IFFCO AONLA UNIT - ENVIRONMENT

INTRODUCTION

During mid- sixties the Co-operative sector in India was responsible for

distribution of 70 per cent of fertilisersconsumed in the country. This Sector

had adequate infrastructure to distribute fertilisers but had

no productionfacilities of its own and hence dependent on public/private

Sectors for supplies. To overcome this lacuna and to bridge the demand

supply gap in the country, a new cooperative society was conceived to

specifically cater to the requirements of farmers. It was an unique venture

in which the farmers of the country through their ownCo-operative

Societies created this new institution to safeguard their interests. The

number of Co-operative Societies associated with IFFCO have risen from 57

in 1967 to 39,824 at present.

Indian Farmers Fertiliser Co-operative Limited (IFFCO) was registered on

November 3, 1967 as a Multi-unit Co-operative Society. On the enactment

of the Multistate Co-operative Societies act 1984 & 2002, the Society is

deemed to be registered as a Multistate Co-operative Society. The Society is

primarily engaged in production and distribution of fertilisers.

The byelaws of the Society provide a broad frame work for the activities of

IFFCO as a Co-operative Society.

IFFCO commissioned an ammonia - urea complex at Kalol and

the NPK/DAP plant at Kandla both in the state of Gujarat in 1975. Another

ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh

in 1981. The ammonia - urea unit at Aonla was commissioned in 1988.

In 1993, IFFCO had drawn up a major expansion programme of all the four

plants under overall aegis of IFFCOVISION 2000. The expansion projects at

Aonla, Kalol, Phulpur and Kandla were completed on schedule. All the

projects conceived as part of VISION 2000 had been realised without time

or cost overruns. All the production units of IFFCO have established a

reputation for excellence and quality. Another growth path was chalked out

to realise newer dreams and greater heights through Vision 2010. As part of

this vision, IFFCO has acquired fertiliser unit at Paradeepin Orissa in

September 2005. As a result of these expansion projects and acuisition,

IFFCO's annual capacity has been increased to 3.69 million tonnes of Urea

and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its growth and

development, IFFCO had embarked upon and successfully implemented its

Corporate Plans, ‘Mission 2005’ and ‘Vision 2010’. These plans have

resulted in IFFCO becoming one of the largest producer and marketeer of

Chemical fertilisersby expansion of its existing Units, setting up Joint

Venture Companies Overseas and Diversification into new Sectors.

IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’ which

is presently under implementation. 

IFFCO has made strategic investments in several joint ventures. Godavari

Fertilisers and Chemicals Ltd (GFCL) & Indian Potash Ltd (IPL) in India,

Industries Chimiques du Senegal (ICS) in Senegal and Oman India Fertiliser

Company (OMIFCO) in Oman are important fertiliser joint ventures. As part

of strategic diversification, IFFCO has entered into several key

sectors. IFFCO-Tokio General Insurance Ltd (ITGI) is a foray into general

insurance sector. Through ITGI, IFFCO has formulated new services of

benefit to farmers. 'Sankat Haran Bima Yojana' provides free insurance

cover to farmers along with each bag of IFFCO fertiliser purchased. To take

the benefits of emerging concepts like agricultural commodity trading,

IFFCO has taken equity in National Commodity and Derivative Exchange

(NCDEX) and National Collateral Management Services Ltd (NCMSL).

IFFCO Chattisgarh Power Ltd (ICPL) which is under implementation is yet

another foray to move into core area of power. IFFCO is also behind several

other companies with the sole intention of benefitting farmers.

The distribution of IFFCO's fertiliser is undertaken through over 39824 Co-

operative Societies. The entire activities of

Distribution, Sales and Promotion are co-ordinated by Marketing Central

Office (MKCO) at New Delhi assisted by theMarketing offices in the field.

In addition, essential agro-inputs for crop production are made available to

the farmers through a chain of 158 Farmers Service Centre (FSC). IFFCO

has promoted several institutions and organisations to work for the welfare

of farmers, strengthening cooperative movement, improve Indian

agriculture. Indian Farm Forestry Development Cooperative Ltd (IFFDC),

Cooperative Rural Development Trust (CORDET), IFFCO

Foundation,Kisan Sewa Trust belong to this category. An ambitious project

'ICT Initiatives for Farmers and Cooperatives' is launched to promote e-

culture in rural India. IFFCO obsessively nurtures its relations with farmers

and undertakes a large number of agricultural extension activities for their

benefit every year.

At IFFCO, the thirst for ever improving the services to farmers and member

co-operatives is insatiable, commitment to quality is insurmountable and

harnessing of mother earths' bounty to drive hunger away from India in an

ecologically sustainable manner is the prime mission. All that IFFCO

cherishes in exchange is an everlasting smile on the face of Indian Farmer

who form the moving spirit behind this mission.

IFFCO, to day, is a leading player in India's fertiliser industry and is making

substantial contribution to the efforts of Indian Government to increase

foodgrain production in the country.

In 1993, IFFCO had drawn up a major expansion programme of all the four

plants under overall aegis of IFFCO VISION 2000. The expansion projects

at Aonla, Kalol, Phulpur and Kandla were completed on schedule. All the

projects conceived as part of VISION 2000 had been realized without time

or cost overruns. All the production units of IFFCO have established a

reputation for excellence and quality. Another growth path was chalked out

to realise newer dreams and greater heights through Vision 2010. As part of

this vision, IFFCO has acquired fertilizer unit at Paradeep in Orissa in

September 2005. As a result of these expansion projects and acquisition,

IFFCO's annual capacity has been increased to 3.69 million tonnes of Urea

and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its growth and

development, IFFCO had embarked upon and successfully implemented its

Corporate Plans, ?Mission 2005? and ?Vision 2010?. These plans have

resulted in IFFCO becoming one of the largest producer and marketeer of

Chemical fertilizers by expansion of its existing Units, setting up Joint

Venture Companies Overseas and Diversification into new Sectors.

During mid- sixties the Co-operative sector in India was responsible for

distribution of 70 per cent of fertilizers consumed in the country. This Sector

had adequate infrastructure to distribute fertilizers but had no production

facilities of its own and hence dependent on public/private Sectors for

supplies. To overcome this lacuna and to bridge the demand supply gap in

the country, a new cooperative society was conceived to specifically cater to

the requirements of farmers. It was an unique venture in which the farmers

of the country through their own Co-operative Societies created this new

institution to safeguard their interests. The number of Co-operative Societies

associated with IFFCO have risen from 57 in 1967 to 39,824 at present.

Awards / Recognition

Awards

Aonla wins CII Environmental Best PracticesAward-2011

Safety Innovation Award - 2010

Greentech Gold Award for Training Excellence

IFFCO Aonla Unit has been awarded the 'EDGE' winner prize

ICWAI Award for Excellence in Cost Management - 2009 for IFFCO

IFFCO Shines at Public Relation Society of India, Grabbed 2 prestigious

awards

IFFCO Aonla & Paradeep Unit have won the prestigious FAI awards

presented on 3rd Dec.'2009

IFFCO Aonla Wins "Gold Award“ - 10th Annual Greentech Environment

Excellence Award 2009

IFFCO bagged First ever dotCoop Global Award for Cooperative Excellence

IBM Awards First Prize to IFFCO for Innovation

IFFCO Phulpur Unit-I bagged "First Prize" by FAI.

CIO 100 & IT Awards

Microsoft Felicitates IFFCO

National Energy Conservation 2008 - 1st Award Conferred on Phulpur Unit

Gujarat State Safety Award : 2007 for Kalol Unit

IFFCO bags three FAI Awards

IFFCO bags Energy conservation award

IFFCO Wins PRSI Award

Phulpur Unit Wins National Energy Conservation Award-2006

Aonla Unit wins National Energy Conservation Award-2006

IFFCO's Corporate Film Wins NCUI's Award.

IFFCO Kalol Wins "National Energy Conservation Award: 2006"

Kandla Unit wins FAI Prize

IFFCO Aonla Wins National Safety Award

Kandla Unit Wins - Golden Peacock Environment Management Award

Phulpur Unit bags National Energy Award from Honourable President of

India

Best Managed Work Force Award for IFFCO

IFFCO Aonla Unit Wins National Safety Council of India Safety Award-

2004

Aim / Vision / Mission

Mission

IFFCO's mission is "to enable Indian farmers to prosper through timely

supply of reliable, high quality agricultural inputs and services in an

environmentally sustainable manner and to undertake other activities to

improve their welfare"

-To provide to farmers high quality fertilizers in right time and in adequate

quantities with an objective to increase crop productivity.

-To make plants energy efficient and continually review various schemes to

conserve energy.

-Commitment to health, safety, environment and forestry development to

enrich the quality of community life.

-Commitment to social responsibilities for a strong social fabric.

-To institutionalise core values and create a culture of team building,

empowerment and innovation which would help in incremental growth of

employees and enable achievement of strategic objectives.

-Foster a culture of trust, openness and mutual concern to make working a

stimulating and challenging experience for stake holders.

Vision

To augment the incremental incomes of farmers by helping them to increase

their crop productivity through balanced use of energy efficient fertilizers,

maintain the environmental health and to make cooperative societies

economically & democratically strong for professionalized services to the

farming community to ensure an empowered rural India.

To keep pace with the stringent environmental regulations and to maintain

ecological balance, zero effluent technology for ammonia and urea plants

have been selected at the outset . The quality of liquid effluent discharge

from the factory is monitored continuously and remains much lower than the

norms prescribed by the Uttar Pradesh pollution control board. The lagoons

constructed to store the treated liquid effluent attract a large number of

migratory birds specially during winter seasons. This speaks of the quality of

the environment near the unit. The air quality is constantly monitored by

providing high volume samplers at different locations around the factory

campus. Eighty meter wide green belt has been developed around the factory

and the township to keep the environment clean. Till date more than 15.0

lakhs trees have been planted

Picture of IFFCO Aonla Township Deer Park

METHODOLOGY FOR ENVIRONMENT PROTECTION

Methodology for environment protection starts with identification of all the

activities, which have a substantial environmental impact. These are:

Air emission quality and quantity

Effluent quality and quantity

Hazardous waste generation

Non hazardous waste generation

Consumption & conservation of Natural resources.

Ensure compliances with National Environmental Quality Standards,

Rules & Regulations covered under Environmental Protection Act,

1986.

Compliances with The Kyoto Protocol (GHG reduction)

Recycle and reuse of the wastes generated

Ammonia odor in the plant

Noise

ENVIRONMENTAL MANAGEMENT SYSTEM AT IFFCO AONLA

IFFCO Aonla Unit has sound environmental management system

comprising of following features:-

Afforestation

Zero Effluent Technology

Social Forestry

Monitoring of ambient air and stack emissions

Well Equipped laboratory & E&PC cell to monitor environmental

parameters

Development of all-round awareness regarding environmental issues

ISO-14001:2004 (EMS) Accreditation

AFFORESTATION

Once a wasteland, IFFCO Aonla not only has come up as a hope for millions

of farmers but also a true success story of unstinted and dedicated efforts of

employees who have turned up the desert land to a Lush Green Fertiliser

Complex. The dream of Green-Land comes through IFFCO’s never ending

commitment to the society, dedicated and innovative handwork of its

employees towards Protection of Environment.

Top management while implementing all the plans for afforestation has

taken the philosophy from the Vedas which has been aptly expressed in the

following Sanskrit Shloka :-

“Moolo Bramharoopaya Madhyalo Vishnuroopaiae,

Agarato Shivaroopay Vraksharayay te Namah”

Meaning – 

“From root to stem to crown,

Thou art the incarnation of Brahma, Vishnu & Shiva

My salutations to the Oh noble tree”

The eco-friendly environment has attracted a large population of birds of

various species. It is ecstatic to watch peacocks dancing all over the green

belt. It is an oasis of serenity and pollution free environment.

The success story of IFFCO Aonla’s 330 acres of green cover embellished

with around 2 lakh trees of wide variety of about 40 species including some

of the exotic species, verdant lawns and recreational parks reveal excellence

attained through hard work of employees and vision of management.

An 80m wide green belt is developed at the Northern and Eastern sides of

IFFCO Fertiliser Complex and 250 m along with interface of township and

plant. Continuous replantation of dead trees is carried out and overall green

cover is also extended

POLLUTION ABATEMENT SCHEMES IMPLEMENTATED/UNDER

IMPLEMENTATION AT IFFCO AONLA UNIT

Purge Gas recovery unit to recover Hydrogen, which was burnt in

reformer.

Condensates stripper for purification and reuse of Ammonia, CO2 and

Methanol bearing process condensate.

Recycle of contaminated turbine condensate by using Carbon Filter

and Polishers.

Reuse of Boiler Blow down.

Separation and collection of oil by means of Disc Oil separator.

Treatment of Ammonia and Urea bearing waste by Deep Hydrolyser

and Distillation Column in Urea Plants.

Provision of Acidic and Alkaline effluent storage and neutralisation

facilities near ION Exchangers in Plant Battery limit and using them

separately for pH adjustment.

Creation of “centralised strippers and 2 nos. of Guard Ponds for

storage/ equalisation of treated effluent before its utilisation in green

belt development or letting on to river Aril. These guard ponds are attracting

lot of birds especially during winter season.

Provision of dedusting system at Prilling tower top to check dust

emission.

In built Sulphur dioxide, Nitrogen Oxide, Analysers in a flue gas

stacks.

Ammonia, pH, Urea analysers and Auto samplers at different location

in treated effluent line.

Use of Eco-Friendly Non-Chromate treatment for cooling towers

since March, 1999.

Dust collection system at PH Plant.

Developed green belt around factory and township complex. A 50 m

wide green belt throughout the periphery of the plant site and 200 m

deep belt on the Southern side of plant alongwith additional

aforestation in township has been completed.

Environment Management System in accordance with ISO-

14001:2004 has been implemented.

Use of 85 % of treated effluent for irrigation purposes in green belt

SOLID WASTE MANAGEMENT AT IFFCO

CEE North is working with IFFCO’s unit based in Aonla, Bareilly on Solid

Waste Management programme since 2006. The main objective of

programme is to create awareness about the importance of waste

management and to operate the SWM system and to handle household and

horticulture waste generated in the residential colony and plant.

The Solid Waste Management (SWM) system is being implemented by CEE

where waste is being collected from the IFFCO, Aonla Township which

includes around 1100 houses, kitchen gardens, canteens, public places, etc.

A project implementation team is working on the site involving Project

Manager, a Supervisor and 10 waste collectors. The process followed for the

SWM system is collection, transportation, making beds, transferring to pits

and final product packaging. The methodology being followed is the

combination of anaerobic composting and vermi-composting. Segregated

non-biodegradable waste goes under recycling process on weekly basis. 

CEE conducts various education and awareness programmes for residents

and school children to sensitize them towards proper disposal of waste. An

awareness and education drive is regularly organized where residents are

told about the SWM process in the area. Training programmes are organized

for the officials and residents of IFFCO Aonla Township. CEE organizes

interactive programme to motivate the maid servants of IFFCO Township

for waste segregation at vermi composting site. Representatives explain the

process of SWM system and emphasize on the need of segregating the waste

properly.

Various school level events are being organized regularly by CEE not only

for the children from the campus but also for the schools of Bareilly.

ZERO EFFLUENT TECHNOLOGY

The environmental management approach adopted at IFFCO Aonla for

pollution abatement is based on following schemes :-

Ammonia and steam/power generation plants utilise the Natural gas from

Bombay High Bassein which contains about 93% methane, 10 ppm (max)

total sulphur as feed and fuel. The two streams Ammonia Plant with a

capacity of 2x1740 MTPD is based on Haldor Topsoe technology. To

achieve zero effluent from the plant, it has Process Condensate Stripper,

Turbine Condensate Polishing unit for recycle of process and turbine

condensates. Boiler blow down is also used as cooling tower make up after

flashing in a flash vessel. The L.P. steam generated is fed to L.P.steam

header.

The Urea Plant is based on Snamprogetti technology having four parallel

streams each with 1515 MTPD capacity each. In this technology, ammonia

acts as a stripping agent and assists in the decomposition of carbamates. The

plant has Waste Water Treatment section, where the Urea bearing waste

containing 0.98% urea and 4.76% ammonia is treated in Deep Urea

Hydrolyser with 37 ata steam which recovers Carbon dioxide and ammonia

from waste-water and recovered materials are recycled in process. There is

one effluent collection pit for collection of floor washings and occasional

waste to be treated separately in “Centralised Effluent Treatment Plant”.

(A) PROCESS CONDENSATE TREATMENT AND RECYCLE

The contaminated process condensate stripping is carried out in the Carbon

dioxide and condensate stripper with L.P.steam. After stripping off the

impurities like CO2, NH3 and CH3OH; the stripped condensate is further

treated in polishing unit before recycling as Boiler Feed Water.

The gaseous overhead product is condensed in overhead condenser for

recycle as reflux and a part is reused in reforming section.

(B) TURBINE CONDENSATE RECYCLE

Turbine condensate coming from the condensers is contaminated with small

quantity of dissolved and undissolved solids. It is treated in the Condensate

Polishing Unit of Ammonia Plant itself. The Polishing Unit comprises of

activated carbon filter to remove organic and undissolved matter and mixed

bed unit to remove dissolved solids.

(C) REUSE OF BOILER BLOW DOWN

The boiler blow-down is flashed in a blow down vessel where flashed

saturated L.P. steam is separated from steam condenste. 

(D) SEPARATION AND COLLECTION OF OIL FROM OILY WATER

The spilled oil in the plant is collected through underground PVC pipes to an

oily-water basin. Here oil and water forms two phases with oily layer at the

top. The oil is skimmed off in the oily-water disc unit of Disc-oil separator

and transferred to slop oil tank. From this tank, oil is collected in drums for

disposal. The waste water from slop oil basin is pumped to the neutralisation

pit.

(E) TREATMENT OF AMMONIA AND UREA BEARING WASTE IN

UREA PLANT

The process drainage containing Ammonia and Urea flows to an

underground tank through S.S.piping which inturn is pumped to Waste

Water Tank. The process drainage from waste water tank is pumped to

stripping column of Distillation Tower. The exhaust solution from the

stripping column containing mainly Urea and traces of Ammonia and

Carbon dioxide is fed to Deep Hydrolyser operating at 37 ata pressure. The

hydrolysed solution is fed to the Distillation Tower where in rest of

Ammonia and Carbon dioxide is distilled out by using L.P.steam. The over

head vapours from the top of Stripping Column containing recovered

Ammonia and Carbon dioxide are condensed and reused. The treated water

is used as C.T.make up or Boiler Feed Water.

(F) NEUTRALISATION OF ACIDIC AND ALKALINE WASTE

Ammonia and Water Treatment plants are having ION exchangers for

turbine condensate and D.M.water preparation. During regeneration of ION

exchangers, alkaline and acidic wastes are generated. To neutralise the

acidic and alkaline waste, both the plants are having independent

neutralisation and pumping facilities. Both the neutralisation pits of

Ammonia and Water Treatment Plants are connected to “Centralised

Effluent Treatment Plant”.

(G) TREATMENT OF OCCASIONAL WASTE FROM AMMONIA AND

UREA PLANTS

The Ammonia bearing waste from Urea plant and/or Ammonia plant during

abnormal condition is collected into a contaminated effluent holding pit of

500 M3 capacity the alkaline effluent from Demineralising Plant and lime

solution is added at controlled rate to maintain pH at 11. The effluent after

filtration and preheating is sent to Air Stripper for stripping of free

Ammonia. The air stripped effluent is further heated and residual Ammonia

is further removed by L.P.steam stripping in Steam Stripper. The treated

effluent is sent to “Treated Effluent Lagoons/Guard ponds”. There are two

numbers of Guard Ponds at the terminal end, each having holding capacity

of 85,000 M3. These ponds are quite safe from environmental angles as they

are double lined with P.C.C. and low-density polyethylene (L.D.P.) sheets.

SOCIAL FORESTRY 

A local nursery was developed at site (in Township) to grow seedlings of a

wide variety of plants. The different varieties are :-

FAST GROWING TREES

Casurina

Accasia

Eucalyptus

Cassia Siamea

Gulmohar

Kanji

USEFUL TREES

Neem

Arjeun

Peepal

Amaltas

Silver Oak

Mango

Guava

Banana

Pomergranate

Ashok

Trees are distributed free of cost to local residents of IFFCO township and

residents of nearly villages as well as utilised for green belt development at

IFFCO Aonla Fertiliser Complex.

Four ambient air-monitoring stations around the factory have been made in

consultation with U.P.Pollution Control Board for monitoring Sox, Nox,

NH3 & dust. The analysis report of ambient air is being forwarded regularly

to UPPCB.

Stack’s Emission

IFFCO Aonla laboratory monitors following stacks regularly for Sox, Nox

& CO etc. and reports are being sent to UPPCB on monthly/quarterly and

yearly basis :

Name of Stack Height of Stack from G.L.

SG stack (01 no.) 120 m

HRSG stack (02 nos.) 30 m

Urea Prilling tower (02 nos.) 96 m & 98 m

HRU stack 30 m

Flue Gas Stack (02 nos.) 30 m

WELL EQUIPPED LABORATORY AND ENVIRONMENT &

POLLUTION CONTROL CELL TO MONITOR ENVIRONMENTAL

PARAMETERS 

A well equipped Environmental Management Laboratory monitors quality

of ambient air samples by analysing suspended particulate matter,

Ammonia, Sulphur dioxide, Nitrogen oxides and Carbon-monoxide

regularly. Anemometer is also installed to know the wind velocity alongwith

wind directions.

One continuous sampler is also installed in the lagoon discharge channel for

composite sampling of treated effluent going to Aril River. River water

analysis are also carried out before and after the point of confluence of

effluent to assess the impact of treated effluent, discharged into river Aril.

IFFCO Aonla Lab is equipped with Gas Chromatograph, U.V.

Spectrophotometer, Plasma Analyser, Flame Photometer, Flue Gas

Analyser, Atomic Absorption Spectrophotometer, Orion analyser etc.

In addition to Env. Management Laboratory, IFFCO Aonla is having an

E&PC cell to fulfil statutory requirements laid down by U.P.P.C.B &

C.P.C.B and co-ordinating activities relating to environment among various

sections.

DEVELOPMENT OF ALL ROUND AWARENESS REGARDING

ENVIRONMENTAL ISSUES

IFFCO Aonla not only operates Pollution Abatement devices successfully

but also provides regular awareness to employees and nearly villagers

regarding environmental issues. Almost all the employees are covered

regularly on various issues like conservation of natural resources, effect of

pollutant on health & various statutory regulations regarding environment.

Moreover nearby villages are also covered by celebrating & participating in

world Environment Day

As no system is contemporary unless standardised against some

internationally approved / adopted system. It is a matter of great pride that

Aonla Unit has been certified for ISO-14001:2004 by M/s BVQI. IFFCO

Aonla Unit is having a well defined environmental policy in line with

corporate SHE (Safety, Health & Environment Policy signed by Managing

Director). The policy states:

IFFCO Aonla Unit is committed for continual improvement and protection

of environment by setting and reviewing the objectives and targets through

Environmental Management Systems focusing at:

- Compliance of applicable legislation at work place and other requirements,

which the organization subscribe. 

- Monitoring and conserving natural resources.

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

- Developing awareness and competence amongst Employees, Contractor’s

Staff and Related Agencies on Environmental issues.

- Emergency preparedness for safety of concerned personnel and plant.

ENVIRONMENTAL OBJECTIVES FOR YEAR 2010-11

- To reduce Urea spillage to 250 MT / month.

- To reduce Water consumption below 5.0 M3 / MT of Urea production.

- To plant minimum 15,000 trees in plant and township.

- To bring awareness among Employees, Trainees and contractor’s staff etc.

on environmental issues to minimum 450 participants.

AWARDS RECEIVED FOR ENVIRONMENTAL MANAGEMENT

IFFCO Aonla Unit has received many prestigious awards in the field of

prevention of Pollution and Protection of Environment by implementing

Environmental Management System.

· 10th Greentech Environment Excellence Gold Award-2009 for outstanding

achievement in Environment Management.

· National Award for Prevention of Pollution for the year 2007-08 under

Fertiliser Category from GOI Ministry of environment & forest.

· 2nd Prize for the 8th TERI Corporate Environment Award-2009 for it’s

efforts towards environmental management and innovative 

initiatives amongst corporations with a turnover above 1000 crore rupees. 

· Golden Peacock Environment Management Award-2008 by World

Environment Foundation, UK for implementation of best

environmental management practices and implementation of CDM project

by the company