation of lumps and some spillage of urea prills cannot be ruled out.

To meet this exigency, a urea melting

system to employed. The melt urea obtained from the spillages and sweeping should be suitably recycled in the processes.

Ambient Air Limit

SPM

500 µ g / NM3

SO2

120 µ g / NM3

NO2 120 µ g / NM3

NH3 400 µ g / NM3

Page 112: Presentation On Environmental Management At Iit Roorkee

NOx 100 PPM

SOx 500 PPM

CO 50 PPM

SPM 500 PPM

Urea

50 mg / NM3

NH3 50 PPM

Stack Limit

Prill Tower Limit

Page 113: Presentation On Environmental Management At Iit Roorkee

Effluent Discharge Limit

MINAS Norms UPPCB Norms

PH 6.5-8.0 5.5-9.00

colour absent absent

NH3 (Total) 50 PPM 100

Free NH3 4 PPM 5 PPM

TKN 100 PPM 150 PPM

COD 250 PPM 250 PPM

BOD 30 PPM 30 PPM

Cl- 600 PPM 600 PPM

Oil & grease 10 PPM 10 PPM

TSS 100 PPM 100 PPM

Cr (Cr+6) 0.1 PPM 0.1 PPM

Po4- - 5 PPM

Zn - 5 PPM

V+5 - 0.2 PPM

Page 114: Presentation On Environmental Management At Iit Roorkee

Raw Water Analysis

PH 8.1

CONDUCTIVITY 560

TH 44

Ca AS Caco3 ppm 29

Mg as CaCo3 ppm 15

P. Alk as CaCo3 NT

M Alk as Ca Co3 219.25

Cl as Cl 17.73

Sulphur as so4 37.03

Iron as Fe 0.08

Silica as Sio2 20

T..D.S 302

Turbidity NTU <1.0

Sodium as Na 106

Nitrite as NO3 0.30

Page 115: Presentation On Environmental Management At Iit Roorkee

CARBON DIOXIDE RECOVERY (CDR) FROM FLUE GASES OF PRIMARY

REFORMER AT IFFCO AONLA UNIT

IFFCO, a premier fertilizer company has installed and commissioned Carbon

Dioxide Recovery (CDR) Plant at it‟s Aonla & Phulpur Units for recovery of CO2

from Primary Reformer Flue Gases based on the technology from M/s Mit

subishi Heavy Industries (MHI) Limited, Japan and Detailed Engineering from M/s

Tecnimont ICB (TICB) Private Limited, Mumbai.

The CO2 recovered from flue gases makes up for deficit of CO2 due to use of Lean

NG / R-LNG & leads to conversion of all the Ammonia produced to Urea, thus

avoiding Ammonia stock build up. The recovery of CO2 from flue gases also

reduces CO2 emissions (Green house gas) to atmosphere and thus contributes to

cleaner environment.

Carbon Dioxide (CO2) Recovery from Flue Gases.

The CO2 Recovery from flue gases is having following distinctive advantages:

It reduces CO2 emissions (Green house gas) to atmosphere, contributes to

cleaner environment, conserves carbon intensive fossil fuels like Naphtha and

thus has a great potential to be covered under Clean Development Mechanism

(CDM) of UNFCCC. The trading of certified emission reductions (CERs) through

CDM generates additional revenues & increases the viability of the CDR Project.

Page 116: Presentation On Environmental Management At Iit Roorkee

Production of additional CO2 from CDR unit in place of costlier Naphtha feed,

shall decrease cost of production of Urea and hence shall reduce Government

of India‟s annual subsidy outgo.

SALIENT FEATURES OF CDR PROJECT

The following are the salient features of CDR Project ordered on M/s TICB,

Mumbai & M/s MHI, Japan :

Source of CO2 : Flue gases from Primary Reformer stack of

Ammonia Plant

Plant Capacity : 450 MTPD CO2 (100% basis)

MHI CDR PROCESS

The CDR plant consist of four main sections; 1) Flue gas pre-treatment section,

2) CO2 absorption section, 3) Solution regeneration section, 4) CO2 compression

section. The following block flow diagram shows the plant configuration.

CO2 RICH

SOLUTION

CO2 LEAN

SOLUTION(2)

CO2

Absorption

(3)

Solution

Regeneratio

n

FLUE

GAS

TREATED

FLUE GAS

Flue Gas Source

(Primary

Reformer)

(1)

Flue Gas

Pretreatment

(4)

CO2

Compressio

n CO2 Product

fnfp’I’I’To Urea Plant

Co2 product

Page 117: Presentation On Environmental Management At Iit Roorkee
Page 118: Presentation On Environmental Management At Iit Roorkee

•1) Flue Gas Pre-treatment

The hot flue gases at about 150 – 180 0C are cooled to 42 0C, using flue gas

cooling system prior to the CO2 absorption in Absorber, to optimise KS-1

solution consumption & lower flue gas temperature which is favourable for

CO2 absorption.

The Flue gas water cooler is a packed column with SS structured packing.

Flue gas is cooled in the upper packing section of the Flue gas water cooler

by direct contact with water supplied from top of the tower. Circulating water

is cooled by a plate type heat exchanger. De-SOx (SOx removal) is carried out

in the lower packing section of Flue gas water Cooler by circulating dilute

caustic solution. Any slippage of SOx in the Flue gas from Flue gas water

cooler to CO2 Absorber shall cause KS-1 Solvent degradation.

A Flue gas blower has been provided at downstream of Flue gas water cooler

to draw the flue gas from existing stack to overcome the pressure drop

across Flue gas water cooler & CO2 Absorber.

•The cooled flue gas from the Flue gas water cooler is introduced into the bottom

section of the CO2 absorber through flue gas blower. The flue gas comes in

contact with the KS-1 solution on the surface of the packing in absorption section,

•2 ) CO2 Absorption

The CO2 absorber is a packed bed column with SS structured packing. The CO2

absorber has two main sections namely, the CO2 absorption section in the lower

part, and the treated flue gas washing section in the upper part.

Page 119: Presentation On Environmental Management At Iit Roorkee

where CO2 in the flue gas is absorbed by the KS-1 solution. The flue gas then

moves upward into the treated flue gas washing section in the upper part of the

CO2 absorber . The flue gas comes in contact with water for washing of entrained

amine content, as well as for cooling down to maintain water balance within the

system. The treated flue gas is exhausted from the top section of the CO2

absorber at sufficient height.

Rich solution from the bottom of the CO2 absorber is pumped to the Regenerator

through Solution heat exchangers to exchange heat with hot lean solution from

Regenerator bottom.

•3) Solution Regeneration

The Regenerator is a packed column with random SS packing, where the rich solution is

steam-stripped and CO2 is removed from the rich solution.

The rich solution (from the bottom of the CO2 absorber) after exchanging heat with the hot

lean solution (from bottom of regenerator) in “Solution heat exchangers” enters the upper

section of the regenerator. The regeneration heat is indirectly supplied by LP Steam

through re-boilers.

The overhead vapor from Regenerator column is cooled to 40C in Regenerator

condenser using cooling water. The condensed water is returned from the Regenerator

reflux drum to the top of the Regenerator by the Regenerator reflux pump to enhance

CO2 purity, remove KS-1 mist entrained in CO2 gas & maintain water balance in the

system .

Page 120: Presentation On Environmental Management At Iit Roorkee

The lean solution is cooled to the optimum reaction temperature of 40C by the

Solution heat exchangers and the Lean solution cooler prior to being fed to the CO2

absorber. 10% of the lean solution flows through a carbon filter system to eliminate

oil and soluble impurities. The mechanical guard filters are provided before and

after the carbon filter to remove insoluble particulate.

•4) CO2 Compression

The CO2 product gas is compressed by the CO2 compressor & then cooled in a

Compressor discharge cooler to supply product CO2 at a pressure of 0.8 Kg/cm2g

& temperature of 40 C at CDR plant battery limit. The product CO2 having purity

around 99.8 %(v/v) is sent to the existing Urea Plants by interconnection with

existing CO2 header.

Page 121: Presentation On Environmental Management At Iit Roorkee

ENVIRONMENTAL POLICY OF IFFCO AONLA

IFFCO Aonla unit is committed for continual improvement and protection of

environment by setting and reviewing the objectives and targets through

Environmental Management System focussing at: :-

•Compliance of applicable legislation at work place and other

requirements, which the organization subscribe.

•Monitoring and conserving natural resources.

•Effluent and waste minimization by way of recycling and reuse.

•Developing awareness and competence amongst Employees,

Contractor’s Staff and related agencies on environmental issues.

•Emergency preparedness for safety of concerned personnel and plant.

Page 122: Presentation On Environmental Management At Iit Roorkee

Achievement of Objective & Target of 2006- 07

No.1. To achieve Urea spillage not more than 397 MT/Month in 2006-07 by

reducing 5% of the value achieved in 2005-06 i.e 418 MT/Month.

Achieved 390 MT/Month Urea Spillage in year 2006-07.

2.To reduce water consumption below 6.70 M3/MT of urea production in year 2006-

07.

Achieved 5.40 M3/MT Urea Production in year 2006-07.

•To plant minimum 10,000 trees in plant and township.

10285 Trees planted during year 2006-07 in plant and township.

•To keep SPM particulate matter in ambient air below 200 micrograms/nm3 in plant.

Achieved annual average value of SPM in Plant 181.75 Microgram/NM3.

•To bring awareness among new / transferred employees, contractor’s staff and

related agencies on relevant environmental issues to minimum 200 participants.

Imparted awareness on environmental issues to 200 participants.

Page 123: Presentation On Environmental Management At Iit Roorkee

Point Quantity

(A)

Occurrence

(B)

Impact

(C)

Legislation

(D)

Detection

(E)

Control

(F)

5 Excessiv

e

Continuous Human

Health

Not

Meeting

More than

24 hours

Absence

4 High Daily Flora

Fauna

and

Global

issue

Within 24

hours

Mechanis

m

Provided

3 Medium Once a

Week

Resource

Depletion

Not

meeting

Company’s

Threshold

Limit

Within 8

Hours

Human

Interventio

n

2 Low Once a

month

Cause

Discomfor

t

Within 1

Hours

In built

secondary

Control

1 Negligibl

e

Very Rare Negligible Complianc

e

Immediatel

y

Available

&

Effective

Environmental Aspects Analysis Criteria :G = AxBxCxDxExF

Page 124: Presentation On Environmental Management At Iit Roorkee

Sr.No. Activit

y

Category of

Area/Zone

Day Time

(6AM to

10PM)

Night Time

(10PM to 6

AM)

Applicable

Section of

Rules

1.0 (A) Industrial area 75 70 Schedule as

per rule 3(1)

& 4(1) The

Noise

Pollution

Rules, 2000

2.0 (B) Commercial

area

65 55

3.0 © Residential

area

55 45

4.0 (D) Silence zone 50 40

AMBIENT AIR QUALITY STANDARDS IN RESPECT TO NOISE

Page 125: Presentation On Environmental Management At Iit Roorkee
Page 126: Presentation On Environmental Management At Iit Roorkee

Journey from barren land

to

large and eco-friendly

fertiliser complex

Page 127: Presentation On Environmental Management At Iit Roorkee

Aonla site in 1984

( Land acquisition )

Page 128: Presentation On Environmental Management At Iit Roorkee

Aonla site in 1988

( Aonla-I commissioned )

Page 129: Presentation On Environmental Management At Iit Roorkee

Aonla site in 2007

( Large & eco-friendly fertiliser complex )

Page 130: Presentation On Environmental Management At Iit Roorkee

N.P.RAO