APPLICATION FOR TERMS OF REFERENCE (ToR)

Transcription

1 APPLICATION FOR TERMS OF REFERENCE (ToR) FOR EXPANSION IN EXISTING PLANT FACILITY (AS-I) FOR PRODUCTION OF AMMONIUM SULPHATE BY GUJARAT STATE FERTILIZERS AND CHEMICALS LTD. [Schedule 5(a) Category A as per EIA Notification 2006] AT PO: FERTILIZERNAGAR, NH#8, TAL. & DISTRICT: VADODARA STATE: GUJARAT. Production Capacity: 400 TPD (1,46,000 TPA) AS-I Unit Area: 2240 m 2 Total Plant Area of GSFC: 32,80,000 m 2 (328 ha) APPLICANT GUJARAT STATE FERTILIZERS AND CHEMICALS LTD. P.O: Fertilizernagar , Tal. & District: Vadodara State: Gujarat jvjani@gsfcltd.com Tel No CONSULTANT ECO CHEM SALES & SERVICES Office Floor, Ashoka Pavilion A, New Civil Road, Surat, (QCI Accreditation No# NABET/EIA/1720/ RA 051) eco@ecoshripad.com Tel No: MARCH-2018 Document No. 2018_ECSS_

2 CONTENTS 1.0 EXECUTIVE SUMMARY INTRODUCTION OF PROPOSED PROJECT Project Proponent Nature of the Project Need of the Project Demand Supply Gap and Import vs Indigenous Production Employment Generation PROJECT DESCRIPTION Type of Project Location of Project Alternative Site Size of Operation Products & Manufacturing Process Resource Requirement Land Water Electricity Fuel Manpower Waste to be generated Sewage Effluent Air Emission Solid/Hazardous Waste Noise Purpose of EIA Study SITE ANALYSIS Connectivity Land form & Land Use Topography Existing Infrastructure (Social/Commercial) Soil Classification Climatic data from secondary sources PLANNING BRIEF Population Projection...30 Project: Expansion 1

3 5.2 Land use Planning Amenities / Facilities PROPOSED INFRASTRUCTURE REHABILITATION& RESETTLEMENT (R&R) PLAN: PROJECT SCHEDULE & COST ESTIMATION: Project Schedule Cost Estimation ANALYSIS OF PROPOSAL: Financial & Social Benefits...32 LIST OF TABLE TABLE 1.1: PROJECT SUMMARY... 4 TABLE 1.2: PROPOSED PRODUCTS...13 TABLE 1.3: RAW MATERIAL REQUIREMENT...16 TABLE 1.4: LAND BIFURCATION...16 TABLE 1.5: WATER CONSUMPTION AND WASTE WATER GENERATION...17 TABLE 1.6: WASTEWATER GENERATION...20 TABLE 1.7(A): FLUE GAS EMISSION...21 TABLE 1.7(B): PROCESS EMISSION...23 TABLE 1.8: SOLID/HAZARDOUS WASTE GENERATION & MANAGEMENT...24 TABLE 1.9: ENVIRONMENTAL SETTINGS...28 TABLE 1.10: PROPOSED INFRASTRUCTURE...30 TABLE 1.11: PROJECT COST...31 LIST OF FIGURE FIGURE 1.1: STUDY AREA MAP... 8 FIGURE 1.2: LOCATION MAP... 9 FIGURE 1.3 : GOOGLE IMAGE OF PROPOSED PLANT...12 Project: Expansion 2

4 1.0 EXECUTIVE SUMMARY Among various sources supplying Sulphur, Ammonium Sulphate is one of the major fertilizer, supplying Ammonical Nitrogen (20.5%) having higher use efficiency, besides 23% Sulphur. Recognizing the importance of Sulphur nutrient in crop production and wide spread deficiency in Indian soil, GoI has included the S content of fertilizers in the FCO specifications since 2003 and covered Ammonium Sulphate fertilizer (Caprolactam route) under NBS policy in force since Ammonium Sulphate fertilizer is the second largest source containing higher percent of Sulphur nutrient after elemental Sulphur, which contains 23% Sulphur (100% water soluble and readily available to the plant), besides 20.5% Nitrogen. Thus each 50 kg bag of Ammonium Sulphate can provide about 11.5 Kg of 100% water soluble Sulphur to the soil. Entire Nitrogen in Ammonium Sulphate is present in Ammonical form, which can be readily available to the plant. Unlike Urea, there is no loss of Nitrogen through either leaching or volatilisation in case of Ammonium Sulphate because Ammonium (NH + 4 ) ions are retained by the clay particles and soil humus near to root zones, which can be slowly available to the plants through denitrification process through microbial activities during the life cycle of the plant and thereby reduces Nitrogen losses through volatilization and leaching. Application of Nitrogen in wetland crops such as paddy is suitable through Ammonium Sulphate because despite its high solubility, its Nitrogen is not lost through drainage and ammonium NH4+ ions of AS are retained by clay particles & soil humus. Gradually, through nitrification, the ammonium ion gets released from soil colloids and Nitrogen is absorbed by the plant roots. In fact, Rice prefers nitrogen in Ammonical form during early stages of the plant growth. Sulphur improves protein & oil percentage in seeds, cereal quality for milling and baking, quality of tobacco and other commercial crops such as tea, coffee, tubers and many horticulture crops. Yield benefits in the range of about 25-30% are evident in various crops through Sulphur application. The extent of Sulphur requirement varies from around 10 kg/hac in case of Pulses to upto 60 kg/hac in Oil seeds, tubers and plantation crops. The pre-feasibility report includes a brief introduction of the company, need and justification of the project, manufacturing process description, required and available resources, proposed Environment Management Systems, land-use and proposed infrastructure, project schedule and cost. Gujarat State Fertilizers & Chemicals Ltd. has engaged Eco Chem Sales & Services, Surat (Accreditation certificate number NABET/EIA/1720/RA 051 is valid up to 3 rd Feb ) as their Environmental Consultant to conduct the EIA studies for obtaining Environmental Clearance (EC). Project: Expansion 3

5 Table 1.1: Project Summary S.No. Description Proposed Project Details 1. Name of project Environmental clearance for Expansion in Existing Plant Facility for production of Ammonium Sulphate (AS-I) by Gujarat State Fertilizers & Chemicals Ltd. 2. Project Site PO Fertilizer Nagar, NH-8, Taluka & District- Vadodara, Gujarat. 3. Project Category 5(a) Category A of EIA notification. 4. Capital Cost Rs. 875 Lakhs for AS-I including EMP Cost 5. Products Ammonium Sulphate ( 1,46,000 TPA) 6. Raw Materials Ammonia: MT/MT Sulphuric Acid: MT/MT 8. Resource Requirement (i) Land Existing Total plot area 32,80,000 m 2 or 328 Ha. Out of total plot area 10,60,000 m 2 has already utilized for Greenbelt development.) Proposed for AS-I plant = 2240 m 2 (ii) Water Source: French well (4 nos.) in Mahi River (GSFC s own source) Construction phase: Domestic 0.7 KLD Construction activities and curing 1.0 KLD Operation phase: Industrial 37 KLD (Fresh Water and Treated water) Domestic 2.0 KLD (Fresh Water) (iii) Electricity 0.5 MW Power requirement will be fulfilled by existing power generation plant i.e. wind mill and joint venture with GIPCL. Further GSFC has connectivity with MGVCL. (iii) Fuel NG for Expansion Sm 3 /day (iv) Man power Construction Phase: Nos. Operation Phase: 50 Nos. (v) Utility Steam Proposed: 36 MT/day 9. Source of Pollution Project: Expansion 4

6 (i) (ii) (iii) Wastewater Generation Effluent from proposed expansion plant in form of condensate and cooling tower blow down will be sent to Phosphoric Acid plant for reuse in process. No additional effluent will be sent to out of company premises. Air Emission Process gas: through stack/vent attached in dryer PM: <150 mg/nm 3 Solid/Hazardo No Solid waste generation from proposed Ammonium Sulphate-I us waste plant except used oil. Generation The solid, liquid and gaseous wastes if any, from the proposed plant will be disposed-off in an environmentally acceptable manner. Process effluents (condensate) will be recycled/reused. Proper precaution will be taken to keep noise level within prescribed limit. Adequate measure has been contemplated to ensure least pollution from the proposed project. 2.0 INTRODUCTION OF PROJECT 2.1 Project Proponent Gujarat State Fertilizers & Chemicals Ltd. (GSFC) is a Public Limited Company incorporated in the State of Gujarat, India, under the Companies Act, 1956, having its Registered Office at P.O. Fertilizernagar , about 10 kms from Vadodara city, District Vadodara, Gujarat and has multi-locational Plant sites. GSFC is one of the leading manufacturers of Nitrogenous and Phosphatic Fertilizers as well as Petrochemical and Industrial products. The Vadodara unit of GSFC complex is situated at Fertilizernagar. There GSFC has Ammonia plants, two Urea plants and a Di-ammonium Phosphate/Ammonium Sulphate Phosphate (DAP/ASP), Ammonium Sulphate (AS) - I plant (Going for revamping) and Urea Phosphate as a part of Fertilizer complex. It also has two Sulphuric Acid plants and a Phosphoric Acid plant. As a part of the Petrochemical Complex, GSFC has two Caprolactam plants, Nylon-6 plants, MEKO plants, Ammonium Sulphate-II & III and two Melamine plants, Methanol, facilities for production of Pure Argon Gas from Ammonia plant, and also has adequate off-site facilities. GSFC has recently commissioned 45 TPD Nylon- 6 plant and TPA Water Soluble Fertilizer (WSF) plant. Commissioning activities of TPA melamine project is under progress. Project: Expansion 5

7 GSFC is having total three Ammonium Sulphate plants. Out of them AS-II & AS-III in are running and AS-I is not in working conditions which is proposed to be revamp and restart for production of 400 MTPD Ammonium Sulphate. 2.2 Nature of the Project Proposed project is Expansion project to be developed at existing premises of Gujarat State Fertilizers & Chemicals Ltd. (GSFC) i.e. P.O. Fertilizernagar , District Vadodara, Gujarat of Gujarat state. This project is fall under 5(a) category A of EIA notification. 2.3 Need of the Project Ammonium Sulphate (AS) is one of the most preferred fertilizers and has giant market in India. GSFC being one of the largest producers of AS in India has great business outlook. The proposed expansion of the AS-I plant is for the fortification of core business of the company and would greatly increase its production capacities as well as turnover and thereby improve its bottom line further. This would also bring higher value addition to its investors and others stake holders. The present capacity of production of AS, does not satisfy the market and higher imports are prevailing. Hence, proposed expansion by reviving of existing unit by Upgradation, GSFC would avoid imports and make country self-sufficient to meet the expected demands. 2.4 Demand Supply Gap and Import vs. Indigenous Production Overall market size of Ammonium Sulphate is about 6 LMT/Annum. accounts for 5.5 to 6 LMT whereas, imports ranges from 0.5 to 1 LMT annually. Domestic production # Year Production Imports Sales * Figures in 1000MT * Sales data of imported AS are not captured in FMS and therefore, it is not included here. Project: Expansion 6

8 With increasing awareness about Sulphur deficiency, we expect better demand for AS in coming years. However, because of very low prices of Urea, besides availability of steel grade AS at half of the price of Capro grade AS, there is a price resistance in case of standard Caprolactam grade AS.MRP of our AS is Rs per MT and subsidy is Rs PMT. Only GSFC and FACT are the domestic manufacturers. GSFC is also importing AS on east coast, besides own production. 2.5 Employment Generation There are possibilities to generate employment during the construction as well as operation phase of the proposed project. Based on organizational pattern, technical staff for plant, General staff for administrative work and other ancillary services i.e. Security, O&M contractor and maintenance services will be required in this phase. It is estimated that around 50 Nos. of employee will get direct/indirect employment during this phase. Existing manpower of all entire GSFC (@ 5000 Nos.) include workers, technical staffs of all the plants and Units of GSFC while proposed manpower include requirement of Ammonium Sulphate-I only. 3.0 PROJECTDESCRIPTION 3.1 Type of Project Expansion in existing production capacity of Ammonium Sulphate (AS) by Gujarat State Fertilizers & Chemicals Ltd Is coming up in existing GSFC complex located at notified industrial area. All the industrial infrastructure facility has been available to support proposed development. 3.2 Location of Project Gujarat State Fertilizers & Chemicals Ltd. decided to set an industrial plant at existing GSFC complex i.e. P.O. Fertilizer Nagar , District Vadodara, of Gujarat state. GSFC has proposed to expand production capacity within existing unit at 32,80, m 2 area Location of plant site and Key map and Google image of proposed project site is depicted as figure 1.1 & 1.2 respectively. Project coordinate is as under: Corners Latitude Longitude South-East 22 22'26.2"N 73 09'05.3"E South-West 22 22'24.9"N 73 09'03.8"E North-West 22 22'26.4"N 73 09'02.9"E North-East 22 22'27.3"N 73 09'04.2"E Project: Expansion 7

9 Figure 1.1: Study Area Map Project: Expansion 8

10 Figure 1.2: Location map Project: Expansion 9

11 Figure 1.3a Layout Plan for Proposed AS-I Plant Project: Expansion 10

12 Figure 1.3b Layout Plan of GSFC Project: Expansion 11

13 Project Site Figure 1.4: Google Image of proposed AS I plant GSFC has already developed complete industrial infrastructure i.e. Plant building, Raw material storage area, finished products shed, treatment facilities, fire hydrant and other ancillary amenities within Hectare. For proposed expansion of Ammonium Sulphate plant, land along with plant infrastructure is already available in existing GSFC complex thus no additional land shall be procured by the industry for proposed expansion. The layout for AS-I and GSFC is attached as Annexure I. 3.3 Alternative Site The expansion project is coming up in existing GSFC complex located in notified industrial area in Vadodara District of Gujarat state. No alternative site study will be carried out as the proposed expansion is to be developed in existing premises by using existing land & infrastructure. 3.4 Size of Operation Project proponent proposes to manufacture Ammonium Sulphate chemical Fertilizer with production capacity of 400 TPD (1,46,000 TPA). Project: Expansion 12

14 3.5 Products & Manufacturing Process Ammonium Sulphate (AS) is one of the most preferred fertilizers and has giant market in India. GSFC being one of the largest producers of AS in India has great business outlook. List of existing products and proposed product (AS) to be manufactured by Gujarat State Fertilizers & Chemicals Ltd. is mentioned in table 1.2 (Annexure 1). Table 1.2: List of Products #. Plant Name Product Unit Existing Production Capacity Proposed Total 1 Ammonia III Ammonia MT/year Ammonia MT/year Ammonia IV Argon NM 3 /year Urea I Urea MT/year Urea II Urea MT/year Melamine I Melamine MT/year Melamine II Melamine MT/year Melamine III Melamine MT/year Phosphoric Acid DAP/ASP/MAP/ NPK Sulphuric Acid- III Sulphuric Acid- IV 12 Cogeneration I 13 Cogeneration II Cogeneration III Caprolactam I (Ammonium Phosphoric Acid MT/year Phosphogypsum* MT/year ASP MT/year Sulphuric Acid MT/year Sulphuric Acid MT/year Power - Steam - 15 MWH (131400MW PY) 130 MT/Hr ( MTPY) MWH (131400M WPY) MT/Hr ( MTPY) Power - 25 MWH MWH Steam MT/Hr MT/Hr Power - Steam - 50 MWH (438000MW PY) 130 MT/Hr ( MTPY) MWH (438000M WPY) MT/Hr ( MTPY) Caprolactum MT/year Nitric Acid MT/year Project: Expansion 13

15 #. Plant Name Product Unit Sulphate-II) Ammonium Sulphate-I Caprolactam II (Ammonium Sulphate-III) 18 Nylon 6 Existing Production Capacity Proposed Total Ammonium Sulfate MT/year Ammonium Sulphate MT/year Ammonium Sulfate MT/year Caprolactum MT/year Nitric Acid MT/year Nylon 6 -- MT/year Continuous/Batch) 19 MEK Oxime I MEK Oxime MT/year MEK Expansion MEK Oxime MT/year Urea Urea Phosphate MT/Year 1500 Phosphate Methanol Methanol MT/year HAS Crystal HAS Crystal MT/year Water Soluble Fertilizer (WSF) & Micronutrient Mixture (MM) plant WSF NPK 19:19:19 WSF - MAP / MKP / KNO3 / SOP Micronutrient Mixture MT/year MT/year MT/year Manufacturing Process of Ammonium Sulphate (AS-I) The facility for making Ammonium Sulphate by Direct Neutralization is provided in view of available Sulphuric Acid and Ammonia in V-313-A, V-313-B and V-313-C to produce around 400 TPD. Ammonium Sulphate is produced by Contact Reaction between Sulphuric acid and Vapor Ammonia as per the below mentioned reaction. For production of proposed 400 TPD Ammonium Sulphate, 100 TPD Ammonia and 305 TPD Sulphuric Acid (98.5 Wt.%) (SA) are required V-313-A Evaporator 2 NH H2SO 4 NH4 SO Initially DM water is fed to fill up by P-308-A/B to V-313-A via circulation loop of V-313-A. Sulfuric acid is fed at the suction side of P-309-A and vapor NH3 is fed at the discharge side of kcal g mole Project: Expansion 14

16 P-309-A. Due to reaction of sulfuric acid and vapor NH3 concentration of V-313-A will increase. ph to be maintained inside V-313-A is around 2.8.LP steam is supplied to E-301-A to heat up the AS liquor. Level in V-313-A will be maintained by LCV-305. Pure condensate from E-301-A goes to flash drum and then to V-315-A which is then supplied to Utility Plant. V-313-B Evaporator cum Crystallizer As liquor from V-313-A goes to V-313-B by level difference and it is controlled by LCV-306. Sulfuric acid is supplied to circulation loop of V-313-B on suction side of P-309-B and vapor NH3 is supplied at the discharge of P-309-B. AS liquor is heated by heat exchanger E-301-B in circulation loop of V-313-B. Heating medium used here is the vapor generated from V-313-A, flash drum and V-315-A. Contaminated condensate generated in E-301-B goes to flash drum V- 315-B. AS liquor in V-313-B gets concentrated and reaches up to super saturation stage for crystal growth due to high temperature and low pressure (vacuum). Crystallization takes place as soon as super saturation state is achieved. The ph to be maintained inside V-313-B around 2.8. V-313-C Evaporator cum Crystallizer AS liquor from V-313-B goes to V-313-C with the help of P-315-A. Level inside V-313-B is maintained by LCV-307. Sulfuric acid is supplied to circulation loop of V-313-C on suction side of P-309-C and vapor NH3 is supplied at the discharge of P-309-C. AS liquor is heated by heat exchanger E-301-C in circulation loop of V-313-C. Heating medium used here is the vapor generated from V-313-B and V-315-B. Contaminated condensate generated in E-301-C goes to flash drum V-315-B and finally goes to Chalk pond for recycling.as liquor in V-313-C gets concentrated and reaches up to super saturation stage for crystal growth due to high temperature and low pressure (vacuum). Crystallization takes place as soon as super saturation state is achieved. ph to be maintained inside V-313-C around 2.8. Vacuum Pulling/Condensation To create vacuum two ejectors EJ-301 and EJ-302 are used. Cooling water is used to condense the vapor from V-313-C is sucked to surface condenser E-302 by EJ-301 and additionally this vapor is condensed by indirect contact of cooling water and the contaminated condensate goes to Hot Well V-317. High temperature cooling water goes to Cooling Tower via cooling water return line. Non-condensable from E-302 is sucked to Barometric condenser V-316 by EJ-302. Here vapor is condensed by direct contact of cooling water and the contaminated condensate generated goes to Hot Well V-317.From Hot well the condensate is diverted to Cooling Tower basin for recycle to cooling loop by P-307 C/D. Process flow diagram with mass balance is being attached as Annexure-II. The P&I diagram of the same is attached as Annexure III. Project: Expansion 15

17 3.6 Raw Materials The major raw materials are Ammonium Sulphate liquor, Ammonia and Sulphuric Acid. The details of raw materials, its quantity, the source and mode of transportation are provided in Table 1.3. # Raw Material Table 1.3: List of Raw Materials and its source Existing Quantity (MT/MT) Proposed Quantity (MT/MT) Total Quantity TPM Mode of Transportation 1. Ammonia Through pipelines 2. Sulphuric Acid 3.7 Resource Requirement from existing Ammonia Manufacturing plant at GSFC Through pipelines from GSFC Storage area Sources Raw materials are manufactur ed in existing GSFC premises Existing resource requirement details include details of all the plants at GSFC Baroda unit while proposed resource requirement to be required pertain to Ammonium Sulphate-I plant only Land GSFC has already developed complete industrial infrastructure i.e. Plant building, Raw material storage area, finished products shed, treatment facilities, fire hydrant and other ancillary amenities within Hectare. For expansion of Ammonium Sulphate plant, land along with plant infrastructure is already available in existing GSFC complex thus no additional land shall be procured by the industry for proposed expansion. Bifurcation of plot area is mentioned in table 1.4. Table 1.4: Land Bifurcation S.No. Particulate Area (Ha.) Existing Proposed Total 1. Total Plant Area * (Processing) 2. GSFC Township Green Belt (In plant) Project: Expansion 16

18 4. Green Belt (Township) Total Area *The area for AS-I plant is already demarcated in Processing Plant are of ha as AS-I was initially started in 1960, after sometime AS-I plant was shut down and till date not in operation Water Source: French well (4 Nos.) in Mahi River (GSFC s own source) - Permission is attached as Annexure IV. Construction Phase: Domestic 0.7 KLD Construction activities, curing and Dust suppression 1.0 KLD Operation Phase: Fresh Water = 39 KLD Domestic 2.0 KLD Industrial 37.0 KLD Fresh water + 18 Recycled Water = 57 KLD Table 1.5: Water Consumption # Activity Water Consumption in KLD 1 Domestic Industrial CT make up DM water (Process) Recycle to System Net Consumption Daily Fresh 1.0 KLD KLD Recovered Water from Ammonium Phosphate Sulphate plant will be utilized as Make up water. Steam (Quantity mentioned is one time requirement of water during start-up of the plant.) (In Close Loop) =439.0 KLD Project: Expansion 17

19 WATER BALANCE DIAGRAM FOR AS-I (Proposed Water Consumption for Ammonium Sulphate (AS-I) Expansion Project) Project: Expansion 18

20 Existing Water Balance Diagram of GSFC Vadodara complex Electricity Electricity requirement for proposed project is estimated 0.5 MW which will be produced by existing power generation plant i.e. wind mill and joint venture with GIPCL. Further GSFC has connectivity with MGVCL Fuel For expansion (AS-I only) Natural Gas 1200 Sm 3 /day for dryer Manpower Based on organizational pattern, technical staff for plant, General staff for administrative work and other ancillary services i.e. Security, O&M contractor and maintenance services will be required in this phase. It is estimated that around 50 Nos. of employee will get direct/indirect employment during this phase. Project: Expansion 19

21 Existing manpower of all entire GSFC (5000 Nos.) include workers, technical staffs of all the plants and Units of GSFC while proposed manpower include requirement of Ammonium Sulphate-I only Utility The requirement of utilities for the proposed project has been estimated based on plant operation capacity. # Description Existing Proposed Total 1. Natural Gas (SM 3 /Day) 2. Steam (MT/Day) Waste to be generated It is envisage that due to proposed project activity various wastes to be generated which are described as under: Sewage Sewage to be generated during construction as well as operation phase from construction Labour and additional technical staff will be treated in existing facility Effluent Effluent from proposed expansion plant in form of condensate will be sent to Phosphoric Acid plant for reuse in process. No additional effluent will be sent out of company premises. Table 1.6: Wastewater Generation # Activity Waste Water Treatment / remarks Generation in KLD 1. Domestic 2.0 KLD (Sewage ) Treated in existing septic tank/soak pit 2. Industrial Steam condensate / Process condensate 337 KLD 312 KLD with in proposed plant (AS-I) will be recycled in process and balance 25 KLD will be sent to Phosphoric Acid plant for reuse. Hence, complete recycle in plant process. Treated waste water -- Sent to Phosphoric Acid plant. For reuse CT blow down 48 KLD in dust suppression/process hence, complete recycle in plant process. Project: Expansion 20

22 Net Total 0 No additional effluent will be sent out of company premises Air Emission Air emission (flue gases stack and process emission), nature of emitted pollutants and system provided for air pollution control in proposed and existing plant is mentioned in table 1.7. Table 1.7(a): Flue Gas Emission from Existing units # Plant Height Type Fuel Stack Stack of Dia. APCD of consumptio No. attached to stack (m) fuel n (M) 5150 Reformer NG NM 3 /HR for 1. Methanol F1 (Furnace) - methanol NG Preheater 231 NM 3 /HR Ammonia Reformer 1071 F3 - NG III (Furnace) NM 3 /HR NG Preheater - NG 91.9 NM 3 /HR Melamine - I 10A Salt furnace - NG 300 NM 3 /HR NG Cogeneration NG + NM 3 /HR F5 Boiler - I LSHS LSHS 8.74 T/HR Cogeneration NG + F6 Boiler - II LSHS Cogeneration III F7 Boiler - NG NM 3 /HR Utility Boiler 4 & 5 F4 Boiler 4 & 5 - NG + LSHS NG 3760 NM 3 /HR Project: Expansion 21

23 LSHS 3.92 T/HR (each) 8. NG: 3580 New CVL NG + Nm3/Hr - New Boiler - Boiler 50TPH LSHS LSHS: 3.36 MT/hr WL I: Capro I F8 Waste liquor Water KG/HR HC unit scrubber WL-II : 405 KG/HR KG/HR 10. Capro II F9 IWI Unit OFF ESP GASES (Eff. HC %) NM 3 /HR Kg/hr Melamine II A-102 Salt furnace - NG 450 NM 3 /HR % Napht NM 3 /HR F0101 Reforming ha - Section % NG NM 3 /HR 12. Ammonia 2121 F0501 Syn. Unit PG IV NM 3 /HR 30 F0901 CRG Unit CRG/ 2088/1110 NG NM 3 /HR 30 F0902 CRG Unit NG 329 NM 3 /HR 30 F1601 Predesulphurizati - TG/N 1316/1445 G NM 3 /HR on - Project: Expansion 22

24 S. No. Plant No. Stack attached to Table 1.7(b): Process Emission APC Device 1. Urea I P1 Prilling Tower Water Scrubber 2. Urea II P2 Prilling Tower Water Scrubber 3. Urea ECS P3 Condenser H 2 SO 4 oxidation Scrubber column (Eff. 99.5%) MOC Dia (m) Para meter Stack height (m) 38 RCC 4 x 1 SPM NH 3 RCC 1.45 x SPM NH 3 MS NH Melamine I P4 Dryer Outlet Filter MS 0.15 SPM 15 NH 3 5. Melamine II P5 Dryer Outlet Filter MS 0.15 SPM 17 NH 3 6. PA P6 Rock grinding Ventury MS 0.8 SPM 30 Scrubber 7. PA P7 Digester Fume MSRL -- F 20 scrubber 8. DAP P8,9 Dryer & Dust Scrubber A&B Cyclone separator &Ventury MSRL 1.43 NH 3 SPMF 32.5 scrubber 9. DAP P10,11 Granulator & Fume Neutralization Scrubber 10. AS-II P12 Dryer Cyclone Separator 11. SA-III P13 Final Final Absorption Absorption Tower Tower 12. SA-IV P14 Final Absorption Tower 13. CAP-I (Old) P15 D Tower O/L 14. CAP-I (Old) P16 D Tower O/L 15. CAP-II Exp. P17 AS Dryer Cyclone Separator & Scrubber 16. CAP-II Exp. P18 AS Vent Scrubber 17. New Nylon 6 P19 Process Plant Vessels 18. WSF & MM P20 Plant Crusher, Hopper, Mixers MSRL 0.74 NH 3 F MS 0.9 SPM 19.2 MS 1.22 SO 2 Acid 52 Final Absorption tower RCC 2.86 SO 2 Acid Mist 100 Scrubber SS 0.43 SO 2 25 NH 3 De Nox unit SS -- Nox 25 NH 3 MS SPM 30 Scrubber MS -- SO 2 30 NH 3 Scrubber CS 0.25 PM 30 Bag Filter SS 0.25 PM 40 Project: Expansion 23

25 GSFC has recently installed 30 Nos. Gas Detectors of Ammonia & Sulphur Dioxide in different plants and 4 Nos. of Online Ambient Air Monitoring Station at four sides of GSFC premise at the cost of 0.43 Crore and 2.9 Crore respectively. Further GSFC has installed Online Monitoring system in the required process as well as flue gas emissions stacks. Air Emission from of Ammonium Sulphate plant (AS-I) Air emission (flue gases stack and process emission), nature of emitted pollutants and system provided for air pollution control in Proposed Ammonium Sulphate-I plant is mentioned in following table: Process Stack of Ammonium Sulphate-I plant # Description Process Emission Existing Plant After Expansion 1. Stack Attached to - Attached to dryer. 2. Stack Height (m) Dia m 4. Nature of Pollutants - PM<150 mg/nm 3 5. Emissions control system - Dust Cyclone is available. 6. MOC - SS-316 L Online Emission monitoring system is included in proposed Ammonium Sulphate-I plant Solid/Hazardous Waste No Solid waste generation from proposed Ammonium Sulphate-I plant except used oil. Detail of solid/hazardous waste generated from various plants of GSFC and solid/hazardous waste to be generated from existing GSFC plants are mentioned in following table. Existing wastes details include details of all the plants of GSFC. Table 1.8: Solid/hazardous Waste Generation & Management # Name of Waste Source Quantity Waste Solid waste Project: Expansion 24

26 Waste category of waste Existin Propose Total storage Disposal / generati g d area Manageme on nt 1 ETP Sludge a. Biological - Biological Stored at Sell to sludge treatment MTPA MTP SDB Farmer as a of A soil effluent conditioner b. Chemical 34.3 Chemical Stored at Collection, sludge treatment SDB/Speci Storage, of fic Storage Transportati effluent & area at on & cleaning ETP in Disposal at of HDPE TSDF site collection bags i.e. NECL tanks 2 Used Oil 5.1 Various Stored at Collection, existing MTPA L/annum MTP MM dept in Storage, Plants A drums Transportati on & Disposal by selling to registered refiners 3 Discarded 33.3 Various 10, ,00 Stored at Collection, Container existing nos./yr 0 MM dept. Storage, Plants nos./ Transportati Yr on & 4 Spent 17.2 Various Stored at Disposal by Catalyst existing MTPA MM dept. selling to Plants in drums registered recyclers Project: Expansion 25

27 # Name of Waste Source Waste category of waste generati on Existin g 5 Spent 18.1 Various 115 Catalyst existing MTPA Plants 6 Organic 1.4 From F & 20 Waste I groups MTPA and cleaning activity 7 Sulphur 17.1 Filtration 350 Muck of molten MTPA sulphur at SA plants Note: Quantity Waste Solid waste Propose d Total storage area Disposal / Manageme nt Stored at Collection, MM dept. Storage, in drums Transportati on & Disposal by selling to registered recyclers Stored in Collection, MTP A MTP A Room at Storage, Caprolactu Transportati m plant in on & drums/ HDPE bags Disposal at Incineration Facility. Stored in specified area Nr. SA plant. Collection, Storage, reuse &/or Transportati on and Disposal at TSDF site 1. All the Hazardous wastes are stored on impervious floor having roof, boundary wall and leachate collection as well as transfer facility. 2. Discarded containers are properly cleaned / decontaminated before disposal. GSFC has membership of TSDF developed by M/s. NECL, Nandesari, Vadodara and M/s SEPPL, Kutch. TSDF membership certificate is attached as Annexure V. Project: Expansion 26

28 3.8.5 Noise Construction Phase: Noise will be generated during construction phase due to vehicular movement, operation of construction equipment. Well maintain vehicles and construction equipment shall be engaged to minimize the noise pollution. Operation phase: During operation phase, noise will be generated due to various industrial activities. Proper mitigation measures will be implemented to control the noise to keep it within the prescribed norms. Greenbelt acts as a noise barrier and restricts noise propagation outside the premises. GSFC has already been developed 33.3 Ha. area as a greenbelt within the factory premises and 72.7 Ha. area in colony and outside area Resource Conservation Effluent (contaminated condensate) from proposed expansion plant in form of condensate will be sent to Phosphoric Acid plant for reuse in process. No additional effluent will be sent to out of plant premises. Further, No additional fresh Water required as Cooling tower make-up as recovered Water from Ammonium Phosphate Sulphate plant will be utilized as Make-up water. Energy conservation measures are considered by utilization of Low pressure steam in Evaporator (E-301), which was vented in Ammonia-IV plant in GSFC complex. Considering Zero discharge plant no effluent is generated out of the plant and hence same can be considered under Cleaner Production unit. 3.9 Purpose of EIA Study As per the provision made in EIA Notification Dated 14 th September 2006 and its amendment till date, it has been noticed that the proposed project to be developed for manufacturing of Chemical fertilizer (Ammonium Sulphate) thus project activity falls under schedule I: 5(a) Chemical fertilizers. Project category is A. It is necessary to get Environmental Clearance (EC) prior to commissioning of the proposed project by applying to EAC, MoEF&CC New Delhi, along with the Environment Impact Assessment Study Report. Therefore, the EIA study is required to be conducted for obtaining the EC. 4.0 SITE ANALYSIS Propose project site were selected for evaluation based upon their general suitability for industrial development. Site analysis was done to ensure that development is undertaken in such a way that reduces negative impacts to the onsite environment and surrounding ecosystems. Propose project site is supported by various basic infrastructure facilities i.e. water supply, transportation, electricity supply, fuel supply etc. Project: Expansion 27

29 4.1 Connectivity Proposed project site is connected with road, rail and air transport. Raw materials, finished products & personnel during the construction and operation phase shall be done by means of existing transportation facility. Railway station : Bajwa (1 km West) & Vadodara (10 km South) Highway : NH-8 adjacent to Project site Airport : Vadodara (10 km) 4.2 Land form & Land Use Proposed project site is in notified industrial area, thus land use pattern is non-agricultural and declared for the industrial activities by town planner. Environmental settings available surrounding the proposed project site are as under, Table 1.9: Environmental Settings # Particulars Description 1. Forest & Marine There is no forest & Marine Sanctuary within 10 kms. Sanctuary radius of proposed project site. 2. Stream / Rivers River Mahi River Approx. 9.0 km 3. Sea Arabian Sea (approx km) 4. Water body/pond/lack Narmada Canal Approx. 4.0 km 5. Hill / Mountain There is no Hill /Mountain within 10 kms. radius of proposed project site. 6. Villages Bajwa (1.0 km) Vadodara (1.5 km) Project: Expansion 28

30 4.3 Topography Proposed project site is located at Latitude N and Longitude E. It has an average elevation of 129 feet above sea level. Proposed expansion shall be carried out within existing premises. Forest, national park, eco sensitive area and wild life sanctuary are not located within 10 km periphery of the proposed project site. There is no change in land use/topography as the proposed project shall be established in existing premises 4.4 Existing Infrastructure (Social/Commercial) Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of proposed project site. 4.5 Soil Classification Proposed project site is located in notified industrial area, where land is already developed for industrial purpose. Quality of soil is not considerably fertile for agricultural activities and no evidence of any influence of soil contaminant has been noticed. 4.6 Climatic data from secondary sources Proposed project site falls under seismic zone III which is not highly earthquake prone area. Aside from the monsoon season, the climate is dry. The average temperature ranging from36 C (max.) to 23 C (mini.) during summer season (March to July).The average temperature ranging from 30 C (max.) to 15 C (mini.) during winter season (Nov. to Feb.). The southwest monsoon brings a humid climate from mid-june to mid-september. The average rainfall is recorded as 93 cm. Project: Expansion 29

31 5.0 PLANNING BRIEF GSFC has proposed to expand production capacity of Ammonium Sulphate plant of 400 MTPD (1,46,000 MTPA) within existing premises to meet the market demand. Resources (i.e. water, electricity, fuel, manpower) requirement for proposed expansion shall be met though sources of existing unit. The proposed expansion will be started after getting Environmental clearance and plant commissioning will be expected in the year Further proposed project activities will take care of all the rules and regulations of statutory authority and provide control measures and devices to achieve the standard norms. 5.1 Population Projection It is estimated that around 50 Nos. of employees will get direct / indirect employment during the operation phase of proposed expansion. There are approx Nos. of employees are already working in GSFC plants. Thus after proposed expansion total no. of employees will be Land use Planning GSFC has proposed to expand production capacity within existing unit at 2240 m 2 area. Existing unit has already developed industrial infrastructure facilities i.e. firefighting system internal asphalted road, rain water harvesting system, area lighting and electrification, water supply system, waste management system, etc. in said plot area. No additional land shall be procured by the industry for proposed expansion. 5.3 Amenities / Facilities All amenities/facilities required to develop expansion project are available in existing plant of GSFC as well as within the colony. 6.0PROPOSED INFRASTRUCTURE Proposed project will require following infrastructure facilities for propose project. Table 1.10: Proposed Infrastructure S.No. Proposed infrastructure Description 1. Industrial area (processing 2240 sq. m. (Revamping of old AS-I plant) area) 2. Green belt Existing: 106 Hectares (GSFC Premise) 3. Social Infrastructure As Above 4. Connectivity As Above 5. Drinking water management Existing pipeline will be used. Project: Expansion 30

32 S.No. Proposed infrastructure Description 6. Sewerage system The domestic effluent from the proposed plant will be treated in septic tank/soak pit. An existing sewage treatment plant (STP) of capacity 3175 KLD is in operation for treatment of sewage coming from GSFC Township. Treated sewage from the same is reused in gardening/horticulture. 7. Industrial waste management Effluent from proposed expansion plant in form of condensate will be sent to Phosphoric Acid plant for reuse in process. No additional effluent will be sent out of company premises. 8. Solid waste management No Solid waste generation from proposed project except used oil. 9. Power requirement & Supply source Power requirements will be met through existing power supply sources i.e. wind mill and joint venture with GIPCL. 7.0 REHABILITATION& RESETTLEMENT (R&R) PLAN: Proposed expansion shall be carried out within existing premises, which is developed for industrial purpose and there is no population or local inhabitant at the proposed project site. Thus Rehabilitation & Resettlement (R&R) Plan is not applicable to propose project. 8.0 PROJECT SCHEDULE & COST ESTIMATION: 8.1 Project Schedule The expansion project will be started after getting Environmental Clearance from EAC, consent to Operate from GPCB and other statutory clearances required for. 8.2 Cost Estimation Capital towards proposed industrial plant development including building construction, plant machinery purchase and commissioning, environmental management, greenbelt development etc. The overall project cost has been estimated Rs Lakhs, and is summarized in table Table 1.11: Project Cost S. No. Description Rs. (Lakhs) 1 Land cost - 1 Piping, Valves, Welding and Insulation Instrumentation PC-PLC based panels Project: Expansion 31

33 4 Civil (including Control room building and offices Revamping of Bagging machine and Conveyor system Misc. expenses like Fire water system, Statutory approvals, ESC-CSR/EMP/Greenbelt etc. Total # All above cost are inclusive of commissioning expanses. 9.0 ANALYSIS OF PROPOSAL & RECOMMENDATIONS 9.1 Financial & Social Benefits Approximately 50 Nos. will be employed directly during operation phase. All local people shall be employed as per their skills, qualifications and company s requirement during operation phase. Proposed expansion project will contribute to state and national economic growth to a measurable extent. Adopt water conservation techniques and pollution abatement measures to protect existing environment and ecology. Resource conservation techniques have been considered in the expansion and no industrial effluent will be discharged outside premises. 9.2 Recommendation Looking to the scenario presented in the proposal for the expansion in existing plant facility (AS- I) for the production of Ammonium Sulphate (400 TPD) is environmentally safe and it will create local employment also. THE END Project: Expansion 32