1. Energy improvement project of Ammonia and Urea plant,
2. 1 million t/y DAP/NPK project
3. Poly Carboxyl Ether project at Mangalore, Karnataka
By
Panambur, Mangalore - 575010 Submitted by:
EIA Consultant:
EQMS INDIA PVT. LTD. INDIA
304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower, Community Centre, Karkardooma, Delhi – 110092
Phone: 011-30003200, 30003219; Fax: 011-22374775 Website: www.eqmsindia.com ; E-mail – [email protected]
Executive Summary
of
EIA & EMP Report
August-2017
Energy improvement project of Ammonia and Urea plant, Brown field DAP/NPK project, Poly Carboxyl Ether project at Mangalore, Karnataka
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Executive Summary
Introduction
Mangalore Chemicals & Fertilizers Ltd (MCF) is an 'Adventz' Group Company, a large
and diversified business house. The main products of MCF are Urea, Di-Ammonium
Phosphate (DAP), NP 20:20:00:13, Ammonium Bi-Carbonate (ABC) - Food grade,
Sulphuric Acid, Specialty Mixtures of Plant Nutrients consisting of Water Soluble
Fertilizers, Micronutrients & Soil Conditioners and an Industrial Product called
Sulphonated Naphthalene Formaldehyde (SNF) used in construction industry. MCF is an
ISO 14001, OHSAS 18001 and ISO 22000 certified Company.
Project Location
MCF is the only manufacturer of chemical fertilizers in the state of Karnataka. The factory
is strategically located at Panambur, 9 km north of Mangalore City, along the National
Highway 66, opposite to the New Mangalore Port Trust. Proposed project will be
implemented inside the premises of Mangalore Chemicals and Fertilizers.
Terms of Reference Issued by MoEF- EAC
As per the Environmental Impact Assessment Notification, S.O. 1533, 14th September
2006, Schedule – I, the fertilizer industry falls under the Category 5 (A).
Based on the application submitted to MoEF and presentation made in 11th EAC held on
20th and 21st July 2016, MoEF has issued TOR on 23rd September 2016 vide its letter no
J-1011/159/2016-IA II (I). The EIA study has been conducted in-line with the approved
ToR by EAC (MoEF) and taking into consideration the structure of the report given in the
EIA Notification 2006.
Project Description
Energy improvement Project of Ammonia & Urea plants by modernization and capacity
enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y
to 5,69,400 t/y. :
Government of India announced new Urea policy No. 12012/1/2015-FPP dated 25-05-
2015 which mandated all Ammonia, Urea manufacturer to improve the energy norms to
particular levels by 2018-19. The norm prescribed for MCF vintage is 6.5 Gcal/t of urea
from present 6.9015 Gcal/t. As the operation profitability depends only on actual energy
consumption and payment of all subsidies are energy dependent, it becomes necessary
for manufacturers like MCF to bring down energy norm to best achievable industry levels
to continue profitable operation. Current energy consumption for Urea production at
MCF is 6.5 Gcal/t and MCF intends to do energy improvement revamp of existing
Ammonia / Urea plants to reduce its energy consumption from present levels.
Also, Urea is an important fertilizer segment. The supply/demand gap is huge and more
than 8 million tons of urea imports are done as of now. The estimated total demand
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supply gap in 2015- 2016 was 8.2 Million MT of urea alone. Government of India is
bound to support this industry through conducive policies/subsidies. All southern states
of India namely Karnataka, Tamilnadu, Kerala and Andhra Pradesh have enough
demand for Urea. In view of this, MCF proposes capacity enhancement of Ammonia
from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to 5,69,400 t/y. The capacity
enhancement proposed by MCF will help towards filling the supply/demand gap.
Additional CO2 required for proposed capacity of 5,69,400 t/y of Urea will be recovered
from reformer flue gas by Carbon dioxide Recovery (CDR) unit of 250 MTPD.
New DAP/ NPK plant
There is increasing demand of DAP/NPK fertilizers in the country. The estimated total
demand supply gap of DAP/NPK would be 11 Million MT by 2017-2018. The proposed
expansion project of DAP/NPK would contribute in reducing the dependence on import
of DAP/NPK fertilizers.
New PCE Plant
Higher grade (> M45 Grade) concrete requires different type of admixtures known as
super plasticizers. Poly Carboxyl Ether (PCE) acts as Super plasticizers and is currently
being imported in the country. The proposed new facility within MCF complex would be
contributing in our country’s “Make in India” Program.
S. No. Plant Capacity(TPA) Methodology
Existing Additional Total
1. Ammonia 2,47,500 81,000 3,28,500 Revamp
2. Urea 4,29,000 1,40,400 5,69,400 Revamp
3. DAP/NPK (Multi grade) (16:20 & 20:20)
4,01,500 10,00,000 14,01,500 Additional Production stream
4. Poly Carboxyl Ether (PCE)
---- 18,000 18,000 New plant
5 Sulphuric Acid 1,46,000 --------------- 1,46,000 Existing Plant
6 Ammonium Bicarbonate (ABC)
24,750 ------------- 24,750 Existing Plant
7 Sulphonated Naphthalene Formaldehyde
85,000 ------------- 85,000 Existing Plant
8 Specialty mixtures of plant nutrients
2,21,000 ------------- 2,21,000 Existing Plant
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Land: The proposed project site is located within the premises of Mangalore Chemicals
and Fertilizers Ltd. No additional land will be required for this project. MCF is located in
the Karnataka Industrial Area Development Board notified Baikampady/ Panambur
industrial area, Mangalore, Dakshina Kannada (Mangalore Industrial Cluster).
Power: The present power requirement is 36MW. After implementation of proposed
projects, power requirement for Ammonia and Urea plants will reduce by about 6 MW.
This will cater to the requirement of the new DAP/NPK and PCE plants.
So no additional power will be required for this project.
Water: Presently, water is supplied by Mangalore City Corporation. No additional water
drawl due to the proposed plants. The marginal increase in the water requirement after
the commissioning of the plants will be met by existing wastewater recovery unit.
Manpower: The unit proposes to provide employment to various skilled and unskilled
people. The existing employment at the site is 680 no of people and proposed
employment generation from the project is estimated to be 200 no of people including
contract labor during operation phase.
ETP Plant: In Mangalore Chemicals & Fertilizers Ltd., (MCF), the Liquid Effluent
streams generated is only from Ammonia, Urea and Water Treatment Plants. The
Ammonium Bi-carbonate and Di-Ammonium Phosphate Plants are designed to have
zero effluent discharge. In Di-Ammonium Phosphate (DAP) Plant a part of ammonia and
urea bearing effluent from Urea/Ammonia plant is used as process condensate. MCF
already installed the ETP in existing plant and the same will be used for the proposed
projects also. The treated effluent will be reused as cooling water makeup.
Sewage Treatment Plant: MCF has put up a centralized sewage treatment unit with the
capacity of 300KLD. The combined sewage from the factory is collected in the sump
tanks and pumped to the bar screen chamber and oil trap to remove floating solids and
oil traces respectively. After this preliminary treatment the effluent is fed to equalization
tank. Effluent from the equalization tank is fed to the Membrane Bio-reactor (MBR) tank.
The treated water is reused in cooling tower as makeup. The additional sewage
generated (about 5 m3/d) after the implementation of the proposed projects will be
treated in the existing STP.
Description of Environment
Baseline data was generated during the period Dec 2016 to Feb 2017. Area covering 10
km radius around the Unit was considered for EIA study. Data was generated by
following the standard procedures of the Ministry of Environment & Forests and the
Central Pollution Control Board.
The altitude of study area varies from 0 to 121 m above mean sea level. The altitude of
project site is 19 to 27 m above MSL. Physio graphically, the study area is characterized
by plain and flat to undulated. The drainage of the study area (10 km radius) is mainly
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controlled by the river i.e. Gurupura River, which are flowing in South-East direction. Sea
coast is 2 km away from the site in west direction. As per the Hazard Risk & Vulnerability
Assessment Atlas, the project site and the surrounding 10 km radius study area lies in
zone-III (Moderate risk Zone).
Meteorology: The predominant wind direction at Mangalore is from E, SE during
morning time in all the months. The second most predominant wind direction is from W,
NW during evening time. The mean wind speed ranges from 8.4 to 9.2 kmph during
winter season, 8.3 to 8.6 kmph during monsoon and 8.9 to 9.8 kmph in pre-monsoon
season.
Air Environment: The PM10 level in all the monitoring location of the study area recorded
are within the NAAQS level (100µg/m³). The PM2.5 level in all the monitoring location of
the study area recorded are within the NAAQS level (60µg/m³). SO2 and NOx levels in all
monitoring locations were found within the NAAQS (80 µg/m³). The minimum, maximum,
average and 98 percentiles of the PM10, PM2.5, SO2 and NOx recorded in study area are
tabulated below:
Location
Code Location
PM2.5 (g/m3) PM10 (g/m3)
Min Max Mean 98%tile Min Max Mean 98%tile
AAQ-1 Project Site 24 41 32 40 56 85 74 85
AAQ-2 Lalbagh 20 34 27 34 48 69 58 68
AAQ-3 Kulur 22 39 30 37 53 82 64 78
AAQ-4 Marakada 18 36 25 34 44 73 57 72
AAQ-5 Kodikal 18 28 23 27 40 69 54 67
AAQ-6 Kulai 21 37 28 35 46 76 59 74
AAQ-7 Purkodi 20 34 26 33 41 72 56 70
AAQ-8 Baikampady 23 46 36 45 58 92 78 91
Location
Code Location
SO2 (g/m3) NOx (g/m3)
Min Max Mean 98%tile Min Max Mean 98%tile
AAQ-1 Project Site 6.7 10.2 8.6 10.2 13.8 17.7 16.0 17.5
AAQ-2 Lalbagh 5.0 9.4 7.2 9.3 8.5 14.3 12.5 14.3
AAQ-3 Kulur 4.1 7.4 6.1 7.3 11.5 15.2 13.0 14.9
AAQ-4 Marakada 5.0 8.6 6.9 8.6 8.7 14.5 12.3 14.4
AAQ-5 Kodikal 4.0 6.8 5.3 6.8 10.1 14.8 12.1 14.8
AAQ-6 Kulai 4.3 8.2 6.4 8.1 10.2 16.5 13.0 16.4
AAQ-7 Purkodi 4.3 7.7 6.0 7.6 8.3 13.4 11.0 13.2
AAQ-8 Baikampady 5.5 9.8 7.8 9.7 11.4 18.6 15.7 18.4
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Location
Code
Location
Name
NH3 (µg/m³)
CO,
mg/m3
(1hrs
Conc.)
HC (µg/m³) HF
(µg/m³) Methane Non-
methane
Min Max Mean 98
%tile
Mean
Value
Mean
Value Mean Value
Mean
Value
AAQ-1 Project Site 14.2 29.7 22.1 29.0 <0.1 <0.1 <0.1 <0.1
AAQ-2 Lalbagh 10.0 19.2 13.4 18.8 <0.1 <0.1 <0.1 <0.1
AAQ-3 Kulur 10.8 21.6 15.6 20.9 <0.1 <0.1 <0.1 <0.1
AAQ-4 Marakada 10.4 23.0 14.0 21.9 <0.1 <0.1 <0.1 <0.1
AAQ-5 Kodikal 9.2 21.2 13.6 20.8 <0.1 <0.1 <0.1 <0.1
AAQ-6 Kulai 10.0 24.4 17.5 23.7 <0.1 <0.1 <0.1 <0.1
AAQ-7 Purkodi 9.1 18.6 12.2 18.3 <0.1 <0.1 <0.1 <0.1
AAQ-8 Baikampady 11.5 27.4 19.2 26.8 <0.1 <0.1 <0.1 <0.1
NAAQ Standard: PM10 (100 µg/m3), PM2.5 (60 µg/m3), SOx (80 µg/m3), NOx (80 µg/m3), HF (25 µg/m3), NH3 (400
µg/m3)
(Source: Primary Data Collection and analysis during study period by Laboratory)
1 hr. concentration of CO level was found below 0.1 mg/m3. Overall the ambient air
quality of the study area is meeting the National Ambient Air Quality Standards 2009.
Noise Environment: The day and night time ambient noise level in the study area is
within the prescribed National Ambient Noise Quality Standard for respective residential,
commercial and industrial category at all the monitored locations.
Groundwater: The study area falls in Dakshina Kannada district. Rainfall is the major
source of groundwater recharge apart from influent seepage from rivers, seepage from
canal, irrigated fields and inflow from upland areas. The 10-km study area falls in
Mangalore block of Dakshina Kannada District. Net ground water resources based on
water level fluctuation method is estimated to be 8068.14 hams. Existing gross ground
water draft for all use is 5234.90 hams and over all stage of development is 64.88%.
Overall about 82% area fall in safe category and 18% area falls in critical category.
Ground Water Quality: The pH value of drinking water is an important index of acidity or
alkalinity. pH value of the sample varies from 6.56 to 7.23 in all locations, which is well
within the specified standard of 6.5 to 8.5.Electric Conductivity levels vary from 132 to
302µmho/cm. Total dissolved solids range from 84 to 196 mg/l which is within desirable
limit.The total hardness is an important parameter of water quality. The hardness values
in ground water of the study area ranges between 28 to 84 mg/l which is well within the
desirable limit. The calcium and magnesium values in ground water of the study area are
well within the specified desirable limit of Indian drinking water standard.The chloride
values in ground water of the study area ranges between 17 to 50 mg/l which is well
within the desirable limit.No biological and metallic contamination has been found in any
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of the ground water sample of the study area. Overall the parameters in ground water
sample were well within the desirable limit of Indian Standard IS: 10500-2012.
Surface Water Quality: The sea water quality parameters are compared with water
quality standards for coastal waters marine Outfalls (EPA Rule 1986). The sea water
quality is complying with the Class SW-II of coastal waters marine Outfalls (EPA Rule
1986) which suits for Contact Water Sports and Commercial marine fishing.
Soil Quality: Reddish color soils are observed in the study area. Texturally the soils of
study area are observed as Silty Loam and Sandy Clay Loam Soils.The soil pH ranges
from 6.2 to 7.0, thereby indicating the soils are slightly acidic to neutral. The Organic
Carbon content of soil varied from 0.48 to 0.72 %( 0.83 to 1.24% as Organic Matter)
thereby implying that soils are low to medium in organic content.
Sensitive Ecosystem: No ecologically sensitive area like national park, wildlife
sanctuary, biosphere reserve, forests, wetland are present in the 10-km radius of project
site. No species of plants and animals in the study area were found to be threatened, rare
or endangered.
Land use: The site is located in the Karnataka Industrial Area Development Board
notified Baikampady/ Panambur industrial area, Mangalore, Dakshina Kannada
(Mangalore Industrial Cluster) for industrial land use. Most of the land within the 10-km
area of the project site is Water body and Vegetation/Plantation. As per the land use
based on satellite image, about 30% land in study area is under Vegetation\Plantation,
about 39% of land is under water body, about 21% land is under settlement, only 5% of
the land is under agricultural and rest of the land is under other uses.
Environmental Impact and Mitigation Measures
Air Quality: For the proposed projects, construction of building premises and other
facilities including roads, sewage network, storm water system, and places required are
proposed at the existing site. According to the engineering assessment; most of the
excavated material shall be reused within the proposed project Area. Most of the
construction dust will be generated by the movement of carrying vehicles on unpaved
roads. Unloading and loading of constructional materials shall also act as a potential
source for dust nuisance.
Ammonia Plant:There will not be any significant increase in pollution load due to
increase in production. The plant will operate on Naphtha till arrival of Natural gas at
site. Energy improvement schemes will reduce raw material consumption and emissions
in Naphtha based operation also. Existing plant is already converted to utilize Natural
gas as feed and fuel.
Urea Plant: There will not be any significant increase in pollution load after the
implementation of energy improvement project. Capacity of Urea plant will be increased
from 4,29,000 t/y to 5,69,400 t/y after the availability of NG in Mangalore.
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The emission of Particulate matter from the urea prill tower will be about 110 mg/Nm3
which is well within standard of 150 mg/Nm³.
DAP/NPK Plant: The proposed project will not have any significant adverse impact on
the existing environment as sufficient pollution control measures are incorporated in the
process technology and plant design. The technology also incorporates special
scrubbing equipment like Dual Mole Scrubbing System and also Dedusting system. In
DAP / NPK plant Air pollution control equipment viz. Cyclone, Scrubber, Mist eliminator
etc. shall be installed during the commissioning of the plant itself.
POLY CARBOXYL ETHER (PCE) Plant:
There will not be any gaseous emission from the proposed plant.
Control Measures during commissioning
The control measures proposed to be taken up are given below.
Water sprinkling on main haul roads in the proposed project site will be done, this
activity will be carried out at least twice a day.
The duration of stockpiling will be as short as possible as most of the material will be
used as backfill material for the open cut trenches for road development.
Temporary tin sheets of sufficient height (3 m) will be erected around the proposed
construction site as barrier for dust control.
Tree plantation already present at the site. About 64 acres (33% of total area) is kept
as greenbelt within the project site. Total 63,000 nos. of trees like Teak, Mangium,
Eucalyptus, Subabul, Acacia, etc. are planted at the site. Every year 2,000 saplings
are planted & maintained.
All the vehicles carrying raw materials will be covered with tarpaulin / plastic sheet,
unloading and loading activity will be stopped during windy period.
To reduce the dust movement from civil construction site to the neighborhood the
external part of the building will be covered by plastic sheets.
Given the implementation of proper control measures for dust suppression, no adverse
impacts are expected and compliance with the Ambient Air Quality is achieved at all time.
Noise Quality: Material handling operations and movement of vehicles will be properly
scheduled to minimize construction noise. The machines, mill operations will be the main
sources of noise. All activities will be carried out inside sheds and maintenance program
for equipment will be routinely followed. Workers working in noisy areas will be given ear
plugs. The noise level will be restricted within the plant boundary to meet the standards.
Water Quality: The fertilizer plant requires water for cooling, boilers, etc. No wastewater
will be generated from the proposed projects. Domestic wastewater from plant will be
treated in the existing sewage treatment plant. No wastewater will be discharged outside
the plant premises.
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Wastewater Generation
Ammonia Plant: There is no additional liquid effluent generation from the plant and will
remain zero liquid effluent discharge plant even after the commissioning of proposed
projects. It is proposed to replace the present low pressure stripper with medium pressure
(MP) stripper which will ensure removal of Ammonia from process condensate. The
gases from the MP stripper will go to primary reformer along with steam. The effluent
generated in the plant shall be treated in the existing effluent treatment facility and
recycled back to the system.
Urea Plant There will not be any additional effluent generation after the proposed
energy improvement project. Effluent generation will reduce because of implementation
of various energy improvement schemes. MCF has installed and commissioned urea
hydrolyser stripper and operated for the treatment of effluent streams from ammonia
plant process, urea plant process and condensates from urea plant compressors. The
urea hydrolyser stripper system consists of hydrolyser, which is operated at high
temperature' and high pressure, where urea gets hydrolyzed to ammonia and carbon
dioxide. Ammonia thus produced is separated in the second desorption column. The
liquid outlet of second desorption column contains less than 10 ppm of ammonia and
urea. The ammonia vapours from the second desorption column is fed to the first
desorber. The desorber overhead vapours are condensed in a condenser and reused in
Urea plant.
DAP/NPK Plant There will not be any trade effluent generation from the proposed
DAP/NPK plant. No solid waste will also be generated. Any spillage will be recycled and
reused in the proposed plant. The marginal increase in the water requirement after the
commissioning of DAP/NPK plant will be met by effluent water recovery unit installed.
PCE Plant There will be no liquid effluent generation in the plant. The spillages if any
from the plant floor will be collected and recycled back.
Solid Wastes Disposal: The process of fertilizer production does not generate any solid
waste. All construction waste shall be stored within the proposed site itself. A proper
screen will be provided so that the waste does not get scattered. Attempts will be made to
keep the waste segregated into different heaps as far as possible so that their further
gradation and reuse is facilitated. Materials, which can be reused for purpose of
construction, leveling, making roads/ pavement will also be kept in separate heaps from
those which are to be sold or land filled. The local body or a private company may be
arranged to provide appropriate number of skip containers/ trolleys on hire.
Traffic Impact: The plant is well connected through the National Highway – 66 and
railway wagon facility. The maximum transportation of products are only done through
railway and it reduces the load on road.
Impact on Ecology: Dust emission will be controlled using different air pollution control
devices so that the impact on the surroundings will be minimized. All air emissions from
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the plant will be kept within the prescribed standards. Wastewater and solid waste will be
reused. Greenery is already developed at the site which is about 33% of the total project
site area. Such measures will be adequate to protect the ecology of the area.
Impact on Public Health: The national ambient air quality standards prescribe level of
air pollutants which is safe for public health and vegetation. Air quality dispersion
modeling study proved that the ambient air quality of the area will remain within the
national air quality standards. Hence there will be no risk to public health.
Risk Mitigation Measures
Necessary risk mitigation measures, including firefighting measures will be implemented.
Hazards due to mechanical injury will be reduced by use of standard design and
operating procedures. Disaster Management Plan shall be implemented in consultation
with the District Administration to take care of health and safety during any untoward
incident. Firefighting system with fire extinguishers, hydrant system, sprinkler system,
pumps and pipeline network will be strengthened as per the recommendation.
Project Benefits
The project envisages reuse of wastewater after treatment. By reusing treated
wastewater, MCFL is not only adding value to wastewater but also helping in improving
the overall environment.
At present the total employment is 680 and expansion project will create additional direct
employment for 200 people during the operation.MCFL will employ local people for plant
construction and operation, depending upon the skill and capability. Several other indirect
employment opportunities will be created in the surrounding area. Transport business,
vehicle drivers and attendants, workshops, grocery and retail, medical, school, coaching
centers, technical institutes, restaurants, self-employed persons like tailors, carpenters,
plumbers, electricians, etc. will get indirect job opportunity. MCFL will take up need based
CSR activities to improve the living conditions of underprivileged and make positive
difference in their lives.
Environmental Management Plan (EMP)
EMP for effective management of environmental impacts and ensuring overall protection
of the environment through appropriate management procedures has been
recommended in the EIA report. The capital cost for environmental management of the
proposed project is estimated at Rs 56 Cr and recurring cost aprox Rs. 3 Cr. This amount
shall be used for procurement of pollution control devices, strengthening of environment
Cell, occupation health and safety Cell, greenery development as a part of EMP.
Environment Management Cell (EMC) will ensure that all pollution control devices
function effectively. EMC will supervise disposal of spent oil and waste oil and used
batteries to the authorized vendors. Plantation will be started from day one and continue
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throughout the life of the project. Schemes for resource conservation, rainwater
harvesting and social forestry development will be taken up.
Regular environment, safety and health awareness programs for the workers will be
conducted by the EMC. EMC will also interact with the regulatory authorities, submit the
monitoring reports and consent applications. The implementation of EMP would ensure
that all elements of project comply with relevant environmental legislation throughout its
life cycle.
CSR Activity: Approximate 2.5% of the project cost will be used for Enterprise Social
Commitment (ESC).
Conclusion: The positive side of the project is that no disposal of solid wastes and no
process contaminated wastewater. Besides above, MCF will reuse all the additional
wastewater generated as cooling tower makeup after treating in wastewater recovery
unit. No additional water drawl, no rehabilitation and resettlement is involved. No forest
land is involved and no problems related to sustainable livelihood problems of vulnerable
people are involved.
EMP for effective management of environmental impacts and ensuring overall protection
of the environment through appropriate management procedures has been
recommended in the EIA report. Environment Management Cell will be responsible for
the implementation of the EMP. The impacts are minimized to the barest minimum level
because of proposed mitigation measures and delineation of sound Environmental
Management Plan.