COMPLIANCE OF EC CONDITIONS FOR REVAMPING OF AMMONIA 1 TO METHANOL PLANT (EC No. - F No. : J-11011/901/2007-IA(II) dated 31/07/08) SPECIFIC CONDITIONS: Sr. No. Conditions Compliance Status on Dec 2017 (Period Apr. 17 to Sept. 17) i) The Project revamping shall be from existing Ammonia Plant to Methanol plant which is a cost effective. Existing Ammonia Plant is revamped to Methanol Plant. Plant commissioning and GTR completed between 11 th to 13 th April 2013. The Urea plant and other infrastructure shall remain same. The Urea Plant and Other infrastructure are remained same. ii) Present Status of the Project : The company shall implement all the recommendations made in the Charter on Corporate Responsibility for Environmental Protection (CREP) for fertilizer industries. iii) The project authorities shall install efficient scrubbing system to control emission and bag filters for dust control in the plant. iv) Permission of the competent authority shall be obtained for drawl of water. Plant is under shutdown since 15/04/2014 due to economic unviability. Complied with relevant CREP points pertaining to fertilizer industries. Details are given in our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. Condition is not applicable as NG is being used as a fuel in reformer. No process stacks. Process Hydrocarbon releases in emergencies are also through Flare System. Complied GSFC is withdrawing water from its own French wells located in Mahi river for operation of the plants. GSFC got permission for 6.75 MGD drawl of water from Vadodara Irrigation Division (VID) for the year 2016-17 vide letter no. VID/GSFC/Contract Renew/159 dated 13/02/17. Avg. water drawl for the year 2016-17 is 6.33 MGD for GSFC complex. Water balance diagram for the financial year 2016-17 is given our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. 1
v) The gaseous emission (SO2, SO3, NOx, NH3, F, fertilizer dust) and particulate matter from various process units shall conform to the standards prescribed by the concerned authorities from time to time. The total fluoride emission shall not increase 25 mg/nm3. Emission data shall be periodically monitored and reports submitted to Ministry s Regional Office, CPCB and SPCB. Complied, Monitoring of gaseous emission (SO2, SO3, NOx, NH3, F, fertilizer dust) and particulate matter from various process units is carried out through NABL approved lab, M/s. Prakruti Environmental Engineers, Vadodara (NABL Certificate No: T-2943, Validity: 18/05/2018). Results for the period Apr. 17 to Sept. 17 are confirmed to standard prescribed by statutory authority i.e. SO2<286 mg/nm3 for flue gas stack & 2.0 Kg/MT of Sulphuric Acid, SO3/Acid Mist<50 mg/nm3, NOx<103mg/Nm3 for flue gas stack, NOx<300 mg/nm3 for process stack, NH3<175mg/Nm3, F<25mg/Nm3, fertilizer dust/particulate matter <150mg/Nm3. Details are given in Annexure I. Total fluoride emission from Phosphoric Acid & APS plant is 7.5 & 8.7 respectively for a period Apr. 17 to Sept. 17, which is well within permissible limit of 25 mg/nm3. The gaseous pollutants emitted from the existing facilities are regularly monitored through NABL approved lab as well as inhouse laboratory. The report is submitted to GPCB on monthly basis & MoEF regional office on half yearly basis. Moreover, GSFC has implemented OMS in 23 nos. of stacks and connected to CPCB & GPCB server. vi) All the waste waters generated from the various processes shall be treated as per the GPCB norms and Methanol is under shut down since 15/04/2014. Complied, Effluent generated from methanol plant is in the form of cooling tower and boiler blow down which is collected in final effluent disposal pond. Condensate is recycled/reused. Contaminated effluent streams of existing plants are treated as per GPCB norms. Analysis of final discharged effluent is carried out 4 to 6 times per month through NABL approved lab, M/s. Kadam Environmental Consultants, Vadodara (NABL Certificate No: T-2158, Validity: 02/02/2018). Avg. results for the period Apr. 17 to Sept. 17 : ph-7.5, SS- 30mg/l, AN-8mg/l, COD-50mg/l, BOD-14mg/l, O&G<1.0mg/l, F<0.05mg/l, Sulphide & Heavy Metal<Permissible limit, Phenolic<0.002mg/l, which is within the permissible limit given by 2
GPCB. Details are given in Annexure I. As per GPCB s Schedule-I Env. Audit Report for the year 2016-17: Insecticide/pesticide Nil; SAR 25.4; Bio-assay 100% survival. Analysis of final discharged effluent is also carried out on daily basis at in-house lab. Avg. in-house results of final discharged effluent for the period Apr. 17 to Sept. 17: ph -7.7, SS- 28.1mg/l, AN-14mg/l, TN-41.8mg/l, PO4-8.3mg/l & COD-126mg/l. Details are given in Annexure I. Moreover, Real time-online Monitoring System is in operation from July 2014 for the effluent parameters i.e. ph, COD, BOD, TSS, NH4-N and it is connected to GPCB as well as CPCB server. efforts shall be made to recycled/reuse the treated waste water. Existing Phosphoric Acid plant and DAP/APS plant has zero effluent discharge system. Moreover, effluent of Urea, Melamine & Ammonium sulphate plant effluent is reused in phosphoric acid plant. As an ISO 9001, 14001, OHSAS 18001, ISO 50001 & RC company, GSFC is continuously making efforts for recycling and reuse of waste. The domestic waste water shall be treated in septic tanks and treated waste shall be used for irrigation in the green belt. The domestic effluent from the plant is being treated in existing Septic tank & Soak Pit system. Domestic effluent from colony is treated in STP and used for irrigation in green belt. vii) Effluent from the process plant and associated facilities shall not be discharged to the storm water drain. The quality of the storm water shall be monitored regularly for ph, NH3 and fluoride. The company shall develop the green belt in at least 33 % land area to mitigate the effect of fugitive emissions and noise as per the guidelines of CPCB. Lean streams like cooling tower & boiler blow down are collected in to pond through storm water drain and then discharged to common effluent channel of M/s. VECL along with other effluent for ultimate disposal to sea. Avg. results of final discharged effluent are given above.. Complied Green belt already exists in GSFC complex. GSFC has developed green belt area in about 32.6 % land area and continuously maintaining the same. Total Area : 811 acre (Factory & Township); Green Belt Area : 264 acre Ha 3
viii) Occupational health surveillance of the workers shall be carried out on a regular basis and records shall be maintained as per the Factories Act. GSFC Limited, Vadodara Complied, Pre and periodical medical examination (six monthly) of employees is carried out on regular basis by Occupational Health Centre located within premises. Records are maintained at OHC. Copy of the health record is enclosed in our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. 4
GENERAL CONDITIONS : Sr. No. Conditions Compliance Status on Dec 2017 (Period Apr. 17 to Sept. 17) (i) The project authorities shall strictly adhere to the stipulations of the SPCB / State Government or any statutory body. Complied, we are ensuring compliance of all the applicable statutory requirements. Compliance of CCA condition & Production are enclosed in our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. Management of hazardous wastes (Annexure III) is carried out as per Rules. The return in Form-4 is also submitted regularly to GPCB. Avg. results of gaseous emission and final effluent discharge are given in point vi) of specific condition. (ii) No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. Moreover, Real time-online Monitoring System is in operation from July 2014 for the effluent parameters i.e. ph, COD, BOD, TSS, NH4-N and it is connected to GPCB as well as CPCB server. GSFC will carry any further expansion or modification in the plants after taking necessary permission and approval from concerned authority i.e. GPCB/SEIAA/MOEF. (iii) In case of deviations or alterations in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any. At no time, the emissions shall exceed the prescribed limits. In the event of failure of any pollution control system adopted by the unit, the unit shall be immediately put out of operation and shall not be restarted until the desired efficiency has been achieved. There are no deviations and alterations in the project proposal. Complied, emissions from the plants are within the prescribed norms. Quality of gaseous emission is given in point no. v) of specific condition. Details are given in Annexure - I. Methanol plant is under shutdown from 15/04/14 Condition is followed strictly. 5
(iv) The locations of ambient air quality monitoring stations shall be reviewed in consultation with the State Pollution Control Board (SPCB) and additional stations shall be installed, if required, in the downwind direction as well as where maximum ground level concentrations are anticipated. (v) Dedicated scrubbers and stacks of appropriate height as per the Central Pollution Control Board guidelines shall be provided to control the emissions from various vents. Complied, Ambient air monitoring is carried out at 4 Nos. locations through NABL approved lab, M/s. Prakruti Environmental Engineers, Vadodara (NABL Certificate No: T-2943, Validity: 18/05/2018). Average conc. for a period Apr. 17 to Sept.17 for SO2, NOx, & NH3 is 17.8, 23.0 & Nil µg/m3 respectively, which is within the permissible limit. RSPM (Avg. all locations - PM10-94.5, PM2.5-52.4 µg/m3) is higher at certain locations due to proximity of local roads & highway. Details are given in Annexure I. AAQM monthly avg. results are also submitted to SPCB as a part of Monthly Patrak and annually as a part of Form 4. Moreover, 4 nos. of online ambient air quality monitoring station (AAQMS) are installed in Nov. 13 at the periphery of premise after intimation to GPCB having PM10, PM2.5, NOx, SO2 & NH3 monitoring facility. Online AAQMS are connected to GPCB & CPCB server. GSFC has installed 22 Nos. Ammonia and 8 Nos. Sulphur Dioxide Gas Detectors in different plants. Complied, The flue gas emission is vented through stack having 33 m height. The height of stack is as per CPCB guideline. (vi) (vii) The scrubbed water shall be sent to ETP for further treatment. All the storage tanks will be under negative pressure to avoid any leakages. Breather valves, N2 blanketing and secondary condensers with brine chilling system shall be provided for all the storage tanks to minimize vapour losses. All liquid raw material shall be stored in storage tanks and drums The company shall undertake following waste minimization measures: Metering and control of quantities of active ingredients to minimize waste. There is no process stack in methanol plant. scrubbing liquor of wash column is recycled. Complied, All the storage tanks are designed with Nitrogen blanketing. Breather Valves are also provided. All liquid material is being stored at atmosphere condition. There are no vapour losses and hence, a secondary condenser with brine chilling is not provided. All liquid raw materials are stored in the storage tanks. Complied Active ingredients such as BFW chemicals are used through metering pumps. 6
(viii) Reuse of by-products from the process as raw materials or as raw material substitutes in other processes. Use of automated filling to minimize spillage. Use of Close Feed system into batch reactors. Venting equipment through vapour recovery system. Use of high pressure hoses for equipment cleaning to reduce waste water generation. Fugitive emissions in the work zone environment, product, and raw materials storage area shall be regularly monitored. Condensate from the process & scrubbing liquor of wash column is recycled in to system. Filling is done through control valve based on batch counter setting. Not Applicable Vapour is scrubbed & recovered in Wash Column and finally mixed with CA to avoid venting. This will be considered as and when required. Complied, Work place monitoring is carried out at regular intervals at 5 locations within Methanol plant during the operation of plant. Moreover, work place monitoring is carried out at 55 different locations in different existing plants through third party. The emissions shall conform to the limits imposed by the State Pollution Control Boards/Central Pollution Control Board. (ix) The project authorities shall strictly comply with the rules and guidelines under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 as amended in October, 1994 and January, 2000 and Hazardous Waste (Management and Handling) Rules, 1989, as amended from time to time. Emissions in the work place are confirmed to limits imposed by DISH i.e. NH3&NOx<25ppm; SO2<2ppm, F<3ppm, Benzene<0.5ppm. Complied, GSFC is adhered to all applicable legal requirements comply with the rules and guidelines of Manufacture, Storage and Import of Hazardous Chemicals Rules. Onsite emergency plant has been prepared and updated in 11/08/2017. Also strictly complied with the rules & guidelines of Hazardous Waste Rules. (x) Authorization from the SPCB shall be obtained for collection, treatment, storage and disposal of hazardous wastes. The overall noise levels in and around the plant area shall be kept well within the standards by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. Authorization under HWMH Rules has been obtained from GPCB vide CCA order No. AWH-78404, valid up to 31/12/21. Complied, At Methanol Plant, Engineering controls has been taken into consideration e.g. silencers are provided to retard noise emission. And the after implementation of these, the noise level in plant is well within level. 7
(xi) The ambient noise levels shall conform to the standards prescribed under Environment (Protection) Act, 1986 Rules, 1989 viz. 75 db(a) (day time) and 70 db(a) (night time). The company shall develop rain water harvesting structures to harvest the runoff water for recharge of ground water. (xii) The company shall undertake ecodevelopmental measures including community welfare measures in the project area for the overall improvement of the environment. (xiii) The eco-development plan should be submitted to the SPCB within three months of receipt of this letter for approval. The project proponent shall also comply with all the environmental protection measures and safeguards proposed in the EIA/EMP report. (xiv) A separate Environmental Management Cell equipped with full fledged laboratory facilities shall be set up to carry out the Environmental Management and Monitoring functions. Presently, Noise monitoring is carried out at 80 different locations within premises and at ambient air monitoring stations. Avg. noise at periphery of premise is 55 db(a) during day time & 50 db(a) during night time for a period Apr.17 to Sept.17, which is well within limit. Details are given in Annexure I. Complied, Rain Water Harvesting System exists at the Guest House, Science Foundation Building and Township s residential areas with well water recharging, Roof Top Rain Water Harvesting and Rain water harvesting ponds. Further to this, GSFC has constructed 16 water harvesting structure (Recharge well & Furrat system) in phase manner in 2009 & 2012. The filtrations rate is in the in the range of 65-70 M3/ Hr. of each wells. Four ponds have also been dug out to store the rain water runoff and percolate the same Complied, it is ongoing activity and @ Rs. 11.0 crore spent as a part of Corporate Social Responsibility (CSR). Details are given in our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. Various other green initiatives are Bio Fertilizers, Tissue culture etc. has been under taken. Details of CSR activities also submitted to GPCB as a part of half yearly compliance report. Complied with all the conditions mentioned in EC. Existing Ammonia 1 Plant has been revamped to Methanol Project. Hence EIA report is not required as per condition no.7(ii) of EIA notification. During granting of EC, only detailed note on various sources of pollution asked by MoEF, New Delhi. Details of the same has been submitted to your office vide our letter no. E/10/Methanol Proj. EC dated 18/01/13. Complied, GSFC has separate environment cell and full fledged laboratory facilities for environment management and monitoring. 8
(xv) The project authorities shall earmark adequate funds to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State Government along with the implementation schedule for all the conditions stipulated herein. GSFC Limited, Vadodara Complied, GSFC has provided adequate funds to implement the conditions stipulated by the MoEF. Expenditure incurred on EMP : Rs. 4.38 crore. Details pertaining to Env. Expenses are given in our earlier compliance vide letter No. E/10/Methanol Proj.EC dated 27/07/17. Rs. 15.72 crore is spent in 2016-17. The funds so provided shall not be diverted for any other purpose. (xvi) The implementation of the project vis-àvis environmental action plans shall be monitored by the concerned Regional Office of the Ministry / SPCB / CPCB. (xvii) A six monthly compliance status report shall be submitted to monitoring agencies and shall be posted on the website of the Company. 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 SPCB/Committee and may also be seen at Website of the Ministry at http://envfor.nic.in. This shall 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 concerned Regional Office of the Ministry. (xviii) 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 start of the project. The fund earmarked to implement the conditions of MOEF has been utilized for intended purpose only. Director of MoEF, Bhopal visited on 09/09/2013, Scientist(D) of MoEF visited on 08/07/17 and GPCB last visited on 14/09/17. Complied, Submitted report in Nov. 2008, Mar. 2010, July 2011 and regularly from Dec 2012. Last compliance status report submitted to MoEF, Regional office in June & July 2017 and also uploaded in GSFC s website www.gsfclimited.com (gsfc@glance-rc-ims- Baroda unit). Complied, EC Advertise has been published in local news papers i.e. Vadodara Samachar & Business Standard newspaper on 03/09/2008. Complied, Project approved on 15/07/2006 by Board of Directors. Start of construction activities - April 2009. 9
Monitoring the Implementation of Environmental Safeguards Ministry of Environment & Forests Western Region, Regional Office, Bhopal MONITORING REPORT PART 1 DATA SHEET No. Conditions Compliance Status on July 2017 (Period Oct. 16 to Mar. 17) 1. Project type: River-valley / Mining/ Industry/Thermal/Nuclear/Others(specify) Revamping of existing Ammonia -1 plant into Methanol Plant. 2. Name of the Project 525 TPD Methanol Plant 3. Clearance letter(s) OM No. and date F. No. J-11011/901/2007-IA(II) dated 31/07/08 4. Location a) District (s) b) State (s) c) Location Latitude / Longitude 5. Address for Correspondence Address of the Concerned Project Chief Engineer (with Pin Code & Telephone/ Telex/ Fax Numbers) 6. Salient Features a) of the Project b) of the Environmental Management Plans 7. Breakup of the Project Area Vadodara Gujarat 20 0 22 27 latitude and 73 0 09 11 longitude Shri K. S. Badlani VP (P-Ammonia Group and Nylon-6) Gujarat State Fertilizers & Chemicals Limited P.O. Fertilizernagar 391750 Dist. : Vadodara, Gujarat a) Submergence area : Forest & Non-Forest Not Applicable Tel:0265-3092831. M: 9909965842 Project: Brown field project utilizing idle asset of existing Ammonia 1 Plant and prevent venting Gas i.e. O 2 & CO 2 from Ammonia IV Plant. EMP: Wash column has been provided for scrubbing of emission from venting equipment. During the emergency, gaseous emission is being released in to Flare system. Condensate from the process & scrubbing liquor of wash column are recycled. 10
b) Others Revamping of existing Ammonia 1 Plant. 8. Break up of the project affected population 9. with enumeration of those Losing Houses / Dwelling Units only, Agricultural Land only, Both Dwelling Units & Agricultural Land &I Landless Laborers/ Artisans : a) SC, ST / Adivasi b) Others (Please indicate whether these figures are based on any scientific and systematic survey carried out or only provisional figures, if a survey is carried out and give details & year of survey) Financial Details : a) Project Cost as originally planned and subsequent revised estimates and the year of price Reference. Not Applicable Original Cost Rs. 259 Crore (Year 2005). Revised estimated cost Rs 301 Cr. (Oct 2010). b) Allocation made for environmental management plans with item wise and year wise break-up. Following expenses made towards EMP. Hot Flare stack Rs. 3.0729 Cr. Vent Wash Column Rs. 0.0746 Cr. (K-803) Deaerator (D-101) Rs. 0.4248 Cr (Condensate recycling) Closed Drain Vessel Rs. 0.810 Cr (V-108) Flue Gas Stack Existing c) Benefit cost ratio/internal rate of Return and the year of assessment d) Whether (c) includes the cost of environmental management as shown in the above e) Actual expenditure incurred on the Project so far. Internal Rate of Return 15.93 % Yes Approx. Rs. 290 Crore expenditure booked. f) Actual expenditure incurred on the Integral part of Project environmental management plans so far. 10 Forest Land Requirement a) The status of approval for diversion of Not Applicable 11
forest land for non-forestry use b) The status of clearing felling. c) The status of compensatory a forestation, if any. Comments on the viability & sustainability Of compensatory a forestation program In the light of actual field experience so far 11 The Status of Clear Felling in non-forest Areas (such as submergence area or Reservoir, approach roads), if any with Quantitative information required. 12 Status of Construction (actual and/ or planned) a) Date of commencement (Actual and/or planned) b) Date of completion (Actual and/or planned) 13 Reason for the delay if the project is yet to start 14 Dates of Site Visits a) The dates on which the project was monitored by the Regional Office on previous occasions, if any b) Date of site visits for this monitoring report. Not Applicable 12 th April 2009 24th February 2013 - Director of MoEF, Bhopal visited on 09/09/2013, Scientist (D) of MoEF visited on 08/07/17 and GPCB last visited on 14/09/17. 12
ANNEXURE - I AVG. CONCENTRATION OF POLLUTANTS FROM EXISTING GSFC COMPLEX (For the period Apr. 2017 to Sept. 2017) A. Effluent Quantity of Effluent Discharged: Month Effluent Discharged GPCB Permissible Limit M3/month M3/month Apr-17 276744 527982 May-17 297121 527982 Jun-17 327665 527982 Jul-17 359735 527982 Aug-17 337547 527982 Sep-17 327708 527982 600000 500000 400000 300000 200000 100000 0 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Effluent Discharged in m3/month 13
Avg. Quality of Effluent Discharged : Analysis by NABL & EPA approved Lab, M/s. Kadam Environmental Consultants, Vadodara (NABL Certificate No: T-2158, Validity: 02/02/2018) Parameters ph value UNIT Permis sible Limit Apr. 17 May. 17 Jun. 17 July. 17 Aug. 17 Sep. 17 Average 6.5 to 8.5 7.6 7.59 7.3 7.248 7.4 7.8 7.5 Colour (Pt.Co.) Units 100 80 64 75 80 74 78 75 S.S mg/l 100 28 29 37 41 21 25 30 COD mg/l 250 49 49 54 52 57 36 50 BOD mg/l 50 14 14 15 14 16 10 14 Oil & Grease mg/l 10 <1 <1 <1 <1 <1 <1 <1 Ammonical mg/l 50 Nitrogen 3 5 25 9 5 3 8 Ph.compounds mg/l 1 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Fluorides mg/l 2 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 Cyanides mg/l 0.2 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 Sulphides mg/l 2 <1 <1 <1 <1 <1 <1 <1 Copper mg/l 3 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 Arsenic mg/l 0.2 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Total mg/l 2 Chromium <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Hexavalent mg/l 0.1 Chromium <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Zinc mg/l 5 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Nickel mg/l 3 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Cadium mg/l 2 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Mercury mg/l 0.01 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Chlorides mg/l 600 454 413.8 437.4 457 591 423.8 462.8 Lead mg/l 0.1 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 100.00 80.00 60.00 40.00 20.00 0.00 Apr. 17 May. 17 June. 17 July. 17 Aug. 17 Sep. 17 ph value Colour (Pt.Co.) S.S COD BOD Ammonical Nitrogen 14
In-house lab Analysis : ph TDS SS AN TN PO4 COD GPCB NORMS 6.5-8.5 100 50 100 15 as PO4 250 Apr-17 7.8 2305 34 19 38 4.8 168 May-17 7.6 1615 35 16 44 7.6 158 Jun-17 7.6 1292 29 20 60 11.9 131 Jul-17 7.6 1719 27 10 46 9.0 102 Aug-17 7.6 1647 21 9 31 7.0 95 Sep-17 7.7 1885 22 11 30 9.5 102 All parameters are expressed in mg/l except ph. Note : Analysis of composite sample is carried out once a day by GSFC s central lab. Conc. of Fluoride is less than 2.0 mg/l. 200.0 150.0 100.0 50.0 0.0 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 SS (mg/l), Limit- 100 mg/l AN (mg/l), Limit - 50 mg/l TN (mg/l), Limit - 100 mg/l PO4 (mg/l), Limit - 15 mg/l Power consumption and Chemical consumption at ETPs/STP : Month Power Consumption HCL 31-32% Chemical Consumption Caustic 100% KWH MT MT Apr-17 421227 80.3 42.56 May-17 453227 57.7 88.66 Jun-17 444387 31.28 64.88 Jul-17 447588 53.7 36.689 Aug-17 438264 92.2 40.9 Sep-17 426951 66.42 43.85 15
Gaseous Emission Avg. quality of emission from Stacks : Carried out By : NABL approved Lab, M/s. Prakruti Environmental Engineers, Vadodara (NABL Certificate No: T-2943, Validity: 18/05/2018) Permissible Limit : For flue Gas Stack : PM : 150 mg/nm3, SO2 : 100 ppm (286 mg/nm3), NOx : 50 ppm (103 mg/nm3) For Process Stack : PM : 150 mg/nm3, NH3 : 175 mg/nm3, F : 25mg/Nm3, SO2 : 40 mg/nm3, NOx : 300 mg/nm3 Urea Plant- PM-2.0 kg/mt, Sulphuric Acid Plant SO2-2.0 Kg/MT MONTH AMMONIA-III AMMONIA-IV SO2 NOX PM SO2 NOX PM Apr.17 to Jun.17 Nil 7.5 Nil Nil 54.5 Nil Jul.17 to Sept.17 Nil 30 Nil Nil 90.4 Nil AVERAGE Nil 18.75 Nil Nil 72.45 Nil MONTH UREA - I UREA - II PM kg/ton PM mg/nm3 NH3 PM kg/ton PM mg/nm3 Apr.17 to Jun.17 0.72 64 34 0.73 50.25 42.03 Jul.17 to Sept.17 0.65 56.67 68 0.68 45.5 49.59 AVERAGE 0.69 60.34 51.00 0.71 47.88 45.81 MONTH UREA ECS MELAMINE-I NH3 MELAMINE-I, DRYER OUTLET SALT FURNACE NH3 SO2 NOX PM PM NH3 Apr.17 to Jun.17 0 Nil 12 Nil 19.33 138.83 Jul.17 to Sept.17 14.17 Nil 9 Nil 13.33 133.3 AVERAGE 7.09 Nil 10.50 Nil 16.33 136.07 MONTH MELAMINE-II MELAMINE-II, AS-II SALT FURNACE DRYER OUTLET SO2 NOX PM PM NH3 PM Apr.17 to Jun.17 Nil 10.8 Nil 16.67 119 24.67 Jul.17 to Sept.17 Nil 15.7 Nil 19.5 104.83 21.71 AVERAGE Nil 13.25 Nil 18.09 111.92 23.19 16
MONTH SA-III SA-IV SO2 SO2 ACID MIST SO2 SO2 ACID MIST kg/ton mg/nm3 mg/nm3 kg/ton mg/nm3 mg/nm3 Apr.17 to Jun.17 1.01 597.33 14.7 1.42 725.33 16.33 Jul.17 to Sept.17 1.11 640 13.88 1.52 778.67 18.78 AVERAGE 1.06 618.67 14.29 1.47 752.00 17.56 MONTH CAPRO.-I WASTE LIQUOR CAPRO.-II WASTE LIQUOR SO2 NOX PM SO2 NOX PM Apr.17 to Jun.17 36.33 20.7 101 8.53 54.9 20.25 Jul.17 to Sept.17 16 24.5 93 7.4 9 16 AVERAGE 26.17 22.60 97.00 7.97 31.95 18.13 MONTH CAPRO.-I SO2 SCR. CAPRO.-I DE-NOX UNIT CAPRO.-II AS VENT SCR. SO2 NH3 NOX NH3 SO2 NH3 Apr.17 to Jun.17 9.6 119 21.9 0 5.33 45.33 Jul.17 to Sept.17 13.87 90.67 17,75 0 4.27 0 AVERAGE 11.74 104.84 21.90 0.00 4.80 22.67 MONTH CAPRO.II DAP DUST SCR. DAP DUST SCR. PA DRYER A B ROCK O/L G. MILL PM NH3 PM NH3 PM PM Apr.17 to Jun.17 16 0 59.5 0 55 144 Jul.17 to Sept.17 12.67 0 59.67 0 66 99 AVERAGE 14.34 0.00 59.59 0.00 60.50 121.50 MONTH DAP FUMES SCR. DAP FUMES SCR. PA Fume A B SCR. NH3 F NH3 F F Apr.17 to Jun.17 56.67 9 36.83 8.81 7.15 Jul.17 to Sept.17 51 8.34 0 8.86 7.9 AVERAGE 53.84 8.67 18.42 8.84 7.53 MONTH COGENERATION PHASE-III UTILITY BOILER -4,5 SO2 NOX PM SO2 NOX PM Apr.17 to Jun.17 - - - Nil 18 Nil Jul.17 to Sept.17 - - - Nil 21 Nil AVERAGE - - - Nil 19.5 Nil 17
MONTH UTILITY CVL BOILER METHANOL REFORMER SO2 NOX PM SO2 NOX PM Apr.17 to Jun.17 Nil 14.5 Nil Not in operation due to financial Jul.17 to Sept.17 Nil 28.33 Nil unviability AVERAGE Nil 21.42 Nil MONTH WSF Nylon 6 - II PM PM Apr.17 to Jun.17 14 11 Jul.17 to Sept.17 9.5 13.5 AVERAGE 11.75 12.25 Note : All parameters are in mg/nm 3 except mentioned. Avg. Ambient Air Quality (Apr. 17 to Sept. 17) Carried out By : Third Party, M/s. Prakruti Environmental Engineers, Vadodara (NABL Certificate No: T-2943, Validity: 18/05/2018) Location SO2, Limit - 80 micro gm/nm3 NOX, Limit - 80 micro gm/nm3 RSPM10, Limit - 100 micro gm/nm3 RSPM2.5, Limit - 60 micro gm/nm3 NH3, Limit - 400 micro gm/nm3 Vadnagar Tank Farm 8.63 12.43 61.98 35.13 Nil Dashrath Village 18.85 23.58 97.15 54.13 Nil Nr. Godama Pump, Channi 24.97 31.77 120.60 65.77 Nil Union Office 18.58 24.28 98.15 54.73 Nil 140.00 120.00 100.00 80.00 60.00 40.00 20.00 0.00 Vadnagar Tank Farm Dashrath Village Nr. Godama Pump, Channi Union Office SO2, Limit - 80 micro gm/nm3 NOX, Limit - 80 micro gm/nm3 RSPM10, Limit - 100 micro gm/nm3 RSPM2.5, Limit - 60 micro gm/nm3 NH3, Limit - 400 micro gm/nm3 Note : Ambient Air Monitoring is carried out as per CPCB guideline. Conc. of Acid Mist, HF & SO3 is nil. With ref. to annual permissible limit, RSPM conc. is high at certain locations due to proximity of roads & national highway no.8 18
ANNUAL WIND PATTERN & PERCENTAGE IN & AROUND GSFC (2016-17) LOCATION: UNION OFFICE WIND DIRECTION WIND VELOCITY, m/sec. 0.5 3.6 3.6 8.8 8.8 TOTAL % Direction Distribution N 6.5 - - 6.50 NE - 4.56 34.12 38.68 E 4.19 - - 4.19 SE - - - - S 2.87 - - 2.87 SW - 7.29 33.45 40.74 W 5.47 0.92-6.39 NW - - 0.63 0.63 CALM 0 0 0 0 Avg. Noise Level (Apr. 17 to Sept. 17) Carried out By : Third Party, M/s. Prakruti Environmental Engineers, Vadodara (NABL Certificate No: T-2943, Validity: 18/05/2018) Location Noise Level, Limit-75 db(a) Daytime Nr Marketing Yard 56 47 Nr Adm Bldg 67 59 B/H Sa-IV at NH-8 53 50 Vadnagar Tank Farm 47 44 Noise Level, Limit-70 db(a) Night time 80 60 40 20 0 NEAR MARKETING YARD ADM TIME OFFICE B/H SA-4 PLANT VADNAGAR TANK FARM Noise Level, Limit-75 db(a) Daytime Noise Level, Limit-70 db(a) Night time Note : Noise level monitoring at the periphery of premises is carried out once in a quarter. 19
B. Generation & Disposal of Hazardous/solid waste Year 2016-17 Sr. No Name of Waste Authorization from GPCB Previous Stock MT Generated during year 2016-17 MT Quantity Disposed during year 2016-17 MT With the Company as on 31.03.2017 MT Method of Collection/ Storage 1 ETP Sludge 40 MT/Year Nil 24.75 24.75 Nil Bio sludge dried on Sludge Drying Bed - - Generated during cleaning of tank/pond, packed in HDPE bags 2 Used Oil* 125 MT/Year 52.796 95.1 0 147.896 Drums/Tanks in Room Method of Disposal Given to farmers for use as manure Dispose at NECL Sell to registered refiner 3 Discarded 10,000 4320 Nos. 6527 Nos. 0 10847 Nos. Storage Yard Sell to Vendor Containers Nos./Year 4 Spent Catalyst ( Acidic)* 35 MT/Year 41.98 14.56 33.67 22.87 Drums in Room Dispose at TSDF/ Sell to register recycler 5 Spent Catalyst ( Alkaline)* 115 MT/Year 100.21 07 12.83 94.38 Drums in Room Sell to register recycler 6 Organic Waste 20 MT/Year 14.84 9.21 17.5 6.55 Drums/Bags stored in Room Dispose at NECL s /SEPPL s incineration facility 7 Sulphur Muck 350 MT/Year 5035.574 322.1 3614.91 1742.764 Stored in the yards Note : GSFC is member of TSDF developed by M/s. NECL, Nandesari, Vadodara & M/s SEPPL, Kutch. All the Hazardous wastes are stored on impervious floor having roof, boundary wall. Discarded containers are properly cleaned / decontaminated before disposal. * Quantity is high due to large generation at a time over a period. BY PRODUCT: Reuse/ authorized secured Disposal facility. 1 Phospho-gypsum 2,53,260 MT/Year 110039.09 0 335637.98 355768.53 89908.580 Stored in the yards Sell to Farmers as Soil conditioner thru authorized dealers. 20