Brief description of Modification/ Revamping of Ammonia-Urea Plant Including installation of GT-HRSG at IFFCO Phulpur.

Transcription

1 Introduction Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit II in Year Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plant is based on Haldor Topsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti s Italy. It is proposed to implement various Modification/ Revamping of Ammonia- Urea Plant including installation of GT-HRSG at IFFCO Phulpur to implement the latest available proven Technological solution to improve Reliability of Process / Equipments and to reduce the Energy Consumption by Gcal per MT Urea in Phulpur-I and Gcal per MT Urea in Phulpur-II. The application for granting TOR for the above project at IFFCO Phulpur was submitted (online) to Ministry on 23 rd July, The Expert Appraisal Committee (Industry 2) during its 46 th meeting held on 20 th and 21 st August, 2015 opined that the proposal is incomplete and to be submitted along with details of existing plant configuration and proposed modifications to be carried out. Further it was suggested to submit the revised proposal along with Form-1 which should include information such as existing water requirement, waste water management, solid waste management etc. Also it was observed by the Committee that there is no increase in production. However, only few units are being changed which involves amendment of existing environmental conditions. The copy of above letter No. J-11011/198/2015-IA II (I) dated 13 th October, 2015 is enclosed. In line with the above the revised proposal is being submitted. Page 1 of 22

2 CHAPTER-I Executive Summary Indian Farmers Fertiliser Cooperative Ltd. (IFFCO) is engaged in large scale production and marketing of Fertilisers with the objective of helping the country to achieve self-sufficiency in food grain production. IFFCO Phulpur Unit-I was commissioned in Year 1981 and Unit II in Year Existing Ammonia-I Plant is based on MW Kellog Technology and Ammonia-II Plant is based on Haldor Topsoe Technology, Denmark. Urea-I & II Plants are based on Process Technology of Snamprogetti s Italy. Total Urea Production Capacity of Phulpur Unit is 5145 TPD (18.78 lakh MT per annum considering 365 stream days). Initially, Phulpur Complex was designed and operated with Liquid Hydrocarbon & Naphtha to be used as Feed and Fuel. In line with the Government of India (GOI) directives, the Feed Stock and Fuel was switched over from Naphtha to Natural Gas in the year The Site occupies an area of 432 hectares out of which about 130 hectares is occupied by the plant where industrial activity is performed. 1. The actual production for last 3 year is given below: Products UNIT-I : Ammonia Urea UNIT-II: Ammonia Urea Total: Ammonia Urea Actual production (MT) The present Raw material consumption: Particulars Unit Phulpur-I Phulpur-II Total Urea Production MTPD Feed NG SM3/day Fuel NG SM3/day Coal MT/day Fuel to SG SM 3 /day Ammonia Energy Gcal/MT Urea Energy Gcal/MT Page 2 of 22

3 3. The utilities (Water, Power & Steam) consumption. The Water consumption of Phulpur Complex is around 35,500 M 3 per day. The water is being sourced through Borewells provided within IFFCO premises. Normally 4,200 M3 per day waste water which includes around 2,400 M 3 per day Cooling water blow down is being generated which is treated in the Effluent Treatment Plant. Part of the treated Waste water is being recycled in the plant after treatment in Reverse Osmosis (RO) Plant. The reject of RO Plant is being used for dust suppression in Coal Yard/Ash Pond. The balance treated waste water is being used for Green Belt development, Horticulture and for dust suppression in Coal Yard and Ash Pond. There is no discharge of effluent from the complex. The quality of treated effluent meets the limit specified by Pollution Control Board. The Online monitoring system for flow and quality of treated Effluent has been installed. The Steam Generation facility consists of 3x125 MT/hr Coal Fired Boilers (2 working and 1 standby), 1x200 MT/hr LSHS/Gas Fired Boiler, with total Steam Generation capacity of 450 MT Steam per hr. Around 32.7 MT per Hour Coal and 12,387 SM3 per Hr NG is being used. For meeting the total power requirement, Phulpur unit is having two Turbo Generators of capacity 12.5 MW and 18 MW respectively. The Offsites facilities include water De-Mineralisation plant, Water Softening Plant, Ammonia Storage Tank, Inert Gas generation unit and Air Compressors for Instruments and Plants. 4. Energy Consumption of Plants: The average Energy Consumption of Phulpur Unit I & II in last 3 years is as follows: Table-1 Unit Average Phulpur-I Gcal / MT Urea Phulpur-II Gcal / MT Urea Revamping / Modification of the Plant: Urea business in India is covered under Essential Commodity Act (ECA) and same is governed by Department of Fertilizer (DoF), Government of India. As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced w.e.f. 1 st June, 2015 tp 31 st March, 2018 to Gcal/MT Urea for Phulpur-I and Gcal/MT Urea for Phulpur-II and for , 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II. Page 3 of 22

4 Unit Unit Energy Norms as per new Urea Policy 2015 Present Average Energy (in last 3 years) Table-2 Difference Phulpur-I Gcal/MT Urea Phulpur-II Gcal/MT Urea From Table 1 & 2, it may be concluded that with present energy consumptions, the operation of Phulpur Complex will become unviable. Therefore, in order to remain competitive, IFFCO has undertaken Modification/ Revamping of its Ammonia Urea Complex to reduce the Specific Energy consumption of Plant. 6. Proposed Modification/Revamping Schemes: It is proposed to implement various Modification/ Revamping of Ammonia- Urea Plant including installation of GT-HRSG at IFFCO Phulpur to implement the latest available proven Technological solution to improve Reliability of Process / Equipments and to reduce the Energy Consumption by Gcal per MT Urea in Phulpur-I and Gcal per MT Urea in Phulpur-II. The configuration of Ammonia Urea Complex of Phulpur Unit along with proposed Revamping/ Modification is placed at Annexure-I. The schemes being implemented are as under: Phulpur-I S. No. Schemes under consideration Plant Modification in CO2 Recovery Process amdea 1. Ammonia Process in place of existing GV Process 2. New Efficient LO / SO Backpressure Turbines Ammonia 3. Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement Ammonia 4. Installation of VAM for Process Air Compressor Suction Chilling Ammonia 5. Ammonia Recovery from Synthesis Loop LP Purge Gases Ammonia 6. Saturated MP Steam Export from Synthesis Loop to Urea Plants Ammonia 7. Installation of MP Stripper for Process Condensate Stripping Ammonia 8. New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C) Ammonia 9. Synthesis Gas Converter (105D) Revamp Ammonia 10. Installation of HP Ammonia Pre-heater Urea 11. Installation of VAM for Urea CO2 Compressor Suction Chilling Urea Page 4 of 22

5 12. New Urea Reactor Trays Urea 13. New GT-HRSG package SGP Phulpur-II Replacement of Process Air Compressor Turbine (101-JT) & Refrigeration Turbine 105JT Installation of New Ammonia Storage Tank (double wall double integrity), Capacity 10,000 MT SGP Offsite S.No. Schemes under consideration Plant 1. Revamping of Synthesis Gas Compressor Ammonia Modification in CO2 Recovery Process amdea Process in place of existing GV Process Ammonia Wash (Syn gas drying) in synthesis compressor interstage and loop reversal Installation of Fuel gas Expander with inter and after preheaters and bypass arrangement Ammonia Ammonia Ammonia 5. Revamping of CO2 Compressors Urea 6. Installation of HP Ammonia Preheater (2 Nos.) Urea 7. New Urea Reactor Trays (2 Set) Urea 7. Consumption of Raw Material and Utilities after Revamp. The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM 3 per day after Revamp at same production level. Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation. The Water consumption of Phulpur Complex will not increase after Revamp and there will be reduction of wastewater generation. There will be reduction in emission of SO 2 due to partial replacement of Coal with NG having Sulphur content as low as less than 10 ppm. Further, there will be reduction in daily consumption of NG which will reduce the over-all pollution load in the surrounding environment. 8. Emission Load- Before and after Revamp: The present emission loads of CO 2 around MT/hour considering the present Fuel consumption. After revamp the emission load of CO 2 would be 95.3 MT / hour considering the projected Fuel consumption maintaining the same production level. Further, the emission level of PM, SOx & NOx is expected to reduce due to reduction in consumption of NG and Coal at same production level as explained above. Further, there will be reduction of wastewater generation around 900 m3 per day at same production level. Page 5 of 22

6 9. Capacity of the Plant after Revamp: The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remain the same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days). 10. Proposal: As per the Notification dated 22 nd August, 2013 of MoEF, any modernization of existing project entailing the capacity addition with change in Process and/ or Technology shall be undertaken only after prior Environment Clearance. The proposed Revamp does not entail any capacity addition and no process change and/or Technology Change are being carried out. Hence, seeking prior Environment Clearance was not applicable in this case. Further, the Expert Appraisal Committee (Industry 2) during its 46 th meeting held on 20 th and 21 st August, 2015 considered the above proposal. The MoEF&CC vide letter dated J-11011/198/2015-1A II (I) observed that there the proposal does not contain details of existing plant configuration and proposed modification to be carried out. Further, the information regarding water consumption, energy requirement, waste water management, solid waste management is incomplete. Further, it was opined that although there is no increase in production but only few units are being changed which involves amendment of existing environmental conditions. Accordingly, it was suggested to submit revised complete proposed with Form-I. In view of the above, the revised proposal has been prepared which includes: (i) details of existing plant configuration and proposed modification to be carried out; (ii) water consumption; (ii) energy requirement; (iii) waste water management; and (iv) solid waste management, etc. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14 th July, 2006 may be amended. Proposed changes in Environmental condition are attached as Annexure-II. Page 6 of 22

7 CHAPTER-II The existing Environment & Pollution Control Management: 1. Various Emission Control Measures: IFFCO Phulpur is committed to reduce Green House Gas (GHG) emissions through implementation of innovative and pioneering projects. The various initiatives that have resulted in significant reduction of GHG emission are: (i) Switchover of Fuel and Feed from Naphtha to Natural Gas (NG); (ii) Installation of Carbon Dioxide Recovery to recover 450 MT CO 2 per day from Flue Gases to meet the short fall of CO 2 for Urea production; and (iii) various energy efficiency measures to reduce the consumption of NG. Further, for control of Air emission, Electro Static Precipitators (ESP), Cyclonic Dust Collectors, Scrubbers for Gaseous Emissions, Flare Stacks, and Chimneys of adequate height for Steam Generation units have been installed and operated efficiently. The Stack emissions are always well within the prescribed limits stipulated by UP State Pollution Control Board (UPSPCB) & National Emission Standards. The copy of report submitted to UPSPCB for Emission from the Stack and ambient air quality for the month of December, 2015 is attached as Annexure-III. Stack Emission Quality (Range) for the last three year ( ) are as under: Sample Point UREA DUST (mg/nm 3 ) PCB limit: (i) 150 mg/nm3 for Prill Tower-I (ii) 50 mg/nm3 for Prill; Tower-II) SPM (mg/nm 3 ) (PCB limit: < 350 mg/nm3) Year Power Plant-I NA NA NA Power Plant-II NA NA NA Prilling Tower-I NA NA NA Prilling Tower-II NA NA NA Sample Point SO2 (mg/nm 3 ) (PCB limit: <200 ppm or 571 mg/nm3) NOx (mg/nm 3 ) (PCB limit: <100 ppm) Year Power Plant-I Power Plant-II < 1.0 < 1.0 < Pri. Reformer -I <1.0 <1.0 < Pri. Reformer -II <1.0 <1.0 < Stack HRU stack <1.0 <1.0 < Page 7 of 22

8 The ambient air quality in surrounding area of the factory is well with-in the limits. Ambient Air Quality (Range) for the last three year ( ) is given below: AAQ Monitoring Stations PM 10 SO 2 (microgram/m 3 ) (microgram/m 3 ) CORDET Central School Railway Gate B.W.No Gate No AAQ Monitoring Stations Ammonia (microgram/m 3 ) NOx (microgram/m 3 ) CORDET Central School Railway Gate B.W.No Gate No A brief description of Air Pollution Management Practices implemented at IFFCO Phulpur Unit is attached as Annexure-IV. 2. Effluent Management: The liquid effluents generated from the various plants are subjected to adequate Treatment viz; (i) Deep Hydrolyser; (ii) Distillation Column; (iii) Stripper; (iv) Effluent Treatment Plant based on Steam Stripping; (v) Disc Oil Separator; and (vi) Reverse Osmosis Plant. The treated water from Reverse Osmosis plant is reused in process as cooling water make up. The domestic Sewage Water is treated in Sewage Treatment Plant and reused as Cooling Water make up and for Irrigation of Farm Land. The Sewage sludge after drying is utilised as manure in our Farm Land. The present facility for liquid effluent treatment is sufficient for present & future need and IFFCO ensure that the treated water quality will confirm to the specification laid down by State Pollution Control Board. The entire effluent generated in the plant is being recycled / reused in plant process and irrigation after adequate treatment in the ETP. There is Zero Discharge of Treated Effluent from the plant premises. The treated effluent quality is well within the specified limit of UPPCB. The copy of the report on quality of effluent at Guard Pond for the month of December, 2015 is placed at Annexure-V. Page 8 of 22

9 The Analysis of Effluent (Guard Pond) for last three year ( ) are as under: Characteristics (All values are mg/l except ph) PCB norms ph TSS < BOD 5 at 20 deg C < Oil & Grease <10 3-N.T Absent Total Chromium as Cr, 2.0 N.T. N.T. N.T. Hexavalent Chromium 0.1 N.T. N.T. N.T. as Cr +6 Zinc as Zn < COD < Chlorides as Cl < Free Ammonia As N < Total Kjeldahl < Nitrogen as N Nitrate Nitrogen as N < Dissolved Phosphate < Vanadium as V <0.2 N.T. N.T. N.T. A brief description of Waste Water Management Practices implemented at IFFCO Phulpur Unit is attached as Annexure-VI. 3. On line Monitoring System: On line monitoring systems for Flow and Quality of Liquid Effluent and emission from Boiler Stack have been installed at IFFCO Phulpur Unit. The Online monitoring system has also been installed at Prill Tower on trial basis as per direction of CPCB. The data connectivity with CPCB server has been established. Detail of this system is attached as Annexure-VII. 4. Solid Waste (Hazardous & Non-hazardous): All the applicable provision of Hazardous Waste (Management, Handling & Trans Boundary) Rule 2008 are being complied as per Authorisation No. 108/ HW- 52/14 dated 10/07/14 issued by UPSPCB. The report on Hazardous Waste for the year is placed at Annexure-VIII. Solid wastes are disposed in efficient manner. Fly Ash is being given to Cement Industry for use in manufacturing of Cement. Also Fly Ash is being used for Fly Ash Brick making, reclaimation of Usar land and Land filling of low lying area. The Spent Catalyst & Waste Oil is being sold to authorized Recycler as per Hazardous Waste Rule is a regular process. Detail of Solid Waste Management practices is attached as Annexure-IX. Page 9 of 22

10 5. Rain Water Harvesting Systems: To conserve the Rain Water, we have installed 8 Nos. Rain Water Harvesting Systems at different places as per detail placed at Annexure-X. 6. Management System as per International Standards: IFFCO Phulpur Unit has established and implemented Environment Management System, Quality Management System, Energy Management System and Occupational Health, Safety Management System as per the Norms of International Organisation for Standardization (ISO). It has been accredited ISO 14001: 2004 for Environment Management System, ISO 9001: 2008 for Quality Management System, OHSAS 18001:2007 for Occupational Health, Safety Management System, & ISO 50001:2011 Certification for Energy Management System. IFFCO Phulpur has received ISO 14001: 2004 Certification for: (i) Factory Premises; (ii) Residential Township, Ghiya Nagar; (iii) IFFCO Hospital, Ghiy Nagar; and (iv) Moti Lal Nehru Farmers Training Institute, Phulpur located nearby the factory. Copy of above certificates is attached as Annexure-XI. 7. Environment Clearance: Existing Environment Clearance was issued by Ministry of Environment and Forest on 14 th July, 2006 vide letter No. J-11011/150/2006-IA II (I) for Capacity Enhancement- De-bottlenecking and LNG Conversion Project of IFFCO Phulpur Unit. Copy of this Environment clearance is attached here as Annexure-XII. This LNG conversion project has been completed in July 2006 & Capacity Enhancement Project in December Inspection of Unit to check the compliance of Environment Clearance condition by Officers of MoEF & CC are being carried out regularly. Certified compliance report of the conditions issued by MoEF&CC, Lucknow vide letter No. IV/ENV/UP/IND-83/204/2006/769 dated 11/09/2015 is placed at Annexure-XIII. The latest compliance report of April, 15 to September, 15 is attached as Annexure-XIV. 8. Consent for Air Emission, Liquid Effluent & their status: Consent for Air Emission under Air Act 1981 (No. 186/C-9/Sahmati8(Vayu) /2/7/2014 dated 3/2/14) and consent for Effluent discharge under Water Act 1974 (No. 191/C-9/sahmati Jal /52/2014 dated 3/2/14), was issued by U.P. Pollution Control Board (placed at Annexure-XV) which is valid upto 31 st December, Applications for renewal of both consents has been submitted to U.P. Pollution Control Board (placed as Annexure-XVI). Page 10 of 22

11 CHAPTER-III Description of Energy saving schemes to be implemented in Ammonia plant Phulpur-I Unit Scheme-1: Reduction in Steam to Carbon ratio in Reforming Section from 3.3 to 3.0 and replacement of existing GV solution based CO 2 removal section by amdea solution based CO 2 removal Section. The existing GV solution based CO2 Removal section shall be replaced by amdea solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in amdea solution from process gas. CO2 rich amdea solution shall be regenerated. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated amdea solution shall be again sent to CO2 Absorber to absorb CO2 from process gas. Scheme-2: Replacement of Process Air Compressor Turbine and Refrigeration Compressor Turbine in Ammonia-I Plant. The Turbines will be replaced with new efficient turbines. The Replacement will be on the same base frame and inlet & outlet connections will be hooked-up with existing lines Scheme-3: New Efficient LO / SO Back Pressure Turbines. After changeover from GV to amdea System the LP Steam reboiler will be no more required. If the inefficient lube oil and seal oil turbines are not replaced, the LP Steam will be required to vent. With the replacement of New Efficient Steam Turbines there will be less generation of LP Steam and avoiding venting of steam. Scheme-4: Installation of Fuel Gas Expander with power generator. NG fuel which is let down in existing system from around 40 kg/cm2g to 4.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW. Scheme-5: Installation of Vapour Absorption Machine for the cooling of inlet air to Process Air Compressor. A Vapour Absorption Machine (VAM) shall be installed in Ammonia-I to generate chilled water for new process air chiller to be installed at the suction of Process Air Compressor. This shall cool the inlet air of Process Air Compressor from 40 C to 15 C, resulting in saving of NG being used as fuel for Gas Turbine drive of Process Air Compressor. The heating medium in VAM machine shall hot water from Primary Reformer Convection Coil. Page 11 of 22

12 Scheme-6: Ammonia Recovery from Synthesis Loop LP Purge Gases. It is proposed to recover ammonia from the flash gas from synthesis loop off gas in new Flash Gas Washing Column. This modification shall result in additional Ammonia Recovery of 2 MT/Day. Sweet Water Cooler system shall be replaced with new heat exchanger using cooling water directly as cooling medium for better cooling of syn gas. This shall also reduce loop pressure by around 5 kg/cm2 and steam saving in Syn Gas Compressor turbine by around 2 MT/hr. Scheme-7: Saturated MP Steam Export to Urea Plant. The Saturated MP Steam will be exported to Urea Plant for use of Process Steam at 25 ata pressure after letdown from 39 ata. This will reduce requirement of Inlet Steam in CO2 Compressor Extraction- cum- Condensing Turbine of Urea Plant as there will be less requirement of extraction steam. The Net Saving will be realized in terms of less condenser load of Synthesis Turbine and CO2 Turbine together. Scheme-8: Installation of MP Stripper for Process Condensate Stripping. The existing system will be replaced with MP Steam Process Condensate Stripper. With the proposed modification, the MP Steam is used which after stripping off the gases goes back to the steam circuit. Scheme-9: New parallel Methanator Effluent Cooler (115-C) and BFW Heater (145-C). Existing 115-C is not sufficient enough to cool down the syn gas to the optimum temperature of degc. With additional Exchanger I parallel the cooling water availability will be increased which will reduce the syn gas temperature. In the new system one additional BFW Heater will be installed to recover heat from the hot process gas before it enters the CO2 Removal Section. Scheme-10: Synthesis Gas Converter (105D) Revamp. It is proposed to revamp the internals of Synthesis Gas Compressor with new patented technology internals. This intervention will result in improvement in the NH3 Conversion from 2.5 to 17 mol% and maximizing the heat recovery in the form of steam generation. Description of Energy saving schemes to be implemented in Urea plant of Phulpur-I Unit Scheme-1: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion. The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, Page 12 of 22

13 by improving the heat and mass transfer phenomena occurring inside the reactor. Scheme-2: Installation of Ammonia Preheaters. In Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce. Scheme-3: Installation of Vapour Absorption Machine for the cooling of inlet CO2 gas to CO2 Compressor. A Vapour Absorption Machine (VAM) shall be installed to generate chilled water required for CO2 Gas chiller to be installed at the suction of CO2 Compressor of Urea plant. This shall cool inlet CO2 gas of CO2 Compressor from 45 C to 20 C, resulting in saving of steam consumption in CO2 Compressor turbine of Urea plant. The heating medium in VAM machine shall be LP steam. Description of Energy saving schemes to be implemented in Ammonia Plant of Phulpur-II Unit Scheme-1: Reduction in steam carbon ratio in Reforming section from 3.3 to 3.0 and replacement of existing GV solution based CO2 removal section by amdea solution based CO2 removal section for less energy requirement. The existing GV solution based CO2 Removal section shall be replaced by amdea solution based CO2 Removal section. A new Bulk Absorber in addition to existing CO2 Absorber shall be used to absorb CO2 in amdea solution from process gas. CO2 rich amdea solution shall be regenerated in three stages, firstly in HP Flash Vessel, then in LP Flash Vessel and finally in CO2 Stripper. The source of regeneration energy shall be only process gas. CO2 separated shall be sent to Urea plant for the production of urea. Regenerated amdea solution shall be again sent to CO2 Absorber to absorb CO2 from process gas. Scheme-2: New Ammonia wash system in Synthesis Gas Compressor 2nd discharge to remove oxygenated compounds from synthesis gas and sending 3rd stage discharge directly to recirculator stage discharge. In order to increase the energy efficiency of the synthesis loop, a syngas dehydration system based on liquid ammonia washing shall be introduced at Synthesis Gas Compressor second stage discharge. The oxygenated compounds (H2O, CO and CO2) available in Syn Gas shall be separated in Page 13 of 22

14 ammonia wash system. With this modification, Syn Gas Compressor 3rd stage discharge which is free from oxygenated compounds, can be mixed directly with recirculator discharge and fed directly to Hot-Hot Heat Exchanger and then to the 1st Ammonia Synthesis converter. With this modification, there shall be reduction in power requirement in tubine drive of Synthesis Gas Compressor by around 900 KW. Scheme-3: Revamp of Synthesis Gas Compressor involving replacement of HP case and LP case barrels by new barrels for increase in efficiency. Existing HP case and LP case barrels of Syn Gas Compressor shall be replaced by new barrels for increasing the efficiency of Syn Gas Compressor. This shall result in saving in steam requirement in turbine drive of Synthesis Gas Compressor by around 10 MT/hr. Scheme-4: Installation of Fuel Gas Expander with power generator. NG fuel which is let down in existing system from around 40 kg/cm2g to 5.5 kg/cm2g, shall be passed through Fuel Gas Expander connected with power generator for generation of electricity of around 1 MW. Description of Energy saving schemes to be implemented in Urea plant of Phulpur-II Unit Scheme-1: Replacement of existing CO2 Compressors by new higher efficiency compressors. In both 31 & 41 Units of Urea plant, existing CO2 Compressor shall be replaced with new CO2 Compressor of higher efficiency. This shall result in saving in steam consumption in steam turbine drive of CO2 Compressor by around 9 MT/hr. Scheme-2: Installation of Casale High Efficiency Trays (HET) in existing Urea Reactors for achieving higher conversion. The existing trays of reactors shall be replaced by CASALE High Efficiency Trays (HET). The function of the HET trays is to increase the CO2 conversion, by improving the heat and mass transfer phenomena occurring inside the reactor. Scheme-3: Installation of Ammonia Preheaters. In both streams of Urea plant, Ammonia Preheater shall be installed in the upstream of existing HP Ejector in ammonia feed line, in order to pre-heat the ammonia entering the reactor. The heating fluid shall be the mixture of vapors coming from the top of LP Decomposer, and the solution coming from Distillation Tower Reflux pumps. The exchanger shall result in energy saving by utilizing energy of LP Decomposer off gas which in existing system is dumped Page 14 of 22

15 to cooling water. With this modification, heat requirement in form of MS steam in HP Stripper shall reduce. Description of Energy saving schemes to be implemented in Steam & Power Generation Plant. Scheme-1: New GTG-HRSG Package for Power and Steam Generation. The Proposed System, GTG-HRSG will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam. In Phulpur Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is Sm3/Hr RLNG and 250 MTPD Coal. Whereas, the same quantity of Electric Power & HP Steam will be generated by only 9455 Sm3/Hr RLNG in GT-HRSG Detail of these schemes (comparison with existing) with estimated saving is attached as Annexure-XVII. Page 15 of 22

16 CHAPTER-IV The Impact of proposed Revamp: 1. Energy Consumption: The average Energy Consumption of Phulpur Unit I & II in last 3 years is as follows: Table-1 Unit Average Phulpur-I Gcal / MT Urea Phulpur-II Gcal / MT Urea As per revised energy norms under new Urea Policy-2015, the Specific Energy consumption norms has been reduced to Gcal/MT Urea for Phulpur-I and Gcal/MT Urea for Phulpur-II for the period of 1 st June, 2015 to 31 st March, 2018 and 6.5 Gcal/MT Urea for Phulpur-I and 5.5 Gcal/MT Urea for Phulpur-II for the period of Table-2 Unit Unit Energy Norms as per new Urea Policy 2015 Present Average Energy (in last 3 years) Difference Phulpur-I Gcal/MT Urea Phulpur-II Gcal/MT Urea Modification/ Revamping of its Ammonia Urea Complex has been undertaken to reduce the Specific Energy consumption of Plant by Gcal per MT Urea in Phulpur-I and Gcal per MT Urea in Phulpur-II. 2. Consumption of Raw Materials: The consumption of Natural Gas as Fuel is expected to reduce by 92,000 SM 3 per day after Revamp. Due to replacement of Steam driven Turbine by Gas Turbine, a reduction of Coal consumption of about 520 MTPD has been envisaged corresponding to reduction in Ash generation from 274 MT to about 91 MT. 3. Consumption of Utilities (Water, Steam & Power); (i) Power Consumption: Presently the total power requirement of 23 MW is being met by two Nos. of Turbo Generator (TG) of 12.5 MW and 18.0 MW Capacity. Now it is proposed to install GTG-HRSG which will operate on Co-Generation Cycle where almost 90% of Fuel RLNG is fired in GTG and its Exhaust Hot Flue Gas Generates Steam in the Heat Recovery Steam Generator (HRSG). Balance 10% of Fuel RLNG is fired in HRSG to Superheat the Generated High Pressure Steam. Page 16 of 22

17 In Utility Plant, presently the raw material required to generate 23 MW Electric Power and 60 MT/Hr HP Steam, is Sm3/Hr RLNG and 250 MTPD Coal. The GTG-HRSG will generate MW Electric Power & 60 MT/Hr HP Steam by using only 9455 Sm3/Hr RLNG in GT-HRSG. Hence, the Coal consumption will reduce by 250 MTPD. After installation of GT- HRSG both the TG will be stopped. Further, one No. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped. The Power Balance before and after Revamp are as under: Before After Increase after Revamp Revamp Revamp 1. Generation MW MW MW (i) TG-I (ii) TG-II (iii) New GT-HRGS Total generation Consumption (i) Ammonia-I (-)0.18 (ii) Urea-I (-)0.01 (iii) Ammonia-II (iv) Urea-II (-)0.32 (v) Ammonia-I CT (vi) Urea-I CT (vii) Ammonia-II CT (viii) Urea-II CT (ix) Offsites & non plants (x) CDR (xi) SGP I&II (-)1.85 Total consumption ~ (ii) Steam (HP) balance: There are three Nos. Coal Fired Steam Generation plants of 125 MT/hr capacity Coal Fired Boilers (2 working and 1 standby), and one No. LSHS/Gas Fired Boiler of 200 MT/hr capacity. Further, in Ammonia-II, MT/Hr HP Steam is generated. After installation of GT-HRSG, one Nos. of Coal Fired Boilers and one No. of NG Fired Boiler will be stopped. The Steam Balance before and after Revamp are as under: Page 17 of 22

18 Before After Decrease after Revamp Revamp Revamp 1. HP Steam Generation MT per hr MT per hr MT per hr (i) SGP-I (ii) SGP-II (iii) Ammonia-II (iv) New GT-HRGS (-)48.80 Total generation HP Steam Consumption (i) Ammonia-I (ii) Urea-I (iii) Urea-II (iv) TG-I (v) TG-II Total consumption (iii) Water Balance: The Water consumption of Phulpur Complex is around 35,500 M 3 per day. Out of this 25,680 M 3 per day is being used in Cooling Tower, 4,345 M 3 per day is being used in DM Plant, 1,370 M 3 per day is being used for Service Water requirement and 4,105 M 3 per day is being used in Township. The Water consumption of Phulpur Complex after Revamp will reduce to 30,120 M 3 per day, at same production level (reduction by 5,400 M 3 per day) which includes 22,800 M 3 per day is being used in Cooling Tower and 1,850 M 3 per day is being used in DM Plant. The Water requirement for Services and Township may remains unchanged. Due to reduction in water consumption, there will be substantial reduction of about 900 m 3 /day of wastewater. The Water Balance before and after Revamp are as under: Before Revamp After Revamp Decrease after Revamp M 3 / hr M 3 / day M 3 /hr M 3 /day M 3 /hr M 3 / day 1. Raw Water supply 2. Consumption (i) Cooling Tower (ii) DM Plant/CPU (iii) Service Water (iv) Township use Total consumption Page 18 of 22

19 3. Waste water generation (i) C.T. Blow down (ii) DM/CPU waste (iii) Waste water from Ammonia/ Urea/SGP (occasional) (occasional) Total waste water generation The Power, Water and Steam balance before and after Revamp is placed at Annexure-XVIII. (iv) Pollution Load: The Natural Gas (NG) is being used as Feed and Fuel whereas Coal is being used as Fuel. The consumption of NG and Coal at three scenario i.e. (i) Present Production of 5145 MTPD Urea; and (ii) Production of 5145 MTPD Urea after Revamp have been derived as under: S No. Particular Plant / Section Unit Present 5145 MTPD 5145 MTPD after Revamp 1) Feed Phulpur-I Sm3/Hr Phulpur-II Sm3/Hr Total Phulpur-I + II Sm3/Hr ) Fuel Ammonia-I Sm3/Hr Primary Reformer Ammonia-I Aux. Sm3/Hr Boiler SGP Boiler 1,2,3 Sm3/Hr Ammonia-II Sm3/Hr Primary Reformer Ammonia-II PAC Sm3/Hr GT-HRSG SGP Boiler 4 Sm3/Hr GTG-HRSG Sm3/Hr Total Phulpur-I + II Sm3/Hr ) Total Feed + Fuel Phulpur-I + II Sm3/Hr MMSCMD ) Coal SGP Boiler 1,2,3 MT/Hr Page 19 of 22

20 MTPD ) CO 2 Emission Phulpur-I + II MT/Hr Emission factors: Source IPCC Gudlines Vol 2 Table 1.4 It may be observed that the NG consumption will reduce by 1,08,800 SM3 per day after Revamp, whereas there will be reduction of 521 MT per day Coal at this production level. Hence, CO 2 emission will reduce by MT/Hr after Revamp. (iv) Production Capacity: The production Capacity of Urea for the Phulpur Unit (P-I & P-II) will remain the same as 5,145 MTPD (18.78 lakh MT per annum considering 365 stream days). Similarly, the production Capacity of Ammonia for the Phulpur Unit (P-I & P-II) will remain the same as 2,955 MTPD (10.79 lakh MT per annum considering 365 stream days). Page 20 of 22

21 Estimated Capital Cost CHAPTER-V The estimated capital cost of these is as under (Rs. in crore): Sr No Units Equipment Cost BEDP DEDP Total (including Contingency) 1. Phulpur-I Phulpur-II TOTAL BEDP : Basic Engineering Design Package DEDP : Detailed Engineering Design Package Pay Back period: The overall saving in Urea specific energy at each Unit and pay back period will be as under: Particulars UNIT P-I P-II Total Urea Plant Capacity MTPD Energy Saving Gcal/MT Estimated Investment Rs in crore Monetary Savings Rs in crore Payback Years Page 21 of 22

22 CHAPTER-VI Request for Amendment in existing Environment Clearance condition: The scope of work includes replacement of 34 years old machineries in the complex. It is envisaged that energy reduction shall be about Gcal/MT of Urea. There shall be savings in consumption of raw materials like NG, Coal & Water as explained earlier. Further, the emission of CO2, PM, NOx, & Sox will reduce. As per the Notification dated 22 nd August, 2013 of MoEF, it is mentioned that the any modernization of existing project entailing the capacity addition with change in Process and / or Technology shall be undertaken only after prior Environment Clearance. The proposed Revamp does not entail any capacity addition and no process change and/or Technology Change are being carried out. Hence, seeking prior Environment Clearance was not applicable in this case. Further, the Expert Appraisal Committee (Industry 2) during its 46 th meeting held on 20 th and 21 st August, 2015 considered the above proposal. The MoEF&CC vide letter dated J-11011/198/2015-1A II (I) observed that there the proposal does not contain details of existing plant configuration and proposed modification to be carried out. Further, the information regarding water consumption, energy requirement, waste water management, solid waste management is incomplete. Further, it was opined that although there is no increase in production but only few units are being changed which involves amendment of existing environmental conditions. Accordingly, it was suggested to submit revised complete proposed with Form-I. In view of the above, the revised proposal has been prepared which includes: (i) details of existing plant configuration and proposed modification to be carried out; (ii) water consumption; (ii) energy requirement; (iii) waste water management; and (iv) solid waste management, etc. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14 th July, 2006 may be amended. Further, the Expert Appraisal Committee (Industry 2) during its 46 th meeting held on 20 th and 21 st August, 2015 considered the above proposal and that observed that there is no increase in production. However, only few units are being changed which involves amendment of existing environmental conditions. Considering the above facts, it is requested that the existing environmental clearance conditions granted vide letter No. J-11011/150/2006-IA II (I) dated 14 th July, 2006 may be amended. Page 22 of 22

23 ANNEXURE-I Page 1 of 1

24 Proposed Changes in Environmental Clearance Condition Annexure-II Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause no. Subject Para 1 Existing Environment Clearance granted vide letter No. J /150/2006-IA II (I) dt Capacity enhancement/de-bottlenecking and LNG conversion of IFFCO at P.O. Ghianagar, Allahabad, U.P. by M/s IFFCO Environmental clearance reg. This has reference to your letter no. nil dated 12 th April, 2006 on the above mentioned subject alongwith questionnaire, EIA/EMP, risk assessment report and CD containing above mentioned document and subsequent communication dated 12 th May, 2006, 22 nd May, 2006 and 1 st June, 2006 seeking environment clearance under the Environmental Impact Assessment Notification, Proposed Modification/ Revamping of Ammonia-Urea plant including installation of GT-HRSG at IFFCO Phulpur Unit, P.O. Ghiyanagar, Allahabad, U.P. Amendment of EnvironmentClearance Condition reg. This has reference to your online application dated on the above mentioned subject seeking amendment of the existing environment clearance conditions under the Environmental Impact Assessment Notification, The Ministry of Environment & Forests has examined the application. It is noted that M/s IFFCO have proposed for the capacity enhancement (debottlenecking and LNG conversion from 4290 to 5145 MTPD Urea and 2497 to 2955 TPD Ammonia at Phulpur, Allahabad in Uttar Pradesh. Feed Naphtha will be replaced with R-LNG (Re-Gasified liquid Nitrogen Gas) except in case of LNG shortage/emergency when LNG will be used. Total Land available is ha and no additional land will be required for the expansion project. 3.0 SO 2 emissions from Ammonia Plant will be reduced due to use of cleaner fuel. Installation of CO2 recovery plant will reduce CO2 emissions in the environment. Total water requirement from the ground water for the existing plant is 35,500 m 3 /day and no additional water will be required for the expansion project. All the treated effluent will be recycled and reused in the process or green belt development.no additional effluent will be generated and discharged outside the premises except during rainy seasons. Ash. Lime sludge and spent catalyst will be generated as solid waste and will be disposed off properly. The Ministry of Environment & Forests and Climate Change has examined the application. It is noted that M/s IFFCO Phulpur Unit has proposed modification/revamping of its Ammonia- Urea plant. The production capacity will reamin same as (i) Urea: 5145 MTPD (18.78 Lakh MTPA); and (ii) Ammonia: 2955 MTPD (10.79 Lakh MTPA). Total Land available is ha and no additional land will be required. Emission and Ash generation is expected to reduce due to implementation of the proposed Schemes including GT-HRSG. Total water requirement from the ground water for the existing plant is 35,500 m 3 /day and no additional water will be required after Revamp / Modification. All the treated effluent will be recycled and reused in the process or green belt development. No effluent will be discharged outside the premises except during plant interruption/ rainy seasons. Ash, Lime sludge and spent catalyst will be generated as solid waste and will be disposed off properly. Page 1 of 5

25 Proposed Changes in Environmental Clearance Condition Annexure-II Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause no. Existing Environment Clearance granted vide letter No. J /150/2006-IA II (I) dt Public hearing meeting was held on 8 th August NOC has been accorded by the UPPCB vide letter no. F55.780/c-2/NOC/3306/05 dated 08/02/2006. Total cost of the project will be Rs Crores. 5.0 The Ministry of Environment and Forests hereby accords environmental clearance to the above unit under the EIA Notification, 1994 as amended subsequently subject to the compliance of the terms and conditions mentioned below: Specific Conditions : Sr.No. Conditions (existing) Conditions to be Change 1. The gaseous emissions (SO2, NOx, NH3, Urea dust) particulate matter from various process unit shall conform to the standards prescribed by the concerned authorities from time to time. CO2 recovery plant shall be installed to reduce CO2 emissions in the environment. At no time, the emission levels shall go beyond the stipulated standards, In the event of failure of pollution control systems(s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency. Proposed Total cost for implementation of the proposed schemes would be Rs crore. The Ministry of Environment and Forests and Climate Change hereby accords approval for amendment of Environment Clearance condition to IFFCO Phulpur Unit as per the EIA Notification, 2006 as amended subsequently subject to the compliance of the terms and conditions mentioned below: The gaseous emissions (SO2, NOx, NH 3, Urea dust), particulate matter from various process shall conform to the standards prescribed by the concerned authorities from time to time. At no time, the emission levels shall go beyond the stipulated standards, In the event of failure of pollution control systems(s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency. 2. In urea plant, particulate emissions shall not exceed 50 mg/m3. Monitoring of prilling tower shall be carried out as per CPCB guidelines. Hydrocarbon monitors shall be installed. 3. Ambient air quality monitoring stations shall be set up in the downwind direction as well as where maximum ground level concentration are anticipated in consultation with the UPPCB and data submitted to the Ministry s Regional Office at Lucknow six monthly and UPPCB quarterly In Urea plant,, particulate emissions shall not exceed the prescribed standard stipulated by CPCB/SPCB / as given in consent. Monitoring of Prilling tower shall be carried out as per CPCB guidelines. Data of Ambient air quality monitoring stations (5 nos.) shall be submitted to the Ministry s Regional Office at Lucknow six monthly and UPPCB quarterly alongwith statistical analysis. Page 2 of 5

26 Proposed Changes in Environmental Clearance Condition Annexure-II Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause no. Existing Environment Clearance granted vide letter No. J /150/2006-IA II (I) dt alongwith statistical analysis. 4. Total water requirement after expansion shall not exceed 35,500 m3/d. All the effluent generated shall be recycled & reused in the process toreduce the fresh water consumption or green belt development. No effluent shall be discharged outside the premises except during the rainy season after meeting the norms prescribed under the E (P) Act, 1986 and UPPCB whichever are more stringent. 5. Regular monitoring of ground water by installing peizometric wells around the guard pond and Chromium sludge disposal site shall be periodically monitored and reports submitted to Ministry s Regional Office at Lucknow, CPCB and UPPCB. 6. As per the Fly ash notification, 100% utilization of the fly ash generated shall be ensured. Ash shall be provided to different users for making bricks etc. or properly used for filling low lying areas of town ship, surrounding villages and developing green belt. Spent catalysts generated shall be properly stored in closed metallic drums before selling to authorized recyclers / re-processors. Waste oil shall be used in steam generation plant as fuel alongwith coal or sold to authorized recyclers/ reprocessors. 7. The company shall undertake adequate protection measures for handling of ammonia vapours in case of plant upset condition. Safety well exhaust and drains shall be connected to a separate close header from which ammonia vapours shall be vented from vent stack after diluting with stream. 8. The company shall implement all the recommendations made in the Charter on Corporate Responsibility for Environmental Protection (CREP) Proposed Total water requirement in the plant after revamping shall not exceed 35,500 m 3 /d. All the effluent generated shall be recycled & reused in the process to reduce the fresh water consumption or green belt development. No effluent shall be discharged outside the premises except during the rainy season after meeting the norms prescribed under the E (P) Act, 1986 and UPPCB whichever are more stringent.. Regular monitoring of ground water around the guard pond and Chromium sludge disposal site shall be done and reports will be submitted to Ministry s Regional Office at Lucknow, CPCB and UPPCB. No change No change. No change. Page 3 of 5

27 Proposed Changes in Environmental Clearance Condition Annexure-II Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause no. Existing Environment Clearance granted vide letter No. J /150/2006-IA II (I) dt for fertilizer industries. 9. The company shall develop rain water harvesting structures to harvest the run off water from the roof tops and by laying a separate storm water drainage system for recharge of ground water. 10. Green belt already developed in 33% shall be properly maintained and an effort shall be made to further increase the percentage by regularly planting trees at all the vacant spaces to mitigate the effects of fugitive emissions all around the plant. Further development of green belt shall be as per the Central Pollution Control Board guidelines. Density of trees at the site shall be maintained as 2,000-2, 500 trees/ha. General Conditions: 1. The project authorities must strictly adhere to the stipulations made by the U.P. Pollution Control Board (UPPCB) and the State Government. 2. No further expansion / modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. 3. The project authorities must strictly comply with the rules and regulations with regard to handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management & Handling) Rules, The project proponent shall also comply with all the safeguards recommended in the EIA/EMP Report. 5. The project authorities will set up a separate environmental management cell for effective implementation of all the above stipulations under control Proposed Rain water harvesting structures (8 Nos.) shall be properly maintained to harvest the runoff water from the roof tops and by a separate storm water drainage system for recharge of ground water. No change. No change No further expansion or modernization of plant entailing capacity addition with change in Process or Technology and or Product Mix shall be under taken without prior approval of the Ministry of Environment and Forests and Climate Change (MoEF & CC). The Unit must strictly comply with the rules and regulations with regard to handling and disposal of hazardous wastes in accordance with the Hazardous Wastes (Management, Handling & Transboundary Movement) Rules, To be deleted. The Unit will maintain a separate environmental management cell for effective implementation of all the above stipulations under control of Page 4 of 5

28 Proposed Changes in Environmental Clearance Condition Annexure-II Name of the Unit: IFFCO Phulpur Unit, Allahabad Clause no. Existing Environment Clearance granted vide letter No. J /150/2006-IA II (I) dt of Senior executive. 6. As proposed in EIA/EMP, Rs Crores and Rs.9.00 Crores allocated towards capital cost and recurring expenditure/annum shall be judiciously utilized to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State Government and a time bound implementation schedule for all the conditions stipulated herein shall be submitted. The funds so provided shall not be diverted for any other purposes. 7. The Regional Office of this Ministry at Lucknow/Central Pollution Control Board/ U.P.Pollution Control Board will monitor the stipulated conditions. A six monthly compliance status report and the monitored data alongwith statistical interpretation shall be submitted to monitoring agencies regularly. 8. The Project Proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the U.P. Pollution Control Board/ Committee and may also be seen at Website of the Ministry of Environment and Forests at This should be advertised within seven days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the Regional Office at Lucknow. 9. The Project Authorities shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of commencing the land development work, if any. Senior executive. To be deleted. No change. To be deleted. To be deleted. Proposed Page 5 of 5

29 Stack, Prill Tower emission Quality: Annexure-III Page 1 of 2

30 Page 2 of 2

31 Ambient Air Quality: Page 3 of 2

32 Annexure-IV AIR POLLUTION MANAGEMENT PRACTICES AT IFFCO Phulpur UNIT: Sr. Plant No. 1. Ammonia Plant Emission Generated Purge gases from hydro-desulphurization section The purge gases from syntheses section of Ammonia Plant-I Pollution Control Device Purge Gas recovery system Method of Control Purge gases are burnt in the primary reformer. The purge gases from syntheses section of Ammonia Plant-I is sent to the purge gas recovery plant for Hydrogen and Ammonia recovery before burning the remaining in Primary Reformer furnace. 2. Urea Plant The relief valves outlets gases and other flue gases CO2 Emission Urea dust from the top of prill towers. 3. Boilers Generation of Ash, SO2 & NOx gases 4. Bagging Plant: 5. Noise Abateme nt in Plant area dust Noise Flare Stacks Carbon Di-Oxide Recovery Plant 96 meter (in Urea-I) high & 104 meter (in Urea-II) high natural draft prilling tower in Combustion air control systems have been provided in each boiler. The electrostatic precipitators provided for each coal fired boiler, Low NOx burners have been provided Cyclone Separator Neutralization pit, ETP & lagoons Gases are burnt in the 30 m & 79 m. high two flare stack located away from Ammonia Plant-I and Ammonia Plant- II respectively. A carbon Dioxide Recovery Plant has been installed to recover the CO2 gas from flue gases of Primary Reformer of Ammonia Plant. This stripped CO2 is utilized for Urea production The height of Prill Towers has been kept sufficient which keeps the dust concentration of urea from the Prill Towers well within the limits laid by the UPPCB and CPCB. The Fly Ash generated from Coal Fired Boilers is recovered from Flue Gases through Electrostatic Precipitators (ESP). Flue gases containing SO2 and NOx are discharged into the atmosphere through a 100 m high chimney (Coal Fired Boilers) & 120m high chimney (LSHS/ Gas fired Boilers). The bagging plant has been provided with cyclone separators to keep the urea handling area dust free. Silencers have been provided at vent stacks to reduce the noise level. The attenuation of noise levels achieved by the green belt all around the plant boundary also contribute positively in minimizing the impact on existing Page 1 of 2

33 noise levels. Acoustic enclosure has been provided in Diesels generator room. We have issued ear muffs / plugs to all the employees and use of ear muffs / plugs while working in noisy environment is already in practice. CO2 Recovery Plant Prill Tower Chimney & Electrostatic Precipitator Cyclone Separator Silencers in Ammonia Plant Acoustic enclosure (Generator room) Page 2 of 2

34 Annexure-V Liquid Effluent (Guard Pond) Quality: Page 1 of 3

35 Page 2 of 3

36 Page 3 of 3

37 Annexure-VI WASTE WATER MANAGEMENT PRACTICES AT IFFCO Phulpur UNIT: Sr. Plant No. 1. Ammonia Plant Effluent Generated Process Condensate Steam Condensate Turbine condensate 2. Urea Plant Process Condensate Steam & Turbine Condensate Pollution Control Device Process Condensate Stripper in both Ammonia plant & Condensate Polisher Unit Condensate Polisher Unit Condensate Polisher Unit Urea Deep Hydrolyser and Distillation Tower in both Urea Plants separately Polishing Units in DM Plant Method of Control Process Condensate from Ammonia plant is stripped in Process Condensate Stripper to remove the dissolved impurities like Methanol, Ammonia and CO 2. The stripped process condensate is reused as Boiler Feed Water after polishing in DM Plant. The Steam condensate from Ammonia plants having traces of dissolved impurities are passed through Condensate Polisher Unit and reused as Boiler Feed Water. The turbine condensate from both Ammonia plants is treated in Activated Carbon Filtration & is reused as Boiler Feed Water after polishing in Condensate Polisher Unit. Process condensates from Urea plants contain 4.0% to 5.0% Ammonia and 1.0% to 1.5% Urea. It is treated in Urea Deep Hydrolyser, where Urea is decomposed to Ammonia and Carbon Dioxide. The Ammonia and Carbon Dioxide are recovered through distillation tower and reused in Urea plant. The remaining condensate is reused either as Boiler Feed Water after further polishing it in Condensate Polisher Unit or as cooling tower make up. The steam and turbine condensates from both Urea plants having traces of dissolved impurities are passed through Condensate Polisher Unit and reused as Boiler Feed Water. 3. Ammonia & Spilled Oil & Gravity Oil The spilled oil / oily water is Page 1 of 6

38 Urea Plants Oily Water separator & Disc Oil Pit with rotating disc for Oil collection in Ammonia and urea plants separately. 4. Ammonia, Steam Generation and Power Plant 5. DM Water Plant 6. Cooling Tower 7. Effluent Treatment Plant (ETP) Continuous Blow Down Acid alkali waste water Cooling Tower Blow Down Occasional wastewater having Ammonia as contaminant Reused as cooling tower make up Neutralization pit, ETP & lagoons Effluent Holding Tank, Sand Filters, Air & steam Strippers and Lagoons collected in Gravity Oil Separator / Disc Oil Pit where it separates in two layers. The top layer of oil is collected via a Rotating Disc in drums and is sold to Authorised Recyclers as per Guideline of CPCB. The remaining wastewater is sent to Effluent Treatment Plant for further Treatment. The Blow Down (BD) from Boilers from Ammonia and Steam & Power Generation plants (SGPG) is reused as Cooling Tower make up. The acid / alkali wastewater generated in DM Plant after regeneration of exhausted cation/ anion resins is collected in the neutralization pit in DM Plant. Its ph is adjusted to 6.5 to 8.0 and is mixed with other treated waste water in Guard Ponds for further treatment in Effluent Treatment Plant based on Reverse Osmosis Technology. The treated water is being reused as cooling tower make up. The Cooling Water treatment is based on Eco-friendly, Non- Chromate based corrosion inhibitor. The Cooling Tower blow down is mixed with other treated waste water in Guard Pond for further treatment in Effluent Treatment Plant based on Reverse Osmosis Technology. The treated water is being reused as cooling tower make up. Occasional waste water generated during upset, start-up and shutdown of the plants which contains Ammonia, is collected in the effluent holding pits provided separately in all the plants, from where it is pumped to Effluent Holding Tank in Effluent Treatment Plant for the treatment. The ammonia is stripped off through steam strippers. The Page 2 of 6

39 treated waste water is being reused as cooling water make up. 8. Guard Pond & Effluent Treatment Plant based on R.O. Technology Cooling water blow down, D.M. Plant regeneration effluent etc. Effluent Treatment Plant based on R.O. Technology The treated waste water collected in Guard Pond is reused for plant process after further treatment in Reverse Osmosis Plant. The reject of RO plant is used for dust suppression in coal yard & ash Pond. The schematic diagram of Effluent Treatment is given below Page 3 of 6

40 Hydrolyser ETP based on Steam Stripping Disc Oil Separator Condensate Polisher Unit Page 4 of 6

41 Neutralization Pit of D.M. Plant Guard Pond Effluent Treatment Plant based on Reverse Osmosis Technology Page 5 of 6

42 Sewage Treatment System at IFFCO Phulpur: TREATMENT AND REUSE OF DOMESTIC EFFLUENT FROM TOWNSHIP (SEWAGE TREATMENT PLANT): The Sewage Treatment plant of 3000 m 3 /day capacity was designed and installed by M/s Hindustan Dorr Oliver, Ltd., Bombay. This treatment plant involves a series of unit processes, i.e. Physical, Biological and Chemical Process. This treatment plant consists of bar screen, grit removal channel, parshall flume indicator, raw sewage collection sump, aeration tank, clarifier, filter feed sump, pressure sand filter, activated carbon filter and disinfectant (bleaching powder) dosing system. The treated water is recycled to plant for Cooling Water makeup and used for irrigation of Farm land as per requirement. The dry sludge generated from domestic sewage treatment plant is being used as manure. Sewage Treatment Plant Page 6 of 6

43 On Line Monitoring System: Annexure-VII Page 1 of 2

44 Page 2 of 2

45 Detail of Hazardous Waste submitted to UPPCB, Lucknow: Annexure-VIII Page 1 of 3

46 Page 2 of 3

47 Page 3 of 3

48 Management of Solid Wastes: Annexure-IX Non Hazardous Wastes : 01. Disposal of Ash : a. Disposal of Dry Ash directly from ESP : A mechanised system to transport fly ash from the Electrostatic Precipitators to a 240 MT capacity silo by pneumatic conveying has been commissioned in April and in operation. With this system, it has been possible to load and dispatch about 80% to 90% of the dry ash generation from the silo to the Cement Factories. The dry ash from the ESP is being directly dispatched to the Cement Industries. b. Utilisation of Pond Ash for Reclamation of Usar Farm Lands The Pond Ash is utilised for Reclaimation of Usar farm land located within a radius of KM. c. Utilisation of Pond Ash by Cement Manufacturers Pond Ash are also being Used by Cement manufacturer for manufacture of Cement. d. Utilisation of Fly Ash for the manufacture of clay Bricks by local Brick kilns. IFFCO Phulpur endeavoured to create awareness among nearby Brick Kiln owners to educate them on the use of Fly Ash mixed with clay for the manufacture of clay bricks by the conventional process. IFFCO Phulpur is also promoting brick kiln owners to mix fly ash with clay. e. Production of Fly ash bricks Fly ash is also being used for production of fly ash brick. A fly ash brick plant has been installed. Last year about 627 MT of fly ash was used in fly ash brick plant for fly as brick manufacturing. 02. Lime Sludge From Water Softening Plant : In the water softening plant approx. 550 m3/day of lime sludge having about 2.5% solids is pumped to a pond to settle down the solids. This lime sludge is dried and then dispatched free of cost to out side parties. Page 1 of 3

49 Including installation of GT-HRSG at IFFCO Phulpur Brick Plant at IFFCO Phulpur Transportation of Ash in closed tankers Telephone Exchange building & Boundary Walls constructed with Fly Ash Page 2 of 3

50 Hazardous Wastes: 01. Spent Catalyst: Brief description of Modification/ Revamping of Ammonia-Urea Plant Catalysts used in different reactors of Ammonia Plant are mainly Nickel, Iron, Copper and Zinc base. After a certain time of interval, these catalysts are checked and if found exhausted, replaced by fresh catalysts. The spent catalysts are stored in closed metallic drums under shed inside the factory premises for sale to outside authorised parties. During , 23.7 MT Spent Catalyst was sold to authorised Recyclers. 02. Waste Oil: Waste Oil is collected and stored in metallic drums. The same is either sold to authorized parties or mixed with fuel oil (LSHS /RFO) for use in Steam Generation Plant as fuel. During , 45 KL Waste Oil was sold to authorised party. Page 3 of 3

51 Rain Water Harvesting System installed at IFFCO Phulpur Annexure-X IFFCO s philosophy does not end with manufacture of fertilizer only It has unstinted commitment toward environmental protection. IFFCO Phulpur is conscious of its responsibilities towards resource conservation. IFFCO is committed to ensure sustainable development & ecological balance. To sustain the ground water availability to all stakeholders, IFFCO Phulpur implemented ground water recharging scheme through installation of several Rain water harvesting system (RWHS) within premises. Artificial recharge to ground water through properly designed structure has now been accepted world-wide as a cost-effective method to augment ground water resources. It also provide an opportunity to utilize the surplus monsoon runoff which otherwise is lost to drains or rivers unutilized. Installation of Rain water harvesting system within premises of IFFCO Phulpur was initiated after a series of consultation with Central Ground Water Board, Allahabad. Rain Water Harvesting Systems (double bore type) have been installed at different places within IFFCO Phulpur s premises viz. RWHS near Gate No.1, behind Gas Godown in Tapti sector, near Borewell No. 12, Central School (Rain water collection system through roof top drains) and 3 Nos Rain water harvesting system in the premises of Guest House (single bore type). Rain Water Harvesting System installed at IFFCO Phulpur Volume of Recharge Sump (each): 310 M 3 No. of Bores : Two Size of Bores : Dia- 6 inch Depth of Bores: 105 m Page 1 of 3

52 RWHS installed at Central School building within IFFCO Phulpur s premises RWHS installed near Borewell No. 12 within IFFCO Phulpur s premises Page 2 of 3

53 RWHS installed near Gate No.1 within IFFCO Phulpur s premises Page 3 of 3

54 Annexure-XI Page 1 of 1

55 Including installation of GT-HRSG at IFFCO Phulpur Annexure-XII Existing Environment Clearance Conditions: Page 1 of 4

56 Including installation of GT-HRSG at IFFCO Phulpur Page 2 of 4

57 Including installation of GT-HRSG at IFFCO Phulpur Page 3 of 4

58 Including installation of GT-HRSG at IFFCO Phulpur Page 4 of 4

59 Certified Compliance report: Annexure-XIII Page 1 of 7

60 Page 2 of 7

61 Page 3 of 7

62 Page 4 of 7

63 Page 5 of 7

64 Page 6 of 7

65 Page 7 of 7

66 Latest Compliance report (Existing Environment Clearance Conditions): Annexure-XIV Page 1 of 6

67 Page 2 of 6

68 Page 3 of 6

69 Page 4 of 6

70 Page 5 of 6

71 Page 6 of 6

72 Copy of Consent Order (Air & Water): Annexcure-XV Page 1 of 8

73 Page 2 of 8

74 Page 3 of 8

75 Page 4 of 8

76 Page 5 of 8

77 Page 6 of 8

78 Page 7 of 8

79 Page 8 of 8

80 Copy of Consent Renewal Application: Annexure-XVI Page 1 of 2

81 Page 2 of 2