For
Proposed Expansion of DAP and Proposal of
Coal Handling Plant, Ammonia, Ammonium
Nitrate, Urea, GSSP, Ammonium Fluoride,
Nitric Acid.
Project Proponent
Paradeep Phosphate Limited, Jagatsinghpur, Odisha
August 2018
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]
EIA/EMP REPORT
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. i
Table of Contents
Executive Summary ...................................................................................................................... viii Chapter 1. Introduction and Background ................................................................................ 22
1.1. ProjectProponent .......................................................................................................... 22 1.2. PPL- Location & Salient Points ..................................................................................... 23 1.3. Purpose of the Study .................................................................................................... 25 1.4. Benefits of the Project ................................................................................................... 26 1.5. Scope & Methodology of the study ............................................................................... 26 1.6. Public Hearing ............................................................................................................... 27 1.7. Approved ToR for EIA Study by MOEF&CC ................................................................ 28 1.8. Structure of the Report ................................................................................................. 35
Chapter 2. Project Description ................................................................................................ 37 2.1. About the Project .......................................................................................................... 37 2.2. PPL- Existing Operation ............................................................................................... 38 2.3. Process Description (Existing) ...................................................................................... 39 2.4. New Project under Construction ................................................................................... 73 2.5. Proposed Expansion Project ........................................................................................ 73 2.6. Process description:...................................................................................................... 74 2.7. Raw Material ............................................................................................................... 117 2.8. Utilities ......................................................................................................................... 120 2.9. Other Offsite Facilities ................................................................................................ 123 2.10. Env. Aspects: Emissions, Effluents & Solid Waste Details from Proposed Plants: .. 123 2.11. Total Cost .................................................................................................................... 134 2.12. Project Implementationschedule: ............................................................................... 135 2.13. Pre-ProjectActivities .................................................................................................... 135
Chapter 3. : DESCRIPTION OF THE ENVIRONMENT ....................................................... 137 3.1. Background ................................................................................................................. 137 3.2. Study Area and Period ................................................................................................ 137 3.3. Environment & Social Settings of the Study Area ...................................................... 142 3.4. Primary Data Collection: Monitoring Plan and Quality Assurance Procedures ......... 145 3.5. Physical Environment ................................................................................................. 147 3.6. Land Environment ....................................................................................................... 152 3.7. Meteorology (Based on Past Historical Data) ............................................................ 161 3.8. Ambient Air Quality ..................................................................................................... 170 3.9. Noise Environment ...................................................................................................... 177 3.10. Water Quality .............................................................................................................. 180 3.11. Ecological Environment .............................................................................................. 188 3.12. Socio-Economic Environment .................................................................................... 194 3.13. Education Facilities ..................................................................................................... 211 3.14. Medical Facilities ......................................................................................................... 212 3.15. Potable Water Facilities .............................................................................................. 212 3.16. Communication, Road & Transport Facilities ............................................................. 212 3.17. Banking Facility ........................................................................................................... 213 3.18. Power Supply .............................................................................................................. 213 3.19. Traffic Study: ............................................................................................................... 218
Chapter 4. Anticipated Environmental Impacts and Mitigation Measures ........................... 221 4.1. General ....................................................................................................................... 221 4.2. Air Environment .......................................................................................................... 221 4.3. Noise Environment ...................................................................................................... 235 4.4. Water Environment ..................................................................................................... 235 4.5. Land Environment ....................................................................................................... 236 4.6. Biological Environment ............................................................................................... 237 4.7. Socio – Economic Environment .................................................................................. 237 4.8. Traffic Study ................................................................................................................ 238
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. ii
Chapter 5. Environmental Management Plan & Environmental Monitoring Program ......... 239 5.1. Introduction ................................................................................................................. 239 5.2. Objectives of EMP ...................................................................................................... 239 5.3. Components of EMP ................................................................................................... 239 5.4. Central Pollution Control Board {CPCB} Guide Lines for Fertiliser Industry ............. 240
Chapter 6. Hazards Evaluation and Risk Assessment ........................................................ 247 6.1. Introduction ................................................................................................................. 247 6.2. Hazard Identification ................................................................................................... 247 6.3. Effect & Consequence Analysis ................................................................................. 254 6.4. Recommendations ...................................................................................................... 259 6.5. Occupational Exposure Mitigation Planning ............................................................... 261 6.6. Other Recommended Measures for Safe Operation of the Plant .............................. 261
Chapter 7. Additional Studies ............................................................................................... 265 7.1. Introduction ................................................................................................................. 265
Chapter 8. summary and conclusions .................................................................................. 266 8.1. Prelude ........................................................................................................................ 266 8.2. Regulatory Compliance .............................................................................................. 266 8.3. Baseline Conditions .................................................................................................... 266 8.4. Environmental Impacts and Mitigation Measures ...................................................... 266 8.5. Recommendations ...................................................................................................... 267
Chapter 9. DISCLOSURE of CONSULTANTS .................................................................... 269
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. iii
List of Tables
Table 1.1 : Financial growth of PPL ............................................................................................. 22 Table 1.2 : Salient Points .............................................................................................................. 23 Table 1.3 : Capacities of Existing and Expansion ........................................................................ 25 Table 1.4 : ToR Compliance Status ............................................................................................. 28 Table 2.1 : Surrounding Area Profile ............................................................................................ 37 Table 2.2 : Details of existing land use in core areas in PPL premises are ................................ 39 Table 2.3 : Raw Material Requirement, Linkages & Specific Consumption ................................ 49 Table 2.4 : Specific Consumption for PAP ................................................................................... 50 Table 2.5 : Specific Consumption for SAP ................................................................................... 50 Table 2.6 : Specific Consumption for DAP/Other complex Fertilizer ........................................... 51 Table 2.7 : Air Emission from Existing plant ................................................................................. 55 : Stack emission Data in Existing phase ..................................................................................... 56 Table 2.8 ....................................................................................................................................... 56 Table 2.9 : Solid/ Hazardous Waste from Existing plant .............................................................. 61 Table 2.10 : Monitoring of Effluent, Emission and Ambient Air Quality (Inhouse/third party) ..... 72 Table 2.11 : Land Requirement for the Expansion Project .......................................................... 73 Table 2.12 : Steam Network in the Urea Plant ............................................................................. 91 Table 2.13 : Various Processes for Ammonium Nitrate ............................................................... 98 Table 2.14 : Raw Material Consumption for Ammonia/Gasification (SES Based) .................... 117 Table 2.15 : Raw Material Consumption of Urea Plant .............................................................. 117 Table 2.16 : Raw Material Consumption of Nitric Acid............................................................... 118 Table 2.17 : Raw Material Consumption of Ammonium Nitrate ................................................. 118 Table 2.18 : Raw Material Consumption of Di Ammonium Phophates ..................................... 118 Table 2.19 : Raw Material Consumption of GSSP ..................................................................... 119 Table 2.20 : Raw Material Consumption of Ammonium Flouride .............................................. 119 Table 2.21 : Plant-wise Water Requirement .............................................................................. 120 Table 2.22 : Plant-wise Power Requirement .............................................................................. 122 Table 2.23 : Plant-wise Land Requirement ................................................................................ 122 Table 2.24 : Plant-wise Manpower Requirement ....................................................................... 123 Table 2.25 : Effluent Details ....................................................................................................... 123 Table 2.26 : Liquid Effluents ....................................................................................................... 124 Table 2.27 : Solid Disposal ......................................................................................................... 125 Table 2.28 : Typical composition (Volume/Volume) ................................................................... 128 Table 2.29 : Off-gas .................................................................................................................... 132 Table 2.30 : Effluent - Wastewater ............................................................................................. 132 Table 2.31 : Diluted Sulphuric Acid ............................................................................................ 132 Table 2.32 : Silica ....................................................................................................................... 132 Table 2.33 : Wastewater sludge (synthetic fluorspar) ................................................................ 133 Table 2.34 : Proposed Plant Stacks ........................................................................................... 133 Table 2.35 : Project Cost ............................................................................................................ 134 Table 2.36 : Expenditure of Environmental Safeguards ............................................................ 134 Table 2.37 : Project Implementation Period ............................................................................... 136 Table 3.1 : Salient Environmental Features of Proposed Site ................................................... 142 Table 3.2 : Summary of Methodology for Primary/Secondary Baseline Data Collection .......... 145 Table 3.3 : Sub-surface Stratigraphy in the Paradeep Depression of Mahanadi onshore areas
............................................................................................................................................. 148 Table 3.4 : Stage of Block wise Ground water Development of Jagatsinghpur District (As on
31st March 2009) ................................................................................................................. 149 Table 3.5 : Land use of the Study Area ...................................................................................... 153 Table 3.6 : Soil Sampling Locations ........................................................................................... 157 Table 3.7 : Physicochemical Characteristics of Soil (Pre-monsoon Season, 2018) ................. 157 Table 3.8 : Area under Major Field Crops (As per latest figures 2008-09) ................................ 160 Table 3.9 : Production and Productivity of Major Crops ............................................................ 161
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EQMS India Pvt. Ltd. iv
Table 3.10 : Long Term Meteorological Data of Paradeep Port, 1981-2010 (30 years average) ............................................................................................................................................. 162
Table 3.11 : No. of Days with Zero Oktas of Cloud Cover (Paradeep Port) .............................. 163 Table 3.12 : Site Specific Meteorological Data .......................................................................... 167 Table 3.13 : Ambient Air Quality Monitoring Locations (Dec, 2013-March,2014) ..................... 171 Table 3.14 : Ambient Air Quality Monitoring Locations (March to May 2018) ........................... 171 Table 3.15 : Ambient Air Quality Monitoring Results (24-hour average) (Dec,2013-Feb,2014)171 Table 3.16 : Ambient Air Quality Data around the project site in 10 km radius (March-May,
2018) .................................................................................................................................... 172 Table 3.17 : Ambient Noise Quality Monitoring Locations ......................................................... 178 Table 3.18 : Ambient Noise Quality Results (Post monsoon Season, 2013-14) ....................... 178 Table 3.19 : Ambient Noise Quality Results (Pre monsoon Season, 2018) .............................. 179 Table 3.20 : Ground Water Sampling Locations ........................................................................ 180 Table 3.21 : Physical and Chemical Characteristics of Ground Water Samples (Post monsoon
season 2018) ....................................................................................................................... 181 Table 3.22 : CPCB Best Designated Use Standard (Source-CPCB) ........................................ 184 Table 3.23 : Surface Water Sampling Locations ........................................................................ 185 Table 3.24 : Surface Water Quality in the Study Area (Pre monsoon Season, 2018) .............. 185 Physical and Chemical Characteristics of Surface Water Samples (Pre monsoon Season-2018)
contd... ................................................................................................................................. 187 Table 3.25 : Receiving Sea Water Standards for SW-II Category ............................................. 187 Table 3.26 : List of Flora present in Study Area ......................................................................... 189 Table 3.27 : List of Herbs & Shrubs ........................................................................................... 191 Table 3.28 : List of the Fauna Recorded in Study Area ............................................................. 192 Table 3.29 : List of the Birds Surveyed / Recorded in the Study Area ...................................... 193 Table 3.30 : Caste-wise Population Distribution of 2.0-km Radial Zone ................................... 195 Table 3.31 : Village-wise Population Distribution of Study Area ................................................ 196 Table 3.32 : Village-wise SC & SC Population Distribution of Study Area ................................ 198 Table 3.33 : Male-female wise Urban & Rural Population Distribution in the Study Area ........ 201 Table 3.34 : SC & ST Population Distribution in the Urban & Rural Parts of the Study Area ... 202 Table 3.35 : Male-female wise Literates & Illiterates ................................................................. 203 Table 3.36 : Village-wise Occupational Pattern in the Study Area (0-10km) ............................ 206 Table 3.37 : Distribution of Work Participation Rate .................................................................. 209 Table 3.38 : Composition of Non-Workers ................................................................................. 211 Table 3.39 : Village-wise details of Basic facilities in Study Area .............................................. 214 Table 3.40 : Transportation route at Project Site ....................................................................... 219 Table 3.41 : Quantitative Details of vehicle used for export and Import .................................... 219 : 220 Table 3.42 Traffic study at PPL Plant road ................................................................................ 220 Table 4.1 : Emission Data and Stack Parameters for Proposed Expansion ............................. 225 Table 4.2 : Summary of Maximum Cumulative 24 hr. GLC (Proposed Expansion Project) ..... 226 Table 4.3 : Summary of Maximum 24-hour GLC for HF ............................................................ 226 Table 4.4 : Summary of Maximum Cumulative GLC at Monitoring Locations ........................... 226 Table 4.5 : Summary of Maximum GLC at Monitoring Locations for HF ................................... 228 Table 5.1 : Compliance Status ................................................................................................... 240 Table 5.2 : List of Plant species to be planted ........................................................................... 243 Table 5.3 : Environmental Monitoring Program.......................................................................... 245 Table 6.1 : Characteristics of Hazardous materials ................................................................... 247 Table 6.2 : Environmental Monitoring Program.......................................................................... 249 Table 6.3 : Petroleum Products in PPL and hazardous nature ................................................. 252 Table 6.4 : Different Failure Scenarios ....................................................................................... 254 Table 6.5 : Hazards Scenario Impact ......................................................................................... 254
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List of Figures
Figure 1.1 : Project Location ......................................................................................................... 24 Figure 1.2 : Satellite View of the Site ........................................................................................... 24 Figure 1.3 : EIA Methodology ....................................................................................................... 27 Figure 2.1 : Process Flow diagram of Sulphuric Acid Plant ......................................................... 41 Figure 2.2 : Process Flow diagram of Phosphoric Acid Plant ...................................................... 44 Figure 2.3 : Process Flow diagram of DAP/NPK Plant ................................................................ 46 Figure 2.4 : Water Balance (Existing) ........................................................................................... 48 Figure 2.5 : Schematic Diagram of ETP ....................................................................................... 58 Figure 2.6 : Schematic Diagram of Project for Reuse of Treated Water of ETP ......................... 59 Figure 2.7 : Gypsum Pond ............................................................................................................ 60 Figure 2.8 : Existing Green Belt in the Plant Area ....................................................................... 71 Figure 2.9 : PFD Coal Handling Plant ........................................................................................... 75 Figure 2.10 : Ammonia Plant Block Diagram ................................................................................ 76 Figure 2.11 : PFD Urea Plant ........................................................................................................ 82 Figure 2.12 : Process flow scheme Weak Nitric Acid (WNA) ........................................................ 94 Figure 2.13 : PFD of Concentrated Nitric Acid .............................................................................. 98 Figure 2.14 : PFD of Ammonium Nitrate ..................................................................................... 100 Figure 2.15 : Block Diagram for production of SSP .................................................................... 110 Figure 2.16 : GSSP ..................................................................................................................... 112 Figure 2.17 : Anhydrous hydrofluoric acid (AHF) from FSA ........................................................ 114 Figure 2.18 : High-bulk-density Aluminium Fluorides (HBD AlF3) from HF ................................. 115 Figure 2.19 : Water Balance in Existing and Expansion Phase .................................................. 120 Figure 2.20 : Water Balance (Proposed Expansion) ................................................................... 121 Figure 2.21 : Emission Details of Urea plant ............................................................................... 126 Figure 3.1 : Road Connectivity Map ........................................................................................... 138 Figure 3.2 : Location Map of Study area .................................................................................... 139 Figure 3.3 : Geographical Cordinates of Existing and Expansion Project Site ......................... 140 Figure 3.4 : Toposheet Map of the 10 km Study area................................................................ 141 Figure 3.5 : Google Map showing environment sensitive features of 10 km Study area .......... 144 Figure 3.6 : Environment Sampling Location Map ..................................................................... 146 Figure 3.7 : Contour Map of the Study Area .............................................................................. 147 Figure 3.8 : Drainage Map of the Study Area ............................................................................. 148 Figure 3.9 : Ground Water Resources of Jagatsinghpur District ............................................... 150 Figure 3.10 : Depth to Water Level (Pre-Monsoon Season)...................................................... 151 Figure 3.11 : Depth to Water Level (Post-Monsoon Season) .................................................... 151 Figure 3.12 : Seismic Zones Map of Odisha .............................................................................. 152 Figure 3.13 : Graphical representation of Landuse of 10 km study area .................................. 153 Figure 3.14 : Land Use Map of the Study Area (10 km Radial Zone) ....................................... 154 Figure 3.15 : Soil Map of Jagatsinghpur District ........................................................................ 156 Figure 3.16 :Wind rose Diagram of IMD Paradeep Port (Pre-monsoon Season) ..................... 164 Figure 3.17 : Wind rose Diagram of IMD Paradeep Port (Monsoon Season) ........................... 165 Figure 3.18 : Wind rose Diagram of IMD Paradeep Port (Post-monsoon Season)................... 166 Figure 3.19 : Wind Class Frequency distribution ....................................................................... 168 Figure 3.20 : Windrose Diagram ................................................................................................. 170 Figure 3.21 : Statistical Comparison of PM2.5 Concentration ..................................................... 174 Figure 3.22 : Statistical Comparison of PM10 Concentration ..................................................... 175 SO2 Concentration (Winter Season): .......................................................................................... 175 Figure 3.23 : Statistical Comparison of SO2 Concentration ....................................................... 176 Figure 3.24 : Statistical Comparison of NOx Concentration ...................................................... 177 Figure 3.25 : Male-Female Wise Population Distribution ........................................................... 202 Figure 3.26 : Percentage of SC/ST Population in Study Area ................................................... 203 Figure 3.27 : Male-Female wise Distribution of Literates & Illiterates ....................................... 203 Figure 3.28 : Workers Scenario of Study Area........................................................................... 209 Figure 3.29 : Gender-wise Distribution of Workers .................................................................... 210 Figure 3.30 : Composition of Marginal Workers ......................................................................... 210
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. vi
Figure 3.31 : Composition of Non-Workers ................................................................................ 211 Figure 4.1 : Isoplethsfor Cumulative PM10 GLC ......................................................................... 229 Figure 4.2 : Isopleths for Cumulative PM2.5 GLC ........................................................................ 230 Figure 4.3 : Isopleths for Cumulative SOx GLC ......................................................................... 231 Figure 4.4 : Isopleth for Cumulative NOx GLC ........................................................................... 232 Figure 4.5 : Isopleth for Cumulative HFGLC .............................................................................. 233 Figure 4.6 : Isopleth for Cumulative NH3 GLC ............................................................................ 234 Figure 6.1 : Ammonia Tank [200 m Puddle] ............................................................................... 255 Figure 6.2 : Ammonia Tank [200 m Puddle] ............................................................................... 256 Figure 6.3 : Heavy Ammonia Leakage and Spillage .................................................................. 256 Figure 6.4 : Heavy Ammonia Leakage and Spillage .................................................................. 257 Figure 6.5 : Nitric (conc.) Acid Tank Leakage ............................................................................ 257 Figure 6.6 : Chlorine Cylinder/Pipe Line Leakage ..................................................................... 258 Figure 6.7 : Chlorine Cylinder/Pipe Line Leakage ..................................................................... 258
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. vii
List of Annexures
Annexure 1: Copy of ToR Letter
Annexure 2: Coal Linkage Documents
Annexure 3: Certified EC compliance report
Annexure 4: Project Site Layout Plans
Annexure 5: Petrological and Chemical analysis and other chemical properties of Raw
Materials Used
Annexure 6: Mass balance for the raw material and products
Annexure 7: Energy Balance Data
Annexure 8: Permission for the drawl of water
Annexure 9: Design details of the ETP and STP
Annexure 10: Waste Water Characteristics
Annexure 11: Detailed Ash Management
Annexure 12: A note on Phosphogypsum
Annexure 13: Prospects of use of Gypsum
Annexure 14: Zypmite Pilot Project details
Annexure 15: Fluoride Recovery Unit Design Details
Annexure 16: Carbon Credit
Annexure 17: Monitoring Report
Annexure 18:Photographs of the proposed site
Annexure 19:Mode of trasport Raw Material & Products
Annexure 20:Rain water Harvesting
Annexure 21: Stock Pile lining
Annexure 22: Corporate Environment Policy
Annexure 23: Infrastructure facilities
Annexure 24:Impact on local infrastructure
Annexure 25:Power Grid Permission letter
Annexure 26:Public hearing report
Annexure 27:NABET certificate
Annexure 28:Achievements of PPL towards ESC
Annexure 29: Onsite Emergency Plan
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. viii
EXECUTIVE SUMMARY
Introduction and Background Project Highlight
Paradeep Phosphates Limited (hence forth ‗PPL‘; incorporated in 1981) is a premier
fertilizer company engaged in manufacturing and marketing of complex Phosphatic
fertilizers. The company was initially commissioned as a joint venture between Government
of India and Republic of Nauru and subsequently, in 1993 it was changed into a wholly
owned Government of India Enterprise. After disinvestment by Government of India in
February 2002, PPL was taken over by Zuari Group the management of the company is
presently with the fertilizer majors - Zuari Group and OCP of Morocco.
PPL produces about 1.3million metric tonnes of DAP and other complex fertilizers annually.
The plant also produces intermediary products like Phosphoric Acid and Sulphuric Acid,
which are critical raw materials in the manufacture of Phosphatic fertilizers. The plant,
located in the port town of Paradeep in the district of Jagatsinghpur in Orissa, has an
installed capacity of 5000 MTPD of DAP. PPL is one of the largest integrated DAP plants in
India. With a market share varying around 13%, it has a strong presence in the complex
fertilizer market its products marketed under the popular NAVRATNA brand represent a
combination of multiple nutrients like Nitrogen, Phosphorus, Potash and Sulphur etc. PPL‘s
range of products caters to almost all agricultural applications.
After disinvestment on February 28, 2002, PPL has been revived to full strength with the
employees' dedication and commitment under extremely difficult conditions. Remarkable
achievements have been achieved in terms of financial turnover. From a loss of Rs. 23,026
lakhs in the year 2001-02 the profitability of the Company has improved by achieving a profit
after tax year after year.
With a stellar turnaround, PPL is a case study in favour of privatization. The company‘s
focus on performance and continuous efforts towards development are reflected in the FAI
Awards for Improvement in Overall Performance of the company in 2002-03, 2005-06, 2008-
09 and the ―Best Technical Innovation‖ in the year 2005-06. PPL received the
ISO14001:2004 certification in May 2006 for good environment management systems,
reflecting the fact that along with technical advancement, the company also values
maintaining and working towards a clean and safe environment.
PPL is a leading fertilizer company with an annual turnover close to Rs. 3,800 Crores.
Its primary focus is the production and marketing of complex Phosphatic fertilizers. It is
committed to improve agriculture productivity and to betterment of the farming community.
Project Categorization
As per the EIA Notification 2006 of Ministry of Environment & Forests and Climate Change
(MoEF&CC), Government of India and its further amendments, PPL proposed Expansion of
project (Ammonia, Urea, Nitric Acid, DAP, GSSP, Coal Handling Plant, Ammonium Nitrate
&Aluminum Flouride) has to require prior environmental clearance for commissioning the
plant. The proposed project is covered under Category 'A' as per the Schedule of EIA
Notification and hence requires environmental clearance from EAC of Ministry of
Environment & Forest and Climate Change, New Delhi.
Project Location
PPL is located at Paradeep in Jagatsinghpur District, Orissa. It is 90kms from Cuttack. The
site is located at 20º16‘56‖ North Latitude and 86º38‘52‖ East Longitude, west side of
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. ix
Paradeep Port. The plant encompasses 2282.4acresarea. Mahanadi River is 5km from the
plant site and meets Bay of Bengal, which is 5.3 km away from the site. Atharbanki creek is
flowing along the boundary wall of the site and is in between Paradeep Port site and the
factory. Location map of the project site is shown in EIA.
Project Description
Existing Operation: The fertilizer complex consists of following manufacturing units.
4400MTPD of Sulphuric Acid Plant(2stream)
1400 MTPD of Phosphoric Acid Plant
5000 MTPD of Di Ammonium Phosphate Plant/NPK Plant (4 trains)
2X16 MW + 1X23 MW Captive Power Plant
240 TPD of Zypmite Plant
The fertilizer complex is using imported Sulphur& rock phosphates to produce Sulphuric
acid and phosphoric acid, along with imported MOP for NPK complex production. Since
captive production of phosphoric acid cannot cater to the four streams of DAP plant, part of
the phosphoric acid requirement is made through imports. The entire ammonia requirement
is met through imports.
New Project under Construction: PPL is carrying out expansion (construction/
commissioning) of existing plant facilities. Some of the projects under execution are:
New Gypsum Pond
Proposed Project:
Coal Handling Plant: Unloading System
Ammonia plant (coal based): [Capacity – 2200 MTPD]
Urea Plant: [Capacity – 3850 MTPD]
Nitric acid plant: [Capacity – 1000 MTPD]
Ammonium Nitrate plant: [Capacity – 1100 MTPD]
DAP PLANT: [Capacity - 0.4 Million tonnes per annum by capacity expansion of
existing DAP plants] – 1300 MTPD
GSSP PLANT: [Capacity – 1650 MTPD]
Aluminium fluoride plant: [Capacity – 9500MTP Annum]
Resources Requirement
Land: Paradeep already have enough Land. The detail requirement of land for Proposed
Plant is 174.82 acres and the total land area of the plant is 2282.4 acres.
Raw Material:
Existing: Basic raw materials handled are rock phosphates, sulphur, MOP, ammonia,
sulphuric acid and phosphoric acids.
Expansion: Basic raw materials handled are Coal/petcake, ammonia, nitric acid, sulphuric
acid and phosphoric acid, rock phosphate, H2SiF6, etc.
Water:
Existing: Existing raw water requirement of the PPL is met from the Taladanda Canal
flowing in the west – north – north east direction of the project site. PPL is permitted to
withdraw 5 MGD (947.08 m3/hr) water from Taladanda canal. The existing plant is utilizing
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. x
approximately 776m3/hr of water. Extra water required if any for the proposed upcoming
plants will be clarified & resolved and approvals and permissions would be taken for the
same.
Proposed: The water requirement of the proposed expansion project is ~1610 m3/Hr and
total water requirement in both existing and expansion phase is 1840 m3/hr. The water will
be made available from the existing source i.e. Taladanda canal. The necessary approval
for the additional water is being obtained.
Power:
Existing: PPL has captive power generation facilities. Captive generation of power is
through co-generation from the waste steam of SAP. In addition, there are three Turbo
Generators. These are extraction cum condensate type, manufactured by BHEL, each
having capacity of 16 MW (one standby) & new TG with 23 MW generation capacity. When
one TG is under operation, other works as spare and vice versa.
Total power requirement in the plant is 34 MW. PPL is capable to generate 39 MW. We are
self-sufficient for our existing requirement and also have grid supply from state electricity
grid for emergency.
In case of total power failure, the backup HT power is supplied through 5 MVA DG set and
LT power through two numbers of 1 KVA DG sets
Proposed: The total power requirement for the proposed project will be ~ 239 MW. The
plant wise requirements are as given below:
The power will be sourced from:
Captive generation
DG set
State grid
Manpower:
Existing:Competent and qualified personnel are employed for various jobs. Direct
employment is around 931. Out of this 540 are executives and 391 are non-executives.
Indirect employment is to the tune of 905 deployed through contractors. Temporary
employment is around 30.
Summing up the figures, PPL has manpower of 1866 as of 30.09.2017.
PPL has provided housing facilities to all its personnel. Maintenance of the colony is taken
care by the civil department. The complex is having all basic minimum amenities like
shopping complex, school, playground, jogging trail, gymnasium, recreational club &
hospital etc.
Proposed:Direct employment shall be around 1017 (133 in DAP Plant, 200 in Coal
Handling plant, 210 in Gasification, 170 in Urea plant, 110 in Ammonium nitrate plant, 80 in
Nitric acid plant, 64 in GSSP, 50 in Aluminium Fluoride)
Environmental Aspects:
Air Emission:
Details of existing stacks and its air emission from existing plant is described in EIA report.
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EQMS INDIA PVT. LTD. xi
Water Pollution
The major sources of waste water generation from PPL are;
Sulphuric Acid Plant
Phosphoric Acid Plant
DAP Plant
Captive Power Plant
Offsite and Bagging Plant
Domestic Waste Water
Scrubbers, condensers of the vacuum evaporators, leakage from pumps, spills, floor
washings, cooling tower blow down, boiler blow down and wash water mainly contribute to
waste water stream from the above-mentioned units. It is apparent that several substances
during the processing of the product are discharged with the effluent that primarily includes
phosphates and fluorides.
PPL plant has been designed with provision of maximum recycling of the wastewater
generated from some of the units like DAP plant and PAP. Water from gypsum pump oil
cooler and filter pump is used in Ball Mill for grinding purpose to the tune of 90 M3/hr.
The total waste water generation from the existing plants to ETP is around 66.6 M3/hr
andwaste water generation from both existing and proposed facilities will be
approx.842M3/hr.
Total waste water generation from domestic use will be 39M3/hrin both existing and
expansion phase.
Noise Pollution
Present noise levels in study area are below the standards except near a station close to
Railway crossing. As all the plant equipment are adequate noise control measures thus
there is not much impact to noise in the plant premises. Major transportation is by either rail
or ship.
Waste Generation
The solid waste generated in PPL can be classified into solid waste from the processing
plant and domestic refuse from the colony.
Solid wastes from the plant are by-product phosphor gypsum, sulphur muck, spent catalyst,
phosphoric acid tank sludge, ETP sludge etc.
Environmental Status of Plant Site and Study Area
Topography
The study area falls in Jagatsinghpur district. The study area is spread over alluvial plains of
the river Mahanadi. The deposit of silt of rivers has built up the present alluvium tracts at
their meeting places with the sea. Due to creation of swamp at the meeting places with the
sea, dense jungles have grown up. The study area is situated in coastal plain zone as per
agro- climatic classification and in deltaic alluvial plains of the Mahanadi river system.
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. xii
The study area being a part of Mahanadi delta is a flat land with hardly a relief. The
topography of proposed site is almost plain. The site elevation ranges between 2 to 7 m
amsl. The site is sloping towards south side.
Climate and Meteorology
Meteorology plays a vital role in affecting the dispersion of pollutants into the environment
after their discharge into the atmosphere. Jagatsinghpur District enjoys a temperate climate.
Winters are cold, while summers are hot and humid. The District is prone to cyclonic rainfalls
during the monsoons. The mean maximumtemperature of the project site is 32.7°C and
mean minimum temperature is 15.7°C. The total annual mean rainfall received at Paradeep
port IMD is about 1529.2 mm.
Seismic Considerations
Based on tectonic features and records of past earthquakes, a seismic zoning map of
Odisha State has been prepared by a committee of experts under the auspices of Bureau of
Indian Standard (BIS Code: IS: 1893: Part-I, 2002). According to the seismic-zoning map of
Orissa, the project area falls in Zone-III (Moderate Damage Risk Zone) of seismicity.
Hydrogeology
As per CGWB classification the 10-km study area falls in Kujang block of Jagatsinghpur
District. The annual replenishable ground water resources in the district are computed as
45029 Ham
The study area falls in Kujang block of the district. The Net Annual Ground Water
Availability in the Kujang block is computed as 6440 Ham. The Existing Gross Ground
Water Draft for all uses in the Kujang block is 3998 ham. Stage of Ground water
development in the Kajung block is 62.38%. Overall the study area including Kajungar block
fall under the safe category. The overall stage of ground water development of the district is
47.37%.
Land use Pattern
The area contains different types of land cover and land use;
Agriculture land
Human Settlement
Vegetation
Open shrub and grass land
Water body
Barren land
Marshy land
As per the land use based on satellite image, about 31.31% of the land is Agricultural land,
about 41.80% land is under water body, 10.78% land is open shrub & grass land and about
3.34% land is under settlement, 6.15% land is under vegetation and rest is other uses.
Micro Meteorology
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. xiii
The predominant wind direction at site is from SSW direction. Average Calm condition
during the entire study period of pre-monsoon season (March to May 2018) was observed
as 8.24%.
Baseline Environment
Baseline environment study was conducted in March 2018 to May 2018 and the detailed
study is mentioned in baseline of EIA report.
Air Environment
Ambient air quality monitoring has been carried out with a frequency of 24 hourly two
samples per week at eight (08) locations in (March-May 2018) phase. The baseline data of
ambient air quality has been generated for PM2.5, PM10 SO2, NOx, CO, NH3, HC and VOCs.
The average PM2.5 level in was found within the NAAQS levels for industrial, Residential,
Rural and other Areas (60 µg/m3).
The average PM10 level was found within the NAAQS levels for industrial, Residential,
Rural and other Areas (100 µg/m3). The highest PM10 levels were found at Paradeepgarh
105 µg/m3while the lowest levels were found at village. Jogidhakud (54.0 µg/m3).
The SO2 level of the study area in both the season was found well under the NAAQS
Standard of 80 µg/m3. The main source of SO2 emission is vehicular.
The NOx level of the study area was well under the NAAQS standard of 80 µg/m3. The main
source of NOx emission is industrial & vehicular.
Noise Environment
The noise level studied in March-May 2018 phase at all residential locations were found
lower than the ambient noise standards. At the project site it was found to be lower than the
ambient noise standards. Only at NH-5A (commercial/mixed use area), the equivalent day
noise level was found higher than the standard noise level day equivalent, which may be
due to heavy vehicular movement and road traffic.
Water Environment
Overall the ground water quality of the study area is found well within the permissible limit of
Indian Standard IS: 10500:2012. No metallic and bacterial contaminations were observed in
ground water samples.
Study shows the surface water quality comes under designed Class-C (Drinking Water
Sources with Conventional Treatment followed by Disinfection) of IS 2296:1982 and can be
used for domestic/ drinking use after conventional treatment and disinfection.
Soil Environment
Texturally the soils in the study area are observed as Sandy Clay and Clay Loam Soils. The
bulk density of the soils was found in the range of 1.24 to 1.46 gm/cm3. Porosity was
observed in the range of 44.9 to 53.2% in the soils of the study area. Water Holding
Capacity of study area soils was observed as 28.9 to 31.2%.
The soil pH ranges from 7.18 to 7.88, thereby indicating the soils are neutral to slightly
alkaline in nature. The organic carbon content of soil varied from 0.54 to 0.86% (0.93 to
1.48% as organic matter). Available nitrogen content in the surface soils ranges between
275.6 & 376.5 kg/ha. Available phosphorus content ranges between 16.2 & 24.5 kg/ha.
Available potassium content in these soils ranges between 87.6 & 175.4 kg/ha. The
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. xiv
available manganese content in surface soils was recorded as 1.05 to 1.44 mg/kg as the
critical limit of available manganese is 2.0 mg/kg. The available Zinc in surface soils of the
study area observed <0.6mg/kg of soil. Above description of study area soils reveals that the
soils in the study area are having moderate fertility index.
Biological Environment
Flora: There are no Reserved Forest Areas present in the project study area. In the present
primary study, a total of 29 trees, 28 shrubs, 36 herbs/grasses species were recorded in the
both core and buffer areas.
Fauna: During the primary study, a total of 23 bird species has been recorded in which
seven species were found as migratory species (V-Visitor) and rest of the species were the
resident species for the area. The common birds recorded from the study area are: Cattle
Egret (Bubulcus ibis), common Pigeon (Columba livia), Darter (Anhinga melanogaster),
Indian Cormorant (Phalacrocorax fuscicollis), Indian Pond Heron (Ardeola grayii), and
Common Myna (Acridotheres tristis).
Socio- Economic Environment
Demographic Profile
Population: As per the ‗Census Records of India, 2011‘ the total population of the study area
is observed as 136078 persons, the total number of Households (Families) are recorded as
31993. Male-Female wise population in the study area was observed as 72015 (52.9%) and
64063 (47.1%) respectively. The child population of the study area is recorded as 14779
and comprising of 7700 (52.1%) males & 7079 (47.9%) females respectively.
Sex Ratio: The Sex Ratio of the Study area is 890 Female / 1000 Male and child sex ratio
(age group 0-6 Years is 919 Female / 1000 Male.
SC / ST Population: A considerable 22% of the population in the Study Area is constituted
by SC/ST of which SC population constitutes 19% and rest 3% is constituted by ST
populations.
Literacy Rate: The literacy rate of the study area is 75.9% of which Male literate are 80.8%
and female literate are 70.4%. The illiterates are 24.1% of the total population of which
Female illiterates are 29.6.
Workers Scenario: Workers Participation Ratio of the Area is 35%. Among this 29% is the
Main workers and 6% are the marginal Workers. 54 % are Non-workers in the study area.
Main Workers: A considerable percentage of Main workers in the Study area belong to
casual labours 14%, agricultural labours 7%, household workers constitute 3% and other
workers 76% respectively.
Marginal Workers: A considerable percentage of Marginal workers in the Study area belong
to casual labours 70%, agricultural labours 9%, household workers constitute 16% and other
workers 5% respectively.
Infrastructure Details (2011)
Education facilities: There are about fifty-six (56) Primary Schools existing in the study area.
Middle Schools are twenty (20 no‘s) in the study area villages.
Medical facilities: The medical facilities are provided by different agencies like Govt. &
Private individuals and voluntary organizations in the study area.
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EQMS INDIA PVT. LTD. xv
Potable Water Facilities: Potable water facility is available in most of the villages/towns of
the study area. The entire study area has plenty of good potable water facilities.
Communication Facilities: Apart from Post &Telegraph (P & T) services, transport is the
main communication linkage in the study area.
Banking Facilities:The study area has almost all the schedule commercial banks with ATM
facility at urban areas and the district HQ.
Environmental Impact Assessment
Air Quality:
PM10: The total impact from the proposed expansion indicates maximum PM10
concentration of 126.35µg/m3 at Project Site with project impacts of 30.35µg/m3 and
baseline contribution of 96.00µg/m3. The total impact from the project exceeds the
stipulated standard of 100 µg/m3 for industrial as well as residential areas. However, it
should be noted that the GLC for PM10 from just the proposed expansion is 30% of the
NAAQS standard and the baseline concentration in the study area is very close to the
NAAQS Standard. The high PM10 in the study area is contributed mainly by industrial
emissions, vehicular emissions, re-suspected dust from paved/unpaved roads and
open areas as well as from industrial activities.
PM2.5: The total impact from the proposed expansion indicates maximum PM2.5
concentration of 59.18 µg/m3 at Project Site with project impacts of 12.18 µg/m3 and
baseline contribution of 47.00µg/m3.The total impact from the projectis within the
stipulated standard of 60 µg/m3for industrial as well as residential areas.
NOx: The total impact from the proposed expansion indicates maximum
NOxconcentration of 48.96 µg/m3 at Project Site with project impacts of 10.96µg/m3
and baseline contribution of 38.00µg/m3.The total impact from the project is within the
stipulated standard of 80 µg/m3 for industrial as well as residential areas.
SOx: The total impact from the proposed expansion indicates maximum
Soxconcentration of 29.14µg/m3 at Project Site with project impacts of 8.94µg/m3 and
baseline contribution of 20.20µg/m3.The total impact from the project is well within the
stipulated standard of 80 µg/m3 for industrial as well as residential areas.
NH3: The total impact from the proposed expansion indicates maximum NH3
concentration of 117.51 µg/m3 at Gopinath Colony with project impacts of 96.51 µg/m3
and baseline contribution of 21.00µg/m3.The total impact from the project is well within
the stipulated standard of 400 µg/m3 for industrial as well as residential areas.
HF: The total impact from the proposed expansion indicates maximum HF
concentration of 8.90µg/m3 at Gopinath Colony. The total cumulative impact from the
project is well within the stipulated standard of NCDAQ‘s AAL of 30 µg/m3.
Noise
The sources of noise during the operational phase of the plant are mainly turbines
compressors, blowers, pumps and furnaces. The other sources of noise are the movement
of vehicles along the road. The proposed expansion project will be similar but will have
advanced technology and improved equipment both in terms of energy efficiency and less
noisy.
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Water Resources and Water Quality
The water requirement of the proposed expansion project is ~1064 m3/Hr and total water
requirement in both existing and expansion phase is 1840 m3/hr. The water will be made
available from the existing source i.e. Taladanda canal. PPL is permitted to withdraw 5 MGD
(947 m3/hour) water from the Taladanda canal. The existing plants are utilizing approx. 776
m3/hr of water. The rest amount of water required for proposed expansion project/plants
shall be sourced through treated effluent recycle and from Talanda Canal. PPL has
submitted application to Government authorities for permission to withdraw additional 5
MGD water. The necessary approval for the additional water is being obtained.
PPL will follow the philosophy of treating the effluents in the well-designed ETP plant and
recycling in the process {process condensates/ cooling/ dust suppression etc.; Refer water
balance in Ch. 2}. PPL Proposed project will be nearly is zero effluent plant. Treated
domestic water is utilized in green belt development.
Land Environment
PPL expansion project is being located within the existing premises and as such no
additional land is required. Since there is no additional land required for PPL expansion
project, no soil erosion or diversion of land is involved.
Low soil fertility is attributable to either to low levels of nutrients {e.g. nitrogen, phosphorus,
potassium etc.} in the soil or their being made unavailable for plant intake in some way. High
levels of elements or compounds being present in the soil cause soil toxicity. Some
elements, which are essential and beneficial for crops at low concentrations, become toxic
to crops at higher concentrations. There can be slight increase in phosphorus/sulphur/
nitrogen content of the soil due to limited plant emission from DAP/Urea/GSSP plants and
this elevated phosphorus / sulphur content will have positive impact on the on the plant
growing in the area. Proposed expansion project will improve the Phosphorus availability in
the area and consequently better crop yield.
The solid wastes (coal ash) generated in the plant will have intrinsic values and will be sold
to interested parties. The plant operations after PPL expansion project will be similar
emission and solid waste and as such not have any impact which is likely to affect soil, or
effluents release likely to affect soil. As such soil chemistry is not going to be affected with
PPL proposed expansion project.
Biological Environment
The quality of soils in the premises of the PPL shows that there is no adverse effect of air,
water and solid effluents on the soil system. A special thrust has been given right from the
beginning to develop the premises into a live green belt. Process effluents after treatment
are recycled back in process. The treated domestic effluent will be used for the irrigation
purposes to the maximum extent within the PPL premises in order to conserve water.
The development of green belt will provide habitat, food and breeding areas to birds, small
animals and insects. No rare or endangered species of fauna are reported to exist in the
area. Thus, no impacts on rare / endangered species are envisaged due to normal
operations. The PPL expansion project would not affect the soil and so the plant growth in
the study area.
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EQMS INDIA PVT. LTD. xvii
Socio – Economic Environment
PPL plan to carry out lots of social work (as a part of its ‗CSR‘ objectives) through with
objectives of:
Natural Resource Management
Infrastructure Development for nearby inhabitants
Health and Hygiene of nearby inhabitants
With these objectives PPL is carrying out study about:
Assessment of local needs within the study area and identification of focus areas
Preparation of phase wise and year wise action plan in consultation with local bodies
based on identified needs
Appointment of community development officer and organize periodic meet with local
people
Establishing open and transparent communication channel with locals
Work out modalities for sustainability of activities/programs
Establishing a well-designed grievance redressal / feedback forum
Management Plan & Environmental Monitoring Program
Charter on Corporate Responsibility for Environmental Protection (CREP)
PPL has adopted the Charter on Corporate Responsibility for Environmental Protection
(CREP)..
Air Environment:
The emission from PPL proposed expansion project shall be mainly from the various stacks
(in Ammonia plant, Urea plant, Acid Plants, DAP/GSSP, HRG and Auxiliary Plant) and will
be limited. Fugitive emissions while handling solid/ granular product will be recovered and
recycled (as PPL has experience of DAP dust collection and recovery system in bagging
plant) or leakages in the plant. In order to mitigate the adverse environmental impact due to
the operation proposed GSSP plant following measures is recommended:
The control measures (through proper up keep / maintenance) and good
housekeeping will considerably reduce the fugitive emission.
AAQ monitoring system of air pollutants SOx, NOx, ammonia, acid mist, fluorides
and SPM should be regularly carried out.
Regular monitoring of shop floor environment is to be carried out to control the
fugitive emission as well as shop floor safety.
Leakages {of gases / liquids/ dust} should be checked and promptly attended.
Noise Environment
The statutory national standards for noise levels at the plant boundary and at residential
areas near the plant are being and are to be met. The following mitigation measures are
proposed to meet the objectives:
The selection of any new plant equipment is to be made with specification of low
noise levels. Noise suppression measures such as acoustic enclosures / cabins,
buffers and / or protective measures are be provided (wherever noise level is around
+80 dB (A) and exposure limits to workers is likely to be more than 8 hours a day) to
limit noise levels within occupational exposure limits. Areas with high noise levels are
to be identified and segregated where possible and will include prominently
displayed caution boards.
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EQMS India Pvt. Ltd. xviii
However, in areas where noise levels are high and exposure time is less, employees
will be provided with ear protection measures like earplugs or earmuffs. Earplug
should be provided to all workers where exposure level is > 85 dB (A). The exposure
of employees working in the noisy area should be monitored regularly to ensure
compliance with the regulatory requirements.
The existing practice of regularly monitoring of noise levels is essential to assess the
efficacy of maintenance schedules undertaken to reduce noise levels and noise
protection measures.
The green belt around the plant to attenuate the noise level but instead of block
plantation there should be variability in tree height and shape, as this would disperse
the sound waves more efficiently. Plant that attenuate should be planted at the noise
zone.
Water Environment
PPL plant should take ample precautions to reduce water consumptions and tackle effluents
problem. The philosophy of segregation of effluent streams and treatment near the source
and recycle back to the system will help in reducing the water consumptions and effluent
generation considerably. Efforts should continue, and new efforts should be directed to:
Possibility of increased use of treated effluents in horticulture and green belt
developments.
Recycle of treated effluents in the system as far as possible.
The treated sewage should be effectively utilized in the plant or for irrigation in green
belt.
The use of any chemical to check microbial activity should be avoided, as it would
harm the human health and fauna.
Use of pesticide and herbicide should be avoided as they can cause ground water
contamination.
PPL should install three or more piezo metric wells at selected places (one near
treated effluent pond) to see and check the ground water contamination.
Water is a precious commodity and it should be conserved.
Rain water harvesting. [Since it is coastal area the sub soil water may be saline and
rain water harvesting may not be useful].
Biological Environment
Of the total area of the proposed project site (core zone) 33% area shall be developed as a
green belt along the periphery of the plant. The goal of installation a greenbelt would also be
to maximize both ecological functionality and scenic beauty of the project area. Some
greenery is already existed in the project area. The present greenbelt area will cover the
37% (854 acres) of the total project area and this greenbelt of different thickness will be
established systematically. Ideal size of greenbelt shall be between 10 and 50-meter-wide
and run the length of roads, major structures and open spaces. Width depends on the
availability of land.
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Land Environment
The proposed expansion project will generate the solid wastes (coal ash and gypsum)
similar (in quality as well as increase in quantity) to the existing system. Mostly the waste will
be sold to actual users. However, some wastes (oily sludge from machines/ empty bags/
paper/cotton wastes etc.) will be similar and the proposed handling philosophy for the same
is to continue. No additional measures are required.
Socio-economic Environment
As a good corporate citizen and major industry PPL may consider adopting few more
selected villages in developing them as model villages.
Awareness program are to be initiated in immediate neighbouring villages about PPL
plant activities and the various EHS measures undertaken to make the plant safe
and environment friendly.
PPL should finalize the study and start carrying out CSR activities in coordination
with district authorities.
Environmental Management Cell
PPL already have an environment management cell headed by a senior executive
supported by DGM (Env Mgt) and other supporting staff. PPL environment laboratory is
accredited by NABL.The laboratory is equipped with necessary sophisticated instruments
including:
Fine Particulate sampler (PM2.5)
Respirable dust sampler (PM10)
Digital Hygrometer
Stack Monitoring Kit
Personal dust sampler
Sound level meter
Multi Gas meter
On line weather monitor
Spectrophotometer
Electronic Balance
Electric oven
DO meter
PH meter
BOD incubator
COD digester
Oil & grease digester
Water bath
Water double distillation system
Multi parameter analyzer for water analysis
A team of well-trained and experienced staff carries out tests in the laboratory. Apart from
this a NABL accredited third party is also engaged for environmental monitoring.
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Post – Operational Monitoring Program
PPL should carry out environment monitoring and with necessary equipment and associated
facilities.
Hazards evaluation and Risk Assessment
Toxic Hazards
This facility stores hand less ammonia and chlorine, which are highly toxic in nature. Also. It
stores and handles combustible materialslike HSD and FO.The following
majoraccidentscenariosmaybevisualized as mentioned chapter 7 of EIA report.
Hazards due to individual soft spots like walking casually and noticing a pit and falling or
colliding/ stumbling or slipping (not noticing a wet place etc.).
Acid spillage-its impact will be limited to spillage area. The spillage if meets metal parts will
produce hydrogen which is highly flammable gas. Any person moving in area and getting
splash will get the injury. In addition, the spillage will cause pollution problem. The spillage is
to be collected and neutralized for toxic contents before disposal.
Fire Hazards
Fire hazards in the proposed expansion project are much less (Fuels-coal, FO/LSHS, HSD
(limited storage only)). These fuels are not highly combustible, and their impacts are limited
only (within short distance). However, process has fire hazards due to hydrogen.
Emergency Management Plan
The organizational set-up necessary for chain of commands during emergency in the plant
is as given below.
Head (CGM-Operations) of the PPL is the Overall Site In charge and he shall be the main
guiding person directing the emergency operations. CGM (operation) will select two rooms
as Emergency Control Centres (ECC). Both these ECC rooms will be strategically
(considering wind direction, safe location, approach etc.) located and furnished. ECC will
have adequate:
Multiple communication facilities (both within and Outside plant); telephone nos. of all
essential personnel, mutual aid group organisations, district and other statutory authorities,
fire and safety and medical personnel nos., will be highlighted, emergency vehicle etc.
Plant Data [personnel working in different plants, Plant‘s Manuals, Specific safety features,
hazardous locations etc.] and documents [Statutory clearances copies, Layout drawings,
Hazardous locations and safety features, Fire circuit, Safety manual, Anti dotes for
hazardous material, MSDS etc.] as may be required during emergencies.
Conclusion:
Based on the environmental impact assessment conducted, the following recommendations
are made:
Systems of periodic auditing and reporting shall be adopted during the construction
period to ensure that the contractors adhere to the Environmental Management Plan.
The project proponent and its team of consultants and contractors are urged to
develop a strategy for effective communication with local people.
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The construction team/ developer should effectively follow the suggestions made in
the EMP and/ or any other environmental measures so as not to damage the
environment of the project area.
The industry shall have to adhere the conditions stipulated in the environmental
clearance as well as in consent/ authorization from OSPCB.
Since regulations are fast changing in India, the project proponent must keep themselves
updated with respect to applicable laws and take appropriate actions in case the provisions
in some regulations undergo change.
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EQMS INDIA PVT. LTD. 22
CHAPTER 1. INTRODUCTION AND BACKGROUND
1.1. ProjectProponent
Paradeep Phosphates Limited (hence forth ‗PPL‘; incorporated in 1981) is a premier
fertilizer company engaged in manufacturing and marketing of complex Phosphatic
fertilizers. The company was initially commissioned as a joint venture between Government
of India and Republic of Nauru and subsequently, in 1993 it was changed into a wholly
owned Government of India Enterprise. After disinvestment by Government of India in
February 2002, PPL was taken over by Zuari Group the management of the company is
presently with the fertilizer majors - Zuari Group and OCP of Morocco.
PPL produces about 1.3 million metric tonnes of DAP and other complex fertilizers
annually. The plant also produces intermediary products like Phosphoric Acid and
Sulphuric Acid, which are critical raw materials in the manufacture of Phosphatic fertilizers.
The plant, located in the port town of Paradeep in the district of Jagatsinghpur in Orissa,
has an installed capacity of 15,00,000MTPA of DAP (5000 metric tones per day). PPL is
one of the largest integrated DAP plants in India. With a market share varying around 13%,
it has a strong presence in the complex fertilizer market its products marketed under the
popular NAVRATNA brand represent a combination of multiple nutrients like Nitrogen,
Phosphorus, Potash and Sulphur etc. PPL‘s range of products caters to almost all
agricultural applications.
After disinvestment on February 28, 2002, PPL has been revived to full strength with the
employees' dedication and commitment under extremely difficult conditions. Remarkable
achievements have been achieved in terms of financial turnover. From a loss of Rs. 23,026
lakhs in the year 2001-02 the profitability of the Company has improved by achieving a
profit after tax year after year.
With a stellar turnaround, PPL is a case study in favour of privatization. The company‘s
focus on performance and continuous efforts towards development are reflected in the FAI
Awards for Improvement in Overall Performance of the company in 2002-03, 2005-06,
2008-09 and the ―Best Technical Innovation‖ in the year 2005-06. PPL received the
ISO14001:2004 certification in May 2006 for good environment management systems,
reflecting the fact that along with technical advancement, the company also values
maintaining and working towards a clean and safe environment.
Table 1.1 : Financial growth of PPL
S.No. Financial Year Financial Growth
i. April ―14‖ – March ―15‖: 433.32 Million net profit after tax
ii. April ―15‖ – March ―16‖: 650.90 Million net profit after tax
iii. April ―16‖ – March ―17‖: 869.14 Million net profit after tax
This Chapter describes about the company M/s Paradeep Phosphate Ltd. and about the
project site, purpose and need of the project, and benefits of the project. It also describes
the structure of EIA and the compliance of ToR as per the detailed EIA report.
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EQMS INDIA PVT. LTD. 23
PPL is a leading fertilizer company with an annual turnover close to Rs. 3800 Crores.
Its primary focus is the production and marketing of complex Phosphatic fertilizers. It is
committed to improving agriculture productivity and to betterment of the farming
community.
1.2. PPL- Location & Salient Points
PPL is located at Paradeep in Jagatsinghpur District, Orissa. It is 90kms from Cuttack. The
site is located at 20º16‘56‖ North Latitude and 86º38‘52‖ East Longitude, west side of
Paradeep Port. The plant encompasses 950 hectares area. Mahanadi River is 5km from
the plant site and meets Bay of Bengal, which is 5.3 km away from the site. Atharbanki
creek is flowing along the boundary wall of the site and is in between Paradeep Port site
and the factory. The location of the proposed project site is shown in Figure 1.1 and Figure
1.2 and the plant layout is attached as Annexure 4.
Table 1.2 : Salient Points
Milestone Details
Date of incorporation 24th December 1981
Commissioning of Phase-1 (DAP
Plant)
February 1986
Commissioning of Phase-2
(SAP,PAP& CPP)
June 1992
Date of Disinvestment from GOI 28th February 2002
Turnover (2017-18)
3800 Crores
Designed/ Present Annual Capacity of
DAP
7,20,000 / 15,00,000 MT
Designed/ Present Annual Capacity of
PAP
2,25,000 / 4,20,000 MT
Designed/ Present Annual Capacity of
SAP
13,20,000 / 14,52,000 MT
Captive Power Plant Two units of 16 MW each+ One unit of 23 MW
Conveyor Belt 3.4 km (from port to Plant Site)
Product Manufactured DAP,NPK, grade fertilizers
Marketing Territory Products distributed in a pan-India market
covering 16 states
Systems PPL has received Integrated Management
system (IMS)certificate as per :
ISO 9001:2008
ISO 14001: 2004
BS OHSAS 18001:2007
EnMS 50001,5S, P&S certified.
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 24
Figure 1.1 : Project Location
(Source: Google Earth)
Figure 1.2 : Satellite View of the Site
(Source: Google Earth)
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 25
1.3. Purpose of the Study
In the proposed expansion project Paradeep Phosphates Limited (PPL) intends to add
some new products and also expand the capacities of existing products as given below:
Table 1.3 : Capacities of Existing and Expansion
Sl.
No.
Particulars Existing Capacity
Expansion Proposed Total Qty.
a) SAP* 0.792
MMTPA
- - 0.792 MMTPA
b) PAP** 0.42 MMTPA - - 0.42 MMTPA
c) DAP** 1.5 MMTPA 0.4
MMTPA
1.9 MMTPA
d) Coal Hand. Plant
- - 7 MTPA 7 MTPA
e) Ammonia - - 2.178 MMTPA 2.178 MMTPA
f) Urea* 1.3 MMTPA 1.3 MMTPA
g) Amm. Nitrate* - - 0.35 MTPD 0.35 MTPD
h) NitricAcid* - - 0.33 MMTPA
(0.05 MMTPA
Conc. Nit. Acid)
0.33 MMTPA
(0.05 MMTPA
Conc. Nit. Acid)
i) GSSP** - - 0.5 MTPD 0.5 MTPD
j) Alu. Fluoride**
- - 9500 MTPA 9500 MTPA
As per the Ministry of Environment & Forests (MoEF), Government of India EIA Notification
2006 and further amendments, the proposed expansion project has to take environmental
clearance prior to commissioning of the plant. The proposed expansion project is covered
under sector 16 (5a) in Category 'A' as per the Schedule of EIA Notification and hence
requires environmental clearance from Expert Appraisal Committee (EAC)of MoEF&CC,
New Delhi. Details of the EIA consultant including NABET accreditation is attached as
Annexure 27.
This Environmental Impact Assessment (EIA) study undertaken is mainly focused on
identification of existing environmental conditions of the project, its impact on pre and post
commissioning. A detailed prediction of all environmental impacts associated with the
various activities during the construction and operation phases of the proposed project
manufacturing units and suggesting suitable measures to navigate the observed adverse
environmental impacts. The study also aims at reflecting the acceptability of the project to
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 26
different stakeholders and at incorporating the concerns raised by them into impact
assessment and of the subsequent Environmental Management Plan (EMP). These all
mentioned above are part of the Environment Impact Assessment (EIA) project study.
1.4. Benefits of the Project
Paradeep Phosphates Ltd is a major manufacturer of phosphatic fertilizers in India and is
Asia‘s second largest producer of DAP containing highest nutrient content (>64%). PPL‘s
wide range of products cater to almost all agricultural applications. PPL is an ISO 9002 and
ISO 14001 company.
Besides manufactured products, PPL also markets its by-product Phospho-Gypsum which
is used for soil conditioning in alkaline soils. Phospho-Gypsum enriches soil with Calcium
and Sulphur, thus increasing the yield. Phospho-Gypsum is also being promoted as
supplement for sulphur deficient soils. Gypsum is also preferred by cement and brick
industries. PPL imports and markets Muriate of Potash (MOP) through its network of
private and institutional trade throughout the country.
1.5. Scope & Methodology of the study
This study is aimed at providing a deeper insight into the proposed project and its various
environmental components. The present study area for the environmental assessment is
within 10 km radius of the location of the project. The methodology used for the study is
given below:
1. Monitoring and collection of baseline data for various environmental components as
per the MoEF guidelines.
2. Identification and quantification of significant environmental impacts due to the
project and associated activities.
3. Evaluation of impacts due to proposed activities and preparation of an
environmental impact statement.
4. Preparation of appropriate Environmental Management Plan (EMP) encompassing
strategies for minimizing identified adverse impacts along with budgetary provisions
to be made by the project authorities for implementation of mitigation measures.
5. Delineation of post Environmental Quality Monitoring Programme (EQMP) along
with organizational setup required for monitoring the effectiveness of mitigation
measures.
6. The flow diagram showing methodology adopted for the EIA study has been
presented in Figure 1.3.
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EQMS INDIA PVT. LTD. 27
Figure 1.3 : EIA Methodology
1.6. Public Hearing
M/s Paradeep phosphate Ltd. has proposed expansion in chemical fertilizer plant by
installing coal handling plant, Ammonia Plant (coal based)-2200 MTPD capacity, urea plant
3850 MTPD capacity, Nitric acid plant – 1000 MTPD, Ammonium Nitrate plant – 1100
MTPD, DAP plant – 1300 MTPD, GSSP plant -1650 MTPD and Aluminium Fluoride plant-
9500 MTPA capacity at Paradeep in the district Jagatsinghpur. Public Hearing for the same
was conducted on 19.05.2017 at 9.00 AM at DAV public school, Paradeep Phosphate Ltd.,
Paradeep in the district of Jagatsinghpur district in accordance with Ministry of Environment
Forest & Climate Change, GOI, EIA Notification Np. SO-1533(E)dt. 14.09.2006. An
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EQMS INDIA PVT. LTD. 28
advertisement was published in newspaper namely The New Indian Express and Dharitri
on 13.04.2017.
Further twenty-four numbers of representations were received during public hearing. The
detail document of public hearing enclosed as Annexure 26.
1.7. Approved ToR for EIA Study by MOEF&CC
The application for the scoping of the said project has been submitted to the Expert
Appraisal Committee (EAC), at MoEF&CC, New Delhidated 1stMay 2018 (online) and
4thMay, 2018 (hard copy). The EAC has issued the TOR for the EIA study on 1stJune, 2018
vides file No. J-11011/370/2009-IA-II(I). Copy of the same is attached as Annexure 1.
EIA report has already been submitted online to MoEF&CC but after conducting Public
Hearing and submitting final EIA report to MoEF&CC, the issue of ToR expired was raised
by MoEF&CC and ask proponent to resubmit fresh application, soon the basis of fresh
application to MoEF&CC, ministry issued the standard ToR letter dated 1stJune, 2018. The
EIA study has been conducted in-line with the approved TOR by EAC and taking into
consideration the structure of the report given in the EIA Notification 2006 and further
amendments. The compliance to the approved TOR has been presented in Table 1.3
Table 1.4 : ToR Compliance Status
ToR No. Points Raised in ToR Compliance
A. STANDARD TERMS OF REFERENCE
1 Executive summary of the project Included in EIA Report
2. Introduction Included in chapter 1
i) Details of the EIA Consultant including NABET
accreditation certificate,
Attached as Annexure 27
ii) Information about the project proponent Provided in section 1.1 and
1.2
iii) Importance and benefits of the project Provided in Section 1.4
2. Project Description
i) Cost of project and time of completion. Provided in section 2.11, 2.12
and 2.13
ii) Products with capacities for the proposed project. Details of proposed
expansion products with
capacities are provided in
section 2.5.
iii) If expansion project, details of existing products withcapacities and whether adequate land is available forexpansion, reference of earlier EC if any.
Details of existing products is
provided in section 2.2
iv) List of raw materials required and their source along
with mode of transportation.
Details of raw material for
proposed expansion project is
provided in section 2.7
v) Other chemicals and materials required with Product bases chemicals and
materials details are provided
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ToR No. Points Raised in ToR Compliance
quantitiesand storage capacities in section 2.7.
vi) Details of Emission, effluents, hazardous
wastegeneration and their management.
Environment aspects for
proposed expansion is
provided in section 2.10
vii) Requirement of water, power, with source of supply,status of approval, water balance diagram, man-power requirement (regular and contract)
Utilities for proposed
expansion project is provided
in section 2.8
viii) Process description along with major equipments and machineries, process flow sheet(quantative) from raw material to products to be provided
Process descriptipn for for
proposed expansion project is
provided in section 2.5
ix) Expansion/modernization proposals:
a) Copy of all the Environmental Clearance(s) including Amendmentsthereto obtained forthe project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of thelatest Monitoring Report of the Regional Office of the Ministry of Environment and Forestsas per circular dated 30
thMay, 2012 on the status
of compliance of conditionsstipulatedin all the existing environmental clearancesincluding Amendments shall be provided. Inaddition, status of compliance of Consent to Operate for theongoing existing operationof the project from SPCB shall be attached with the EIA-EMP report.
b) In case the existing project has not obtainedenvironmental clearance, reasons for nottaking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies ofConsent to Establish/No Objection Certificate andConsent to Operate (in case of units operating prior toEIA Notification 2006, CTE andCTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further,compliancereport to the conditions of consents from the SPCB shall be submitted.
EC letter 5th Oct 2010 and
half yearly certified
compliances report dated 4th
June 2018 are attached as
Annexure 3
NA
4. Site Details
i) Location of the project site covering village,Taluka/Tehsil, District and State, Justificationforselecting the site, whether other sites were considered.
Provided in section 3.1.2 and
section 3.5.
ii) A toposheet of the study area of radius of 10km and sitelocation on 1:50,000/1:25,000 scaleon an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)
Topographical map of the
study area is provided in
Figure 3.6 of chapter 3
iii) Details w.r.t. option analysis for selection of site Provided in section 3.1.2 and
section 3.5.
iv) Co-ordinates (lat-long) of all four corners of the site. Coordinates of the project site
are mentioned in Table 3.1
and Figure 3.1 of section
3.1.1.
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ToR No. Points Raised in ToR Compliance
v) Google map-Earth downloaded of the project site. Provided in Figure 3.4 of
section 3.1.1.
vi) Layout maps indicating existing unit as well as proposed unit indicating storage area, plantarea, greenbelt area, utilities etc. If located within an Industrialarea/Estate/Complex, layoutof Industrial Area indicating location of unit within the Industrial area/Estate.
Attached as Annexure 4.
vii) Photographs of the proposed and existing (if applicable) plant site. If existing, showphotographs of plantation/greenbelt.
Photographs of existing and
proposed site are attached as
Annexure 16
viii) Landuse break-up of total land of the project
site(identified and acquired), government/private -
agricultural, forest, wasteland, water bodies,
settlements, etc shall be included. (notrequired for
industrial area)
Landuse of the study area is
provided in section 3.3.
Landuse break-up of the
existing and expansion
project site is provided in
section
ix) A list of major industries with name and type with in study area (10km radius) shall beincorporated. Land use details of the study area
List of major industries within
study area is given in Section
2.1.
x) Geological features and Geo-hydrological status of the study area shall be included.
Provided in section 3.2.3 and
3.2.4
xi) Details of Drainage of the project upto 5km radius of study area. If the site is within 1 kmradius of any major river, peak and lean season river discharge as well as flood occurrencefrequency based on peak rainfall data of the past 30 years. Details of Flood Level of theproject site and maximum Flood Level of the river shall also be provided. (mega green fieldprojects)
Provided in section 3.2.2
xii) Status of acquisition of land. If acquisition is notcomplete, stage of the acquisition processand expected time of complete possession of the land.
NA
xiii) R&R details in respect of land in line with stateGovernment policy.
NA
5) Forest and wildlife related issues (if applicable):
i) Permission and approval for the use of forest land (forestry clearance), if any, andrecommendations of the State Forest Department. (if applicable)
NA
ii) Landuse map based on High resolution satellite imagery
(GPS) of the proposed site delineatingthe forestland (in
case of projects involving forest land more than 40 ha)
NA
iii) Status of Application submitted for obtaining the stage I forestry clearance along with lateststatus shall be submitted.
NA
iv) The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves,Migratory Corridors of Wild Animals, the project proponent shall submit the map dulyauthenticated by Chief Wildlife
NA
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ToR No. Points Raised in ToR Compliance
Warden showing these features vis-à-vis the project locationand the recommendations or comments of the Chief Wildlife Warden-thereon.
v) Wildlife Conservation Plan duly authenticated by theChief Wildlife Warden of the StateGovernment for conservation of Schedule I fauna, if any exists in the study area.
NA
vi) Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to theStanding Committee of the National Board for Wildlife.
NA
6) Environmental Status
i) Determination of atmospheric inversion level at the project site and site-specific micro-meteorologicaldata using temperature, relative humidity, hourly wind speed and directionand rainfall.
Atmospheric inversion level at
the site is described in
chapter 4.
Site specific meteorological
data is provided in section
3.4.1
ii) AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and otherparameters relevant to the project shall be collected. The monitoring stations shall be basedCPCB guidelines and take into account the pre-dominant wind direction, population zoneand sensitive receptors including reserved forests.
AAQ data for period
(Dec,2013-March 2014) and
period (March-May,2018) is
provided in section 3.5.
iii) Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.
AAQ data for period
(Dec2013-March 2014) and
period (March-May,2018) is
provided in section 3.5.
iv) Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.
Provided in section 3.7.2.
v) Whether the site falls near to polluted stretch of riveridentified by the CPCB/MoEF&CC, ifyes give details.
None of the polluted river falls
in the surrounding area.
vi) Ground water monitoring at minimum at 8 locations shall be included.
Provided in section 3.7.1.
vii) Noise levels monitoring at 8 locations within the study area.
Provided in section 3.6
viii) Soil Characteristic as per CPCB guidelines. Provided in section 3.8
ix) Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.
Since the major
transportation of the raw
material and products is
through jetty and railway
wagons, so, there will be
negligible load on the road
traffic.
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ToR No. Points Raised in ToR Compliance
x) Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule- I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and
furnished.
Provided in section 3.9
xi) Socio-economic status of the study area. Provided in section 3.10
7) Impact and Environment Management Plan
i) Assessment of ground level concentration of pollutants from the stack emission based onsite-specific meteorological features. In case the project is located on a hilly terrain, theAQIP Modelling shall be done using inputs of the specific terrain characteristics fordetermining the potential impacts of the project on the AAQ. Cumulative impact of all sourcesof emissions (including transportation) on the AAQ of the area shall be assessed. Details ofthe model used and the input data used for modelling shall also be provided. The air qualitycontours shall be plotted on a location map showing the location of project site, habitationnearby, sensitive receptors, if any.
There is no change in design
of stacks and their emissions,
area is flat, and modelling
was done by using AERMOD,
The GLC was found nominal
the results are given in
chapter 4, The transportation
was not included as most of
the material is brought from
jetty Byconveyer belt and
through pipeline.
ii) Water Quality modelling - in case of discharge in water
body
NA
iii) Impact of the transport of the raw materials and end products on the surrounding environmentshall be assessed and provided. In this regard, options for transport of raw materials andfinished products and wastes (large quantities) by rail or rail-cum road transport or conveyorcum-rail transport shall be examined.
Provided in section 4.2.2.
Transport route of raw
materials and finished
products and wastes is
mentioned section wise in
chapter 2. Also, the
quantitative analysis of traffic
study is discussed in section
3.12.
iv) A note on treatment of wastewater from different plant operations, extent recycled and reusedfor different purposes shall be included. Complete scheme of effluent treatment. Characteristicsof untreated and treated effluent to meet the prescribed standards of discharge under E(P)Rules.
Provided in section 2.7 and
2.10.
v) Details of stack emission and action plan for control of emissions to meet standards.
Details of stack emissions is
provided in section 4.2.2.2.
vi) Measures for fugitive emission control Provided in section 5.4.3,
section 6.4.1, 6.4.2,
vii) Details of hazardous waste generation and their storage, utilization and management. Copiesof MOU regarding utilization of solid and hazardous waste in cement plant shall also beincluded. EMP shall include the concept of waste-minimization, recycle/reuse/recovertechniques, Energy conservation, and natural resource conservation.
Solid/ Hazardous waste
generation, storage and
management from existing
and expansion plant is
provided in Table 2.8
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ToR No. Points Raised in ToR Compliance
viii) Proper utilization of fly ash shall be ensured as per FlyAsh Notification, 2009. A detailedplan of action shall be provided.
NA
ix) Action plan for the green belt development plan in 33 % area i.e. land with not less than1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shallbe included. The green belt shall be around the project boundary and a scheme for greeningof the roads used for the project shall also be incorporated.
Green area is 37% of plot
area. Details provided in
section 2.3.15 and figure 2.8
x) Action plan for rainwater harvesting measures at plant site shall be submitted to harvestrainwater from the roof tops and storm water drains to recharge the ground water and also touse for the various activities at the project site to conserve fresh water and reduce the waterrequirement from other sources.
Storm water drains are
proposed for harvesting rain
water
xi) Total capital cost and recurring cost/annum forenvironmental pollution control measuresshall be included.
Section 2.11
xii) Action plan for post-project environmental monitoring shall be submitted.
Provided in section 5.4.10
xiii) Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency ManagementPlan including Risk Assessment and damage control. Disaster management plan should belinked with District Disaster Management Plan.
Provided in chapter 6 &7
8) Occupational health
i) Plan and fund allocation to ensure the occupationalhealth & safety of all contract and casualWorkers
Occupational health and
safety plan are provided in
section 6.5
ii) Details of exposure specific health status evaluation of worker. If the workers' health is beingevaluated by pre-designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far& Near vision, colour vision and any other ocular defect) ECG, during pre-placement andperiodical examinations give the details of the same. Details regarding last month analyzeddata of above-mentioned parameters as per age, sex, duration of exposure and department\ wise.
Health status evaluation is
being done in existing plant
and same will be maintained
in expansion phase.
iii) Details of existing Occupational & Safety Hazards. What are the exposure levels of hazardsand whether they are within Permissible Exposure level (PEL). If these are not within PEL,what measures the company has adopted to keep them within PEL so that health of the workerscan be preserved,
Details are maintained at
project site and in expansion
phase, it will be maintained
accordingly.
iv) Annual report of heath status of workers with special reference to Occupational Health andSafety.
Annual report is maintained at
project site and will be
maintained in expansion
phase.
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ToR No. Points Raised in ToR Compliance
9) Corporate Environment Policy
i) Does the company have a well laid down Environment Policy approved by its Board ofDirectors? If so, it may be detailed in the EIA report.
Existing unit is having ISO
OHSAS attached as
Annexure 22
ii) Does the Environment Policy prescribe for standard operating process / procedures to bringinto focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.
The standard operating
procedures are prepared by
plant officials for different
activities.
iii) What is the hierarchical system or Administrative order of the company to deal with theenvironmental issues and for ensuring compliance with the environmental clearanceconditions? Details of this system may be given.
Environment management
cell already exists in the plant
as described in section
2.3.15.
iv) Does the company have system of reporting of non-compliances / violations of environmentalnorms to the Board of Directors of the company and / or shareholders or stakeholders atlarge? This reporting mechanism shall be detailed in the EIA report.
The company is certified for
ISO 9001 and ISO 14001 and
OHSAS 18001 attached as
Annexure 22, and NCs are
discussed for their corrective
actions in MRM.
10) Details regarding infrastructure facilities such assanitation, fuel, restroom etc. to be provided to thelabour force during construction as well as to the casual workers including truck drivers duringoperation phase.
Details regarding facilities are
attached asAnnexure 23 and
24
11) Enterprise Social Commitment (ESC)
i) Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the EnterpriseSocial Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to beelaborated upon.
Yes, complied, as provided in
section 2.3.16 and
achievements with reference
to the ESC is attached as
Annexure 28
12) Any litigation pending against the project and/or anydirection/order passed by any Court of Lawagainst the project, if so, details thereof shall also be included. Has the unit received any noticeunder the Section 5 ofEnvironment (Protection) Act, 1986 or relevant Sections of Air and WaterActs? If so, details thereof andcompliance/ATR to the notice(s) and present status of the case.
Not any
13) 'A tabular chart with index for points wise compliance of above TOR.
Provided in Table 1.2 of
section 1.7
SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FORCHEMICALFERTILIZER
1) Details on requirement of energy and water alongwith its source and authorization from the concerned department.
A detail on requirement of
energy and water source is
detailed in chapter 2. And
permission letter of water and
energy source are attached
Annexure 7 and Annexure 8
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ToR No. Points Raised in ToR Compliance
2) Energy conservation in ammonia synthesis for urea production and comparison with besttechnology.
Provided in section 2.6.3
3) Details of ammonia storage and risk assessment thereof. Provided in section 2.6.3 and
4) Measures for control of urea dust emissions from prilling tower.
Provided in section 2.6.3
5) Measures for reduction of fresh water requirement. Provided in 5.4.5 and water
balance is provided in chapter
2
6) Details of proposed source-specific pollution control schemes and equipments to meet thenational standards for fertilizer.
Described in chapter 2
7) Details of fluorine recovery system in case of phosphoric acid plants and SSP to recover fluorine as hydrofluorosilicicacid (H2SiF6) and its uses.
Attached as Annexure 15
8) Management plan for solid/hazardous waste including storage, utilization and disposal ofbye products viz., chalk, spent catalyst, hydro fluoro silicic acid and phosphor gypsum, Sulphur muck,etc.
Provided in chapter 2
9) Details on existing ambient air quality for PM10, PM2.5, Urea dust*, NH3*, SO2*, NOx*,HF*,F*, Hydrocarbon ( Methane and Non-Methane) etc., and expected, stack and
fugitive emissions and evaluation of the adequacy of the proposed pollution control devices to meet standards for point sources and to meet AAQ standards. (*as applicable)
Provided in section 3.5
10) Details on water quality parameters in and around study area such as pH, Total KjeldhalNitrogen, Free Ammonical Nitrogen, free ammonia, Cyanide,Vanadium, Arsenic, SuspendedSolids, Oil and Grease, *Cr as Cr+6, *Total Chromium, Fluoride, etc.
Provided in chapter 3 and
location details are also
given,report of result
isenclosed as annexure no 23
1.8. Structure of the Report
This EIA report has been prepared on the basis of available on-site primary data (survey/
monitoring) and secondary/literature data. The EIA report contains project features,
baseline environmental setup, assessment of environmental impacts, and formulation of
mitigation measures, environmental management and monitoring plan with risk & disaster
management plan.
The report includes 8 Chapters. The executive summary has been at the beginning of the
report. The structure of the EIA Report with necessary tables, drawings and Annexure is as
follows:
Chapter 1: Introduction
This chapter provides background information on need of project, need of EIA study and
brief of the project. The scope and EIA methodology adopted in preparation of EIA report
have also been described in this Chapter. It also covers the identification of project &project
proponent, brief description of nature, size, location of the project and its importance to the
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 36
country and the region. Scope of the study details about the regulatory scoping carried out
as per the generic structure given in the EIA Notification, 2006.
Chapter 2: Project Description
This chapter deals with the project details of the proposed Chemicals Manufacturing Plant,
with type of project, need for the project, location, size & magnitude of operation including
associated activities required by and for the project, proposed schedule for approval and
implementation, including technical details of raw material, quality and quantity etc.
Chapter 3: Description of the Environment
This chapter presents the existing environmental status of the study area around the
proposed project including topography, drainage pattern, water environment, geological,
climate, transport system, land use, flora & fauna, socio-economic aspects, basic amenities
etc. Environmental assessment of the proposed project site in regard to its capability to
receive the proposed new development is also discussed in this Chapter.
Chapter 4: Anticipated Environmental Impacts and Mitigation Measures
This chapter describes the overall impacts of the proposed project activities and
underscores the areas of concern, which need mitigation measures. It predicts the overall
impact of the proposed project on different components of the environment viz. air, water,
land, noise, biological, and socio-economic.
Chapter 5: Environmental Management Plan&Environmental Monitoring Program
This chapter details the inferences drawn from the environmental impact assessment
exercise. It describes the overall impacts of the proposed activities during construction and
operation phases and underscores the areas of concern, which need mitigation measures.
It also provides mitigation and control measures for environmental management plan
(EMP) for minimizing the negative environmental impacts and to strengthening the positive
environmental impacts of the proposed project. Technical aspects of monitoring the
effectiveness of mitigation measures have been given in this Chapter also.
Chapter 6: Risk Assessment & Disaster Management Plan
This chapter deals with the risk assessment carried out for the proposed Synthetic Organic
Chemicals manufacturing plant and disaster management plan.
Chapter 7: Summary & Conclusion
This chapter provides the summary and conclusions of the EIA study of the proposed
project with overall justification for implementation of the project and explanation of how,
adverse effects will be mitigated. This chapter also includes the conclusions of the Public
Hearing.
Chapter 8: Disclosure of Consultants Engaged
This chapter provides the disclosure of consultants engaged to carry out the EIA study
along with other additional studies.
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CHAPTER 2. PROJECT DESCRIPTION
2.1. About the Project
The demand of the product among the farmers and also industrial consumers (for industrial
products), is one of the strong factors besides contribution to the agricultural growth of the
country, considered by Paradeep Phosphate Limited (PPL) in the setting of this proposed
expansion of Ammonium/Urea/DAP/GSSP and other industrial products at the present
location of Jagatsinghpur, Orissa.
M/s Paradeep Phosphate Limited proposes unit area profile that includes latitude and
longitude of the site are presented in the following Table 2.1:
Table 2.1 : Surrounding Area Profile
S. No. Particular Details
1 District Jagatsinghpur
2 Latitude 20º16‘56‖ North
3 Longitude 86º38‘52‖ East
4 Defense Installations None
5 Ecological Sensitive Areas/ Protected Areas
as per Wildlife Protection Act 1972 (National
Parks / Wild life sanctuaries / bio-sphere
reserves / tiger reserves)
None
6 Reserved / Protected Forest
None
7 Inland, Coastal, Marine Water Ocean 5.30 km (South), Bay of Bengal
8 Nearest National Highway NH 5A (0.42 km North West)
9 Nearest Rail Head Paradeep Railway Station (02 km)
10 Nearest Airport Bhubaneshwar (120 Km)
11 Nearest Town/ Tourist Place Paradeep (06 km)
12 Nearest Village Jhimani (3 Km)
13 Water Body Mahanadi river 5 km
Atharbanki creek (along the boundary wall
of the site)
This Chapter describes the brief about the expansion project, i.e. surrounding area profile
within the 10-kms radial zone of the study area, brief of operation process in existing phase
and proposed operation process during expansion expansion at project site. This chapter
also describes the basic amenities to be used at site i.e. water requirement, power supply,
etc.
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Location of the project in village survey map has been presented in Figure 1.1. The project
site is directly accessible from NH-5A. The project site is regular in shape. The industries
near the project site are mentioned below
Sl.No. Industries Aerial Distance from PPL
1. IFFCO 3.6 KM
2. PARADEEP CARBON 4.0 KM
3. PARADEEP PORT 2.5 KM
4. CARGIL INDIA 3.0 KM
5. SKOL BREWERIES 3.0 KM
6. IOCL 4.0 KM
7. ESSAR STEEL‘S PELLAT PLANT 6.4 KM
2.2. PPL- Existing Operation
2.2.1. Introduction
Paradeep Phosphates Limited (PPL) is operating a large Fertilizer complex in Paradeep,
Orissa, India where PPL manufacture various grades of NPK fertilizer. PPL is a prime
player in the Phosphatic fertilizers which have applications in a wide range of crops. The
fertilizer complex consists of following manufacturing units.
4400 MTPD of Sulphuric Acid Plant(2stream)
1400 MTPD of Phosphoric Acid Plant
5000 MTPD of Di Ammonium Phosphate Plant/NPK Plant (4 trains)
2X16 MW + 1X23 MW Captive Power Plant
240 TPD of Zypmite Plant
The fertilizer complex is using imported sulphur& rock phosphates to produce sulphuric
acid and phosphoric acid, along with imported MOP for NPK complex production. Since
captiveproduction of phosphoricacid cannot cater to the four streams of DAP plant, part
of the phosphoric acid requirement is made through imports. The entire ammonia
requirement is met through imports.
Installing coal handling plant, Ammonia Plant (coal based)-2200 MTPD capacity, urea plant
3850 MTPD capacity, Nitric acid plant – 1000 MTPD, Ammonium Nitrate plant – 1100
MTPD, DAP plant – 1300 MTPD (0.4 Million Tonne per Annum capacity expansion of
existing DAP plants), GSSP plant -1650 MTPD and Aluminium Fluoride plant- 9500 MTPA
capacity.
The other facilities available are as follows:
Rock Silo
Sulphur Silo
MOP Silo
Sulphuric Acid Storage
Phosphoric Acid Storage
Ammonia Storage
Di-Ammonium Phosphate Storage & Bagging
Marine Jetty
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ETP & STP
Other Auxiliary systems include:
HSD/LFO/HFO storages
Fuel Oil Storage
LPG Cylinder Storage
Captive Power Plant
2.2.2. Land Distribution in Existing Plant
Table 2.2 : Details of existing land use in core areas in PPL premises are
S.No. Land-Use Area covered
1) Plant Building (including vacant spaces), Railway
siding & Road
333.21 acres,
2) Gypsum Ponds 349.00 acres
3) Raw water Reservoir 230.00 acres
4) Water Treatment Plant 7.19 acres
5) Plantation 854.00 acres
(GREEN BELT- 37%)
6) Colony 300.00 acres
7) Total 2073.40 acres
8) Open area and Water bodies* 209.00 Acres
Total 2282.4 acres
* Paradeep already have sufficient Land The detail requirement of land for Proposed Plants
(Area required 174.28 acres)
2.3. Process Description (Existing)
2.3.1. Sulphuric Acid Plant
Sulphuric Acid (SA) plant is based on the most modern double conversion double
absorption process of M/s Lurgi GMBH, West Germany (DCDA process). It is laid in two
streams, each of 1200 MTPD capacity. And a new SAP of 2000 MTPD capacity was
commissioned in 2016. The technology was from M/s. MECS, USA. The raw material,
elemental sulphur is transported by means of belt conveyor to the sulphur bin. Sulphur is
melted in a melting pit by means of heating coils, heating media being steam. The molten
sulphur is stored in a liquid sulphur storage tank after passing through filters. The molten
sulphur is fed to the sulphur furnace where complete combustion takes place which gives
rise to a SO2 concentration of about 11.5%. The heat of combustion is removed bya waste
heat boiler where steam (approximately 60 MT/hr) is produced.
The furnace gas cooled to a temperature of 420ºC- 430º C is fed to a converter having 4
catalyst beds. SO2 to SO3 conversion takes place in first three beds and first absorption of
SO3 gases takes place in intermediate absorber. Remaining SO2 gases from Intermediate
absorber is passes through the fourth bed for optimum conversion of remaining SO2 to
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EQMS INDIA PVT. LTD. 40
SO3. SO3 gas from fourth bed is cooled to a temperature of 170 º C before entering to the
final absorber where SO3 is absorbed by 98.5% sulphuric acid. In absorption towers gases
are passed through mist eliminators to trap the liquid entrainments. From the final absorber
after absorption of SO3 gas, remaining gases are discharged into atmosphere through
stack within prescribed emission limit set by State Pollution Control Board.
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SULPHURIC
ACID PLANT
Figure 2.1 : Process Flow diagram of Sulphuric Acid Plant
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EQMS INDIA PVT. LTD. 42
2.3.2. Process Description of Phosphoric Acid Plant
The 1400 MTPD single stream Phosphoric Acid (PA) Plant is based on Di Hydrate Process
technology where basic engineering and technology is supplied by M/s Jacob International
Inc. U.S.A the Hindustan Dorr Oliver Ltd. Mumbai was the Indian partner. Wet grinding
process is adopted where rock phosphate is fed to ball mill through extractor weighed
where wet grinding slurry of 67-69% solids is prepared. In the ground rock hopper, a dust
scrubber is provided to entrap the dust coming out of the dust hopper.
From the ball mill, the rock slurry is pumped to the product tank. The slurry containing 67-
69% solids from product tank is fed to the reactor at first and third agitator point.
Concentrated sulphuric acid having 98.4% concentration and recycle phosphoric acid are
fed to the reactor. The reaction slurry proceeds through reaction section and underflows
into the vacuum cooler feed compartment where degassing takes place and the slurry is
then pumped to the vacuum cooler. Deformer is added to the reactor to inhibit the formation
of foam/froth.
The slurry is cooled down in the vacuum cooler by maintaining a vacuum of 150-300mm Hg
absolute by evaporation of water. A barometric condenser and vacuum jet system remove
the vapours. The slurry from the vacuum cooler flows down the reactor to filter feed tank
through a vertical seal by a vacuum cooler tank. Filter feed is distributed on a horizontal
filter through feed box, where phosphoric acid is separated from gypsum. The cake in the
filter is given four successive washes by a filtrate of 12% P2O5, heated pond water and a
final wash. The de- watered cake after fourth wash is removed, slurries and pumped to the
gypsum pond. Air that passes through the cake is disengaged from the filtrates in the
filtrate recovery system and passes through the filter condenser where gas is cooled, and
vapours condensed. The pond water used in the filter condenser discharges through the
pond water tank.
The scrubbing system provides a preliminary pond water quench to cool the vent gases.
The gases are then scrubbed in the first stage in a cross flow packed bed scrubber using
cold pond water. The gases then pass through a second packed bed, which reduces the
emission below 0.0058 kg fluorine per tonne of acid. A mist eliminator eliminates droplet
entrainment. Acid from filter is pumped to a clarifier. The clarifier overflow goes either to a
product acid tank or to the evaporator as required. The sludge from the clarifier is either
recycled to the clarifier or to the reactor or transferred to the DAP plant. Concentration of
the acid, whenever necessary is carried out in the evaporators. The concentrated acid
overflows from the flash chamber through a barometric condenser. The non-condensable
are removed by a vacuum jet system in condenser operating for the cooling water system.
The by-product Gypsum, as Gypsum slurry is discharged from the Gypsum Slurry pump of
Phosphoric Acid Plant to Gypsum Pond through HDPE pipeline.
The Gypsum Pond consists mainly of four settling compartments & Perimeter surge ditch.
The perimeter ditch is bound by perimeter dike. The total area of Gypsum pond is 77
hectare. Normally one settling compartment is taken on line & the other are kept as stand
by. The Gypsum Slurry at about 11-15% solid is discharged to one settling compartment. It
has to travel a horizontal length of approximately 1000m by which the solids get settled in
the settling pond & water is decanted to perimeter ditch. This water is known as Pond
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Water. The pond water comes to a pit & pumped back to plant through Pond Water Return
Pump.
Brief of Gypsum Pond
Area : 77 Hectare
Number of settling compartment : 4
Perimeter ditch length : 1000 meter
Pond water circulation pump : 2
Designed by M/s Andaman & Associates Inc., USA.
Lined with thick layer of Impervious Clay compacted to permeability of 10 -7cm/sec.
Pond water is completely re-cycled and re-used in PAP.
There is a motor able Ring Road around the pond.
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Figure 2.2 : Process Flow diagram of Phosphoric Acid Plant
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2.3.3. Process Description of Di-Ammonium Phosphate/NPK Plant (DAP/NPK):
DAP/ NPK plant is based on Dorocco Granulation Process consisting of four identical
streams and has capacity to produce 5000 MT per day. The main raw materials are
phosphoric acid, ammonia, sand (as filler) and Defoamer. Phosphoric acid (54%) and
anhydrous ammonia are pumped from storage tanks to pre- neutralizers (PN Reactor)
reaction takes place because of which DAP and mono- ammonium phosphates are formed.
The slurry contains 80% solids and is pumped to rotary granulators where further ammonia
is fed to convert mono-ammonium phosphate to di-ammonium phosphate in a mole ratio of
1.8.
The recycle material along with the filler mixed in the fine‘s conveyors are fed to the
granulators. Wet DAP granules flow by gravity to rotary dryers where they are dried in a co-
current stream of hot air. The dried granules are screened for size separation in double
deck vibrating screens where oversized and under sized material are sent back to the
system by means of fine conveyors. The product falls into the product compartment of the
screen hopper and is withdrawn through product coolers and dispatched to product storage
(50000MT capacity) or direct to the Bagging Plant as required.
The wet process system consists of scrubbing and reaction sections. Scrubbers, which are
ventury cyclone type, handle the ammonia and dust bearing fumes and gases evolved from
the pre-neutralizer, granulator, drier and dust systems. The scrubbing medium for the three
scrubbers is re-circulated phosphoric acid solution. The fumes and gases from dryer and
fume scrubbers are forced by respective fans to a tail gas scrubber where gases and fumes
from pre-neutralizer granulators and coolers are scrubbed and exhausted to atmosphere
through the fume stack.
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Figure 2.3 : Process Flow diagram of DAP/NPK Plant
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2.3.4. Utilities and Off-site Facilities
2.3.4.1 Water
Water Intake and Distribution System
Existing raw water requirement of the PPL is met from the TaladandaCanal flowing in the
west – north – north east direction of the project site.
Raw water intake pump house called as Canal Pump house is located at canal side near
village Bijay Chandrapur at 3 to 4 kms by road from the plant. Water so drawn is pumped to
a reservoir inside the PPL township campus through a pipe line. The storage capacity of
the reservoir is around 17 lac KL. Raw water from the reservoir is taken to Water Treatment
Plant through a secondary reservoir. In the process the silts and mud are settled in the
main reservoir. The treated water from WTP is then pumped to the plant side as well as to
the township area by two different distribution systems. Water cess is being paid to
Irrigation department regularly.
Two process water tanks are installed to cater to the needs of process water from the plant
as well as supply of firewater. In the process water pump-bay a jockey pump is installed to
keep fire hydrant pressure at required level. There are one diesel driven and two motor
driven fire water pumps. Pumps are kept connected so that they could be started
immediately whenever necessary. Firewater inlet to the pumps is at a lower level than the
process water intake. Process water clarifier is provided which takes water from a huge
water reservoir, before pumping.
PPL is permitted to withdraw 5 MGD (947.08 m3/hr)water from Taladanda canal. Presently
PPL is being drawning approx. 776 m3/hr.Necessary approvals and permissions would be
taken for extra water required for the proposed upcoming plants.
Existing water consumption is as below
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Figure 2.4 : Water Balance (Existing)
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2.3.4.2 Power & Distribution:
PPL has captive power generation facilities. Captive generation of power is through co-
generation from the waste steam of SAP. In addition, there are three Turbo Generators.
These are extraction cum condensate type, manufactured by BHEL, each having capacity
of 16 MW (one standby). A new TG of 23 MW has been commissioned in 2016.
The waste HP steam from SAP at 40/60 kg/cm2 pressure and 405/485ºC temperature is
used in Turbo Generator to produce power. In case of shutdown of any stream of Sulphuric
acid plant, the low-pressuresteam is met through two nos of package boilers installed at
Offsite.
Total power requirement in the plant is 34 MW. PPL is capable to generate 39 MW. We are
self -enough for our existing requirement but also have grid power supply from state
electricity Grid for emergency.
In case of total power failure, the backup HT power is supplied through 5 MVA DG set and
LT power through two numbers of 1 KVA DG sets.
2.3.4.3 Raw Material Handling
Basic raw materials handled are rock phosphates, sulphur, MOP, ammonia, sulphuric acid
and phosphoric acids. Mostly all are imported from different countries. The solid cargo
(sulphur, rock phosphatesand MOP) are unloaded from ships at the company‘s captive
jetty by means of a cross country conveyor system. The length of the conveyor gallery is
3.3 kilometers and is completely enclosed. The liquid cargo (sulphuric acid, phosphoric acid
and ammonia) are unloaded from ships at the same jetty through cross country pipeline.
While the solid cargo is stored in respective silos and fed into the individual plants, the
liquid cargo is stored in dedicated storage tanks in off-site areas for onward transfer to
production plant.
Table 2.3 : Raw Material Requirement, Linkages & Specific Consumption
Raw
Material
Approximate
Requirement
(Tons / Day)
Consumin
g Plant
User Plant
Origin Source Supplier
Rock 4600 Phosphoric
Acid Plant
Morocco/ Togo/
Peru/ Vietnam/
Egypt
M/s OCP, Morocco, Peru
Sulphur
1500
Sulphuric
Acid Plant
UAE/ Iran/ Qatar/
Singapore
M/s Havi Ocean Co.(LLC),
Dubai, M/s Midgulf
International Ltd,Limassol
MOP 1100 DAP &
Trading
Belarus / UK
M/s JSC Belarusian
Potash Company, Belarus
M/s International Potash
Company (UK) Ltd,
M/s Rusagro
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Raw
Material
Approximate
Requirement
(Tons / Day)
Consumin
g Plant
User Plant
Origin Source Supplier
Ammonia 1150 DAP IRAN/ S.ARABIA/
MALAYSIA/
BANLGADESH
M/s Transammonia Ag, A
Swiss.
M/s SABIC
M/s Compagnie Indo
Francaise De
Commerce(P) Ltd,
Sulphuric
Acid
5000 DAP& PAP Japan Mitsubishi Corporation
Phos. Acid 2350 DAP Morocco M/s Marocco Phosphore
Filler 250 DAP Local Paradeep
2.3.5. Specific consumptions
2.3.5.1 Specific consumptions for PAP
Table 2.4 : Specific Consumption for PAP
Raw Material Unit Consumption
Rock phosphate T/T 3.25
Sulphuric acid T/T 2.80
Defoamer T/T 1.00
Power KWH/T 155.000
Water T/T 1.18
Water(conc.) M3/T 0.00597
Power(conc.) KWH/T 75.0000
Steam(conc.) T/T 1.96
2.3.5.2 Specific consumptions for SAP
Table 2.5 : Specific Consumption for SAP
Sl.
No
Raw Material Unit Specific
Consumption
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Sl.
No
Raw Material Unit Specific
Consumption
1 Sulphur MT/MT 0.330
2 Ammonia kg/MT 0.182
3 Filter Aid MT/MT 0.135
4 Hydrazine gm/MT 0.0275
5 T.S.P Kg/MT 0.00225
6 Process water (Including make up to
C.T)
m3/MT 3.156
7 D.M. Water m3/MT 1.165
8 L.P. Steam MT/MT 0.225
9 Instrument Air m3/MT 1.8
10 Hydrated Lime Kg/MT 0.075
11 Soda Ash Kg/MT Occasional
12 Elec. Power KWH/MT 74.4
2.3.5.3 Specific consumptions for DAP/Other complex Fertilizer:
Table 2.6 : Specific Consumption for DAP/Other complex Fertilizer
Sr.
No
RM
Products
DAP NP-20 NP-10 NP-12 NP-15
01 NH3 0.222 0.249 0.125 0.15 0.1892
02 P2O5 0.471 0.21 0.27 0.332 0.1604
03 H2SO4 0.016 0.433 0.01 0.01 0.339
04 MOP - - 0.44795 0.27519 0.2578
05 Filler 0.05 - 0.04725 0.04811 -
06 Anticaking
agent
0.0008 - 0.0008 0.0008 0.0008
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07 Defoamer 0.000157 0.00009269 0.00010109 0.00011257 0.000157
08 F.O.(
KL/MT)
0.0083 0.0087 0.00813 0.0086
2.3.6. Finished Product Handling
Bulk fertilizers are received in the bagging plant directly from the production plant as well as
from the product silo. This is then bagged, stitched and loaded in wagons for dispatch.
There are nine numbers of slats for carrying out the activities and three numbers of
platforms for loading the fertilizers in the rakes. Controlling the weight variation of the
bagged fertilizers is the most important function of the bagging plant. It is a labor oriented
department. Around 600 persons are deployed in the bagging plant. The average capacity
of each slat is around 45 Ton per hour.
2.3.7. Bulk Storages
2.3.7.1 Ammonia Storage
Imported liquid ammonia is stored in 5 atmospheric storage tanks, each having a capacity
of 10,000 MT totaling to 50,000 MT. The tank is of 'Cup-in-tank' type. These are double
shelled tanks with double bottom and double cylindrical shell with a single roof fabricated
from low temperature carbon steel. The space between the shells relates to ammonia
vapour. Outer tank is insulated with polyurethane foam ―foamed in-situ‖ (100mmthick) and
has aluminium sheet cladding. Insulation is secured with stainless steel hoops to withstand
wind velocity of 260-km/hr. Tank bottom is insulated with foam glass and roof is insulated
with fibre glass stacked to a thickness of 250 mm on deck suspended from dome roof. The
roof top is painted with polyurethane paint. Ammonia is stored at atmospheric pressure and
temperature of-33ºC. Each tank has three safety valves at different points for protection.
These safety valves are connected to a relief header and the header is connected to vent.
Normal operating pressure of the storage is 600mm water column (WC). There are two
vents at a height of 60.2metres and 70.15 meters. Three safety valves provided on each
tank are having following set pressures.
1st safety valve : 950 mm WC
2nd safety valve : 1000mmWC
3rd safety valve : 1050 mm WC
Safety valves can be locked either in open or closed position. Without inserting key,
these cannot be opened or closed, once locked.
All the ammonia tanks are connected to a common refrigeration system.
2.3.7.2 Sulphuric Acid Storage Tank
There are five numbers of sulphuric acid storage tanks three of each 10,000 MT capacity
and one of 5000MT capacity. A pump bay is situated near the tanks and sulphuric acid
from the storage tanks is pumped to the day tank (2000 MT capacity) situated in
Phosphoric Acid Plant premises and to DAP plant for injection. Leakage from the pump and
the overflow from the storage tank are connected to sulphuric acid sump pit from where
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acid is pumped back to No.1 tank. Over flow from the sump is neutralized and discharged
to the effluent drain, which leads to Effluent Treatment Plant (ETP).
A 10000 MT capacity of Sulphuric acid tank is to be commissioned in near future.
2.3.7.3 Phosphoric Acid Storage Tanks
For phosphoric acid solution, six numbers of mild steel rubber lined storage tanks of each
10,000 MT capacity is installed. Pumps situated near the tank, pump phosphoric acid to
daytanks (2 numbers) situated in DAP plant. Spillages, over flows and leakage are
connected to a sump it where phosphoric acid sludge accumulates. A sump pump installed
in the pit pumps over flow back to the storage tank.
Presently 2 nos. of Phosphoric acid tanks Have been commissionedeach of holding
capacity of 5000 cubic m. One more tank is to be commissioned in near future.
2.3.7.4 Heavy Fuel Oil/ LSHS Storage Tanks
There are two heavy fuel oil (FO) storage tanks each having a capacity of 1800 KL. Tanks
are equipped with steam heating. All the tanks are insulated with 50 mm thickness glass
wool. Tanks are enclosed in a dike wall having a holding capacity of 2000 m3. Unloading
facilities by trucks exist. Leakage form tanks drain and overflow along with tank‘s steam
heating condensate arecollected through a drainage system inside the dyke wall to
control the spillage flow from pump bay and is directed to the sump pit. For reclaiming oil
from the pit, one submerged oil reclaiming pump is provided which reclaims oil from the top
of the pit and discharges into storage tanks provided. Water collected in the pit goes to the
effluent drain pump and the fuel oil is pumped back to the storage tank.
One High Speed Diesel (HSD) oil day tank having a capacity of 15 KL is located behind the
emergency power house building of off-site storages.
2.3.7.5 Chlorine Storage
Chlorine is stored in tonners at Water Treatment Plant. The factory stores a maximum of 2
tonners at a time. One tonner is equivalent to 930 kg. This chlorine is in liquid form and is
being used to treat the water. The empty cylinders will be replaced by the filled ones on
regular basis.
2.3.7.6 Mutrate of Potash Storage
The mutrate of potash is stored in a silo of capacity 35000 MT. Being transported from jetty
through the conveyors.
2.3.7.7 Rock Phosphate Storage
The rock phosphate is stored to the extent of 65000 MT. It is stored in an enclosed shed
called silo. Rock Phosphate is being transported from jetty through the conveyors. The
expansion of the silo has been done to 1, 20,000 MT.
2.3.7.8 Sulphur Storage
The sulphur is stored in solid state to the extent of 55000 MT. It is stored in an enclosed
shed called silo. Sulphur is being transported from jetty through the conveyors. The storage
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shed approximate dimensions are 194 m x 42 m x 10 m. The stored sulphur is transported
through conveyors to SAP.
2.3.7.9 LPG Storage
LPG cylinders are stored in a Go down. There are total 102 cylinders for industrial use and
153 cylinders for domestic use. Go down has approximate dimensions of 12 m x 8 m x 4 m.
2.3.8. Offsite Facilities
The important OFF-Site facilities required for the smooth operation of the plant are briefly
given below.
2.3.8.1 Instrumentation
Automation and control system being an important feature, all parameters are measured by
instruments. PPL can regulate the production process and improve the productivity.
DAP Plant, Phosphoric Acid plant; Captive Power Plant and Sulphuric Acid Plant have
adopted the Distributed Control System (DCS) whereby the intricate details also are
captured by the system.
2.3.8.2 Plant Lighting
The entire plant along with township is provided with adequate lighting facilitated by energy
efficient, high luminescent sodium vapor lamps and high mast for widespread coverage.
2.3.8.3 Fire Fighting, Safety & Security
The fire fighting system is very important. The fire fighting personnel and security guards
are specially trained for all types of fire-oriented contingencies and also other safety
emergencies in a simulated real-life situation. The preventive measures for fire and Safety
incidents and accidents:
Regular testing of fire pumps and fire tenders
Regular inspection and upkeep of fire and safety equipment/vehicles
Emergency preparedness and response /mock drills
Creating awareness and formation of safety committees in all the plants
Accident reporting, investigation and analysis
Well-equipped with relevant infrastructure and manned round-the-clock
PPL has a battalion of 206 well trained and efficient security personnel headed by Chief
Security Officer. Security system and guards are equipped with best safety appliances
adequate to protect the plant and personnel against any adverse situations.
The safety and security operations are carried out round the clock with meticulous planning
and vigorous implementation techniques, which consider the risk and hazards factors.
2.3.8.4 Electrical & Mechanical Maintenance
The company adorns a full-fledged electrical and mechanical workshop within the plant
premises with state-of-the-art machines and facilities to cater to the day to day in-house
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maintenance jobs. Some of the major breakdown jobs are done by employing certified and
enlisted contractors.
2.3.9. Environment Aspects
PPL is having a well-organized Environment department to take care of various
environmental issues of the industry, which includes but not limited to compliance of
statutory provisions of environment legislations. Operation of Effluent Treatment Plant,
regular monitoring of environmental parameters and coordination with different
departments in the plant for effective environmental management are some of the activities.
PPL is having a well-equipped laboratory to carryout day to day analysis of environmental
parameters. PPL has installed a Weather Station to monitor ambient temperature, wind
speed, wind direction, rain fall and relative humidity.
2.3.10. Man Power
Competent and qualified personnel are employed for various jobs. Direct employment is
around 931. Out of this 540 are executives and 391 are non-executives. Indirect
employment is to the tune of 905 deployed through contractors. Temporary employment is
around 30.
Summing up the figures, PPL has manpower of 1866 as of 30.09.2017.
PPL has provided housing facilities to all its personnel. Maintenance of the colony is taken
care by the civil department. The complex is having all basic minimum amenities like
shopping complex, school, playground, jogging trail, gymnasium, recreational club &
hospitaletc.
2.3.11. Air Emission
Table 2.7 : Air Emission from Existing plant
Sl. Description ofStack
Stack Coordinate
Stack Height(m)
Stack Dia.(m)
Exit Velocity (m/ Sec)
Temp
(0K)
X – Coord
Y – Cord
01 DAPA 850 550 50 2.8 13.14 343
02 DAPB 800 550 50 2.8 14.17 342
03 DAPC 800 600 50 2.8 14.91 344
04 DAPD 850 600 50 2.8 15.14 343
05 PAP 1400 400 50 1.5 11.68 321
06 SAP Stream A
1350 575 120 1.8 8.05 330
07 SAP Stream B
1400 575 120 1.8 8.1 335
07 SAP Stream C
1450 580 120 1.8 17 350
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Table 2.8 : Stack emission Data in Existing phase
STACK EMISSION DATA
Stack Location
PM ( mg/ Nm3)
SO2 kg/te of 100% H2SO4 prodn.
SO3 ( mg/ m3)
TF ( mg/ Nm3)
DAP-A 76.18
NA
2.02
DAP-B 70.49 1.86
DAP-C 79.44 2.74
DAP-D 77.8 2.46
Zypmite-1 55.19
NA Zypmite-2 56.18
Zypmite-3 51.36
SAP-A NA 0.61 21.85
NA SAP-B NA 0.60 21.58
SAP-C NA 0.83 27.32
PAP 52.76 NA 3.05
mg / Nm3 100 1.5 Kg/T/ 1.0Kg/MT 50 25
2.3.12. Effluent
The major sources of waste water generation from PPL are;
Sulphuric Acid Plant
Phosphoric Acid Plant
DAP Plant
Captive Power Plant
Offsite and Bagging Plant
Domestic Waste Water
Scrubbers, condensers of the vacuum evaporators, leakage from pumps, spills, floor
washings, cooling tower blow down, boiler blow down and wash water mainly contribute to
waste water stream from the above-mentioned units. It is apparent that several substances
during the processing of the product are discharged with the effluent that primarily includes
phosphates and fluorides.
PPL plant has been designed with provision of maximum recycling of the wastewater
generated from some of the units like DAP plant and PAP. Water from gypsum pump oil
cooler and filter pump is used in Ball Mill for grinding purpose to the tune of 90 M3/hr.
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The total waste water generation from the existing plants to ETP is around 66.6M3 /hr. (As
given in Water Balance) as mentioned in Figure 2.4.
Waste Water from Phosphoric Acid Plant
The major source of waste water from this unit is gypsum slurry. The by-product gypsum is
slurried with water and pumped to gypsum pond, where the fluoride compounds form stable
calcium fluoride and settle down. The plant has been designed with a zero-discharge
concept. The supernatant from the gypsum pond, which also accommodates the return
water from various condensers, seal water, plant washings and cooling tower blow down is
recycled back into the system. The phosphoric acid plant area is also paved to prevent
ground percolation.
Waste Water Generation from SAP
There is as such no liquid effluent from the process area of sulphuric acid plant except
plant washings, blow down from cooling tower & boilers and condensate from sulphur
melting pit. During start-up or upset condition of the plant the alkali scrubber is put into
operation and scrubbed liquor is taken to ETP for treatment through a central effluent
sump. The entire quantity is highly acidic. In case it finds its way to percolate through soil
then there are all possibilities of ground water contamination. Thus, steps are taken to pave
the whole SAP area to prevent ground percolation.
Waste Water from Di-Ammonium Phosphate Plant (DAP)
The plant is based on negative water balance and thereby no sources of liquid effluent are
anticipated except for the occasional washing and spillage. Such discharges are
intermittent in nature and in small quantities. Zero discharge is attained through complete
recycle of the scrubber water back into the system. Steam condensate generated during
heating of the furnace oil lines forms a part of the effluent
Captive Power Plant
The sources of waste water generation from captive power plant include cooling tower blow
down, DM plant backwash and boiler blow down.
Domestic Waste water
Sanitary Waste Water: The generation of sanitary waste water from the plant and township
is approx. 191m3/hrand is a major source of waste water generation. An adequately
designed STP is provided to treat the same. The treated sanitary waste water is used for
green belt development.
Effluent Treatment Facilities and Waste Water Discharge
The waste water generated from PAP and DAP is completely recycled into the system
whereas of CPP is separately treated in the neutralization tank. Occasional leakages /
overflow from PAP, DAP plant, off sites and entire effluent from SAP are taken to ETP for
treatment. The said ETP has been installed based on the feasibility study carried out by
NEERI, Nagpur and comprises of a collection sump, grit chamber, oil & grease trap,
equalization basin and physio-chemical treatment units like clarifloculators, thickener, filter
press etc. ETP process is based on double stage lime treatment. The treated effluent is
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neutralized using sulphuric acid before discharge. A schematic diagram of ETP is given in
the following Diagram
A project is under way for total reuse of treated effluent water from ETP in Ball Mill of PAP.
A schematic diagram of the project is given under in Figure 2.5.
Figure 2.5 : Schematic Diagram of ETP
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Figure 2.6 : Schematic Diagram of Project for Reuse of Treated Water of ETP
2.3.13. Solid Waste Generation, Management and Handling
The solid waste generated in PPL can be classified into solid waste from the processing
plant and domestic refuse from the colony.
Solid wastes from the plant are by-product phosphor gypsum, sulphur muck, spent catalyst,
phosphoric acid tank sludge, ETP sludge etc.
By-Product Phospho gypsum
Rock phosphates are treated with sulphuric acid producing phosphoric acid and calcium
sulphate. The slurry from the reactor is routed through the filtration unit where calcium
sulphate is obtained as a filter cake. This is called by-product phospho gypsum. It is
slurried with recycle pond water and pumped to the gypsum pond. There are two
compartments in gypsum pond. It is located within the factory area. The area occupied by
the pond including perimeter ditches and dykes is 77 hectares. The pond is provided with
compacted embankments. The supernatant flows out of the pond and is collected in a
perimeter ditch. From the perimeter ditch, the supernatant is pumped and reused in the
process according to the requirement. It is utilized to slurry the gypsum and to wash the
filter cake.
The quantity of phospho gypsum generated at present is 7000 tones / day. Considerable
quantity of it is sold to outside parties for cement manufacturing and also as calcium
supplement. PPL is planning to put a granulation plant to utilize phospho gypsum. Initially
the plant will be set up as a trial unit. The details of the plant are explained in the next
chapter. Location of gypsum pond is shown in the master plan in Figure 2.7
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Figure 2.7 : Gypsum Pond
Spent Catalyst
Spent vanadium catalyst is generated occasionally from the sulphuric acid manufacturing
process. Spent catalyst (V2O5) is being stored in a covered shed inside the plant premises
in ETP area.
Sulphur Muck
Sulphur muck is obtained during melting of sulphur ore in melting pit and subsequent
filtration of molten sulphur. The impurities are obtained as residue. Daily generation of
sulphur muck is 5 Metric Ton. It is used in the DAP plant as filler.
ETP Sludge
The ETP sludge is produced during the wastewater treatment facilities. About 3100 ton of
sludge is generated per annum. Sulphur muck and ETP sludge are stored in a covered
shed and reused in the process.
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Table 2.9 : Solid/ Hazardous Waste from Existing plant
Sl.
No.
Waste
Description,
Waste Stream,
Waste Category
and Schedule.
Source of
Generation and
Quantity
Method of Handling including Disposal
01 Spent Catalyst
(Process Based)
Converters of
SAP Quantity of
Generation: It
varies from year
to year
depending upon
activity of the
catalyst.
Collection: During annual shutdown
deactivated catalyst is segregated. This
deactivated catalyst is called Spent Catalyst. It is
collected in plastic bags.
Storage: Spent Catalyst so collected is taken to
a designated Storage Site located at the ETP
using tractor trolley. Storage areas well covered
and protected from rain water.
Disposal: PPL have located a party who has
obtained authorization from its state
Environment Conservation Board for collection,
storage, treatment, transport and disposal of
vanadium pentoxide spent catalyst. PPL have
written to OSPCB for NOC for sale of spent
catalyst to this party.
02 Sulphur Muck
(Concentration
Based)
Sulphur Filter
cake at SAP
Collection: Filter cake is collected on the
concrete flooring the SAP.
Storage: The material is shifted to RMS (Raw
Material Silo) of DAP Plant by using pay loaders.
Disposal: The total quantity of Sulphur muck
generated is used in house as filler in DAP
production.
03 Acid Residue
During Cleaning
of Acid Storage
Tanks (Process
Based)
H2SO4&H3PO4
Storage Tanks at
off sites
a. Sludge from H2SO4 Storage
Tank at offsite:Storage Tank of H2SO4 is made
up of carbon steel. The threshold concentration
of sulphuric acid for possibilities of corrosion and
generation of sludge is 88% or below. PPL
maintains the concentration >98% as a process
requirement. Sludge generation due to lime
treatment fromH2SO4 Storage Tank during
cleaning is used in DAP.
b. Sludge from H3PO4 Storage
Tank at offsite.
Collection: Phosphoric acid is stored in MSRL
tanks at offsite. The fine particles of gypsum
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Sl.
No.
Waste
Description,
Waste Stream,
Waste Category
and Schedule.
Source of
Generation and
Quantity
Method of Handling including Disposal
present in acid settles in the tank bottom. When
the level of bottom sludge increases to a
considerable height it is cleaned. The clear acid
form top is pumped out. Next the sludge is
collected in a sump by a slurry pump. From the
sump it is pumped to Gypsum Slurry Tank in
PAP.
Disposal: The sludge along with gypsum slurry
is pumped from the Gypsum Slurry Tank to the
Gypsum Pond.
Note: 1. Residues are generated only during
tank cleaning.
2. We have not yet discarded any of the storage
tanks.
04 Discarded
Containers/
Liners used for
Hazardous
Waste/
Chemicals
Discarded
Container of Lube Oil Barrel from SAP,PAP and DAP
Collection: It is collected at individual plant.
Storage: Presently all empty barrels are shifted
to a designated storage room near Labour
Canteen by tractor trolley.
Disposal: Mostly these are used for storing
spent oils and disposed off to authorized re-
processor along with spent oil.
05 Sludge from Wet
Scrubber (Phos
Acid Process
Based),
Scrubber Settling
Pit of PAP
Collection& Storage: In PAP the Fume
Scrubber is used for scrubbing fumes coming
from various sections of the plant. Scrubbing is
done using the Gypsum Pond Recirculation
water.
Sludge from the scrubber accumulates in a
sump.
Disposal: Sludge from this sump is taken to the
Reclaim Pit from where it is flushed to the
Gypsum Pond along with the Gypsum Slurry for
disposal.
06 Drain & ETP
Sludge
Generated from
sump, filter press. (Concentration Based)
Effluent Drains,
Sump and ETP
Collection: It is collected manually, kept aside
along the drain/ ETP Sludge Drying Bed. Once
dried the material is shifted to RMS (Raw
Material Storage) by tractor trolley.
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Sl.
No.
Waste
Description,
Waste Stream,
Waste Category
and Schedule.
Source of
Generation and
Quantity
Method of Handling including Disposal
Storage: It is stored in the RMS.
Disposal: It is used as filler in DAP Plant.
07 Cooling Tower
Sludge
(Concentration
Based)
Cooling Tower
Sump of PAP
Collection: Sludge of cooling tower sump of
PAP is gypsum in slurry form. The sludge
removal is done after dewatering the cooling
tower pit. Then the material is shifted to
Reclaim Pit.
Disposal: From Reclaim Pit it is flushed to
gypsum pond along with gypsum slurry.
08 Spent Resin
from DM Plant
(Process Based)
DMPlant of CPP of CPP Collection:Spent resin in DM plant is generated
only at the time of replacement with fresh resin.
The spent resin is collected manually in barrels.
Storage:Around 400 Ltrs are kept inside the DM
plant.
Disposal: The material is not yet disposed off
outside the premises or sold to any external
agency. It is kept in a safe condition at the
above-mentioned area.
09 Used Oil or
Spent Oil
(Process Based),
SAP, PAP, DAP,
CPP & Off sites
Collection: It is collected at individual plant in
barrels.
Storage: Used oil is stored in barrels.
Temporary storage is at the generating plants
from where it is shifted to the designated storage
room near canteen by tractor trolley from time to
time.
Disposal: Disposed off to authorized
reprocessor.
10 Waste containing
Oil (Process
Based),
Mechanical
Workshop and
other
departments
such as CPP FO
area, 5 MW DG
room, Bagging
Plant, DAP plant,
Collection: It is collected in containers
separately for oily sand/soil and oily cotton
waste.
Storage: Temporary storage is at the
generating plants which are shifted to DAP plant
by tractor trolley from time to time.
Disposal: Oily sand/soil is used as filler in the
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Sl.
No.
Waste
Description,
Waste Stream,
Waste Category
and Schedule.
Source of
Generation and
Quantity
Method of Handling including Disposal
Diesel store,
SAP, PAP
Mechanical
Maintenance &
Offsite FO
Handling areas
plant. Whereas oily waste cotton is used as fuel
in the DAP furnace.
11 Phospho gypsum
(Both processes
based, and
concentration
based),
Phosphoric Acid
Plant
Collection: It is generated in PAP Reactor and
separated in the filters. The filter cake is then
collected by scroll drives and made slurry
by adding return gypsum pond water.
Storage: The gypsum slurry is pumped to
gypsum pond where the gypsum settles down
and supernatant liquid decanted into the
perimeter ditch.
Disposal: Water from the perimeter ditch is re-
circulated to PAP. From gypsum pond ordered
quantity of phosphor gypsum is lifted and
transported to Railway Siding by using
excavator and dumpers.
From Railway siding the said material is
dispatched to the user agencies both by rail and
road bulk and in bags. PPL is constructing a 0.7
Km. long covered shed for handling gypsum at
the railway siding.
2.3.14. Noise Environment
Impact
Present noise levels in study area are below the standards except near a station close to
Railway crossing. As all the plant equipment are adequate noise control measures thus
there is not much impact to noise in the plant premises. Major transportation is by either rail
or ship.
Mitigation Measures
Towards mitigation measures the following are in practice. Less noise generating
machines/ vehicles, maintenance of machines/ requirements/ vehicles in good condition,
ear muffs or other protecting device or sound proof cabins to employees near noise
generating source. In addition, there is development of green belt barriers and plantation.
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2.3.15. Charter on Corporate Responsibility for Environment Protection (CREP)
Guidelines:
PPL has adopted the Charter on Corporate Responsibility for Environment Protection
(CREP).
Conservation of Water
Impacts on water environment particularly on surrounding surface water in a Phosphatic
fertilizer plant are primarily caused by improper management of waste water or generation
of contaminated water. Its impact on ground water is caused by seepage or percolation
through contaminated soil.
The major sources of waste water generation from PPL are;
Sulphuric acid plant
Phosphoric acid plant
DAP plant
Captive power plant
Offsite & Bagging plant
Domestic Waste Water
Scrubbers, condensers of the vacuum evaporators, leakage from pumps, spills, floor
washings, cooling tower blow down, boiler blow down and wash water mainly contribute to
waste water stream from the above-mentioned units. It is apparent that several substances
during the processing of the product are discharged with the effluent that primarily includes
phosphates and fluorides.
PPL plant has been designed with provision of maximum recycling of the wastewater
generated from some of the units like DAP plant and PAP. Water from gypsum pump oil
cooler and filter pump is used in Ball Mill for grinding purpose to the tune of 90 M3/ Hr.
The total waste water generation from the existing plants to ETP is around 66.6M3/hr.
Waste Water from Phosphoric Acid Plant
The major source of waste water from this unit is gypsum slurry. The by-product gypsum is
slurred with water and pumped to gypsum pond, where the fluoride compounds form stable
calcium fluoride and settle down. The plant has been designed with a zero-discharge
concept. The supernatant from the gypsum pond, which also accommodates the return
water from various condensers, seal water, plant washings and cooling tower blow down is
recycled back into the system. The phosphoric acid plant area is also paved to prevent
ground percolation
Waste Water Generation from SAP
There is as such no liquid effluent from the process area of sulphuric acid plant except
plant washings, blow down from cooling tower & boilers and condensate from sulphur
melting pit. During start up or upset condition of the plant the alkali scrubber is put into
operation and scrubbed liquor is taken to ETP for treatment through a central effluent
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sump. The entire quantity is highly acidic. In case it finds its way to percolate through soil
then there are all possibilities of ground water contamination. Thus, steps are taken to pave
the whole SAP area to prevent ground percolation.
Waste Water from Di-Ammonium Phosphate Plant (DAP)
The plant is based on negative water balance and thereby no sources of liquid effluent are
anticipated except for the occasional washing and spillage. Such
Discharges are intermittent in nature and in small qualities. Zero discharge is attained
through complete recycle of the scrubber water back into the system. Steam condensate
generated during heating of the furnace oil lines form a part of the effluent.
Captive Power Plant
The sources of waste water generation from captive power plant include cooling tower blow
down, DM plant backwash and boiler blow down.
Sanitary Waste Water
The generation of sanitary waste water from the plant and township is around 191 M3/ hr
and is a major source of waste water generation. An adequately designed STP is provided
to treat the same.
Conservation of Material
Control philosophy of the plant is to
Reduce
Recycle
Reuse
Recover
For example, the waste like sulphur muck is being reused as a filler in DAP plant. Acidic
sludge from Phosphoric acid tanks is being reused in plant during process. ETP sludge is
being reused in PAP along with Rock Phosphate as a raw material.
Elimination of Toxic Substances
Through there is no toxic material involved in our process, kindly let us know the subject we
would be addressing regarding elimination of toxic material.
Wastewater Treatment
Influent and effluent of waste water treatment plants and combined discharge
are monitored daily. Performance of each unit of the waste water treatment
plant and sewage treatment plant are evaluated at regular intervals for
relevant parameters.
Structural stability of gypsum pond treated effluent pond with respect to
leakage and other factors are ensured.
All the effluent drains are separated/ isolated from the storm water drain.
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The waste water from the individual process unit are properly segregated,
collected in ETP and stored in guard ponds, treated before discharge into
Atharbanki creek.
Dilution factor during lean season is considered before discharge of treated
effluent. The guard pond water is partially used for gardening purpose.
Minimum waste water discharges are made in dry season keeping the
discharges rates in receiving water body in view. Maximum emphasis is given
for waste water recycling.
Vigorous in plant measures are initiated to reduce the concentrations of
pollutantsa and flow rates of waste water streams.
Daily effluent discharge is continuously monitored for pH, fluoride and
phosphate.
Management of Storm Water
There is a well-designed storm water drainage network covering all the areas
and the total length is 14.5 kms.
Storm drain water is tested for pH, Fluoride and Phosphates before being
discharged to the river.
Storm water drain is regularly cleaned before rainy season for free flow of
storm water.
Emission Control
Control Measures at SAP
DCDA process: Best design for high conversion Efficiency
IMPORTED V2O5 CATALYST: High conversion efficiency, less prone to
catalyst poisoning, low SO2/SO3 emission
CANDLE FILTERS: improved efficiency/ low emission
CONTINUOUS SO2 MONITOR IN STACK: Regular basis as per OPCB norms
ALKALI SCRUBER: To scrub the off-gases
Control Measure at PAP
WET GRINDING SYSTEM: To eliminate the dust generation & hence reduce
fugitive emission
FUMES SCRUBBER: To scrub the fluoride compounds released from
reactors, filter, VCC & Evaporator.
STACK: Scrubber air emitted through stack of 50 mts. Height.
Control Measures at DAP Plant
CYCLONES: To recover fertiliser dust from air and combustion gases up to
sizes 20 microns.
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VENTURI SCRUBBERS: To recover noxious fumes and fertilizer not
recoverable through cyclones for size lower than 20 microns.
MIST ELIMINATORS: To control the escape of mist through stack tail gas
(with demister pads) scrubber.
EXHAUST FANS: To ward off respirable dust
STACK (50 mts ht.): To emit the ―controlled‖ exhaust air at a higher elevation
(with port hole for SPM analysis)
Control Measures at CPP
Operating on by-product steam from waste heat boilers of SAP leading to
Zero emission and Stack of 105 mts. Ht. (with port holes) for dispersion at
much higher level.
Fugitive Control Measures
All internal roads are black topped.
All open areas are covered with either plantation or grass.
Agglomerative dust suppression systems installed at transfer points of
material conveying system.
Cross country conveying system from jetty to plant about 3 kilometres in
length is housed in a concrete enclosure having facilities of water spraying
nozzles inside.
Sulphur and rock phosphate storage silos are of solid structures.
Management of Hazardous Chemical
Solid Waste Management:
The solid waste generated in PPL can be classified into solid waste from the processing
plant and domestic refuse from the colony.
Solid wastes from the plant are by-product phospho gypsum, sulphur muck, spent catalyst,
phosphoric acid tank sludge, ETP sludge etc.
By-Product Phospho gypsum:
Rock phosphates are treated with sulphuric acid producing phosphoric acid and calcium
sulphate. The slurry from the reactor is routed through the filtration unit where calcium
sulphate is obtained as a filter cake. This is called by-product phospho gypsum. It is
slurried with recycle pond water and pumped to the gypsum pond. There are two
compartments in gypsum pond. It is located within the factory area. The area occupied by
the pond including perimeter ditches and dykes is 77 hectares. The pond is provided with
compacted embankments. The supernatant flows out of the pond and is collected in a
perimeter ditch. From the perimeter ditch, the supernatant is pumped and reused in the
process according to the requirement. It is utilized to slurry the gypsum and to wash the
filter cake.
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The quantity of phospho gypsum generated at present is 7000 tones / day. Considerable
quantity of it is sold to outside parties for cement manufacturing and as calcium
supplement. PPL is in project phase to put a granulation plant (Zypmite) to utilize phospho
gypsum. Initially the plant will be set up as a trial unit. The details of the plant are explained
in earlier chapters.
Spent Catalyst
Spent vanadium catalyst is generated occasionally from the sulphuric acid manufacturing
process. Spent catalyst (V2O5) is being stored in a covered shed inside the plant premises
in ETP area.
Sulphur Muck
Sulphur muck is obtained during melting of sulphur ore in melting pit and subsequent
filtration of molten sulphur. The impurities are obtained as residue. Daily generation of
sulphur muck is 7 Metric Ton. It is used in the DAP plant as filler.
ETP Sludge
The ETP sludge is produced during the wastewater treatment facilities. About 3100 ton of
sludge is generated per annum. Sulphur muck and ETP sludge are stored in a covered
shed and reused in the process
Phosphoric acid sludge removed from the storage tanks are being utilized in DAP plant or
pumped to gypsum pond. The tanks are cleaned once in two years.
The detail of generation and handling of all these wastes are tabulated and given in the
above table.
Safety Precautions:
All hazardous chemicals at PPL are stored and handled in accordance with
material safety data sheets.
Training and awareness are given to all concerned for its use.
All care is taken to prevent any leakages/ spillages.
Work Permit system is strictly followed.
All persons handling chemicals are required to use appropriate PPEs.
Regular inspection of pipelines, tanks etc is carried out by NDT.
Safety showers are installed at all critical locations.
Management and Action plan of Green belt
Plantation and Green Belt Development:
PPL is having 2282.40 Acres of land out of this around 854 Acres of land has been
developed as a green belt and landscaping, which is around 37% of the total land.
Preference has been given for the local and fast-growing plant species for the green belt
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development; i.e. australian acacia, paltaforam, Neem, phycus, karanj, ashoka, kajurina,
etc. Existing green belt developed within the plant area is as given in Figure No 2.9.
Plantation within the Factory:
Attenuation of Noise levels: It is possible to reduce the noise levels by 3–5 dBA per 50m
width of the greenbelt. However, a thinner strip of trees with in the industry, outside the
administrative and canteen building can reduce the noise resulting from constant
movement of trucks, tankers, wagons etc. within the campus.
To arrest particulate and gaseous emissions: Aerosols are trapped effectively by trees. Few
units from the industry, through in significant in size, would possibly generate aerosols with
gases like SO2, NOx
Protection against cyclonic wind: Area of PPL, being cyclonic prone, is protected against
damaging action of cyclonic winds. The tree species that exhibit significant check and
break force can thus be potentially useful to protect, glass windows and other weak
structures within industry from wind force.
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Figure 2.8 : Existing Green Belt in the Plant Area
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Creation of Environment Management Cell
PPL is having a well-established Environment management department to take care of
various environmental activities of the industry, which includes but not limited to:
Compliance of statutory provisions of environment legislations.
Regular monitoring of environmental parameters and coordination with different
departments in the plant for effective environmental management.
Operation of Effluent Treatment Plant.
PPL is having a well-equipped Environmental laboratory to carryout day to day
analysis of environmental parameters.
The department is headed by a DGM (ENV) and supported by other executives
and staff.
Table 2.10 : Monitoring of Effluent, Emission and Ambient Air Quality (Inhouse/third party)
S.N. Description Parameters to be
Analyzed
No of stations
(min.)
Frequency
01 Ambient Air Quality
Monitoring
12 parameters As per
CPCB guideline
4 24 Hour samples (twice a week)/Monthly
02 Soil As per OSPCB
guideline
11 Quarterly/Yearly
03 Ground Water
Level
As per OSPCB
guideline
8 Weekly/Monthly
04 Drinking Water
Quality (Dug Well /
Bore Well)
As per IS:10500 5 Twice in a month/yearly
05 Surface water
including intake
water before and
after treatment
As per 422 (E) of
19.05 1993
6 Once in a Season for 4 seasons
06 Noise Level dB(A) 9 Monthly
07 Air Quality Fugitive
Emissions
RPM, SO2 , NOx& NH3 14 Monthly
08 Stack Emission
Monitoring
DAP : PM & F
PAP : PM & F
SAP : SO2 / SO3
DAP : 4
Stack PAP: 1
Stack SAP: 3
Once in a Month
09 Weather
Monitoring
Temp, WS, WD, RH
and Rain Fall
1 Hourly (Automatic)
Besides those parameters the following are also to be included in regular monitoring
schedule.
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Performance of ETP
Performance of STP
Hazardous Waste Handling
Gypsum Pond Area Management
2.3.16. CSR Activities: Peripheral Development:
PPL has carried out numerous CSR activities and contributed significantly for the peripheral
development of the area. A few of such activities recently carried out from 2010 till 2017 are
attached as Annexure 28.
2.4. New Project under Construction
PPL is carrying out expansion (construction) of below facility:
2.4.1. New Gypsum Pond
New gypsum pond west of existing pond using latest technology from M/S Ardman
Associates Inc. Florida, USA is under construction. Feature as below:
Covering about 70-80-hectare area
New pond will be with geo-textile and HDPE liner.
HDPE liner from world class manufacturer.
Use of natural resources to level the surface
2.5. Proposed Expansion Project
This section gives brief details of the proposed expansion project of PPL plant including land
requirement, process, environmental aspects and cost.
2.5.1. Land Requirement
The Project will be in the existing compound of PPL in Jagatsinghpur District, Orissa. It is 90
kms from Cuttack. The site is located at 20º16‘56‖ North Latitude and 86º38‘52‖ East
Longitude, west side of ParadeepPort.Mahanadi River is 5km from the plant site and meets
Bay of Bengal, which is 5.3 km away from the site. Atharbanki creek is flowing along the
boundary wall of the site and is in between Paradeep Port site and the factory. The
expected land requirement for the proposed project is given below:
Table 2.11 : Land Requirement for the Expansion Project
Sl. No Plants Land
1 COAL HANDLING PLANT 150 Acres
2 GASIFICATION
3 AMMONIA
4 UREA
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Sl. No Plants Land
5 DAP 1.2Acres
6 NITRIC ACID
13.5 Acres 7 AMMONIUM NITRATE
8 SSP 8.42 Acres
9 ALUMINIUM FLUORIDE 1.16 Acres
Total 174.28 Acres
Note: No fresh land is to be acquired for the expansion project and hence no R&R is involved.
2.6. Process description:
2.6.1. Coal Handling Plant: Unloading System
(-) 300 mm domestic coal will be received at plant through railway and (-) 150 mm imported
coal will be received through conveyor system from the jetty of Paradeep port. Petcoke can
also be used for gasification. Two separate dedicated conveyors have been envisaged for
gasification plant. 7 MMTPA coal assuming 7 MMTPA coal could be domestic or 7 MMTPA
could be imported depending upon availability. And. 2 nos. Rota Side Wagon Tippler has
been envisaged for domestic coal unloading through railway conforming the latest RDSO
guideline. Wagon tippler will discharge the coal at wagon tippler hopper. From the hopper
material shall be extracted by apron feeder and which will feed to the subsequent conveyors
for screening and crushing the incoming coal at desired output size. Crushed material can
be directly fed to gasification plant simultaneously or coal can be stacked at stockpile
through individual Stacker Reclaimer. Imported coal shall be received at plant through
conveyor shall be stacked at shed. From the shed, imported coal shall be dozed to reclaim
hopper by bull dozer. Vibrating feeder will extract the material from the hopper and shall
feed to conveyor. Domestic coal coming from wagon tippler hopper and imported coal
coming from reclaim hopper can be blended at required proportion at junction towerwhere
both the conveyor is feeding to the same conveyor. Imported coal capacity can be
controlled through vibrating feeder and domestic coal capacity can be controlled through
apron feeder. There will be a layer of domestic coal over which another layer of imported
coal will exist. In the process subsequent blending of coal will be carried out at transfer
chutes, crusher house and junction tower.
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Figure 2.9 : PFD Coal Handling Plant
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2.6.2. Ammonia plant (coal based):[Capacity – 2200 MTPD] (Description of 1 stream, PPL intends for 3 streams)
The process utilizes a single gasifier block with two gasifiers (2+1) to provide syngas for ammonia production and for power generation. The
following block flow diagram shows the arrangement of unit blocks.
Figure 2.10 : Ammonia Plant Block Diagram
Coal handling &
Storage
Gasifier
ASU
Sour Water
Treatment
Syngas
Compression
NH3 Synthesis &
Refrigeration
Heat Recovery,Gas
Cleaning, Ash
Hnadling
Acid Gas
Removal
Liquid N2 Wash Acid Gas
Removal
CO Shift
Sulphur
Recovery Unit
WHRU
GT
Sulphur
Flue Gas
Steam
NH3
Steam
Steam
O2
Air
Coal
Steam
Air
N2/H2
Liq N2
HP N2
Ash
Flue Gas
CO2
Recycle N2/H2
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Coal Preparation
The coal preparation is designed at the coal handling plant itself to prepare the coal feed to
the required standard for the gasification plant. The coal from the coal handling plant area
is conveyed to a kiln type dryer that contacts the coal with heated air, ina way reducing the
moisture content in it.
A bucket conveyor lifts dried coal to the top of the coal hoppers.
Air Separation Unit
The Air Separation Unit (ASU) supplies high pressure oxygen to the gasifiers and the
Sulphur Recovery Unit (SRU). The ASU also supplies nitrogen for the ammonia process,
utility usage, liquid for storage and the Nitrogen Wash Unit. The ASU produces O2 and N2
via cryogenic distillation and generates its own refrigeration by compression of the inlet air.
The inlet air compressor is one of the largest drivers on site and can be either electric or
steam powered. At this time the air compressor is listed as electric.
Gasifier Feed System
The gasifier feed system consists of weight bins, conveyors, and lock hopper systems that
supply the gasifier with coal at pressure. Carbon dioxide from the acid gas removal system
(AGS) is used as transport gas to improve the syngas yield. The coal feed is pressurized in
a lock hopper system and metered into the gasifier using a rotary or screw feeder. Steam
and Oxygen are injected at the bottom of the gasifier, beneath the grid. Together they
provide the energy to fluidize the gasification mixture.
Gasification
Within the fluidized bed the coal reacts with steam and oxygen. The process accomplishes
four important functions; it decakes, devolatilizes, and gasifies the feedstock and if
necessary, agglomerates and separates ash from the reacting coal. At the specified
operating conditions, coal is gasified rapidly to produce a synthesis gas product consisting
of hydrogen, carbon monoxide, water vapor, and methane. Additionally, the gas
containssmall amounts of ammonia, hydrogen sulfide, and other impurities. The syngas
exits the top of the gasifier through a refractory lined to the inlet of the primary cyclone.
Fines Recovery
The primary fines recovery and recycle system consists of two cyclones in series, the
primary and secondary cyclones. The cyclones collect most of the fines from the gas
stream leaving the gasifier. The primary cyclone is refractory lined due to the temperature.
Syngas from the primary cyclone enters the secondary cyclone which is similarly refractory
lined. The fines collected in the cyclones are returned to the fluidized bed of the gasifier by
means of a dip-leg.
Ash Disposal
Coarse ash is removed from the bottom of the gasifier, cooled, and discharged through a
lock hopper system. Ash is conveyed by water cooled screw conveyors for further cooling
and discharged to an ash storage silo. Ash from the silo is mixed with water in a pug mill
before loading on a truck for disposal.
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Waste Heat Recovery
The heat recovery steam generator (HRSG) increases the plant‘s efficiency by generating
steam from the hot syngas leaving the secondary cyclone. The HRSG is a natural
circulation boiler which has a single drum and steel structure. The syngas flows
sequentially through the steam generator section, the superheater, and the economizer
before leaving the bottom of the HRSG. Steam produced by the HRSG is used as feed to
the gasifier and produced in excess for use elsewhere.
Syngas Clean-up
The cool syngas from heat recovery passes to a third high efficiency cyclone and then to a
ceramic/metal filter for further dust removal. The collected fines are recycled to the gasifier
through the fines management system. The syngas is then washed in counter current
scrubber to remove the residual solids. Evaporation of water in the scrubber cools the gas
and concentrates the water so a continuous blow-down is required.
Fines Handling
Dry fines collected from syngas clean-up are routed to a fines silo through a lock hopper
system. They are collected in the silo and returned to the gasifier. The system is referred to
as the Fines Management System and is included to maximize the carbon conversion.
Normally all fines are recycled to the gasifier where they agglomerate and are discharged
with coarse ash.
Sour Water Treatment
The blow-down water from the syngas scrubber is saturated with hydrogen sulfide that is
produced in the gasifier from sulphur in the coal. The blow-down is stripped in packed
column and the overhead gas sent to the sulphur recover unit. The stripped bottoms is
cooled and treated by a clarifier to settle the ash. The solids containing underflow is used to
wet the dry ash in the pug mill during loading. Clarified overflow is reused in the process if
possible or treated for discharge.
Sour Gas Shift
Clean syngas from the scrubber is mixed with steam prior to entering the three-stage sour
gas shift reactors. The syngas from the gasifier is rich in hydrogen, carbon monoxide, and
carbon dioxide. The shift reactors convert carbon monoxide and steam to more hydrogen
and carbon dioxide. The first shift reactor is operated at high temperature to encourage the
rate of conversion. The second two reactors operate at reduced temperatures to
encourage complete reaction of the carbon monoxide. Heat exchange at the exit of the first
reactor produces high pressure steam which can be used to drive power turbines.
After the shift reactors a mercury guard bed is provided. The guard bed is filled with
sulphur impregnated activate carbon. Any mercury present from the coal is reacted
with the sulphur and retained.
Acid Gas Removal (AGR)
At this point in the process the syngas contains Hydrogen Sulfide (H2S) and
approximately 40 mole percent carbon dioxide (CO2). These acid gas components are
removed in a two step absorption process. Selexol is a UOP licensed process that absorbs
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acid gases and upon regeneration releases the H2S and CO2 in two separate streams.
This allows the H2S to be recovered in the SRU and the CO2 to be safely vented. AGR
unit includes a refrigeration package for chilling the absorption solution. The SES based
gasifier utilizes CO2 to inject coal into the gasifier. The CO2 affects the reaction
equilibrium in the gasifier and improves efficiency of the system. CO2 from the AGR is at
low pressure, therefore a CO2 compressor has been provided.
Nitrogen Wash
Ideally the syngas feed to the ammonia synthesis loop has a ratio of 3 moles of
hydrogen per mole of nitrogen, and no other components present. Following the AGR
there remains trace impurities in the synga that include methane, water, carbon
monoxide, and carbon dioxide. Oxygen containing components must be removed
because they will oxidize the ammonia synthesis catalyst and reduce its activity.
Methane in the synthesis loop is an inert that accumulates and must be purged. The
nitrogen wash unit accomplishes both cleaning of the syngas and addition of nitrogen to
produce a stoichiometric mixture.
The syngas to the nitrogen wash unit is first dried in molecular sieve dryers to remove all
traces of water. The dry syngas is cooled and then washed by direct contact with liquid
nitrogen. Nitrogen and hydrogen have the lowest boiling point of the components
present, so the liquid nitrogen stream from the tower contains all the unwanted
components. The syngas from the top of the tower is virtually pure and in the correct
hydrogen to nitrogen ratio.
The nitrogen wash unit also recovers purge from the ammonia synthesis loop. The liquid
nitrogen wash stream is vaporized for heat recovery and then sent as fuel to the gas
turbine.The technology that this system is based upon produces the fuel gas at relatively
low pressure, therefore a fuel gas compressor is provided.
Synthesis Gas Compression
Syngas from the Nitrogen Wash Unit is ready for addition to the ammonia synthesis loop as
make-up. The syngas is compressed to approximately 155 barg by the Syngas
Compressor. The last stage of the compressor is the synthesis loop circulator.The
compressor is driven by HP superheated steam generated by the process.
Ammonia Synthesis
Hydrogen and Nitrogen are reacted to produce ammonia in a fixed bed converter. The
converter is multi-staged with inter-cooling. Each bed is filled with promoted iron catalyst.
Converter effluent is cooled by producing steam and preheating boiler feed water. Make-
up gas and recycle gas from the syngas compressor is preheated by cross exchange with
converter effluent. Converter effluent is further cooled by cooling water. The reactor
effluent is then chilled by ammonia refrigeration in two stages to produce a liquid ammonia
stream. The separated syngas is warmed by cross exchange with reactor effluent and
recycled by the syngas loop circulator Ammonia Refrigeration
The liquid ammonia from the synthesis loop is flashed at two levels to provide the
refrigerant to the synthesis loop chillers. The refrigeration compressor recovers the
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refrigerant ammonia vapors by recompressing and condensing the ammonia with cooling
water. The refrigeration compressor is driven by HP steam turbine.
The refrigeration system is configured for production of ammonia at warm conditions for
storage at ambient temperatures and pressure. The refrigeration system can be configured
to produce liquid ammonia at atmospheric pressure and -33°C for storage in atmospheric
tanks. Atmospheric pressure storage requires additional refrigeration and power.
Fuel Gas Treatment
A portion of syngas from the gasifier block is used as fuel for power generation. The fuel
gas contains sulphur from the coal as Hydrogen Sulfide. There is currently no need to
remove carbon dioxide from the fuel. Therefore, the amine system for treating the fuel gas,
MDEA, is selective for H2S. The fuel gas is scrubbed by amine solution in an absorber. The
amine solution is stripped in a second tower to regenerate the solution and produce an H2S
rich stream.
Sulphur Recovery Unit
The sulphur laden streams from fuel gas treatment and from the AGR are combined and
processed by the Sulphur Recovery Unit (SRU). The SRU is a package unit also referred
as a ―Claus Unit.‖ The sulphur laden stream is burned over catalyst that reduces the H2S to
molten elemental sulphur. Molten sulphur from the unit would be consumed in the
sulphuric acid plant already operating at the site. The SRU produces some steam for
export.
Electric Power Generation
Power for the entire plant site, 120 MW, will be produced by a gas turbine driven generator
(GTG). Fuel gas from fuel gas treating will be combined with the nitrogen/methane
rich fuel from the fuel gas compressor. The GTG drives its own air compressor for
combustion air. The exhaust from the gas turbine will be used to generate and superheat
HP steam. To meet a discharge limit of 25 ppm of NOx, the gas turbine vendor has
included a steam diluents flow of 77.6 Tons per hour. The steam flow has been added to
the steam balance and produces approximately 19 additional MW of electric power.
At this time no other special equipment is included for boosting power generation (e.g. inlet
air chilling, fuel gas saturation) or for environmental control (e.g. selective catalytic
reduction). Since natural gas is not available and the gasification block cannot operate
continuously, the operation of the GTG on diesel fuel oil as an alternate fuel is
anticipated.
Steam System
The steam system recovered as waste heat by cooling process streams and powers some
major equipment. Steam is generated at 103 barg by process heat in the CO shift area, the
ammonia synthesis loop, and the waste heat recovery unit on the exit of the GTG. HP
steam is also superheated by the waste heat recovery unit. The superheated HP steam is
let-down to MP steam through the Syngas Compressor Turbine. To provide sufficient HP
steam, supplemental fuel (treated syngas) is fired in the WHRU.
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MP steam at 41 barg is generated and superheated by the gasifier unit. The MP steam is
used as feed to the gasifier, but a significant amount of steam is exported for use by the
rest of the plant. The SRU also produces some saturated MP steam for export. MP steam
is also used as process feed in the CO shift area, power for the Syngas
Compressor and Ammonia Refrigeration Compressor. Both compressor turbine drives are
condensing type.
LP steam at 10 barg is provided by let-down from the MP. The steam is used in the Sour
Water Stripper and Sulphur Pit Eductors. LLP steam at 2 barg is also provided. The some
steam is provided by flashing condensate from process heaters. The de-aerator is the
largest user.
Condensate and Boiler Feed Water Systems
The de-aerator is the centre of the condensate and boiler feed water systems. The packed
section of the de-aerator strips dissolved gases from the water entering the de-aerator.
The de-aerator collects condensate from the process heaters, condensate from the turbine
condensers, and fresh demineralized water for make-up.
The de-aerator drum is the reserve of treated boiler feed water available for feed to the
various boilers. Boiler feed water is provided at the appropriate pressure by the HP BFW
Pump and the MP BFW Pump. Both pumps are currently included as electric powered but
BFW pumps are usually the first pumps to be made steam turbine drive.
2.6.3. Urea Plant: [Capacity – 3850 MTPD]
2.6.3.1 Main Plant Details
The capacity of Urea plant has been considered as 3850 MTPD. The most popular and
widely used urea process technologies at present are ammonia stripping process of
Saipem (SNAM Progetti) and CO2 stripping process of Stamicarbon. The ACES process of
M/s. Toyo, has also been adopted in quite a number of plants across the globe, and is very
much in commercial operation. However, for this process, the reference list is much
shorter. In terms of overall efficiency, plant cost, specific consumption etc., all the three
processes are very much competitive. The SnamProgetti ammonia stripping process has a
major share of the urea plants in India with very good operational records in terms of
achieving target production with very high on-stream efficiencies. The share of
SnamProgetti is around 70% of the total urea capacity installed all over the world in last 10
years.
The raw material Ammonia and CO2 shall be provided at battery limit. The plant will have a
normal on-stream efficiency of 330 days.
2.6.3.2 Plant Description (Urea Plant)
Urea Plant has many renowned technologies which are equally comparable with respect to
plant cost and energy consumption. For the proposed study, Saipem‘s ammonia stripping
process technology has been considered as depicted in below given Figure 2.13.
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Figure 2.11 : PFD Urea Plant
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Saipem ammonia stripping process is characterized by an urea synthesis loop operating at
about 160 ata with an ammonia to carbon dioxide molar ratio at urea reactor inlet of 3.3 –
This allows a CO2 conversion of 63% into urea in the reactor itself, fitted with approximately
10-12 nos. of perforated trays which helps in preventing back-flow of the reactants as well
as enhances the rate of absorption of the gaseous phase into the liquid phase of reactants.
It may be mentioned that, urea synthesis reaction takes place in liquid phase only. Two
major type of chemical reactions take place simultaneously inside the urea reactor:
2NH3+CO2=NH2-CO-O-NH4+32560 kcal/kmol of carbamate(at 1 atm, 25◦C)
NH2-CO-O-NH4=NH2-CO-NH2+H2O -4200 kcal/kmol of urea(at 1 atm, 25◦C)
First reaction is very strongly exothermic while the second reaction is moderately
endothermic and takes place in the liquid phase at low speed.
In the downstream of the urea synthesis, the decomposition along with associated recovery
of unconverted chemical reactants are carried out in three subsequent stages, namely,
High Pressure Decomposition in HP Stripper, MP Decomposition in MP Decomposer and,
finally, LP Decomposition in LP Decomposer. The decomposition reaction is the reverse of
the first reaction one as shown above, viz.
NH2-CO-O-NH4=2NH3+CO2 -Heat
As can be inferred from the aforesaid chemical equation, the reaction is favoured by
reducing pressure and/or adding heat.
The urea reactor effluent solution enters the stripper, operating at the same pressure
level as urea reactor, where a fair part of the unconverted carbamate is decomposed, by
heat liberated from condensing steam on the shell side along with combined stripping
action of excess NH3. As a result, the overall yield of the HP synthesis loop referred to
conversion of CO2 fed for urea synthesis, is as high as 83 to 85% (on molar basis).
Downstream of the stripper, the residual carbamate solution and ammonia are recovered in
two recycle stages operating at 18 ata (namely MP section) and 5 ata (namely LP section)
respectively.
Ammonia and carbon dioxide vapours from the stripper top, after mixing with the carbonate
recycle solution from MP section, are condensed, at the same pressure level of the stripper
itself, in the HP carbamate condenser, thus producing LP steam which is used in
downstream sections. After separating the inert gases which are passed to MP section, the
carbamate solution is finally recycled to the reactor bottom by means of a liquid/liquid
ejector, which exploits HP ammonia feed to reactor as the motive fluid.
The liquid/liquid ejector and the kettle-type HP carbamate condenser as mentioned above
are arranged in a horizontal layout which is considered to be one of the main features of
Saipem process.
Waste heat recovery from process streams in some parts of the process layout have been
introduced as a part of recent modifications, thus allowing considerable savings in overall
steam and fresh water consumption, viz.:
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HP ammonia to urea reactor preheating with off-gas from LP
decomposition stage
Heat to vacuum pre-concentrator with off-gas from MP decomposition
stage
Total recovery of process condensate as boiler feed water.
Urea plant based on Saipem urea technology is, characterized by the following main
process steps:
Urea Synthesis and NH3, CO2 recovery at high Pressure
Urea Purification and NH3, CO2 recovery at medium and low Pressure
Urea Concentration
Urea Prilling
Waste Water Treatment
Auxiliary Installation
Steam Networks
Flushing networks
Urea Synthesis and NH3, CO2 Recovery at High Pressure
Urea is produced by synthesis from liquid ammonia and gaseous carbon dioxide. In the
urea reactor, the ammonia and carbon dioxide react to form ammonium carbamate, a
portion of which dehydrates into urea and water. The reactions are as follows:
2NH3+CO2 ↔ NH2COONH4
NH2COONH4 ↔ NH2CONH2+H2O
The conditions prevailing inside urea synthesis reactor, i.e., (T = 188-190ºC, P =160 ata),
favours reaction rate for the first reaction which occurs rapidly and goes to completion. The
second reaction is very slow and reaction rate of second reaction determines the reactor
volume.
The fraction of ammonium carbamate that dehydrates is determined by the ratios of the
various reactants, the operating temperature and the residence time in the reactor.
The mole ratio of ammonia to carbon dioxide is maintained around 3.3 -3.6. The mole ratio
of water to carbon dioxide is maintained around 0.5 -0.7.
The liquid ammonia feed provided at BL at around plus 20ºC, to urea plant, is filtered
through NH3 filters which, then enters urea plant via NH3 recovery tower and is collected in
the ammonia receiver tank. From receiver, it is drawn and pumped to about 24 ata
pressure by means of centrifugal ammonia booster pump. Part of this ammonia is sent to
medium pressure absorber, the remaining part enters the high pressure synthesis loop.
The ammonia is pumped by centrifugal HP ammonia pump to the urea synthesis loop, at a
pressure of about 230 ata. Before entering the reactor, ammonia is heated in the ammonia
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preheater and used as propelling fluid in the carbamate ejector is propelled up to the
synthesis pressure.
The liquid mixture of NH3 and carbamate enters the urea reactor from the bottom where it
reacts with the compressed carbon dioxide feed.
Carbon dioxide from regenerator of de-carbonation section of ammonia plant is drawn as
feed to urea plant via CO2 booster compressor, and enters the suction of CO2 compressor
at around 1.4-1.5 ata and 40ºC where it is compressed to a pressure of about 160 ata.
A small quantity of air is added to carbon dioxide feed at CO2 compressor suction in order
to passivate the stainless-steel surfaces of HP loop equipment, thus protecting them from
corrosion from the reactants and reaction products.
The reaction products, leaving the reactor, flow to the upper part of stripper which operates
at about 150 ata. It is a vertical falling film decomposer in which the liquid is distributed on
the heating surface as a film and flows by gravity to the bottom. The HP stripper is
essentially a vertical shell & tube exchanger with heating medium on the shell side, with an
extended tube side top channel head specially designed for permitting uniform distribution
of carbamate/urea solution over the top/inlet tube sheet. In fact, each tube has an insert-
type distributor (ferrule) designed to distribute the feed uniformly around the tube wall in the
form of a film. The holes of the ferrule act as orifices and their diameter and liquid head
control the flow rate. As the liquid film flows downwards, it is heated, and decomposition of
carbamate and surface evaporation occurs. The carbon dioxide content of the solution is
reduced by the stripping action of the ammonia as it boils out of the solution. The vapour
formed (essentially ammonia and carbon dioxide) flows out from the top of the tube. The
carbamate decomposition heat is supplied by condensation of saturated steam at 23 ata.
The mixed stream of overhead gases from the stripper and the recovered solution from the
bottom of medium pressure absorber enters carbamate condenser where the condensing
components of overhead gases other than the non-condensable get condensed and the
solution is recycled back to the urea reactor through carbamate ejector.
Condensation of overhead gases from stripper at a high pressure and temperature permits
production of steam at 6 ata in the carbamate condenser and steam at 4.5 ata in the
carbamate condenser.
The non-condensable gases coming out from the top of the carbamate separator consist of
inert gases (passivation air plus inert with CO2 from B.L) containing little quantities of NH3
and CO2, which are sent directly to the bottom of the medium pressure decomposer.
Urea Purification and NH3, CO2 recovery at Medium & Low Pressures
Urea purification and associated recovery of the overhead gases take place in two different
pressure stages as mentioned below:
1ststage at 18 ata pressure
2ndstage at 5 ata pressure
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The exchangers where urea purification takes place are generally termed as decomposers
because in this equipment the residual carbamate present in urea solution, are
decomposed.
1st Purification and Recovery Stage at 18 ata Pressure
The solution, with low residual CO2 content leaving the bottom of the stripper is expanded
to a pressure of around 18 ata and enters the upper part of medium pressure decomposer.
This equipment is mainly divided into three sections.
Top separator: The released flash gases are removed here before the solution enters the
tube bundle.
Falling film type decomposer: The carbamate solution is decomposed here. Required heat
is supplied by means of condensing steam at 6.0ata (in the upper part of the shell) and
sub-cooling of steam condensate flowing out of the stripper steam saturator (in the lower
part of the shell).
Urea Solution Holder: Purified urea solution obtained from the1st stage and having a
concentration ofaround60-63%wt., is collected here.
The NH3 and CO2 rich gases, leaving the top of separator are sent to the shell side of the
falling film vacuum pre concentrator, where they are partially absorbed in aqueous
carbamate solution coming from the recovery section at 5 ata.
The total heat generated in the shell side, due to condensation/absorption/reaction of the
reactants, is removed by evaporation of urea solution, coming from the 2nd purification
step. In the process, concentration of urea solution increases to 84-86% wt., thereby
resulting in considerable saving of LP steam in the vacuum concentration stage.
From the shell side of vacuum pre concentrator, the mixed phase is sent to medium
pressure condenser where CO2 is almost totally absorbed and condensation/ reaction heat
is removed by cooling water coming from ammonia condenser.
The mixed phase effluent from MP condenser flows to medium pressure absorber bottom
where the released gaseous phase moves upwards across tower and enters the
rectification section. The medium pressure absorber tower is fitted with bell cap trays. The
bottom section of the tower is used for CO2 absorption while the top part of the tower is
utilised for NH3 rectification.
Pure ammonia is added as reflux to the top trays in order to balance the energy entering
the column, and to remove residual CO2 and H2O contained in the rising stream of gaseous
ammonia and inerts. Reflux NH3 is drawn from the ammonia receiver and sent to column by
means of ammonia booster pump.
Saturated ammonia vapour along with inert, containing few ppm of CO2 (20-100 ppm), and
coming out from top of the rectification section, is partially condensed in the ammonia
condenser and the condensate is sent to the ammonia receiver.
Uncondensed vapours, saturated with ammonia, from ammonia receiver goes to ammonia
recovery tower where additional amount of ammonia is condensed out from the vapours by
scrubbing with liquid ammonia coming from the B.L.
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The gaseous stream, leaving from top of ammonia recovery tower enters at the bottom of
medium pressure falling film absorber. The residual ammonia content in the gas is
drastically reduced by absorption in a counter current downward flow of ammonia water
solution. Heat generated by ammonia absorption, increases the temperature of descending
liquid, thereby tending to impede further ammonia absorption. To maintain the temperature
at a reduced level, the heat of absorption is removed by cooling water flowing through the
shell side of MP ammonia absorber.
The MP inert washing tower connected to the upper part of MP absorber consists of three
valve trays where the inert gases are subjected to last stage of washing by means of pure
water. Here the ammonia content of rising gas stream is minimal and consequently the
temperature is less sensitive to absorption heat. Inerts containing traces of ammonia are
finally vented through the vent stack.
From the bottom of MP ammonia absorber the NH3-H2O solution is recycled back to the
medium pressure absorber by means of a centrifugal pump.
The MP absorber bottom effluent is recycled by means of centrifugal HP carbonate
solution pump to the synthesis recovery section.
2ndPurification and Recovery Stage at 5 ata
The solution, with very low residual CO2 content, leaving the bottom of the MP decomposer
is expanded to a pressure of 5 ata and enters the upper part of low pressure decomposer,
which is mainly divided into three sections:
Top separator: Released flash gases are removed here, before the solution enters the
tube bundle.
Falling film type Decomposer: Decomposition of carbamate solution is carried out here and
the required heat is supplied by means of condensing LP steam at 6 ata (saturated).
Urea Solution Holder: Purified urea solution obtained from the 2nd stage and having a
concentration of around 69-71%wt., is collected here.
The gases leaving the top of separator are first mixed with the vapours coming from
rectification section of the distillation tower and subsequently sent to shell side of HP
ammonia preheater where they are partially condensed. The condensation heat is
recovered by preheating of HP liquid ammonia (feed to urea reactor) in the tube side.
The ammonia preheater shell side effluent is sent to LP condenser where the remaining
NH3 and CO2 vapours are totally condensed. Condensation heat is removed by cooling
water flowing in the tube side.
The carbonate solution at the exit of LP condenser is collected in carbamate solution
accumulator. The carbonate solution is recycled back to the MP absorber, bottom by
means of centrifugal, MP carbonate solution pump through the shell sides of vacuum pre
concentrator and MP condenser respectively.
It is also possible to use part of the low-pressure carbamate solution as reflux in
rectification section of distillation tower.
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The carbonate solution accumulator is designed with a low pressure-washing tower in
order to help the pressure control of 2nd recovery stage.
Urea Concentration
In order to prill urea, it is necessary to concentrate the urea solution up to 99.7% by wt. For
this, two vacuum concentration stages are provided.
The solution leaving the LP decomposer bottom having about 70 % wt. urea, is sent first to
the tube side of vacuum pre-concentrator and then pumped by to 1st vacuum concentrator
both operating at a pressure of 0.33 ata.
The urea solution leaving the bottom of LP decomposer is expanded to the
pressure of 0.33 ata and enters the upper part of vacuum pre-concentrator.
The vacuum pre-concentrator is mainly divided in three parts:
Top Separator: Released flash gases are removed before the solution enters the tube
bundle. Vapours are extracted by1stvacuum system:
Falling Film Type Evaporator: In evaporator, low residual carbonate is decomposed and
water is evaporated. The required heat is supplied by partial condensation (in the shell
side) of overhead gas coming from the MP Decomposer;
Bottom Liquid Holder: Urea solution having concentration 84-87%wt., is collected here.
The urea solution leaving the vacuum pre concentrator holder is sent by urea solution
pump to the bottom of 1st vacuum concentrator operating at around the same pressure (i.e.
0.33 ata) of tube side.
Saturated steam at 4.5 ata is supplied to the1st vacuum concentrator shell side to
concentrate the urea solution flowing in the tube side.
The mixed phase of gas and liquid coming out from the process side of 1st vacuum
concentrator enters 1st vacuum separator from where vapours are again extracted by the
1st vacuum system while the urea melt (~95% by wt.), enters the bottom of 2nd vacuum
concentrator operating at a pressure of 0.03 ata by gravity flow.
Saturated steam at 4.5 ata is supplied to the 2nd vacuum concentrator shell side to
concentrate the urea solution flowing in the tube side.
The mixed phase of gas and liquid coming out from the process side of 2nd vacuum
concentrator enters 2nd vacuum separator, from where vapours are extracted by the 2nd
vacuum system while the urea melt (~99.75% by wt.) is sent to prilling section by means of
urea melt pumps.
Urea Prilling
Urea melt leaving the 2nd vacuum separator holder is sent to the prilling bucket by means
of a centrifugal pump.
Droplets of molten urea from the prilling bucket fall downwards along the natural draught
prilling tower and gets solidified and cooled while encounters a counter current air flow. The
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solid prills are collected at the centre of prilling tower bottom by means of the conical
double arm rotary scrapper and through a conical hopper, they fall on prilling tower belt
conveyor.
The urea lumps separator downstream removes any urea lumps or agglomerates which are
eventually discharged directly and dissolved in the underground urea close drain Tank.
Finally, the urea product is sent to B.L by belt conveyor.
Waste Water Treatment
This section treats the water containing NH3-CO2 and urea coming out of vacuum system,
so as to have an almost NH3-CO2-urea free process condensate to be sent to B.L.
The process water containing NH3, CO2 and urea, coming from the vacuum systems, is
collected in the process condensate tank, together, if necessary, with the drain solutions
accumulated into underground carbonate close drain tank and fed to process condensate
tank by means of pump. From process condensate tank the condensate is pumped by
means of distillation tower feed pump to the upper part of distillation tower.
Before entering the column, the process condensate picks-up heat from the purified
condensate leaving the bottom of distillation column itself, by means of distillation tower
preheater.
The distillation column is provided with 55 nos. of trays and is separated into two main
portions by a chimney tray between the trays numbered (from the bottom) 35 and 36.
Column process conditions are:
Pressure (top) : 5 ata
Temperature (top) : 130ºC
The condensate from the chimney tray is pumped by centrifugal hydrolyser feed pump to
urea hydrolyser where process conditions are suitable to decompose urea into CO2 and
NH3. In the hydrolyser live steam is added so as to provide enough heat to decompose
urea.
Hydrolyser process conditions are:
Pressure : 35 ata
Temperature :
:
235◦C
Steam available
at B.L
:
Temp. 380◦C, press. 45-42 ata
The vapours coming out from the hydrolyser as well as the vapours from the top of the
distillation tower are mixed with the LP decomposer overhead gas, upstream of ammonia
preheater for heat recovery.
The hydrolyzed condensate leaving the bottom of the hydrolyser is cooled by passing
through hydrolyser preheater before entering distillation tower at the bottom of chimney tray
where the final NH3 and CO2 stripping take place. LP steam (at a press. of 6 ata), injected
directly at the column bottom, provides the necessary driving force for stripping.
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The purified process condensate leaves the column bottom at 155ºC and subsequently
cooled to around 50ºC in the following manner:
Distillation tower feed preheating by means of preheater.
Process condensate cooler.
The contaminants (i.e. NH3-CO2-urea) in this treated water are reduced to few ppm.
During start-up and upsets in waste treatment section, the processed condensate is
generally recycled to the process condensate tank until specified ppm of NH3 and urea are
obtained.
Auxiliary Installation
In addition to main plant the following auxiliary installations are being provided for its
smooth operation.
Flare System
The flare system shall comprise of the following two flares:
Continuous Flare from MP section.
Discontinuous Flare from the following streams:
Vents from tanks
Process Condensate Treatment Section vent
Low Pressure Section vent
High Pressure Section vent
Carbonate Close Drain Tank
Tank is used to collect the drain solutions from various section of urea plant. These
solutions by means of pump are sent to the process condensate tank for further processing
in the waste water treatment section.
Urea Solution Tank
Tank is used to collect both the 70-75% urea solution in case of tripping of concentration
sections, or urea melts in case of prilling section failure. In the same tank it has also been
envisaged to recover the urea solution recycle coming from urea close drain tank after
being filtered through filters.
Urea Solution Recovery Pumps
This pump is used for recycling the urea solution from urea solution tank to 1st vacuum
concentrator. The urea solution contained in urea solution tank can be heated by means of
LP saturated steam.
Urea Close Drain Tank
The buried tank is used for collection of urea solution drains and dissolving of lumps by
means of stirrer. The submerged pump is used to send back the urea solution to the urea
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solution tank. The duty required for the urea lumps dissolution and the heating of the urea
solution has been envisaged by direct injection with LP saturated steam.
Steam Networks provided in the Urea Plant
Following steam network have been provided in urea plant.
Table 2.12 : Steam Network in the Urea Plant
1. KP steam network at P=111 ata &T= 510oC
2. HP steam network at P=45 ata &T=385oC
3. MP steam network at P=24.5 ata &T=325oC
4. MP saturated steam
network at
P=23.2 ata &T=219oC
5. LMP steam network at P=6-6.5 ata &T = 158-161oC
6. LP saturated steam
network at
P=4.5 ata &T= 147oC
KP Steam Network P=111 ata and T =510°C
This steam is used to drive the CO2 compressor by means of CO2 compressor steam
turbine driver.
HP Steam Network P=45 ata and T =385°C
This steam is used to feed the urea hydrolyser.
MP Steam Network P=24.5 ata and T = 325°C
This steam is withdrawn from the CO2 compressor steam turbine driver and/or HP
networks. After de-superheating, this is used in stripper.
MP Saturated Steam Network P= 23.2 ata and T = 219°C
This steam is used in stripper. The condensate coming from stripper is collected in the
stripper steam saturator and utilized in the lower part of MP decomposer. The condensate
coming from decomposer is used to feed the carbamate condenser.
LMP Steam Network P= 6-6.5 ata and T = 158-161°C
The steam of this network is produced in boiler. It is utilized in the following equipment:
MP Decomposer
LP Decomposer
Distillation Column
The condensate is used to feed the carbamate condenser.
LP Saturated Steam Network P= 4.5 ata and T = 147°C
The steam of this network is produced in boiler and is utilized in the following equipment:
1st vacuum concentrator
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1st vacuum system ejector
2nd vacuum concentrator
2nd vacuum system ejector
Steam tracing, flushing
Reinjection to turbine
The condensate coming from exchanger and tracing is collected in the steam condensate
accumulator. Inside steam condensate accumulator the flash steam is condensed in steam
recovery tower by means of the sub-cooled steam condensate coming from steam
condensate cooler.
The condensate collected in the steam condensate accumulator is returned to
Battery Limits by means of centrifugal pump.
Flushing Networks
Three flushing networks are being provided in the plant operating at the following
pressures:
1) Very high pressure flushing (KW) P=176 ata
2) High pressure flushing (HW) P=24 ata
3) Low pressure flushing (LW) P=10 ata
Very high pressure flushing is used in the urea synthesis and HP recovery stages. High
pressure flushing is used in the purification and recovery cycle, which operates at
about 18 ata.
Low pressure flushing is used in the remaining parts of urea melt sections.
The condensate required for feeding the above flushing networks is taken from steam
condensate accumulator at a temperature of 120°C.
Centrifugal pump is used for 24 ata and 10 ata flushing. Reciprocating pump is used for
176 ata flushing.
2.6.4. Nitric acid plant: [Capacity – 1000 MTPD]
2.6.4.1 Process Description: Weak Nitric Acid (WNA)
The proposed Nitric Acid project is based on Ammonia as feed stock.
Nitric Acid processes can be classified into 4 categories according to pressure.
Atmospheric pressure process
Medium pressure process
High pressure process
Dual pressure process
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The choice of process route to be adopted in a specific project depends on factors like
capacity of the plant, cost of raw material & utilities and NOx content in tail gases. Notable
amongst them as offered by various licensors are:-
Low-pressure of about 1 ata: Khulman, Sumitomo, Stamicarbon, UHDE, PDIL.
Medium pressure of about 5 ata: Technimont, Pochiney, St. Gobin, UHDE, PDIL
High pressure of about 8-9 ata: Chemico, Du Pont, Bemag, Grand Parroisse,
UHDE, PDIL
Duel pressure (where oxidation is effected at medium pressure and absorption
reaction occurs at high pressure);
UHDE, Chemico, Stamicarbon, Grand Parroisse & Bemag
The different variation of process mentioned above follows common process principles.
Ammonia gas is mixed with air and oxidized over Platinum-Rhodium (Pt-Rh) catalyst. The
heat of reaction, to the large extent, is used to produce steam which is used to heat tail gas
from the absorption unit. The generated steam and heated tail gas are utilized to drive air
compressor. The oxides of N2 are further oxidized and absorbed in water to form Nitric
Acid.
The pressure converters are most compact, but associated with lower conversion
efficiency, which require multi layers of Pt-Rh catalyst gauge. The reactor is operated at
higher temperature range up to 960°C. The conversion efficiency is lower because side
reactions are enhanced due to greater contact time between ammonia and converted gas
as they travel through greater depth of catalyst bed.
Weak Nitric Acid (WNA)
The Weak Nitric Acid (WNA) plant process description is based on UHDE‘s Mono-High
pressure technology. As per process flow scheme, following sequence will be followed.
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Figure 2.12 : Process flow scheme Weak Nitric Acid (WNA)
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Air Compression System
Air shall be made available at the battery limit of the unit. The required pressure is around
9.0 to 8.5 kg/cm2. The air shall be compressed to the required pressure, if required, by an
Air Compressor through an air prefilter. To utilize the energy of the tail gas and generated
steam the air compression system shall consist of the following items:
Air Compressor
Tail Gas Expander
Steam turbine
The air is compressed to 8.5 kg/cm2 absolute and is divided into two parts; one is primary
air going to Air-Ammonia Mixer and the other is secondary air stream. In case air at
required pressure, is provided at B.L the steam and tail gas energy shall be utilized
elsewhere.
Ammonia Evaporation
Liquid ammonia from the battery limit is passed through Liquid Ammonia Filter before
entering Ammonia Evaporator in which ammonia is evaporated by close Circuit Cooling
Water System. Oil and water present in the ammonia feed is separated out in Oil
Separator. The vapour ammonia is superheated to about 80°C.
Combustion and Heat Recovery
Primary airflow is measured and ammonia flow is automatically controlled in a pre-
determined ratio. Both are intimately mixed in Air Ammonia Mixer, which is of special
design and then filtered in Mixed Gas Filter.
Thoroughly mixed air ammonia mixture enters the top of the ammonia burner and is
distributed over the catalyst gauge through an integrated perforated plate located at the top
of the Burner in order to provide an optimum gas distribution over the total surface of the
catalyst. The platinum and rhodium catalyst gauge is there in the catalyst basket at the
lower part of the burner. Ammonia is oxidized to nitrous oxide over the catalyst gauge at a
temperature of about 860-870°C. The hot gas then passes through Waste Heat Boiler
whereby the gas is cooled down to about320°C. Beneath the catalyst gauge a filling ring
package is inserted into the lower catalyst basket in order to support the catalyst and to
create an equalized gas and heat distribution by a certain gas pressure drop. The burner
load is selected in view of optimized ammonia conversion rates and reduced pressure
losses considering a certain margin to the flame velocity of the ammonia.
Cooling of Nitrous Gas
The nitrous Gas mixture leaving the boiler is further cooled down in a series of heat
exchangers including Tail Gas Heater-II, Boiler Feed Water Heater, Tail Gas Heater-I and
Cooler Condenser. The final gas temperature is about 50°C. The reaction water gets
condensed in the Cooler Condenser and is separated as Weak Nitric Acid. The weak acid
is pumped to the appropriate plate in Absorption Tower.
The cooled nitrous gas is mixed with secondary air from Bleaching Tower and is fed to the
bottom of the Absorption Tower.
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Catalyst Recovery System
The oxidation catalyst comprises a number of platinum/rhodium gauges. Provision is made
for catalyst recovery. Catalyst is recovered in PLUSPAC Recovery System. It is placed
below oxidation catalyst gauge. Recovered catalyst is refined for reuse.
Absorption System
The absorption system consists of Tower equipped with sieve trays and cooling coils.
Demineralized water, pre cooled with chilled water, is fed at the top of the Absorption tower.
The absorption heat is removed in the tower by circulating cooling water. Arrangements of
the cooling coils are governed by process design consideration. The product at 60%
concentration is extracted from the bottom tray of Absorption Tower and fed to the
Bleaching Tower.
De-nitration
The brown nitric acid containing absorbed nitrous gases is denitrated in the Bleaching
Tower by contacting hot secondary air in bubble cap trays. The nitric acid is extracted from
the bottom of the tower and sent to storage tank under the system pressure after cooling it
in Product Acid Cooler. The secondary air laden with nitrous gas is mixed with main nitrous
gas flow before feeding to Absorption tower.
Tail Gas
The tail gas after absorption tower having NOx 500 ppm goes to Catalytic Converter for
lowering NOx level in the Tail gas. Tail gas after NOx reduction through Catalytic Converter
is returned back to weak Nitric Acid plant and passes through Tail Gas Pre heater, Tail Gas
Heater-I and then Tail Gas Heater-II in sequential order. The hot tail gas is then led to the
Tail Gas Turbine for recovery of part of the total compression power. Finally, the tail gas
having ≤ 50 ppm is sent to NOx abatement section after exchanging heat with DM water.
The residual gas which has NOx well below the Permissible limit is vented to the
atmosphere through Tail Gas Stack.
Steam and Boiler Feed Water System
Steam is produced in the Waste Heat Boiler at a pressure of about 42 kg/cm2abs and
420°C, part of which is supplied to steam turbine and excess steam is exported. A
minimum flow of saturated steam is required for process heating duties for Deaerator, Oil
Separator and Ammonia Superheater. Deaerator accepts Deminerelized water from battery
limit. Deaerated boiler feed water is pumped by boiler feed water pump to the Boiler Drum
through BFW heater where it is heated at 160ºC.
Cooling System
Cooling water from battery limit runs in parallel through lower part of absorption tower and
product acid cooler. Exit water from lower part of absorption tower runs through cooler
condenser. The rest of the trays of absorption tower are cooled with recirculated chilled
water available by the evaporation of liquid ammonia through ammonia evaporator.
Weak Nitric Acid (60% conc.) of annual capacity 0.33 MMTPA is produced as an
intermediate product which will be used for the production of ammonium nitrate.
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Concentrated Nitric Acid which has a vast demand market in India will also be produced
from PPL using weak nitric acid as raw material for it.
Out of 0.33 Mil MTPA, 0.05 Mil MTPA will be concentrated to 98-99 % and termed as
concentrated nitric acid and would be in the final product portfolio of PPL.
2.6.4.2 Process Description: Concentrated Nitric Acid (CNA):
Concentrated Nitric Acid (98 to 99 percent concentrations) can be obtained by
concentrating the weak nitric acid (30 to 70 percent concentration) using extractive
distillation. The distillation is carried out in the presence of a dehydrating agent.
Concentrated sulphuric acid (typically 60 percent sulphuric acid) is most commonly used for
this purpose. The nitric acid concentration process consists of feeding strong sulphuric acid
and 55 to 65 percent nitric acid to the top of a packed dehydrating column at approximately
atmospheric pressure. The acid mixture flows downward, counter current to ascending
vapors. Concentrated nitric acid leaves the top of the column as 99 percent vapor,
containing a small amount of NO2 and oxygen (O2) resulting from dissociation of nitric acid.
The concentrated acid vapor leaves the column and goes to a bleacher and a counter
current condenser system to effect the condensation of strong nitric acid and the separation
of oxygen and oxides of nitrogen (NOx) by-products. These by-products then flow to an
absorption column where the nitric oxide mixes with auxiliary air to form NO2, which is
recovered as weak nitric acid. Inert and unreacted gases are vented to the atmosphere
from the top of the absorption column. Emissions from this process are relatively minor. A
small absorber can be used to recover NO2. The enclosed figure presents a flow diagram
of concentrated nitric acid production from weak nitric acid.
Emissions consist primarily of NO, NO2 (which account for visible emissions), trace
amounts of HNO3 mist, and ammonia (NH3). By far, the major source of nitrogen oxides
(NOx) is the tailgas from the acid absorption tower. In general, the quantity of NOx
emissions is directly related to the kinetics of the nitric acid formation reaction and
absorption tower design.
The 2 most common techniques used to control absorption tower tail gas emissions are
extended absorption and catalytic reduction. Extended absorption reduces NOx emissions
by increasing the efficiency of the existing process absorption tower or incorporating an
additional absorption tower. An efficiency increase is achieved by increasing the number of
absorber trays, operating the absorber at higher pressures, or cooling the weak acid liquid
in the absorber. The existing tower can also be replaced with a single tower of a larger
diameter and/or additional trays.
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Figure 2.13 : PFD of Concentrated Nitric Acid
2.6.5. Ammonium Nitrate plant:[Capacity – 1100 MTPD]
2.6.5.1 Technology(Ammonium Nitrate Plant)
Ammonium nitrate is manufactured by neutralization of nitric acid with ammonia. Products
can be made available in solution, crystal and prilled form. There are number of processes
available in the international market for ammonium nitrate production. The main differences
between these processes are, concentration of reactants, pressure of neutralization and
method used to remove solid phase from the solution. The following Table 2.15 shows the
various processes with special features.
Table 2.13 : Various Processes for Ammonium Nitrate
Name of Process Special Features
Espindesa Process High versatility, different grades can be made.
Mississippi Process Good efficient control prilling.
Fisons Process Low solution hold up of Ammonium Nitrate. Simplicity and ease of
control.
ICI Process Neutralization, evaporation, incorporating anti- caking treatment
prilling.
Stamicarbon Process Low & high-density products.
Name of Process Special Features
Mitshubishi Process High purity, non-caking, adequate hardness, high oil absorption for
ANFO.
Sumitomo Process Prilled or crystal form produces High yield, improved product
quality by additives.
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UHDE Process Low temperature & high concentration in single step.
Norks Hydro Process Pressure neutralization, high concentration melts to prilling
resulting less water to be removed from drying section, high-
density product.
The chemistry and basic process steps followed in all these processes are essentially
same with minor changes in design of particular equipment or control system. The
processes offered by various licensors are all proven and plants based on these processes
are in operation in various parts of the world.
2.6.5.2 Process Description
The proposed Ammonium Nitrate project is based on Ammonia & Nitric Acid as a feed
stock. Ammonium nitrate is manufactured by neutralization of nitric acid with ammonia.
Products can be made available in solution, crystal and prilled form. There are number of
processes available in the international market for ammonium nitrate production. The main
differences between these processes are, concentration of reactants, pressure of
neutralization and method used to remove solid phase from the solution. The process
description of Ammonium Nitrate plant is given in Figure 2.16.
The process will be based on neutralization of ammonia and nitric acid in one stage. The
scheme envisages production of low density Ammonium Nitrate prills. The main sections of
the plant are described below:
Vapour Ammonia Superheating
Vapour ammonia will be received from weak Nitric Acid plant at 7.0 kg/cm2abs pressure
and 13°C temperature. It will be superheated to 120ºC by steam before feeding to the
neutralizer.
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Figure 2.14 : PFD of Ammonium Nitrate
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Neutralization
60% nitric Acid will be directly taken to the Head Tank located within the plant. Nitric acid
from Head Tank will be fed to the Neutralizer. Liquid entrained in neutralizer vapour will be
separated and returned to Neutralizer. Then the vapour will be scrubbed with acidic liquor
to minimize loss. Recovered liquor will be fed to Neutralizer. The Neutralized Ammonium
Nitrate at about 82% concentration will be taken to a tank where small amount of ammonia
vapour will be bubbled to make the liquor alkaline.
Neutralization will take place according to the following exothermic reaction at about 130ºC
temperature and 1.1 kg/cm2 pressure.
NH3 (g) + HNO3 (1) = NH4 NO3 (1) + 350 kcal/kg
The neutralized liquor will be stored in Evaporator Feed Tank and will be pumped to the
Evaporator Head Tank through a solution filter.
Concentration
The feed liquor and the recycle solution will be concentrated to 97-98% melt in a single
effect natural circulation type evaporator provided with one steam heated external calendria
heater. A pressure of 250 mmHg will be maintained in Evaporator by a Surface Condenser
and Steam Ejector. The Ammonium Nitrate melt will be taken to Melt Tank via a filter. A
submerged pump will be provided in Melt Tank to pump melt to Head Tank at the top of the
Prilling Tower.
Prilling
Ammonium Nitrate melt will flow by gravity from Prilling Tower Head Tank to the sprayer
provided at the top of the Prilling Tower chamber. Droplets of the melt will shower down the
tower counter-current to an upward flowing stream of air forced through the tower by
centrifugal fans provided on ground floor. Melt droplets will be cooled by the air stream to
approximately 80oC and formed into small prills with 2 to 3% moisture. Prills will be
collected at the base of the tower over a belt conveyor.
Salt Handling
Wet prills will be conveyed to the Feed Hopper where lumps will be separated and recycled
back. Correct size material from the hopper will be elevated by a Bucket Elevator and fed to
the Dryer. In the Dryer moistures content in Prills will be reduced to 0.3% (max) by hot air.
The air will be heated by steam in Dryer Air Heater. The dry prills will be cooled in Cooler
with dehumdised air. The prills from cooler will be fed by a Bucket Elevator to product
screen in which oversize and undersize prills will be separated from the correct size prills.
The correct size prills will be coated with liquid coating agent in Coating Drum.
Bagging
Correct size prills will be taken to the product bunker from the bottom of the product bunker.
The prills will be weighed in 25 kg batches by weighing cum tipping machine and filled in
polythene-lined bags, which are kept inside hessian bags to provide strength. After heat-
sealing the polythene bags the hessian bags will be separately stitched. The bagged
product will be shifted to the product storage.
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Recovery Section
Dust laden air from dryer and cooler will be sucked by exhaust fans and scrubbed in a Dust
Scrubber with dilute Ammonium Nitrate solution. A circulation pump will be provided to
circulate the solution. Condensate from Surface Condenser will be collected in a tank and
pumped to Head Tank. Condensate from Head Tank will be fed to the top of Neutralizer
Scrubber and the suction side of the Dust Scrubber Circulation Pump for makeup. Overflow
from the Dust Scrubber bottom and recovered liquor from Neutralizer Scrubber will be
taken to the Dissolution Tank.
Lumps from the Feed Hoper will be shifted by a Wheel Burrow. Oversize and undersize
prills will be directly discharged from the Product Screen. All the recycle Ammonium
Nitrate will be taken to the Dissolution Tank where these will be dissolved in dilute
solution coming from the Dust Scrubber. The recycle solution will be transferred to
Evaporator by Recycle Solution Pump through Solution Filter and Head Tank.
2.6.6. DAP PLANT: [0.4 Million Tonne per Annum by capacity expansion of existing
DAP plants]
2.6.6.1 Technology
The technology for the expansion project is same of the existing plant we have here at
Paradeep site. The process is described in chapter 2.
2.6.6.2 Expansion project description:
Following are the modifications done as a part of expansion project:
2.6.6.2.1 Wet Section
Pre-neutralizer
A new 904L pre-neutralizer (05-1R-101-A) of Jacobs design will be installed in the open
area near the existing pre-neutralizer. The new pre-neutralizer will be equipped with a new
agitator supported externally and new instrumentation for level and temperature
measurement.
Jacobs uses the reduced retention time pre-neutralizer where the diameter at the bottom of
the tank is smaller than the top. The advantage of this design is that the citrate insoluble
losses will be decreased while still maintaining the liquid level necessary to absorb
ammonia and to not entrain liquid in the existing gas. The citrate insoluble losses increase
with increased retention time, so it is necessary to minimize the liquid volume in the pre-
neutralizer. Larger diameter on the top will provide higher volume for liquid disengagement
and will reduce or eliminate the carry over to the vapor duct. Three (3) new liquid ammonia
and three (3) new vaporous ammonia spargers will be installed to distribute ammonia
through the reactor slurry. Vaporous ammonia and liquid ammonia will be distributed
through dedicated ring headers located on the top side of pre-neutralizer. A low-pressure
steam ring header will also be installed at the top of the pre-neutralizer for flushing the
ammonia spargers inside pre-neutralizer as required. All the input streams to the existing
pre-neutralizer will be routed to the new location. Two new slurry pumps (05-1P-501-A &
05-1P-501-E) with cross-connected, parallel, independent piping systems will be provided
to deliver ammonium phosphate slurry from the pre-neutralizer to the existing rotary drum
granulator through the new spray nozzles. This arrangement permits washing or
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maintenance of one complete line while the other is in service, an important feature, which
increases on-stream operating factor. The new slurry pumps will have a new motor with
variable speed and will be controlled by variable frequency drives, thus eliminating the
need for control valves in this difficult application. A new vapor outlet duct from the newly
located Pre-neutralizer will be routed to the new pre-scrubber (05-1G-607-A).The existing
pre-neutralizer, vapor outlet duct and the slurry pumps with slurry lines will be demolished.
Pre-Scrubber
A new pre-scrubber (05-1G-607-A) will be installed. This high mole ratio scrubber of Jacobs
design will be provided in place of the existing fume scrubber (05-1G-605-A). The existing
fume scrubber will be demolished and necessary changes will be completed to the existing
civil structure to support the new pre-scrubber vessel. Since, the pre-scrubber will operate
at a high mole ratio (approximately 1.5), the efficiency will only be around 60-70% due to
the ammonia vapor pressure. A high pressure drop Venturi is therefore not warranted.
Instead of a Venturi, the Pre-Scrubber features a series of sprays in a duct. The inlet duct
to the cyclonic separator is also fitted with sprays. The cyclonic separator will have an
integral sump. Two (2) new pre-scrubber pumps (05-1P-509-A and 05-1P-509-E) will be
installed; one operating and the other on standby. These pumps will be provided to
circulate scrubber liquor through the pre-scrubber sprays and to feed the pre-neutralizer.
Gasses from the pre-neutralizer (05-1R-101-A) will flow through new ducts and enter the
new pre-scrubber at the same elevation. Existing duct for the gases from the existing
granulator (05-1A-601-A) will be connected to the new pre-scrubber along with the new
duct from the pre-neutralizer. New differential transmitters will measure the pressure drop
across the pre-scrubber. Level and density will be measured and controlled by the scrubber
liquor flow from the scrubber effluent tank (05-1S-202-A). Level transmitters will be purged
with low pressure steam routed from the existing steam header during cases of blockage.
The pre-scrubber will be fitted with a nozzle for a weak phosphoric acid feed line tie-in from
existing supply network with flow control to control mole ratio.
RG Scrubber
A new venturi-cyclonic RG scrubber (05-1G-605-A) of Jacobs design will be provided. The
new RG scrubber will have sprays located above the venturi and in the inlet duct to the
cyclonic section. The venturi will have a variable throat to maintain the pressure drop at 425
mm WC. The new RG scrubber will be located in the space currently taken by the existing
pre-neutralizer. The existing civil structure will be modified as necessary to support the new
RG scrubber vessel.A new RG scrubber sump (05-1S-204-A), with conical bottom and
constructed of 904L stainless steel, will be installed to collect scrubber liquor exiting the
bottom of the RG scrubber. A new launder will be installed and connected to the existing
launder to transfer scrubber liquor by gravity flow from the overflow of the RG scrubber
sump (05-1S-204-A), to the existing scrubber effluent tank (05-1S-202-A).New RG
scrubber pumps (05-1P-510-A & 05-1P-510-E) will be installed; one operating and the
other on standby. These pumps will be provided to transfer scrubber liquor from the
existing scrubber effluent tank (05-1S-202-A) to the new RG scrubber and the new pre-
scrubber. The existing fume scrubber (05-1G-605-A- old), along with all related
appurtenances, will be removed. The existing fume scrubber sump (05-15-204-A-old) will
also be removed to accommodate installing a new pre-scrubber.
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Tail Gas Scrubber
A new 316L SS, cyclonic Tail gas scrubber (05-1G-606-A) vessel will be installed in the
open area near the existing tail gas scrubber. New tail gas scrubber pumps (05-1P-511-A &
05-1P-511-E), one operational and one in-line spare, will be installed to circulate tail gas
scrubber liquor through the new tail gas scrubber. The new tail gas scrubber will be
operated with good quality raw water available from the existing network. A new control
loop and a new control valve will be installed on level control for the new tail gas scrubber.
Tail gas scrubber circulation liquor will be bled off to the existing cooler scrubber sump (05-
1S-203-A) and make up of raw water will be provided by level control.A new mixing tee will
be provided in the circulation line to the tail gas scrubber to inject small amounts of sulfuric
acid into the large flow of scrubber liquor. On-line pH measurement will be provided. The
pH will automatically be controlled by adjusting the flow of sulfuric acid to the mixing tee.
The new tail gas scrubber will discharge airflow to the existing stack (05- 5D-101-A).The
existing tail gas scrubber, associated ducting and tail gas scrubber liquor sump (05-1S-
206A) will be demolished.
Dryer and Dust Scrubber
Neither the dryer scrubber (05-1G-603-A) nor the dust scrubber (05-1G-602-A) will be
modified. The dryer scrubber venturi throat portion shall handle higher airflow and higher
scrubber liquor circulation flow. Thus, no modification on throat portion is required. Existing
Dust scrubber liquor circulation lines are of rubber lined carbon steel and reported frequent
leakage of rubber lined pieces. To avoid frequent leakage and undue downtime, it was
requested to upgrade material of construction for that system. Dust scrubber circulation
piping will be replaced with 904L. With the upgraded material of construction, undue
downtime as well as scale deposition inside piping will be reduced.
RG Exhaust Fan
A new higher capacity RG exhaust fan (05-1B-206-A) will be installed. The new RG
exhaust fan will be sized to overcome the higher pressure drop of the new RG scrubber
and the new pre-scrubber. The new RG exhaust fan will be located near the existing fume
scrubber fans. The new RG exhaust fan will discharge into the new tail gas scrubber. New
RG exhaust fan will be equipped with a new inlet damper operated electrically and on line
flushing arrangement to minimize scale deposits on the impeller vane. The existing fume
scrubber fans and the associated ducts will be demolished.
Dryer Exhaust Fan
To meet higher production rate and higher pressure drop through the new tail gas scrubber
as well, the dryer exhaust fan (05-1B-202-A) will be replaced with a new higher capacity fan
and will discharge to the new tail gas scrubber (05-1G-606-A). Existing dryer scrubber
outlet duct will be routed and connected to the new dryer fan. New duct will be routed from
the new dryer exhaust fan discharge to the new tail gas scrubber. No change is anticipated
in Dryer scrubber and Dryer cyclones. New Dryer exhaust fan will be equipped with the
new suction damper operated electrically and on line flushing arrangement to minimize
scale deposits on the impeller vane. The existing dryer exhaust fan and its discharge duct
will be demolished along with existing tail gas scrubber.
Dryer Scrubber Pump
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To meet the higher Scrubber circulation rate matching with increased airflow through the
dryer scrubber, the dryer scrubber pump (05-1P-506-A) will be replaced with a new higher
capacity pump. Dryer scrubber liquor circulation lines will be replaced to accommodate
higher circulation rate and with upgraded material of construction. Carbon steel rubber lined
piping will be replaced with new piping material of 904L.Existing dryer scrubber pump will
be demolished or it can be used as warehouse spare for the dust scrubber pump.
Scrubber Effluent Tank
There will be no change to the existing scrubber effluent tank (05-1S-202-A) and scrubber
effluent tank agitator (05-1A-204-A). A new weak phosphoric acid line tie-in from existing
acid line will be provided with flow control to the scrubber effluent tank to feed the weak
phosphoric acid. In the new configuration, the scrubber effluent tank will operate at low
mole ratio (approximately 0.7). New flow control will act as a cascade control, receiving set
point from the existing level control. New RG scrubber pumps (05-1P-510-A/E) will be
installed in place of existing scrubber effluent pumps (05-1P-504-A) as existing scrubber
effluent pump will no longer be required. Existing Fume scrubber liquor pump (05-1P-508-
A) along with connected piping will also be demolished as it will no longer require with
modified scrubbing system. No change in the existing dryer scrubber outlet, dust scrubber
outlet and cooler scrubber outlets to the scrubber effluent tank. Refer to process and
instrumentation diagram DAP- A-PID-110 for the Tie- ins related to the scrubber effluent
tank.
Cooler Gas Scrubber
There will be no change to the existing cooler gas scrubber (05-1G-604-A) and the cooler
scrubber sump (05-1S-203-A).In the new configuration, the existing cooler and tail gas
scrubber circulation pumps (05-1P-505-A/E) will be used only for circulation of scrubber
effluent through the cooler gas scrubber (05-1G-604-A). Cooler scrubber nozzles are
evaluated and seem capable of handling new higher flow of approximately 15 m3/hr. per
nozzle.
Stack
Due to the new higher capacity discharge duct from the tail gas scrubber, the existing stack
(05-5D-101-A) will need to be modified. Existing rubber lined nozzle for the tail gas
scrubber discharge duct will be modified with larger size to connect the new tail gas
scrubber discharge 316L SS duct. No change to the existing nozzle for the dust scrubber
discharge duct to the stack.
Air Chiller System
The existing air chiller system (05-1V-101-A) will be modified to be in alignment with the
capacity increase. Additional surface area and a new bank of tubes will be added to the
existing air chiller. Condensate from air chiller will feed to the existing scrubber effluent tank
(05-1S-202-A).
Steam Vaporizer
new Jacobs‘s designed vertical shell and tube steam vaporizer (05-1V-102-A) will be
installed for Train A. Each of the four production trains will have dedicated standalone
steam vaporizer. Air chiller and steam vaporizer will be operated in parallel. Ammonia
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vaporizing load will be divided between air chiller system and steam vaporizer. Steam
vaporizer will be designed with adequate vaporizing capacity to operate each train entirely
on steam vaporizer during unavailability of Air chiller system. Steam import and condensate
export will be tied in with the existing network.
2.6.6.2.2 Dry Section
Granulator
The existing granulator (05-1A-601-A) will be modified with new internals including a slurry
header, slurry distribution nozzles, and ammonia spargers to support the capacity increase
and to achieve uniform granulation. Ammonia spargers and slurry header supports will also
be modified to minimize chances of material build up on the supports and to improve
distribution. The granulator outlet retention plate will be modified and an adjustable weir will
be installed to adjust the material bed inside the granulator. A new grizzly attached to the
existing rotary drum will be installed at the granulator discharge to avoid lumps passing
through to the dryer. A self-cleaning mechanism consists of two individual wipers supported
at center and operated electrically, will be installed on the top of the new central support
beam. These wipers will help in keeping the support beam clean by removing wet slurry
clumps continuously. Thus, by improving solids deposition on central support beam,
cleaning requirements as well as extent of cleaning will be less. On stream factor will be
improved.
Combustion Chamber and Fans
Due to the new increased capacity, the existing Combustion Chamber (05-1F-501-A) will
be modified to operate at a higher internal temperature of 400°C. The burner will be
replaced to provide an increased heat duty. The shell of the unit will remain unchanged for
now pending plant trials to determine its ability to operate under the new conditions. If trials
suggest a change is required, the new design will be applied to the designs of trains B,C,D
and the train A unit will be replaced and/or modified accordingly as needed. The
Combustion Air Fan (05-1B-207-A) will be replaced with one at a higher design flow
capacity which corresponds to the increased heat duty in the Combustion Chamber. The
Quench Air Fan (05-1B-205-A) will be replaced with one at a higher design flow capacity
which corresponds to the increased capacity of the new Dryer Exhaust Fan.
Dryer
Due to the new increased capacity, the existing dryer (05-1D-101-A) will be required to run
at a higher speed. Drive unit shall be modified or replaced to achieve higher speed of 5
RPM.The dryer shell will be modified with 1.165m long integral grizzly at discharge. Any
lumps will be broken by falling on grizzly rods and not allowed to discharge until they break
in to small pieces.With grizzlies at granulator outlet and the dryer outlet, there will be no
requirement for having a lump breaker.The existing lump breaker (05-1J-303-A) will be
removed, as it will no longer be required.
Polishing Screen
A new double deck Eccentric (gyratory) polishing screen (05-1M-401-A) will be installed to
improve product quality, size distribution and limit the percentage of fines and oversize
material being sent to the storage warehouse.The new polishing screen will be installed
downstream of the existing product conveyor (05-1C-103-A). Fines and oversize will be
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sent back to the fines conveyor (05-1C-203-A) as recycle material. Product material
between 2 to 4 mm sizes will be discharged onto a new polishing screen discharge
conveyor (05-1C-401-A).Polishing screen will be connected to the existing de- dusting
system through a new duct.
Polishing Screen Discharge Conveyor
A new polishing screen discharge conveyor (05-1C-401-A) will be installed downstream of
the new polishing screen (05-1M-401-A). Due to space constrain and to accommodate over
size and undersize material chutes the polishing screen discharge conveyor selected of
special type enclosed conveyor and will be installed in ‗Z‘ shape.Product material between
2 to 4 mm sizes from the new polishing screen will be discharged onto a new polishing
screen discharge conveyor. The polishing screen discharge conveyor will discharge
product material onto a new diverter (05-1H-101-A) which will divert product onto one of the
two product conveyors that send product to the storage warehouse.Polishing screen
discharge conveyor will be connected to the existing de- dusting system through a new
duct.
Product Conveyor
Existing product conveyor (05-1C-103-A) length will be modified and extend with relocating
tail end side pulley to fit with the new polishing screen (05-1M-401-A). Existing product
conveyor is bi-directional. Same configuration is maintained.
Primary Screens
Over size screens of the existing primary screens (05-1M-101-A, B, C, and NA) are of 4
mm, 3.6 mm and 3.8openings. It is recommended to replace all the oversize screens with
new 4 mm openings. No change in undersize screens is recommended at this point
assuming all are of 2.8 mm opening screens. However, it is recommended to replace all the
screens cloths during performance testing if the screen cloths are observed damaged.
Screen Feed Conveyor (Screen Drag Feeder)
Screen feed conveyor (05-1C-202-A) discharge chutes may need to be modified in order to
install new hydraulically operated gates (05-1X-101 A, B, C, and NA). This is to improve
product distribution across the primary screens (05-1M-101 A, B, C, and NA) and aid in
increasing production rates. A new common hydraulic unit is also specified to operate all
four (4) new hydraulic gates.
Cooler Feed Conveyor
A variable frequency drive (VFD) will be installed for the existing cooler feed conveyor (05-
1C-101-A) to control the production rate and to divert the balance of the material to the
fines conveyor (05-1C-203-A) to maintain the required recycle ratio.
Primary Elevator
Existing primary elevator (05-1C-501-A) speed will be increased from 0.608 m/s to 0.762
m/s (120 fpm to 150 fpm) to compensate for increased production rates. Its drive unit will
be modified or replaced as needed to achieve the proposed speed.
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Secondary Elevator
Existing secondary elevator (05-1C-502-A) speed will be increased from 0.608 m/s to 0.762
m/s (120 fpm to 150 fpm) to compensate for increased production rates. Its drive unit will
be modified or replaced as needed to achieve the proposed speed.
Coating Drum
With proposed installation of the new polishing screen (05-1M-201-A) and associated new
―Z‘ shape enclosed polishing screen discharge conveyor, the existing coating drum (05-1A-
6XX-A) needs to be demolished to create space for the new equipment.
Cyclone Air Seal Valves
Dryer cyclones (05-1G-101-A), dust cyclones (05-1G-102-A), and cooler cyclones (05-1G-
103-A) dust discharging air sealing valves will be replaced by Jacobs preferred ―trickle‖
type valves for efficient air sealing and timely discharging of collected dust at cyclones.
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Figure 2.15 : PFD of DAP Plant
2.6.7. GSSP PLANT: [Capacity – 1650 MTPD]
2.6.7.1 Technology
The unit operation of SSP production is a very simple. The process involves rock
phosphate grinding and mixing with sulphuric acid. No process license etc. is required to be
obtained from any process licensor. It has been considered that the proposed plant shall
achieve 300 days of operation at 100% capacity utilization. This requirement is vital for
profitability as well. This can be achieved only through robust plant design, equipment
selection, reliable equipment fabricator and a competent plant designer with proven
capabilities.
2.6.7.2 The Chemistry
Single super phosphate is produced in a two steps process.
2Ca5 (PO4)3F+7H2SO4+3H2O → 7CaSO4+3Ca (H2PO4)2.H2O +2HF
Step1 -Phosphate rock blending and grinding
The phosphate rock is ground until at least 75% is less than 75 µm (microns) in diameter,
and then analysed for composition. The proportions of various rock varieties are blended to
give the desired composition.
Step2 – Superphosphate manufacture
Ground Phosphate rock, sulphuric acid and water are mixed and then allowed to dry and
react to give the superphosphate - a mixture of CaSO4 and Ca(H2PO4)2.H2O.
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The SSP manufacturing process will comprise of two basic steps: The basic reaction in
the manufacture of superphosphate is the reaction of insoluble phosphate rock with
Sulphuric Acid to form the soluble Calcium di- Hydrogen Phosphate, Ca(H2PO4)2.
This is described by the following equation:
(PO4)-3+H2SO4→ H2PO4-+ (SO4)-2
The phosphate rock imported from various sources, is mainly fluorapatite, (Ca5 (PO4)3F).
The actual composition of the phosphate rock varies with the source. The reactions
occurring during the production of superphosphate are complex and are usually
summarized as follows:
Ca5 (PO4)3F + 5H2SO4 → 5CaSO4 + 3H3PO4 + HF
Ca5 (PO4)3F + 7H3PO4 + 5H2O → 5Ca (H2PO4)2.H2O + HF
These reactions can be combined to give the overall equation:
2Ca5 (PO4)3F + 7H2SO4 + 3H2O → 7CaSO4 + 3Ca (H2PO4)2.H2O + 2HF
There are other reactions occurring at the same time. For example, virtually all the HF
reacts with other silica minerals associated with the fluorapatite (silicates, quartz) to form
silicon tetra fluoride. These gaseous emissions are recovered as hydro flurosilicic acid
(H2SiF6) in the scrubbing system. Carbonates in the rock also react with sulphuric acid.
Figure 2.15 : Block Diagram for production of SSP
The production of super phosphate consists of three distinct steps.
Step1 - Phosphate Rock Blending and Grinding
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Phosphate rocks, from different sources have different phosphate, fluoride and silica
contents. These rocks are mixed in the blending plant to produce a product with a total
phosphate concentration of 31.5%. The phosphate rock mixture is passed through a
ball/hammer mill which reduces the particle size to 0.5cm or less. The coarsely ground rock
is then passed through an air swept roller mill (Bradley Mill) to attain a rock grist of
approximately 75% less than 75 microns. The powdered rock is stored in a large hopper.
The powder handling system is fitted with a dust collection system.
Fine Phosphate is transported to ground Phosphate Hopper to be used for PSSP
production. Dilution and Cooling Systems are used to Dilute the concentrated Sulphuric
Acid 98.5% to 70% concentration, and to cool down the produced Diluted Acid (178°C),
because the Dilution Process is exothermic. Dilution Process (as a result of mixing
water with Conc. Acid) and cooling system is sophisticated systems due to the highly
corrosive effect of the Diluted Acid. For that, all parts in contact with Diluted Acid made
from special Graphite can bear the operating conditions such as: Diluted acid inlet
Temperature: 178 °C Pressure inside the cooler: > 2 bars
This system is fully automated and provides all the safety precautions necessary to
guarantee safe operation not only for operators but also for the Graphite Cooler and cable
to control the outlet concentration and temperature. The Diluted Acid (DSA) is stored in
Storage Tank lined with Rubber and acid bricks. The cooling water necessary to cool the
DSA is re-circulated in water Cooling Tower to minimize the consumed water and in turn
the waste water.
Step2 –Super Phosphate Manufacture
Ground Phosphate is sent to the PSSP production plant using suitable material handling
equipment such as completely sealed Screw Conveyors, Bucket Elevators etc. Diluted Acid
is pumped to PSSP production plant using special chemical pumps. PSSP plant is
designed to use 70% Sulphuric Acid, recycled scrubber liquor and ground phosphate rock.
It is based on the most technically and economically up to date feasible process and is
compatible with Environment Protection Requirements
Feed Metering is achieved with Automatic Control System. The ground rock and sulphuric
acid are reacted in a horizontal mixer. A continuous flow of the sloppy mix drops out of the
mixer into the Broad field Den. Broad Field Mixer developed specially for PSSP
manufacture is a large two stage horizontal paddle mixer, the two stage design ensures
complete mixing and good chemical reaction (quality) of SSP powder. Varying speed drive
and adjustable paddle configuration allows selection of optimum mixing conditions for all
phosphate rocks with Acid.
The den consists of a slowly moving floor (approx. 300 mm/min), built from steel tee slats,
with polypropylene sealing strips, to prevent leakage, to enable setting of the cake and
reciprocating sides, lined with cement fondu (special tile) and are driven by two geared
motor units through two heavy crank arms which prevent the superphosphate adhering to
the walls. The partially matured superphosphate cake is cut out of the den with a rotating
cutter wheel after a retention time of approximately 30 minutes.
A sturdy steel framework carries the den and mixer. A rotary cutter excavates the SSP
cake from Den. Stainless steel blades are mounted on a steel frame and shaft carried on
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externally mounted Plummer block bearings. The outlet PSSP fertilizer conveyed to storage
area where remaining reaction of the SSP is completed by spreading the cut lumps on the
floor and reshuffling the hips by means of overhead crane situated in the curing building.
The SSP is allowed to complete the reaction and attain the powdered form which takes
around 21 days.
Granular Single Super phosphate
The SSP powder will be fed to the granulation plant. In the rotating granular drum the
powder SSP will be mixed with water up to 14%, which results in the formation of
granules. The granules will then be sent to the Dryer Drum for heating up to 600°C
temperatures to reduce of the moisture content to 6 %. The hot granules will then be cooled
in the cooler drum from where they will be send to the vibrating screens for desired mesh.
Two types of screens will be used; Undersize Vibrating Screen and Oversize Vibrating
Screen.
Figure 2.16 : GSSP
Under Size Vibrating Screen (Size-1mm)
The oversize material of this screen will be sent to the grinding unit and the undersize
material will be recycled to the granulator drum.
Oversize Vibrating Screen(Size+1.4mm)
The oversize material of this screen will be sent to the crusher from where it will be taken to
the granulator drum. The properly sized material will be packed in 50kg HDPE Bags.
SSP dust evolved in the process of granulation will be scrubbed with the help of twin
cyclone system through blower provided for dryer drum and the clean air will then be
discharged through a stack of 30 m height.
The grinding of rock phosphate may lead to emissions of dust. Pulse jet dust collector will
be provided to control dust emissions. A stack will be provided at the ball mill. At mixer and
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Den, during acidulation, gases will be liberated. These gases from mixer and Den will be
passed through absorption stages as under;
Ejector
Cyclone separator
Venturi Scrubber
Multi Stage Scrubbing Towers
Fresh water or effluent water will be charged in to sumps of the ejector, Cyclone separator,
Venturi and scrubbing towers on the day to day basis. After utilization of water in the
circulation for gas scrubbing system, the dilute acid (H2SiF6) will be taken from all the
circulation sumps to a common thickener sump every day. The ejector, Venturi and
separator will scrub the gases and gases will go further to blower and will be discharged
through stack of 30 meter height where the wind velocity is high and thus get further
diluted.
The effluent will be collected in a common sump along with silica. This silica will settle
down and will be used as filler material for SSP. The dilute acid (H2SiF6) will be discharged
in to the same sump and will be reused for acid dilution in SSP Process. Thus a Zero
Discharge system will be achieved.
2.6.8. Aluminium fluoride plant: [Capacity – 9500MTP Annum]
2.6.8.1 Anhydrous hydrofluoric acid (AHF) from FSA
HF Gas Generation:
Hydrogen fluoride (HF) is produced by the decomposition of an aqueous solution of strong
Fluosilicic acid (45% H2SiF6.SiF4) in the presence of Sulphuric acid (H2SO4) in a stirred
reactor under closely controlled conditions. Strong sulphuric acid 98% is fed and is acting
as a dehydrating agent.
Products of decomposition of fluosilicic acid are gaseous silicon tetra fluoride (SiF4) and
hydrogen fluoride (HF). The HF is absorbed into the sulphuric acid and leaves the reactor
with the sulphuric acid. Hydrogen fluoride (HF) is recovered by evaporation and dried with
fresh sulphuric acid. A two-stage evaporation system using boiler and stripper column is
used. Gaseous hydrofluoric acid generated as described is then condensed and purified by
distillation to obtain the desired product quality and finally is sent to the intermediate AHF
Storage Tank.
H2SiF6.SiF4 (aq.) + H2SO4 2 SiF4 + 2 HF (aq.) + H2SO4 (aq.)
Next the Silicon tetra fluoride (SiF4) gas leaving the reactor after drying column is absorbed
into the Fluosilicic acid (H2SiF6) feed solution to generate additional acid and silica
according to the chemical reaction:
SiF4 + 2 H2O 2 H2SiF6.SiF4 (aq.) + SiO2 (hydrate)
The strong solution of flurosilicic acid is sent to the silicon tetra fluoride reactor. The diluted
sulphuric acid stream obtained after stripper is cooled down prior storage and recirculation
to the phosphoric acid plant.
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AHF liquefaction and Purification
The crude HF gas is sent the purifying column. From this column the gases pass to two
condensers in series, where the bulk of the hydrofluoric acid is liquefied using chilled water
of controlled temperature.
Condensed hydrofluoric acid from the first condenser is sent back as reflux to the top of the
purifying column. From the second condenser the partially purified hydrofluoric acid is fed
to a pressurized rectifying column, where light impurities, mainly sulphur dioxide and silicon
tetra fluoride, are removed as overhead stream. The pure hydrofluoric acid leaves the
rectifying column via the distilled acid cooler to AHF storage tank, using the pressure of the
rectifying column as the driving force. The gaseous overhead products stream from the
rectifying column and second HF condenser are passed through a packed H2SO4
absorption column, down which sulphuric acid is circulated to absorb most of the remaining
hydrofluoric acid. A stream containing hydrofluoric acid in sulphuric acid is then pumped
back. Gases leaving the H2SO4 absorption column are contacted with water in two ejector
scrubbers in series. These remove silicon tetra fluoride as fluosilicic acid. This stream is re-
circulated.
Water effluent sent to the neutralisation is adjusted to minimize the losses of fluorine and
decrease the costs of treatment. Tail gases leaving these scrubbers via the tail gas exhaust
fan are given a final cleaning in the central absorption scrubber washed with water before
emission to atmosphere.
Figure 2.17 : Anhydrous hydrofluoric acid (AHF) from FSA
AHF Safety Storage
HF sub-cooled is stored under atmospheric pressure in tanks installed inside a larger
containment tank. The heat losses are minimized by drying the air inside the containment
tank. The air is monitored continuously to detect any leaks of HF. A back-up chiller is
provided on emergency power. The system is corrosion free after 20 years operation.
The product AHF delivered by Containers flows under pressure via the AHF Circulation
Cooler to the AHF Storage Tanks. The main storage system comprises of AHF Storage
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Tank(s), T-421 A/B/C, within the AHF Storage Containment Tank, T-422. The stored acid is
re-circulated through the AHF Circulating Cooler, E-420 and can be cooled down to say +5
to -8 °C according to coolant.
The combination of storing AHF acid at low temperature within a double skin system offers
maximum safe storage of this dangerous chemical.
The storage system is equipped with adequate pressure control and safety instrumentation.
The gas from the inside of the outer containment is being continuously dried and sampled
for HF. A cabinet including a detector for fluorine is included. Hardwired level switch is
provided to trip in case of high alarm all feeds of fluorspar, acid, oleum, acid recycling and
any pump that could fill the tanks with AHF.
Double bottom valves welded are provided on each tank for maximum safety. Manual
operated is making the system simpler and safer to operate.
2.6.8.2 High-bulk-density Aluminium Fluoride (HBD AlF3) from HF
The Alumina hydrate is stored into the ―Day-Shift‖ Silo (Hydrate Silo). The Hydrate is
discharged batch wise from the Silo by operating the Discharge Screw (Hydrate Silo
Discharge Screw) for feeding the Hydrate Feed Bin.
The Discharge Screw is controlled by switches onto the Hydrate Feed Bin which is
suspended on two Load cells and switch onto the Hydrate Distributor Bin. The Hydrate is
then fed batch wise from the Hydrate Feed bin to the Hydrate Distributor Bin where a level
of hydrate is maintained which acts as a vacuum seal and keeps the vacuum in the system.
Figure 2.18 : High-bulk-density Aluminium Fluorides (HBD AlF3) from HF
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The load cells are used to totalize the alumina fed to the Aluminium Fluoride Reactor. It is
furthermore indicating exactly the capacity of the Aluminium Fluoride Reactor. The alumina
tri-hydrate is fed continuously to the Reactor via two Feed Screws.
First Hydrate Feed Screw is feeding most of the material and is controlling the temperature
in the top bed. The speed of the Hydrate Feed Screw is adjusted according to the
temperature in the bottom bed and top bed.
The Feed Screw is feeding the material via a fluidisation cup and this for avoiding the
agglomeration of hydrate especially at start-up. Hydrate Bottom Feed Screw feeds the
bottom bed at a small feed rate for diluting the bottom bed and for obtaining a lower grade
for the aluminium fluoride product. This is controlled manually by setting the speed of this
screw manually.
The reaction can be represented by the following equations:
Al2O3.3H2O Al2O3 + 3 H2O
Al2O3 + 6 HF 2 AlF3 + 3 H2O
Since the overall reaction is exothermic, the AlF3 Reactor does not need supplementary
heat during normal operation. During start-up it does need to be preheated using the
Combustion Chamber. This item is also used for keeping warm the aluminium fluoride
Reactor if the feed of HF gas is interrupted. Solids carried out of the Reactor are recovered
by cyclone separators. Under rated capacity, the dust collected in cyclone 1 is not re-
circulated to the Aluminium Fluoride Reactor. Only under high load or if the quality needs to
be improved dusts are re-circulated to the aluminium fluoride reactor preferably to the top
bed if the grade has to be increased and preferably to the bottom bed if both the grade has
to be improved and the content of silica to be reduced significantly. Whether or not dusts
are re-circulated to the Aluminium Fluoride Reactor, the discharge of dusts from Cyclone
directly to product into the Aluminium Fluoride Cooler, is always operated.
Vacuum is kept at discharges of cyclones by level maintained in Cyclone Bin installed
underneath and equipped with discharge device and valve.
The aluminium fluoride is discharged from the bottom bed of the Aluminium Fluoride
Reactor through the discharge and then cooled down into a fluidised bed cooler to a
temperature preferably lower than 80°C.
The Off-gases from aluminium fluoride reactor after Cyclones are quenched and
condensed in the absorber and then are scrubbed.
The condensation of HF, H2O, etc occurs in the Absorber and HF Scrubber without addition
of water. The concentration of fluorine in the liquor formed provides a good indication of the
efficiency of the reactor and is used for its control.
The diluted acid solution produced will be sent to the neutralization plant or reused. The
second column is used to remove the traces of Fluorine, S, dusts, etc. This column is the
stand-by unit for the third column in case of fouling and vice versa.
The fluidisation in the Aluminium Fluoride Reactor is maintained by the vacuum obtained
from the operation of a Steam Ejector. An Absorption System common to the
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Aluminiumfluoride plant and hydrofluoric acid is provided Water is sent to the final absorber
in order to absorb totally HF and reach the emission limit for F in the off-gases in all modes
of operation of the plant. This effluent water is also sent to the neutralization plant or
reused.
2.7. Raw Material
2.7.1. Ammonia/gasification:
Raw material Consumption for 2200 TPD Ammonia:
Table 2.14 : Raw Material Consumption for Ammonia/Gasification (SES Based)
SL. No. Input Requirement UOM
1. Coal/petcoke 5,633 TPD
2. Oxygen 70,000 Kg/Hr
3. Power 70,553 KW
4. Cooling Water 17,582 TPH
5. BFW-(HP+LP) 431 (227.9+203.1) TPH
6. Raw Water 800 TPH
7. Service Water 425 TPH
8. DM Water 273 TPH
9. Portable Water 13.6 TPH
10. Instrumental Air 2,038 Nm3/Hr
11. Plant Air 510 Nm3/Hr
12. LP Nitrogen 43 Nm3/Hr
13. HP Nitrogen 82,237 Nm3/Hr
14. Diesel 0.8 M3/Hr
15. Fuel Gas 11,703 Nm3/Hr
16. Steam-(LP+MP+HP) (645.8)1.8+421+223 TPH
17. Condensate-(LP+MP) 33 (2+31)
2.7.2. Urea plant:
Table 2.15 : Raw Material Consumption of Urea Plant
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Sl.
No.
Raw
Material/UtilitiesRawMaterial/Utilities
Unit(hourly) Requirement
1. Ammonia MT 91.67
2. CO2 MT 118.7
3. HP Steam MT 126
4. MP Steam MT 21
5. Power KWh 8000
6. Makeup Water m3 256
2.7.3. Nitric acid :
Table 2.16 : Raw Material Consumption of Nitric Acid
Sl. No. Raw Material/Utilities Unit(Hourly) Requirement
1. Ammonia MT 13
2. Process Air 1000 m3 180
3. MP Steam MT 14
4. Power kW 3000
5. Treated Water m3 190
2.7.4. Ammonium Nitrate :
Table 2.17 : Raw Material Consumption of Ammonium Nitrate
Sl. No. Raw Material/Utilities Unit(Hourly) Requirement
1.0 Ammonia MT 10.00
2.0 Nitric Acid MT 36.67
3.0 MP Steam MT 6
4.0 Power KW 5000
4.0 Makeup Water m3 47
2.7.5. Di Ammonium Phosphates :
Table 2.18 : Raw Material Consumption of Di Ammonium Phophates
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Sl. No. Plant /Raw Material/ Utility Unit Consumption
1.0 Sulphuric Acid MTPD 305
2.0 Phosphoric acid MTPD 438
3.0 Ammonia MTPD 320
4.0 Filler MTPD 42
5.0 Electric Power MWhPD 67
6.0 Process Water m3/day 500
7.0 Fuel Oil KLPD 12
8.0 Steam MTPD 130
2.7.6. Granulated Single Super Phosphates:
Table 2.19 : Raw Material Consumption of GSSP
Sl. No. Plant /Raw material/
Utility
Unit(Daily) Consumption
1.0 Sulphuric Acid MT 594
2.0 Rock Phosphate MT 957
3.0 Electric Power MWh 41.25
4.0 Process Water m3 480
5.0 Fuel Oil KL 18.15
2.7.7. Aluminium Fluoride:
Table 2.20 : Raw Material Consumption of Ammonium Flouride
Sl. No. Plant / Raw material/
Utility
Unit Consumption
1.0 H2SiF6 T/T 1.05
2.0 Sulphuric acid T/T 20.5
3.0 Sulphuric acid(*) T/T 16.1
4.0 Al(OH)3 T/T 1
5.0 Limestone/Lime as
required
T/T --
*with optimized recirculation
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2.8. Utilities
2.8.1. Water
The total water requirement of the proposed expansion project is 1800.43 m3/hr (1064
m3/hr from Taladanda Canal & rest from recycling from plant).The plant wise water
requirement is as given in Figure 2.19 The water Balance diagram of expansion phase is
given in Figure 2.20.
Figure 2.19 : Water Balance in Existing and Expansion Phase
Table 2.21 : Plant-wise Water Requirement
The water will be made available from the existing source i.e. Taladanda canal. The
necessary approval for the additional water is being obtained.
Sl. No. Particulars Water Requirement (cubic.
metre/hr)
1 DAP 20.83
2 Coal Hand. Plant 90
3 Ammonia Gasification 390 X3= 1170
4 Urea 256
5 Amm. Nitrate 47
6 Nit. Acid 190
\7 GSSP 20
8 Aluminium. Fluoride 6.6
39
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Figure 2.20 : Water Balance (Proposed Expansion)
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2.8.2. Power
The total power requirement for the proposed project will be ~ 239MW. The plant wise
requirements are as given below:
The power will be sourced from:
Captive generation
DG set
State grid
Table 2.22 : Plant-wise Power Requirement
2.8.3. Land Requirement:
Table 2.23 : Plant-wise Land Requirement
2.8.4. Man Power Requirement
Sl. No. Particulars Power Requirement
(KW)
1 DAP 3125
2 Coal Hand. Plant 5500
3 Gasification 70553 * 3
4 Urea 8000
5 Amm. Nitrate 5000
6 Nit. Acid 3000
7 GSSP 1720
8 Alu. Fluoride 580
Total 238584 KW
Sl.
No.
Particulars Land Requirement
(Acres)
1 DAP 1.2
2 Coal Hand. Plant 150
3 Gasification
4 Urea
5 Amm. Nitrate 13.5
6 Nit. Acid
7 GSSP 8.42
8 Alu. Fluoride 1.16
9 Total 174.28 acre
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Table 2.24 : Plant-wise Manpower Requirement
2.9. Other Offsite Facilities
Other off site facilities like firefighting system, laboratory, safety set up, stores, first aid/
medical Township etc will be associated with existing facilities. The existing facilities will be
suitably augmented.
2.10. Env. Aspects: Emissions, Effluents & Solid Waste Details from Proposed
Plants:
2.10.1. Effluents Detail:
Table 2.25 : Effluent Details
Sl. No. Particulars Waste Water Generation
(cubic. metre/hr) 1. DAP Total recycled
2. Coal Hand. Plant 19.5
3. Gasification & Ammonia 205 X 3
4. Urea 90
5. Amm. Nitrate 47
6. Nit. Acid 1.20
7. GSSP 0
8. Alu. Fluoride 2.76
Total 775.46
2.10.2. Specific Environmental Aspect
2.10.2.1 Coal Handling Plant Emission Details
Only emission from CHP would be the dust generated.
The dust extraction emission would be kept below 50 mg/Nm3.
Water spraying would be done to suppress the dust.
2.10.2.2 Gasification & Ammonia Plant
Sl. No. Particulars Man Power Requirement
1 DAP 133
2 Coal Hand. Plant 200
3 Gasification 70 *3
4 Urea 170
5 Amm. Nitrate 110
6 Nit. Acid 80
7 GSSP 64
8 Alu. Fluoride 50
Total 1017
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Based upon gasifier design, the facilities are anticipated to produce the following emission
and effluents.
Atmospheric vents/Emission
Carbon Dioxide Vent
The vent stream from the Acid Gas Removal Unit will be vented to the atmosphere. Total
CO2 emissions from the site including the gas turbine exhaust is estimated to be 327 tonne
per hour.
Gas Turbine Flue Gas
All of the flue gas from the gas turbine will be vented via the waste heat recovery boiler.
Flue Gas
Flue gas from the Auxiliary Boiler will be vented to the atmosphere.
Flared Gas
An emergency flare will be provided forth venting of syngas during start-up and shut-down
operations. No gas is normally vented to flare.
Other Vents
Other atmospheric vents have been identified. They include:
De-aerator vents, consisting of steam and non-condensables.
Steam ejector vents, consisting of steam.
Coal Dryer vent, consisting of hot wet air.
Miscellaneous vents from dust collection associated with coal handling.
The vent specific emission details would be available at DPR staged. However, PPL will
ensure discharge to meet applicable emission discharge standards.
Liquid Effluents
The following liquid streams, total ~211m3/hr, will be treated by the waste water treatment
facilities:
Table 2.26 : Liquid Effluents
Source Item Composition Normal Rate(M3/hr)
Gasifier Sump Oily Water 5.7
Power Area Sump
Oily Water 5.7
Ammonia Area Sump Oily Water 5.7
Cooling Tower BD CW Blow down 157
Gasifier BD Oily Water 7.2
Selexol Sump Amine Sewer 5.7
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MDEA Sump Amine Sewer 5.7
Water Softeners Hard Water 7.5
Condensate Polishers Hard Water 8
Sanitary Waste Water Waste Water 3.2
Other Sources Waste Water 8.1
Oil collected from API separator
An API separator will skim oil from a variety of oily water sources. The oil is barreled and
shipped away by truck.
Solids Disposal
The Gasifier will produce 51,380 kg/hr of Bottom Ash. The material may be shipped to land
fill if no beneficial user is available.
Solid waste produced by the biological waste water treatment is sent by truck to landfill.
Spent catalyst frequently contains valuable metals, therefore, it is typically returned to
catalyst vendors for recovery. The following quantities and frequencies are anticipated.
Table 2.27 : Solid Disposal
Usage Type Volume, m3 Weight, kg Life, years
CO Shift R.1 Catalyst Katalco K8-11HA 85 55,845 3
CO Shift R.2 Catalyst Katalco K8-11HA 131 86,067 5-7
CO Shift R.3 Catalyst Katalco K8-11HA 114 74,989 8-10
HG Removal Adsorb. Activated carbon 21.7 12,152 -
Ammonia Synthesis Katalco 126 340,200 10
2.10.2.3 Urea plant:
Emission Details
The details of the emission sources and quantities are shown in following Figure 2.23.
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Figure 2.21 : Emission Details of Urea plant
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Emissions into air:
Continuous gaseous Emissions:
Sources of this emission are: The point of the plant from where inert, effluents are
continuously discharged is medium pressure inert washing tower. This vent is connected to
flare and burnt.
The process steps responsible for and approx. quantity of emissions into air are:-
NH3, N2, CO2, vented through continuous flare as scrubber vent-gas from MP
decomposition section. The approximate quantity of vent is1600NM3/Hr.
Ammonia in the vent is around 12ppm max.
Inert from urea hydrolyser stripper and vent from LP section containing inert
with ammonia content 10 ppm max.
Exhaust air from prilling tower around 1500000 Nm3/hr containing urea fine
dusts 40-50 ppm max.
Prilling Tower size: 30 mDia X 130 m height approx.
Discontinuous gaseous Emissions
The HP vent and the remaining process vents, normally closed, are collected to
discontinuous flare to be burnt in case of vents opening.
Effluents:
Continuous liquid effluent
No effluent is emitted to water source. Treated condensate is sent to battery limit at 50°C
and 5.0 Kg/Cm2 pressure. The quantity generated is process water 90MT/hr. and steam
condensate 50 MT/hr. approx. ammonia and Urea are 1 ppm Wt max.
Discontinuous liquid effluent
All the occasional drains containing carbamate or ammonia solutions from process are
collected in carbonate close drain tank to be recovered later.
Solid waste
No solid waste is produced in the urea production process.
Fugitive emissions
These are discontinuous releases of NH3, CO2, urea dust, oil and steam. Typical sources
include: storage tanks, valves including PRVs, flanges, pumps/compressor seals, sewer
system vents/drains, waste water treatment units, solid urea transfer points, screens, etc.
2.10.2.4 Nitric Acid Plant
Emissions
Continuous Gaseous Effluents: The residual nitric oxide is, in practice, re-oxidized to
nitrogen dioxide for further conversion to nitric acid. There is an economic limit to the size
of the absorption tower that is practical and the adsorption efficiency achieved is generally
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in the range 98.2 to 99.3%. It is the residual concentrations of nitrogen dioxide and nitric
oxide (commonly referred to as NOx) that give rise to the pollution problem in the vent
stack.
Tail Gas
Sources of this emission are the point of the plant from where inert, effluents are
continuously discharged is NOx abatement section vent. This is discharged to atmosphere
through vent.
The following TG quality will be discharged to atmospheric under design operation
conditions. A typical composition of the tail gas is as follows:
Table 2.28 : Typical composition (Volume/Volume)
Gas Percentage
composition
N2 95.62%
H2O 0.68%
O2 2.2 %
NOx <50 ppm
N2O Approx500 ppm
NH3 <15 ppm
Discontinuous Emissions
Gaseous effluents from safety devices i.e. from Ammonia line, Compressor air, steam and
feed water and Gaseous effluents from acid containing equipment like sample collection
box and drip acid tanks are categorized in this type of effluent.
Quality of Gaseous Effluent
Gas composition at absorption tower outlet exit to stack is described below:
NOx : 100-3500 ppmv
N2O : 300-3500 ppmv
O2 : 1-4%
H2O : 0.3-2%
N2 : balance
NOx at scrubber outlet : 100 ppmv max
Quantity of StackGas : 130,000-142,000 NM3/hr
Stack Size : 1.25 m Dia X50 m height approx
Effluents
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Continuous Liquid Effluent
Mainly Blow Down from Steam Generation (2% approximately) is continuous effluent
generated from the unit. No Continuous liquid effluent is emitted to water source.
Discontinuous Liquid Effluent
Ammonical water from NH3 Stripper is the major discontinuous liquid effluent. The stripping
of Ammonical water outlet from ammonia evaporator will be done batch wise and the
drained liquid is collected for disposal. Liquid effluent is mainly from waste heat boiler blow
down.
Quantity : 1.20 MT/hr
Composition: Residual Phosphate-20-40ppm,TDS–300ppm,
Silica –15 ppm.
Due to use of relatively high steam pressure of 15 bar abs. in stripping, a stripping
temperature of approximately 160ºC can be reached at the end. Therefore the liquid drain
can be kept to a minimum and will mainly contain oil. This liquid drain will be collected in
barrels for disposal. The stripping period per day depend on the purity of ammonia liq.
entering B.L.
Solid Waste
No solid waste production is envisaged in the Nitric Acid production process.
Fugitive Emissions
All the discontinuous and contaminated water e.g. wash water containing lube oil etc and
occasional drains shall be treated for oil recovery and send to neutralization pond in
ETP before using it in non-process non drinking purposes.
Typical sources include flanges, pumps/compressor seals, sewer system vents/drains,
waste water treatment units, etc
2.10.2.5 Ammonium Nitrate Plant
The details of the emission sources and tentative quantities are discussed in following
paragraphs:
Emissions into Air
Continuous gaseous effluents
Atmospheric effluents result from the loss of ammonia and ammonium nitrate. Small
particles of ammonium nitrate (mini prills) are carried out with the air. Ammonium nitrate
fume is also lost from the surface of the prills and this is sub- micron in size
Source of these are neutralisers, evaporators and prilling towers. These give rise to the
pollution problem in the vent stack and prilling tower top.
Stack Exit Gas (temperature of gases entering stack: 40-45◦C)
Composition:
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Ammonia : 50 mg/NM3 max
Particulate Matter : 100mg/NM3 max
Quantity : 135,000 m3/hr approx.
Stack Size : 1.8 m Dia X40 m Height approx.
Discontinuous Emission
Gaseous effluents from safety devices i.e. from Ammonia line, Compressor air, steam and
feed water and Gaseous effluents from acid containing equipment like sample collection
box and drip acid tanks are categorized in this type of effluent.
Effluent
Continuous Effluents
No liquid effluent is generated in Ammonium nitrate plant. Around 15 MT/hr of process
condensate produced is treated and reused.
Discontinuous liquid effluent
Ammonium nitrate, ammonia or nitric acid (which are normally neutralised) can arise from
equipment cleaning and a wide range of points specific to a given site.
Solid Waste
No solid waste production is envisaged in the Nitric Acid production process.
Fugitive Emissions
All the discontinuous and contaminated water e.g. wash water containing lube oil etc. and
occasional drains shall be treated for oil recovery and send to neutralization pond in
ETP before using it in non-process & non drinking purposes. Typical sources include:
flanges, pumps/, sewer system vents/drains, waste water treatment units, etc.
2.10.2.6 Di-ammonium Phosphates Plant
The possible pollutants from the complex and their sources will be similar for all the four
trains are explained below:
Gaseous Emissions
The emissions from this unit arise mainly from the reactor and granulator. These emissions
include gaseous NH3 and HF. It is caused by the volatilization due to incomplete chemical
reactions and excess free ammonia. Also, fluoride and V2O5 emissions due to the
dissociation of the fertilizer product, and particulate emissions due to the DAP dust
entrainment in the ventilation air streams; are expected. Added to that; SOx, NOx, CO, and
CO2 gases are expected due to heavy fuel oil combustion in the burner.
Quality of Gaseous Effluent
The quantity of gaseous effluent of the proposed DAP plant is described below:
Ammonia : 50 mg/Nm3max
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Particulate Matter : 50mg/Nm3max
Fluorine as„F‟ : 5 mg/Nm3max
Quantity of stack exit gas : 3, 57,400m3/hr approx.
Stack Size : 2.8 m Dia X50* m height approx.
Liquid Effluents
The only source is the washing water from the scrubbers installed at the stack. It is usually
mixed with diluted phosphoric acid and make-up water and recycled to the scrubbers.
Solid Wastes
No solid waste has been envisaged for the proposed fertilizer complex.
2.10.2.7 Granular Single Super Phosphate Plant
The acidulation of rock phosphate with sulphuric acid shall lead to emission of HF, SiF4,
acid mist etc
Gaseous Effluent
Ball Mill Exit Air (Exit velocity: 20m/s, Exit temperature: 400C)
Particulate Matter : 100mg/Nm3max
Stack Size : 0.8 m Dia X 40 m height approx.
Scrubber Outlet Gas (Exit velocity: 20m/s, Exit temperature: 400C)
Quantity : 120,000 m3/ hrapprox
Composition
Flourine as‖F‟ : 20 mg/Nm³max
Particulate Matter : 100mg/Nm³max
Stack Size : 1.0 m Dia X 40 m height approx.
Hot Air Generator
Particulate Matter : 100mg/Nm³max
SO2 : 100 ppm max
NOx : 100 ppmmax
Stack Size : 0.6 m DiaX 30 m height approx.
The emission control of these fumes and gases shall be achieved by venturi scrubbing
followed by efficient wet scrubbing to limit total fluoride emission well below statutory
requirement of 25 mg/Nm3.
Effluents
There shall be no wastewater effluent discharge to outside of plant B/L. The acidic effluent
generated in the gas scrubbing section shall be recycled in the acidulation process. The
plant is being operated as Zero discharge system.
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Solid Wastes
No solid waste has been envisaged for the proposed fertilizer complex.
2.10.2.8 Aluminum Fluoride Plant
The details of the emission sources and tentative quantities are discussed in following
paragraphs:
Gaseous Emissions:
Table 2.29 : Off-gas
Quantity per hour (approx.) 4‘000 m3/h
F ppm Max.
Table 2.30 : Effluent - Wastewater
With reduced and optimized utilization of sulphuric acid
Table 2.31 : Diluted Sulphuric Acid
With reduced and optimized utilization of sulphuric acid
Table 2.32 : Silica
Quantity per ton AlF3 (expected) 4 m3
F 1 % wt
Quantity per ton AlF3 (expected) 9 m3
F 1 % wt
Quantity per ton AlF3 (expected) 28 T
H2SO4 70 - 75 % wt.
HF 0.2 % wt. max
Quantity per ton AlF3 (expected) 22 T
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Solid Waste:
Table 2.33 : Wastewater sludge (synthetic fluorspar)
Quantity per ton AlF3 (expected) 0.15 - 0.40 m3
CaF2 40 - 45 % wt
H2O 30 Max. % wt
Proposed Plant Stacks
Table 2.34 : Proposed Plant Stacks
Plant Stack Stack Spec. Emission Load (kg/hr)
Stack
Height
(m)
Stack Diameter
(m)
Exit
Temp.
(K)
Exit
Velocity
(m/s)
SPM SOx NOX F NH3
WHRU /
Auxiliary
Boiler
30 5.5 573.15 16.25 99.3 9 64.7 NA NA
Sulphur
Recovery
Unit
20 0.6 573.15 20.20 NA 0.8 NA NA NA
Urea PT 130 30 351.15 0.76 75 NA NA NA NA
Nitric Acid 50 1.25 380.15 44.76 NA NA 100 NA NA
Ammonium
Nitrate
40 1.8 318.15 17.17 20.25 NA NA NA 6.75
DAP-A 50 2.8 337 16.13 50 NA NA 5 50
DAP-B 50 2.8 337 16.13 50 NA NA 5 50
DAP-C 50 2.8 337 16.13 50 NA NA 5 50
Quantity per ton AlF3 (expected) 0.9 T
SiO2 40 (approx.) % wt.
H2SiF6 2 - 5 % wt.
H2O balance
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DAP-D 50 2.8 337 16.13 50 NA NA 5 50
GSSP Ball
Mill
40 0.8 313.15 15.21 3.6 1.8 NA NA NA
GSSP
Scrubber
Outlet
40 1.0 313.15 12.74 4.7 NA NA 0.68 NA
GSSP—Hot
Air Generator
30 0.6 473.15 21.28 1.87 2.06 NA NA NA
Aluminium Flouride
2.8 0.25 327.15 22.65 NA NA NA 0.0136
NA
2.11. Total Cost
Total project cost for the proposed project is Rs 9459 Crores. The estimated cost (in
Rupees/ US Dollar) of the proposed project (plant-wise) and the estimated expenditure on
pollution control measures are as given below:
Table 2.35 : Project Cost
S.N. Plant Cost in Rupees
1 CHP 2750 Million
2 Ammonia 54489 Million
3 Urea 17605.6 Million
4 Nitric Acid 7907.7 Million
5 Ammonia Nitrate 5839.5 Million
6 Di-Ammonium Phosphate 4417.4 Million
7 Granulated Single Super
Phosphate
1484 Million
8 Aluminium Fluoride 1860000 USD (98.5 Million INR)
Environmental measure expenditure by PPL
Table 2.36 : Expenditure of Environmental Safeguards
Year wise expenditure for implementation of environmental
safeguards
Items Details 2014-15 2015-16 2016-17
Expenditure for
implementation of
environmental
safeguards
269.59 Lakhs 2089.92 Lakhs 10010.2 Lakhs
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The expenditure made for the purpose of environmental management in the plant premises
for the period 2016-17 is as follows: (Environmental Laboratory/ APCE installation cost
included)
Capital Recurring
Rs (Lakhs) Rs (Lakhs)
Environmental equipment : 753.2 28
Maintenance of ETP/ Pollution Control : 532.0 54
Equipment/ Manpower cost/ Greenbelt
Development
GP-II : 8725.0
Total cost in lakh : 10010.2 82
For the proposed project fund allocated towards environment management is Rs 479 crore
(capital cost) and recurring cost for environment management is Rs 100 crore.
2.12. Project Implementation schedule:
The proposed project shall be implemented based on either LSTK (Lump Sum Turnkey)
mode or EPCM mode. In LSTK mode, the owner can engage LSTK engineering contractor
for B/L proposed plant, or, if found more economical or more convenient, PPL may adopt
EPCM mode (cost plus fee mode). In either mode of implementation the overall project
monitoring, progress review, reporting and coordination between the different agencies
could be entrusted to an independent Project Management consultant. Alternatively, these
functions could be performed by experienced project group, specially set up by the owners
for thispurpose.
2.13. Pre-ProjectActivities
The pre-project activities to be completed before the physical execution of the project are
briefly enumerated below:
a) Preparation of feasibility report and submission of same to DoF for gettingclearance
b) Clearance and approval of the project, by the board of thecompany.
c) Firming up of arrangement for supply of power & water, ifrequired, from
concernedagency.
d) Preparation of ITB for selection of LSTK/EPCM Contractor for B/L Plants by appointing
an experienced engineeringconsultant.
e) Selection of Prime Engineering Consultant (PEC). PEC will mainly prepare engineering
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packages for all off site and utility units and assist the Owner in procurement,
construction and commissioning supervision.
f) Soil investigation work for ascertaining soil characteristics of the area identified for
location of the newfacilities.
g) Preparation of Environment Impact Assessment (EIA) study and clearance by State and
Central Pollution ControlBoards.
h) Preparation of PDFR/DPR based on selected LSTK Contractor for B/L Plants.
i) Preparation of Risk AnalysisStudy.
j) Final approval of the project byGovernment.
k) Obtaining financial clearance and commitment from financial
institutions and creditors for financial closure of theproject.
All the project execution related activities, as mentioned earlier, are interlinked and have
impact on the final outcome. The execution of the relevant project activities has to be
planned and controlled in such a way that the goals of the project are achieved in the set
time frame. During the execution, the main time consuming activity is delivery of critical
equipment and machineries. The implementation time is for mechanical completion
&commissioning.
Table 2.37 : Project Implementation Period
Sl. No. Projects Project Implementation Period
1. CoalHandling Plant 30 Months
2. Gasification based Ammonia Plant 36 Months
3. Urea Plant 36 Months
4. Nitric Acid Plant 24 Months
5. Ammonium Nitrate Plant 24 Months
6. Di-ammonium Phosphate Plant capacity expansion
48Months
7. Single Super Phosphate Plant 18 Months
8. Aluminium Fluoride Plant 24 Months
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CHAPTER 3. : DESCRIPTION OF THE ENVIRONMENT
3.1. Background
Generation of environmental baseline of a project area is an important phase of any
Environmental Assessment process. Baseline data provide vital information on the existing
environmental quality in which a development is planned In this study, the environmental
characteristics of the project area (10 km study area) were established and grouped into
physical, biological, social and economic environment. Physical environment includes air,
meteorology, noise, water, soil, land, biological environment includes aquatic and terrestrial
flora & fauna while social environment includes demographic details, civic infrastructure,
public services, surrounding monuments, commercial facilities, employment levels, sources
and levels of income, economic base of the area, land values, land ownership, etc.
Baseline conditions at and around the project are described in following sections:
3.2. Study Area and Period
The M/s Paradeep Phosphates Ltd. has proposed expansion of DAP and proposal of Coal
Handling plant, Ammonia, Ammonium nitrate, urea, GSSP, Aluminium fluoride, Nitric acid
at at Paradeep in Jagatsinghpur District, Orissa. It is 90-kms from Cuttack. The location
map and the geographical coordinates of the corner of project site is given in Figure 3.2
and 3.3 respectively.The total land area is 924.05 Ha. The proposed expansion shall be
done within the existing premises.
The baseline environmental data generation has been done for the period of December,
2013- March, 2014. Based on above baseline data the draft report has been prepared for
the Public hearing. Public hearing for the above project was conducted on 19thMay 2017.
The TOR for the proposed project as per old ToR letter issued was expired on 6th Dec,
2015, hence the baseline data was again repeated for the period of 1st March 2018 to
30thMay 2018. The final report has been updated on the basis of latest baseline data. The
study area within a 10 km radius around the proposed plant site has been considered as
impact zone for EIA study. Primary and secondary data has been collected for 10 Km
radius of the project site. Secondary data from literature search were also obtained from
the Govt. sources i.e. Meteorological Department, CPCB Publications, Forest Department
and other Govt. Sources. Following section describes the nature, type and characteristics
of the following heads:
• Natural & Physical Environment
• Land Environment
• Water Environment
This Chapter describes the baseline environmental conditions around the M/s Paradeep
Phosphates Limited’ (PPL)project site for various environmental attributes, i.e. physical,
biological and socio-economic conditions, within the 10-kms radial zone of the proposed
project site, which is termed as the study area. Topography, drainage, meteorology, air,
noise, water, soil and land constitute the physical environment, whereas flora and fauna
constitute the biological environment. Demographic details and occupationalpattern in the
study area constitute Socio-economic environment.
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• Air Environment
• Noise Environment
• Biological Environment
• Socio-Economic Environment
3.2.1. Connectivity:
NH-5A is located about 1.26 km from plant site in east. Nearest railway station is Paradeep
Railway Station, 3.6 km west from the project site. Road and rail connectivity map of the
site is provided in Figure 3.1.
Mahanadi River is 5.0 km away from the plant site in north direction and meets Bay of
Bengal, which is also 5.3 km away from the plant site. Nearest settlement to the site is PPL
Township located about 340 m southwest of the site. The other nearest villages are
Chauliaplanda, Udayabhata and Abbhayachandpur. Paradeep town is located about 5 km
north of the site. Paradeep port is located about ~1.75 km east of the site.
Figure 3.1 : Road Connectivity Map
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Figure 3.2 : Location Map of Study area
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Figure 3.3 : Geographical Cordinates of Existing and Expansion Project Site
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Figure 3.4 : Toposheet Map of the 10 km Study area
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3.3. Environment & Social Settings of the Study Area
Mahanadi river, Santra nala, Musadia pond and Paradeep sea (Bay of Bengal) are the
main surface water bodies located within the study area.Mahanadi River is located about 5
km northeast of the project site. Santra nala is located about 3.9 km southwest of the
project site. Musadia pond is located about 4.7 km northeast of the site. Paradeep sea
beach is about 5.34 km in east of the project site. Atharbanki creek is flowing along the
boundary wall of the site and lying between Paradeep Port and PPL plant site.
There are no environmentally sensitive components such as National Park, Wildlife
Sanctuary, Elephant / Tiger Reserve, migratory routes of fauna and wet land present within
10 Km radius of plant site. Google map showing environment features within 10 km radius
is provided in Figure 3.5. The Salient Environmental Features of plant site within 500m, 2
Km and 10 Km radius is summarised at Table 3.2.
Table 3.1 : Salient Environmental Features of Proposed Site
S. No.
Environmental Features
Within 500 m area around Project Site
Within 2-km area around Project Site
Within 10 km area around Project Site
1 Ecological Environment
A Presence of Wildlife Sanctuary/ National Park/Biosphere Reserves
None None None
B Reserved /Protected Forests
None None None
C Wetland of state and national interest
None None None
D Migratory route for wild animals
None None None
E Presence of schedule-I Fauna
None None None
2. Physical Environment
F Road connectivity None Yes, NH-5A about 0.42 km NW
G Rail connectivity None None Paradeep Railway Station (3.6 km, west)
H Defence Installation None None None
I Densely Populated Area
None None Paradeep Town 5 km N
J Other settlement close to plant site
PPL township 0.34 km, SW, Chaulipalanda: 1.40 km, W Other nearest villages:Udayabata, Musadia, Abbhayachandpur
K Topography Plain, elevation of site ranges between 2-7m amsl.
The study area elevation ranges between 0 to 12 m amsl
L Seismicity Seismic zone-III ( Low damage Risk Zone)
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M Surface Water Resources (Rivers)
None Atharbanki creek is flowing along the boundary wall of the site Taldanda canal: 1.98 km NE
Mahanadi River: 5 km NE, Santra nala: 3.9 km SW Musadia pond: 4.7 km NE of the site. Gopin river: 6.87 km N Nuna River: 7.39 km NW Mahanga Nala: 8.70 km W Jatadhar Mohan Creek: 5.91 km SW Bay of Bengal: 5.34 km E
N Groundwater Safe category
O Soil and Land-use Sandy clay, landuse of site is barren land
Sandy loam & sandy clay. landuse agriculture, water body and settlement
Sandy loam & sandy clay loam landuse agriculture, waterbody and settlement
3. Social Environment
P Physical Setting Induatrial land Urban, rural and Rural
Uraban, rural and agricultural
Q Physical Sensitive Receptors
None School, Hospitals, Temple etc.
School, Hospitals, Temple etc.
R Archaeological Monuments
None None None
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Figure 3.5 : Google Map showing environment sensitive features of 10 km Study area
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3.4. Primary Data Collection: Monitoring Plan and Quality Assurance
Procedures
The baseline environmental data generation has been done for the period of December,
2013- March, 2014. Based on above baseline data the draft report has been prepared for
the Public hearing. Public hearing for the above project was conducted on 19th May 2017.
The TOR for the proposed project as per old ToR letter issued was expired on 6th Dec,
2015, hence the baseline data was again repeated for the period of 1st March 2018 to 30th
May 2018. The final report has been updated on the basis of latest baseline data. The
study period and methodology for primary data collection is summarised in Table 3.3.
Table 3.2 : Summary of Methodology for Primary/Secondary Baseline Data Collection
Parameters No. of Sampling
Locations Frequency/ Season
Remark
Ambient Air Quality
PM10, PM2.5, SO2 NOx, NH3, CO, HC and HF
Eight (08) locations (Refer Fig. No.3.6 )
Twice a Week For winter season
AAQ monitoring was carried out at eight (08) locations (representing upwind, downwind and sensitive locations). 24 hourly sampling at each location was carried out as per CPCB guide lines (CPCB Gazette notification dated 18.11.2009 on AAQ).
Meteorology
Temperature, Humidity, Wind speed, Direction, Rainfall etc.
One location
Hourly for winter season
Met station was established close to the site to record the site specific hourly met data.
Ground Water Quality
Physical, chemical and biological parameters as per IS: 10,500
Eight (08) locations in study area (Fig 3.6)
Once in a season
Ground water: Sampling was conducted at eight (08) locations. Samples were preserved, transported and analysed for different parameters based on APHA methods. Temp, conductivity and pH which were measured instantly at site itself.
Surface Water Quality
Physical, chemical and biological parameters as per IS: 10,500
Five (08) locations in study area (Fig 3.6)
Once in a season
Surface Water: Sampling was conducted at five (05) locations. Samples were preserved and transported for analysis for different parameters based on APHA methods. Temp, conductivity, DO and pH which were measured instantly at site itself.
Soil Quality Environment
Texture, bulk density, pH, conductivity, cation exchange capacity, organic matter, Total N,P & K
Six (08) locations in study area (Fig 3.6)
Once in a season
Soil samples were collected at six (06) locations within the study area and analysed as per IARI methods.
Noise Environment
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Parameters No. of Sampling
Locations Frequency/ Season
Remark
Noise profiling for 24 hrs
Eight (08) locations in study area (Fig 3.6)
Once in a season
Noise measurement survey was conducted at different location within the 10-km area of project site for noise profiling for 24 hrs using integrated sound level meter, as per CPCB guidelines.
Ecology (Flora & Fauna)
Flora & Fauna - Once in a season
Primary survey and Secondary sources
Demography & Socio-economics
Demography & Socioeconomic
- Once in a season
Primary survey / Secondary sources
Standard methods and procedures have been strictly adhered to in the course of this study.
QA/QC procedures were strictly followed which covers all aspects of the study, and
includes sample collection, handling, laboratory analyses, data coding, statistical analyses,
presentation and communication of results. All analysis was carried out in NABL/MoEF
accredited/recognized laboratory. Environment sampling location map is shown below as
Figure 3.5.
Figure 3.6 : Environment Sampling Location Map
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3.5. Physical Environment
3.5.1. Topography and Physiography
The study area falls in Jagatsinghpur district. The study area is spread over alluvial plains
of the river Mahanadi. The deposit of silt of rivers has built up the present alluvium tracts at
their meeting places with the sea. Due to creation of swamp at the meeting places with the
sea, dense jungles have grown up. The study area is situated in coastal plain zone as per
agro- climatic classification and in deltaic alluvial plains of the Mahanadi river system.
The study area being a part of Mahanadi delta is a flat land with hardly a relief. The
topography of proposed site is almost plain. The site elevation ranges between 2 to 7 m
amsl. The site is sloping towards south side. The study area elevation ranges between 0 to
12 m amsl. The site is sloping towards south side. The contour map of the 10 km study
area is shown in the Figure 3.7.
Figure 3.7 : Contour Map of the Study Area
3.5.2. Drainage
The study area is drained by Mahanadi River and other seasonal streams which ultimately
meets the Bay of Bengal. The north eastern part of the study area is drained by the
Mahanadi, Taladanda Canal, Atharbanki Creek and Bay of Bengal, and other perennial
water bodies and streams in the study area. All drainage of the northern and western part
of the study area flows into south towards Bay of Bengal. The Bay of Bengal in the eastern
part of the study area confluence point of river Mahanadi river. The western and southern
part of the study area is drained by Santra nala, Mahanga Nala and Jatadhar Mohan
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Creek. All the drainage of the study area is towards sea cost/Bay of Bengal in southern
direction. Drainage map of the study area is shown as Figure 3.8.
Figure 3.8 : Drainage Map of the Study Area
3.5.3. Geology
The study area forms a part of the Mahandi valley overlain by the Quaternary formation.
The study area is floored by thick Quaternary sediment that is underlain in the sub-surface
successively by rocks from early Cretaceous resting on metamorphic basement. The
thickness of the Quaternary deposit is in excess of 500-m. It is built up by stacking of
repeated sequences of sand, silt and clay beds. On the surface the delta plain could be
divided into two broad areas. The upper delta plain (UDP) lying beyond the tidal influence
has been shaped by the fluvial action of the distributaries of the Mahanadi
River system providing the landscape of point and channel bars, levee, back swamp,
abandoned meander loops and undifferentiated flood plains. On the seaward side of the
UDP, the lower delta plain (LDP) represents a zone shaped by fluvial action, tides and the
marine processes. Therefore the geomorphology is variable with low levee on banks of the
distributaries, inter-distributary marshes in between the distributaries, stranded beach
ridges amidst flood plains, wide mud flats, lagoons, creeks, sand bars, barrier beach/sand
spit and active dune -berm-beach face complex facing the open sea. Geological
succession of the area is presented in Table 3.4.
Table 3.3 : Sub-surface Stratigraphy in the Paradeep Depression of Mahanadi onshore areas
Sl. No. Age Lithology
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1 Pleistocene to Recent Unconsolidated sand and clay 2 Pliocene Sandstone and claystone/clay 3 Middle Miocene Sandstone and claystone 4 Early Miocene Sandstone and claystone with occasional coal streaks 5 Precambrian Unconformity Precambrian Metamorphics
3.5.4. Ground water Resources
As per CGWB classification the 10-km study area falls in Kujang block of Jagatsinghpur
District. The annual replenishable ground water resources in the district are computed as
45029 Ham. The ground water draft for irrigation is through dug wells and shallow tube
wells. So far ground water development in the district has been meager and all the blocks
fall under the safe category. The stage of ground water development varies from 31.53 %
to 67.26 in different blocks.
The study area falls in Kujang block of the district. The Net annual Ground Water
Availability in the Kujang block is computed as 6440 Ham. The Existing Gross Ground
Water Draft for all uses in the Kujang block is 3998 ham. Stage of Ground water
development in the Kajung block is 62.38%. Overall the study area including Kajungar
block fall under the safe category. The overall stage of ground water development of the
district is 47.37%. The block wise computation of ground water resources in the district has
been presented in the Table 3.5 and Figure 3.9.
Table 3.4 : Stage of Block wise Ground water Development of Jagatsinghpur District (As on 31st March 2009)
Sl. No
Assessment Unit/Block
Net annual Ground Water
Availability
Existing Gross
Ground WaterDraft for
irrigation
Existing Gross
Ground Water
Draft for domestic
and industrial
water supply
Existing Gross
Ground Water Draft for all uses
Allocation for
domestic and
industrial requirem
ent supply
upto next 25 years
Net Ground Water
availability for future
irrigation develop
ment
Stage of
Ground
Water Developme
nt (%)
1 Balikuda 5052 1890 281.90 2172 360 2802 42.99
2 Biridi 6814 2813 190.28 3004 233 3767 44.09
3 Erasama* 0 0 0.00 0 0 0 0.00
4 Jagatsinghpur 8222 3167 376.97 3545 479 4575 43.12
5 Kujang 6409 3583 415.16 3998 554 2272 62.38
6 Naugaon 2786 1752 122.27 1874 162 872 67.26
7 Raghunathpur 7340 2106 208.31 2314 239 4995 31.53
8 Tirtol 8406 4086 339.57 4425 436 3884 52.64
Total 45029 19397 1935 21332 2463 23167 47.37
Source-http://www.cgwb.gov.in/District_Profile/Orissa/jagasingpur.pdf
*-Fresh water unconfined aquifers either absent or available in pockets
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Figure 3.9 : Ground Water Resources of Jagatsinghpur District
3.5.5. Depth to Ground Water Table
The 10 km study area falls in Kujang block of Jagatsinghpur District. The depth to water
level in the study area during pre monsoon season varies from 2 m bgl to 5 m bgl and in
post monsoon season depth to water table ranges 2 m to 4 m.
Project Site
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Figure 3.10 : Depth to Water Level (Pre-Monsoon Season)
Figure 3.11 : Depth to Water Level (Post-Monsoon Season) (Source-http://www.cgwb.gov.in/District_Profile/Orissa/jagasingpur.pdf)
3.5.6. Seismicity of the Study Area
Orissa is vulnerable to multiple disasters. Due to its sub-tropical littoral location, the state is
prone to tropical cyclones, storm surges and tsunamis. Though a large part of the state
Project Site
Project Site
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comes under Earthquake Risk Zone-II (Low Damage Risk Zone), the Brahmani Mahanadi
graben and their deltaic areas come under Earthquake Risk Zone-III (Moderate Damage
Risk Zone).
Based on tectonic features and records of past earthquakes, a seismic zoning map of
Odisha State has been prepared by a committee of experts under the auspices of Bureau
of Indian Standard (BIS Code: IS: 1893: Part-I, 2002). According to the seismic-zoning map
of Orissa, the proposed PPL project area falls in Zone-III (Moderate Damage Risk Zone) of
seismicity. The seismicity map of study area is shown in Figure 3.12.
(Source-http://www.ndma.gov.in/en/odisha-sdma-office)
Figure 3.12 : Seismic Zones Map of Odisha
3.6. Land Environment
3.6.1. Land-use
Land use analysis was carried out using remote Sensing Data. Interpretation approach
based on systematic digital imaging was used for delineating the land use classes. The
Project Site
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demarcation of boundaries falling under different land use/land cover units is done using
different colours assigned to different land use/land cover units of satellite imagery1.
Most of the land within the 10 km area of the project site is under agricultural land. As per
the land use based on satellite image, about 31.31% of the land is Agricultural land, about
41.80% land is under water body, 10.78% land is open shrub & grass land and about
3.34% land is under settlement, 6.15% land is under vegetation and rest is other uses.
(Refer Figure: 3.13 and Table 3.6). Land use map of the 10 km study area is shown in
Figure 3.14.
Table 3.5 : Land use of the Study Area
Sl.No. Class Area(Sq km) Percentage
1 Agricultural land 148.05 31.31
2 Settlement 15.79 3.34
3 Vegetation 29.07 6.15
4 Open shrub and grass land 50.98 10.78
5 Water body 197.63 41.80
6 Barren land 20.31 4.30
7 Marshy land 10.95 2.32
Total 472.78 100
Figure 3.13 : Graphical representation of Landuse of 10 km study area
1The satellite Imagery of Indian Remote Sensing Satellite (IRS- ID, sensor P6, LISS III) of 24 m
resolution was used. The Swath of the imagery is 141 Km x 141 Km. Band used are 4, 3, 2 and 5. LANDSAT imagery of 30 meter resolution and 185 x 185 km swath is also used for the comparative and overall analysis of the area. LISS III imagery and LANDSAT 8 TM imagery were used for the complete coverage of the study area
Agricultural land31%
Settlement4%Vegetation
6%
Open shrub and grass land
11%
Water body42%
Barren land4%
Marshy land2%
Landuse Pattern of the Study Area
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Figure 3.14 : Land Use Map of the Study Area (10 km Radial Zone)
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3.6.2. Soil Quality
Soils may be defined as a thin layer of earth's crust that serves as a natural medium for the
growth of plants. It is the unconsolidated mineral matter that has been subjected to and
influenced by genetic and environmental factors. Soils serve as a reservoir of nutrients for
plants and crops and also provide mechanical anchorage and favorable tilts.Soil is our most
important natural resource and a natural resource is anything that comes from the earth and
is used by us. We depend on the soil for food, clothing, shelter, minerals, clay & water. Soil
is the seat of many macro and micro flora like algae, fungi, earthworms, bacteria etc. These
are very beneficial in promoting soil reactions and decomposing the organic matter by which
essential nutrients for plants are liberated. Most of the soils are made-up of two main parts:
Tiny bits of mineral particles which come from larger rocks, and humus, which is dark
brown in color and consists of decaying remains of plants and animals.
Soil also contains water, air and living organisms, such as fungi, bacteria, earthworms,
roundworms, insects, etc. Actually more living organisms live in the soil than above it.
For general characterization of soil a few random samples from the study area to the depth
of about 15-cm may sufficient. Deeper soil samples may be needed only for the study of soil
Profile.
3.6.3. General Characteristics of the Soil in the District
Different types of soils are encountered in different topographical, biological, hydrological
and geological conditions within the district. Coastal Saline and Alluvial Soil are also
observed in the district. Alluvial soils of clayey texture crack upon drying and become sticky
when wet. Water holding capacity (WHC) of this type of soil is high. Once water-logged, the
clay soil takes more time to become ready to plough. Drainage is also difficult due to slow
permeability. The coarse textured soil (sands) are deficient with N, P, K and S. Texturally
the soils of the district are sandy, sandy loam, silty loam & clay loam. Salinity is the
important factor effecting soil characteristics, texture and mineral content of soil, which has
adverse effect on plant growth2. Soil map of the district is presented by Figure 3.25.
2Source:http://www.orissa.gov.in/eagazine/Orissareview/nov2005/engpdf/Soil_of_Orissa_and_Its_Management.pdf)
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Figure 3.15 : Soil Map of Jagatsinghpur District3
3.6.4. Methodology
The soil samples were collected from Six (08) selected locations during the post-monsoon
season (Dec, 2013 to Feb 2014) and pre monsoon season (March-May, 2018). The
samples collected from all the locations were homogeneous representative of each location.
At random eigh sub-locations were identified at each location and soil samples were
collected from 5 to15-cm below the surface. It was uniformly mixed before homogenizing the
soil samples. The samples about 500-gms were packed in polythene bags labeled in the
3Source-ttp://agricoop.nic.in/Agriculture%20Contingency%20Plan/Orissa/Orissa%2018%20Jagatsinghpur%2031.05.2011.pdf)
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field with location & number and sent to the laboratory for the analysis of physicochemical
parameters.
3.6.5. Soil Sampling Locations
Soil sampling was conducted once during the study period of pre-monsoon season. Six (08)
soil samples were collected from selected locations in the vicinity of the proposed project.
For studying soil quality in the study area, sampling locations were selected to assess the
existing soil conditions in and around the existing plant area representing various land use
conditions. The homogenized samples were analyzed for physicochemical characteristics.
Soil sampling locations with their distance & directions with respect to the proposed project
site are presented in Table 3.6.
Table 3.6 : Soil Sampling Locations
Soil (March, 2018-April, 2018)
S01 Project Site 00 20°16'45.75"N 86°38'10.68"E
S02 Udayabhata 2.7km,N 20°18'31.16"N 86°37'24.01"E
S03 Denkia 2.5, SW 20°14'39.21"N 86°35'16.68"E
S04 Abbhayachandpur 1 km,S 20°14'15.96"N 86°36'15.85"E
S05 Pitambarpur 5.75km,NW 20°18'26.93"N 86°35'5.58"E
S06 Nuagarh 4.7, N 20°20'31.47"N 86°37'13.97"E
S07 Bagdia 2.0, W 20°16'50.61"N 86°34'53.43"E
S08 Musadiha 3.84,NE 20°19'0.59"N 86°39'57.77"E
3.6.6. Analysis of Soil Samples
The soil samples were examined for various physicochemical parameters, to determine the
existing soil characteristics of the study area. Soil samples were collected from the vicinity of
proposed project site. Physicochemical characteristics of soil for pre monsoon season
monitoring are presented in Table 3.7 and sampling of season (Dec,2013-March, 2014) is
attached as Annexure 17.
Table 3.7 : Physicochemical Characteristics of Soil (Pre-monsoon Season, 2018)
S. No.
Parameters
Unit S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8
Physical Characteristics 1. Colour - Light
Grey Grey Grey Light
Grey Grey Grey Grey Grey
2. Texture USDA Sandy Clay
Clay Loam
Clay Loam
Clay Loam
Clay Loam
Sandy Clay
Sandy Clay
Sandy Clay
3. Porosity % 46.4 52.5 52.1 53.2 52.1 44.9 47.9 45.3
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4. Bulk Density
gm/cc 1.42 1.26 1.27 1.24 1.27 1.46 1.38 1.45
5. Water Holding Capacity
% 30.5 29.2 31.5 30.8 31.2 28.9 30.1 29.8
6. Particle Size Distribution i). Sand % 66 23 30 25 22 58 62 46 ii). Silt % 18 35 22 23 26 23 15 18 iii). Clay % 16 42 48 52 52 19 23 36
Chemical Characteristics 7. pH 20%
Slurry 7.46 7.55 7.18 7.82 7.45 7.37 7.88 7.66
8. Conductivity (EC)
µmhos/cm
395 358 396 388 485 385 376 415
9. CEC meq/100gm
18 24 21 18 20 25 28 22
10. Organic Carbon
% 0.65 0.72 0.76 0.86 0.74 0.65 0.54 0.56
11. Organic Matter
% 1.12 1.24 1.31 1.48 1.28 1.12 0.93 0.96
12. Calcium as Ca
meq/100gm
2.12 2.45 0.74 0.92 2.12 2.52 2.64 3.22
13. Magnesium as Mg
meq/100gm
0.24 0.48 0.59 0.49 0.38 0.48 0.82 0.64
14. Sodium as Na
meq/100gm
0.45 0.26 0.19 0.66 0.26 0.55 0.36 0.24
15. Manganese as Mn
mg/kg 1.25 1.05 1.26 1.44 1.14 1.35 1.28 1.24
16. Zinc as Zn mg/kg <0.60 <0.60 <0.60 <0.60 <0.60 <0.60 <0.60 <0.60 17. Boron as B mg/kg 0.52 0.62 0.65 0.74 0.69 0.59 0.57 0.70 18. Iron as Fe mg/kg 3.84 4.15 5.26 4.55 4.86 5.06 4.95 4.77 19. Copper as
Cu mg/kg 0.44 0.56 0.48 0.52 0.49 0.53 0.42 0.46
20. Fluoride mg/kg <1.5 <1.5 <1.5 <1.5 <1.5 <1.5 <1.5 <1.5 21. Available Nutrients i). Nitrogen
as N kg/ha
284.5 275.6 376.5 296.5 345.5 289.5 355.8 336.5
ii). Phosphorus as P
kg/ha 21.6 20.5 18.4 16.2 24.5 20.6 18.9 17.4
iii). Potassium as K
kg/ha 87.6 175.4 96.5 126.4 174.2 116.2 144.5 152.2
22. SAR - 0.35 0.51 0.61 0.45 0.38 0.45 0.44 0.53
3.6.7. Observation on Soil Quality
On the basis of above Soil Testing results in the study area the conclusion may be revealed
as follows;
Physical characteristics of soil
Physical characteristics of soil greatly influence its use and behavior towards plant growth.
Physiochemical Characteristics of Soil
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• Physical Properties
Texturally the soils in the study area are observed as Sandy Clay and Clay Loam Soils. The
bulk density of the soils was found in the range of 1.24 to 1.46 gm/cm3. Porosity was
observed in the range of 44.9 to 53.2% in the soils of the study area. Water Holding
Capacity of study area soils was observed as 28.9 to 31.2%.
• Chemical Properties
Soil Reaction Classes and Critical Limits for Macro & Micro Nutrients in Soil
According to Soil Survey Manual (IARI, 1970), the soils are grouped under different soil
reaction classes viz; extremely acidic (pH<4.5), very strongly acidic (pH 4.5-5.0), strongly
acidic (pH 5.1-5.5), moderately acidic (pH 5.6-6.0), slightly acidic (pH 6.1-6.5), neutral (pH
6.6-7.3), slightly alkaline (pH 7.4-7.8), moderately alkaline (pH 7.9-8.4), strongly alkaline (pH
8.5-9.0).The soils are rated as low (<0.50%), medium (0.50-0.75%) and high (>0.75%) in
case of organic carbon, low (<280kg/ha), medium (280 to 560kg/ha) and high (>560kg/ha) in
case of available Nitrogen, low (<10kg/ha), medium (10 to 25kg/ha) and high (>25kg/ha) for
available Phosphorus, low (<108kg/ha), medium (108 to 280kg/ha) and high (>280kg/ha) for
available Potassium & low (<10mg/kg), medium (10-20mg/kg) and high (>20mg/kg) for
available Sulphur (Singh et. al. 2004, Mehta et. al.1988). Critical limits of Fe, Mn, Zn, Cu and
B, which separate deficient from non-deficient soils followed in India, are, 4.5, 2.0, 0.5, 0.2 &
0.5mg/kg respectively. (Follet & Lindsay 1970 and Berger & Truog 1940)
The soil pH ranges from 7.18 to 7.88, thereby indicating the soils are neutral to slightly
alkaline in nature. The organic carbon content of soil varied from 0.54 to 0.86% (0.93 to
1.48% as organic matter), thereby implying that soils are medium to high content. Available
nitrogen content in the surface soils ranges between 275.6 & 376.5 kg/ha thereby indicates
that soils are low in available nitrogen content. Available phosphorus content ranges
between 16.2 & 24.5 kg/ha thereby is indicating that soils are medium in available
phosphorus content. Available potassium content in these soils ranges between 87.6 &
175.4 kg/ha thereby is indicating that the soils are low to medium in potassium content.
The available manganese content in surface soils was recorded as 1.05 to 1.44 mg/kg as
the critical limit of available manganese is 2.0 mg/kg. The available Zinc in surface soils of
the study area observed <0.6mg/kg of soil. As per the critical limit of available Zinc as 0.5
mg/kg, most of the study area soils are observed as deficient in the study area. Above
description of study area soils reveals that the soils in the study area are having moderate
fertility index.
3.6.8. Cropping Pattern
Agriculture is the main occupation of the district ‗Jagatsinghpur‘ population. The rich fertile
soil of Mahanadi, make the region good for cultivation of different crops. The district is also
having some problems in relation to agriculture, such as saline soils, water logging area,
which have some adverse effect on agricultural production & productivity of cultivated crops.
Paddy is the main staple food crop of the area as well as the district. Cropping Pattern (for
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Kharif and Rabi season) along with the production and productivity of major crops in
Jagatsinghpur District are presented in Table 3.8 and 3.9.
Table 3.8 : Area under Major Field Crops (As per latest figures 2008-09)
Major Cultivated
Field Crops
Area („000 ha) Kharif Rabi Summer Grand
Total Irrigated
Rain fed
Total
Irrigated
Rain fed
Total
Cereals 90.2 -- 90.2 3.3 -- 3.3 -- 93.5
Paddy 90.2 -- 90.2 3.07 -- 3.1 -- 93.2
Wheat -- -- -- 0.14 - 0.1 -- 0.1
Maize -- -- -- 0.09 - 0.1 -- 0.1
Ragi -- -- -- 0.006 -- 0.00
6 -- 0.006
Pulses -- -- -- 19.7 28.8 49.1 -- 49.0
Mung -- -- -- 12.6 16.3 28.9 -- 28.9
Biri -- -- -- 7.1 10.1 17.2 -- 17.2
Kulthi -- -- -- -- 2.4 2.4 -- 2.4
Cow pea -- -- -- 0.5 -- 0.5 -- 0.5
Gram -- -- -- 0.05 -- 0.05 -- 0.05
Oilseeds -- -- -- 10.6 -- 10.6 -- 10.6
Groundnut -- -- -- 6.9 -- 6.9 -- 6.9
Mustard/Toria -- -- -- 2.8 -- 2.8 -- 2.8
Til -- -- -- 0.4 -- 0.4 -- 0.4
Sunflower -- -- -- 0.4 -- 0.4 -- 0.4
Sugarcane 0.6 -- -- -- -- -- -- 0.6
Condiments & Spices
5.3 -- -- -- -- -- -- 5.3
Chilli 0.3 -- -- -- -- -- -- 0.3
Turmeric 0.2 --- -- -- -- -- -- 0.2
Other Spices 2.6 --- -- -- -- -- -- 2.6
Total Condiments & Spices
8.4 - -- -- -- -- -- 8.4
S. No.
Horticulture Crops -Fruits
Area („000 ha)
Total Irrigated Rain fed
A Fruits 0.2 0.2 0.03
Kagji Lime (Neebu)
0.04 0.04 --
Mango 0.04 0.02 0.03
Banana 0.15 0.15 -
B Horticulture Crops-Vegetables
Potato 0.4 0.4 -
Onion 1.7 1.7 -
Other 18.3 18.3 -
C Coconut
75000 bearing Coconut trees (0.43)
0.08 0.35
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(Source-http://agricoop.nic.in/Agriculture%20Contingency%20Plan/Orissa/Orissa%2018-
%20Jagatsinghpur%2031.05.2011.pdf)
Table 3.9 : Production and Productivity of Major Crops
(Average of last 5 years, 2004-08)
Name of Crop
Kharif Rabi Total
Prodn. ('000 t)
Prodty. (kg/ha)
Prodn. ('000 t)
Prodty. (kg/ha)
Prodn. ('000 t)
Prodty. (kg/ha)
Major Field Crops (Crops to be identified based on total acreage)
Paddy 87.794 2064 3.7 3070 91.6 2890
Wheat -- -- 0.1 1806 0.1 1806
Maize --- -- 0.1 1891 0.1 1891
Ragi -- -- 0.006 833 0.006 833
Gram -- -- 0.04 826 0.04 826
Mung -- -- 28.9 371 28.9 371
Biri --- -- 17.2 443 17.2 443
Kulthi -- -- 2.4 442 2.4 442
Cowpea -- -- 0.5 471 0.5 471
Groundnut -- -- 6.9 2078 6.9 2078
Til -- -- 0.4 343 0.4 343
Sunflower -- -- 0.4 436 0.4 436
Mustard/ Toria -- -- 2.8 250 2.8 250
Sugarcane 0.6 50083 -- -- 0.6 50083
Major Horticultural Crops (Crops to be identified based on total acreage)
Potato -- -- 4.9 13006 -- --
Onion -- -- 16.1 9503 -- --
Other Vegetables -- -- 243.1 -- -- --
Total Veg. -- -- 264.0 -- --
Chilli 4.5 -- -- 850 -- --
Ginger 0.5 -- -- 1852 -- --
Turmeric 0.5 -- -- 2238 -- --
Other Spices 3.8 -- -- -- -- --
Total Condiment s & Spices
9.3 -- -- -- -- --
(Source-http://agricoop.nic.in/Agriculture%20Contingency%20Plan/Orissa/Orissa%2018
%20Jagatsinghpur%2031.05.2011.pdf)
3.7. Meteorology (Based on Past Historical Data)
Areca nut 0.03 - 0.03
Cashew 0.490 - 0.490
D Hybrid Napier 0.02 0.02 0.003
Fodder Oat 0.01 0.01 -
Barseem 0.008 0.008 -
Total Fodder Area
0.04 0.04 0.003
Grazing Land 7.4 - 7.4
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The meteorological parameters play a vital role in transport and dispersion of pollutants in
the atmosphere. Historical meteorological data were obtained from climatological tables
pertaining to Paradeep Port, Odisha (as per the nearest representative IMD station) for the
period of 1981-2010 and is summarized in Table 3.10.
Table 3.10 : Long Term Meteorological Data of Paradeep Port, 1981-2010 (30 years average)
Month Temperature (oC)
Relative Humidity (%)
Rainfall, mm
Predominant Wind Direction (from)
All Cloud Amounts
Oktas
Wind Speed, kmph
Max Min 08:30 17:30 08:30 17:30 08:30 17:30
January 27.0 16.5 80 71 9.4 N, NE NE, E 1.6 1.5 6.4
February 28.9 19.9 80 75 19.4 N, NE S, E 2.1 1.8 6.8
March 31.0 23.5 79 80 33.5 SW, W S, SW 2.7 2.5 7.7
April 32.0 25.7 80 84 33.3 SW, S SW, S 3.4 3.3 9.6
May 32.9 26.6 80 83 95.2 SW, S SW, S 4.1 3.9 9.5
June 32.5 26.7 83 83 222.9 SW, W SW, S 5.8 5.9 9.4
July 31.4 26.0 86 85 282 SW, W SW, W 6.4 6.4 8.1
August 31.3 26.0 86 85 367.6 SW, W SW, W 6.3 6.3 8.0
September 31.7 26.0 84 83 284.3 SW, W SW, S 5.4 5.7 6.8
October 31.8 24.4 80 78 195.9 N, NW NE, E 3.6 4.1 5.7
November 30.1 20.2 77 71 86.5 N, NW NE, E 2.4 2.9 6.5
December 28.0 16.7 76 68 10.8 N, NW NE, E 1.5 1.8 6.1
Yearly average/
Total 30.7 23.2 81 79 1640.9 SW, N SW, S 3.8 3.8 7.6
(Source: Climatological Normals, IMDParadeep Port)
Temperature–During the summer months i.e., April - June, the daily mean minimum
temperature are around 25.70C and daily mean maximum temperature around 32.90C.
During winter months i.e. December – January the daily mean maximum temperature
remains around 28.00C and daily mean minimum temperature remains around 16.50C
Relative Humidity–The humidity remains high throughout the year. The relative humidity
ranges between 68-86% throughout the year. The maximum humidity observed during rainy
season is 86%.
Rainfall–The total annual mean rainfall received at Paradeep port IMD is about 1640.9 mm.
Maximum of the Rainfall occurs during in the month of August (mean monthly being about
367.6 mm) followed by July (mean monthly being about 277.4 mm) with the four monsoon
months (June to October) contributing about 70.5% (about 1156.8 mm) of the total annual
rainfall.
Cloud Cover – In the study area, clear weather prevails in most of the time during post
monsoon, winter and summer seasons. Only during monsoon months of July, August and
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September, moderate to heavy clouds are observed. Relevant details about the number of
days with zero oktas of cloud cover (all clouds) for all months are presented in Table 3.11.
Table 3.11 : No. of Days with Zero Oktas of Cloud Cover (Paradeep Port)
Cloud Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Time 08:30 19 14 8 4 2 0 0 0 1 6 12 18
17:30 17 13 11 5 3 0 0 0 0 3 8 15
(Source: Climatological Normals, IMDParadeep Port)
Wind Speed–Generally, light to moderate winds prevail throughout the year. Winds were
light and moderate particularly during the morning hours. While during the afternoon hours
the winds were stronger. The mean wind speed ranges from 5.7 to 6.5 kmph during post-
monsoon, 6.8 to 9.4 kmph during monsoon and 7.7 to 9.6 kmph in pre-monsoon season.
Wind Direction– The predominant wind direction at IMD Paradeep Port is from north and
northeast direction during winter months and rest of the season the wind blows from south
and southwest direction. Season wind rose of Paradeep Port IMD sites is presented in
Figure 3.16 to 3.18.
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Figure 3.16 :Wind rose Diagram of IMD Paradeep Port (Pre-monsoon Season)
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Figure 3.17 : Wind rose Diagram of IMD Paradeep Port (Monsoon Season)
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Figure 3.18 : Wind rose Diagram of IMD Paradeep Port (Post-monsoon Season)
3.7.2. Cyclone & Strom Surge:
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The most destructive element associated with an intense cyclone is storm surge. Past
history indicates that loss of life is significant when surge magnitude is 3 m or more. The
severity of cyclone occurs when wind speed reaches 89 to 118 kmph, very severe cyclone
when wind speed ranges in between 119 to 221 kmph and the wind speed due to Super
Cyclonic storm exceeds 222 kmph. Paradeep and its adjoining areas in recent times faced
super cyclones on 29th October 1999 having wind speed as high as 260 kmph and the
radius of maximum wind was 10 to 15 km. While crossing the coast, the Super Cyclone
produced 5.5 m storm surge above Chart Datum for above 6-7 hours duration, which
inundated land up to about 30 km inland. This had a toll of nearly 9500 human lives and 10
million people got affected.
Special Weather Phenomena- The occurrence of thunderstorm is 13.3 days per year,
mostly spread across the months of May to September. No annual Dust Storm is reported in
the area. Annually one day has visibility less than 1 km, 16 days has visibility in the range of
1 - 4 km, 214 days have visibility in the range of 4 -10 km, 69 days between 10 - 20 km and
65 days have visibility above 20 km.
3.7.3. Met Data Generated at Site
Met data was generated in December 2013 to March 2014 and again repeated for the
period of March 2018 to May 2018. An automatic weather monitoring station was installed at
Project site, keeping the sensors free exposed to the atmosphere and with minimum
interference with the nearby structures. The micro-meteorological data like wind speed, wind
direction, temperature, relative humidity and atmospheric pressure were collected using the
weather stationed cloud cover was recorded manually for the study period.
The wind directions, wind speed, temperature, rainfall and humidity recorded at site for
March 2018 to May 2018. are presented in Table 3.12. Graphical representation of wind
class frequency distribution pattern and wind rose for season Dec, 2013-March, 2014 and
March, 2018-May-2018 is provided in Figure 3.19 and 3.20.. Site specific wind rose
diagram for study period i.e. Dec, 2013-March, 2014 and (to May 2018 is presented in
Figure 3.24.
Table 3.12 : Site Specific Meteorological Data
Month/Year Temperature
(deg 0C)
Relative
Humidity, %
Average
Wind Speed
(m/s)
Predominant wind Direction (Blowing from)
Calm
Period,
% Min Max Min Max
March 2018 21 40 12 100
4.17
SSW
8.24 April 2018 20 41 19 100
May 2018 23 38 34 100
(Source: Field Survey)
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Temperature –During the study period daily mean minimum temperature was 200C and
daily mean maximum temperature was 410C.
Relative Humidity –The maximum relative humidity during entire study period of March to
May 2018 was recorded as 100% and minimum was recorded as 12%. Highest relative
humidity was observed during night time and lowest relative humidity value was recorded
during day time.
Wind Speed–The wind speed was recorded between 1.0 to >6 m/sec during study period.
Average wind speed during the whole study period was observed as 4.17-m/sec. Wind class
frequency distribution is presented in Figure 3.19.
Wind Direction –The predominant wind direction at site is from SSW direction. Windrose
diagram presented in Figure 3.20.
Calm Periods – Calm period was observed more during night time comparatively day time.
Average Calm period is shown in windrose diagram.
March to May 2018
Dec-2013 to March 2014
Figure 3.19 : Wind Class Frequency distribution
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March to May 2018
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Dec-2013 to March 2014
Figure 3.20 : Windrose Diagram
3.8. Ambient Air Quality
CPCB guidelines were applied for selecting the appropriateness of monitoring locations. The
location and height of the stations were so selected (>5 m from base) to avoid the capture of
re-suspended road dust and fugitive domestic emissions due to burning. All the ambient air
analysis with respect to each parameter were analysed as per CPCB guidelines. AAQ
monitoring was done at eight (8) locations within the study area considering dominant wind
direction, populated area and sensitive receptors. Monitoring of baseline Environmental
quality of the study area has been done during December 2013- March 2014 and again
repeated March, 2018-May, 2018. The monitoring locations were selected based on the
wind pattern. AAQ monitoring was conducted in two different seasons hence there was
some change in AAQ locations in both season. Details of monitoring locations are shown in
Table 3.13 (Dec 2013- Mar 2014) and Table 3.14(March-2018-May-2018). Monitoring
Location map for season (March-2018-May-2018) is shown in Figure 3.6.The summary of
Ambient Air quality results is presented in Table 3.15 (Dec 2013- Mar 2014) and Table
3.16(March-2018-May-2018).A graphical representation of AAQ monitoring parameters is
shown in Figure 3.25, 3.26, 3.27, and 3.28.
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Table 3.13 : Ambient Air Quality Monitoring Locations (Dec, 2013-March,2014) Code Location
(2018)
Distance (Km) Coordinates Terrain Features
A01 Project Site 00 20°16'52.93"N
86°38'47.92"E
Flat, Industrial
A02 Trilochanpur 2.6, SW 20°15'20.88"N
86°34'56.12"E
Flat, Residential, close to
plant site
A03 Denkia 2.5, SW 20°14'41.32"N
86°35'6.64"E
Flat, Residential, close to
plant site
A04 PratapPura 4.24, W 20°16'1.12"N
86°34'2.74"E
Flat, Residential
A05 Mangrajpura 5.5, NW 20°18'18.89"N
86°33'58.58"E
Flat, Residential
A06 Nuagarh 4.7, N 20°19'16.21"N
86°37'8.10"E
Flat, Residential
A07 Bagdia 2.0, W 20°16'38.15"N
86°35'20.84"E
Flat, Residential
A08 Musadiha 3.84,NE 20°18'59.69"N
86°39'30.29"E
Flat, Residential
Table 3.14 : Ambient Air Quality Monitoring Locations (March to May 2018) Code Location
(2018)
Distance Coordinates Terrain Features
A01 Project Site
00 20°16'36.93"N 86°38'3.30"E
Flat,Industrial
A02 PPL Township
00 20°15'51.42"N 86°36'41.89"E
Flat, Residential, inside the plant site
A03 Chaulipalanda
0.200,W 20°16'39.16"N 86°36'32.69"E
Flat, Residential, close to plant site
A04 Gopinath Colony
0.47,N 20°17'15.61"N 86°38'29.79"E
Flat, Commercial, close to plant site
A05 Udayabata
2.79,N 20°18'30.10"N 86°37'38.54"E
Flat, Residential, close to plant site
A06 Paradeepgarh
4.88,N 20°19'38.26"N 86°36'16.65"E
Flat, Residential, close to plant site
A07 Musadia
4.22,NE 20°19'0.75"N 86°39'41.12"E
Flat, Residential, close to plant site
A08 Jogidhankud 5.73,NE 20°19'10.26"N 86°41'22.83"E
Flat, Residential, close to plant site
Table 3.15 : Ambient Air Quality Monitoring Results (24-hour average) (Dec,2013-
Feb,2014)
Location PM2.5 (µg/m³)
PM10
(µg/m³) SO₂
(µg/m³) NOx
(µg/m³) CO
(µg/m³) NH3
(µg/m³) HC(µg/
m³)
Project Site Max 52 72 24.8 17.8 600 45.9 <0.05
Min 44 65 19.2 12.2 468 40.3 <0.05
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Location PM2.5 (µg/m³)
PM10
(µg/m³) SO₂
(µg/m³) NOx
(µg/m³) CO
(µg/m³) NH3
(µg/m³) HC(µg/
m³)
Mean 47.7 68.3 22.0 15.0 556 42.9 <0.05
98 Percentile
52.0 71.5 24.8 17.7 599 45.5 <0.05
Trilochanpur
Max 44 67 20.6 13.6 525 41.9 <0.05
Min 36 54 15.0 8.1 411 36.0 <0.05
Mean 40.0 60.7 17.4 10.9 486 38.7 <0.05
98 Percentile
44.0 65.6 20.5 13.5 523 41.9 <0.05
Denka Vill.
Max 38 60 18.6 11.6 493 39.9 <0.05
Min 32 51 13.0 6.1 401 34.0 <0.05
Mean 34.8 55.9 16.2 9.0 446 36.8 <0.05
98 Percentile
38.0 60.0 18.5 11.4 489 39.8 <0.05
Pratappur Vill.
Max 36 62 17.7 10.5 472 38.0 <0.05
Min 30 51 12.0 5.1 401 33.0 <0.05
Mean 33.1 55.0 14.4 7.8 426 35.7 <0.05
98 Percentile
36.0 60.6 17.6 10.4 466 38.0 <0.05
Bagdia Vill.
Max 48 69 22.9 15.6 586 43.0 <0.05
Min 40 60 17.0 10.1 442 38.0 <0.05
Mean 44.0 64.5 19.8 12.7 527 40.5 <0.05
98 Percentile
48.0 69.0 22.8 15.6 580 43.0 <0.05
Mangrajpur Vill.
Max 40 63 19.7 12.9 503 40.9 <0.05
Min 34 53 14.2 7.0 429 35.1 <0.05
Mean 36.9 57.3 16.8 9.6 463 37.9 <0.05
98 Percentile
40.0 62.5 19.6 12.7 493 40.9 <0.05
Musadia Vill.
Max 50 72 23.9 16.8 575 44.9 <0.05
Min 42 61 18.1 11.1 437 39.2 <0.05
Mean 46.2 66.6 20.9 13.7 541 42.0 <0.05
98 Percentile
50.0 71.5 23.8 16.7 574 44.8 <0.05
Nuagarh Vill.
Max 46 68 21.5 14.9 523 42.7 <0.05
Min 38 58 16.0 9.0 457 37.1 <0.05
Mean 42.5 62.3 18.9 12.2 487 39.8 <0.05
98 Percentile
46.0 67.5 21.4 14.9 520 42.5
Source: Primery Data Collection and analysis during study period by Laboratory
Table 3.16 : Ambient Air Quality Data around the project site in 10 km radius (March-
May, 2018)
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Location PM10 (µg/m³)
PM2.5(µg/m³) SO₂ (µg/m³)
NOx (µg/m³)
NH3 (µg/m³)
CO (mg/m³)
Project Site
Min 76 32 8.2 14.4 15 0.62
Max 96 47 20.2 38.0 24 0.95
Mean 85 38 13.7 25.3 19 0.77
98 Percentile
95 46 19.5 36.9 23 0.91
PPL Township
Min 64 29 7.2 13.2 13 0.51
Max 87 45 16.0 29.1 21 0.82
Mean 74 36 11.5 22.4 17 0.68
98 Percentile
86 43 15.7 28.4 21 0.81
Chaulipalanda
Min 60 25 7.6 14.2 14 0.56
Max 84 39 17.8 34.1 29 0.88
Mean 73 30 13.2 22.8 22 0.73
98 Percentile
83 37 16.9 32.6 28 0.87
Gopinath Colony
Min 64 29 7.0 12.4 14 0.45
Max 90 42 15.3 26.0 21 0.90
Mean 77 36 10.9 18.8 17 0.70
98 Percentile
89 42 15.1 25.0 21 0.89
Udayabata
Min 69 32 7.9 13.8 18 0.41
Max 93 46 19.2 29.8 36 0.75
Mean 78 36 13.0 20.4 25 0.58
98 Percentile
92 45 19.1 29.3 35 0.75
Paradeepgarh
min 71 35 8.0 14.4 11 0.68
Max 105
49 19.5 36.4 19 1.05
Mean 88 41 13.5 22.0 15 0.88
98 Percentile
104 48 18.8 33.7 19 1.04
Musadia
Min 57 25 6.4 10.8 18 0.48
Max 81 41 17.8 21.5 45 0.95
Mean 68 33 11.6 16.5 30 0.72
98 Percentile
80 41 17.4 20.9 43 0.92
Jogidhankud
Min 54 22 4.8 9.5 13 0.35
Max 75 37 14.0 18.4 20 0.73
Mean 65 28 9.1 12.7 16 0.59
98 Percentile
75 36 13.4 17.8 20 0.73
Source: Primery Data Collection and analysis during study period by Laboratory
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Graphical Presentation of AAQ PM2.5Concentration
Figure 3.21 : Statistical Comparison of PM2.5 Concentration
Observations:The average PM2.5 level in both the seasons was found within the NAAQS
levels for industrial, Residential, Rural and other Areas (60 µg/m3).
0
10
20
30
40
50
60
Project Site Trilochanpur Denka Vill. Pratappur Vill
Bagdia Vill. Mangrajpur Vill
Musadia Vill. Nuragrah Vill.
µg/
m3
PM2.5 (season Dec 2013-March2014)
Max Min Mean 98 Percentile
0
10
20
30
40
50
60
Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
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Min
Max
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98
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98
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Min
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n
98
Per
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98
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Min
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n
98
Per
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Min
Max
Mea
n
98
Per
cen
tile
A1 A2 A3 A4 A5 A6 A7 A8
µg/
m³
PM2.5 (Season Mar-May 2018)
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EQMS INDIA PVT. LTD. 175
Figure 3.22 : Statistical Comparison of PM10 Concentration
Observations: The average PM10 level was within the NAAQS levels for industrial,
Residential, Rural and other Areas (100 µg/m3).
The highest PM10 levels were found at Paradeepgarh (105µg/m3) while the lowest levels
was found at vill. Jogidhakud (54.0 µg/m3).
SO2 Concentration (Winter Season):
0
10
20
30
40
50
60
70
80
Project Site Trilochanpur Denka Vill. Pratappur Vill
Bagdia Vill. Mangrajpur Vill
Musadia Vill. Nuragrah Vill.
µg/
m³
PM10 (Season Dec 2013-Mar 2014)
Max Min Mean 98 Percentile
0
20
40
60
80
100
120
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
Min
Max
Mea
n 98
…
A1 A2 A3 A4 A5 A6 A7 A8
µg/
m³
PM2.5 (Season Mar-May 2018)
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EQMS INDIA PVT. LTD. 176
Figure 3.23 : Statistical Comparison of SO2 Concentration
Observations: The SO2 level of the study area in both the seasons was found well
under the NAAQS Standard of 80 µg/m3. The main source of SO2 emission is
vehicular.
NOx Concentration:
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Project Site Trilochanpur Denka Vill. Pratappur Vill
Bagdia Vill. Mangrajpur Vill
Musadia Vill. Nuragrah Vill.
µg/
m³
SOx (Season Dec 2013-Mar 2014)
Max Min Mean 98 Percentile
0
5
10
15
20
25
Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
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Min
Max
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98
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98
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Max
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n
98
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Min
Max
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98
Per
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Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
cen
tile
A1 A2 A3 A4 A5 A6 A7 A8
µg/
m³
SO2 (Season Mar-May 2018)
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EQMS INDIA PVT. LTD. 177
Figure 3.24 : Statistical Comparison of NOx Concentration
Observations: The NOx level of the study area was well under the NAAQS standard of
80 µg/m3. The main source of NOx emission is industrial & vehicular.
Overall the ambient air quality of the study area was found within the national ambient air
quality standards in all the monitoring locations. However, at one location, Paradeep garh,
the ambient air quality was fi=ound above NAAQS standards. HC (methane and non
methane) and HF were also monitored but not detected.
3.9. Noise Environment
Noise after a certain level can have a very disturbing effect on the people and animals
exposed to it. Hence, it is important to assess the present noise quality of the area in order
to predict the potential impact of future noise levels due to the proposed project. Ambient
0.0
5.0
10.0
15.0
20.0
Project Site Trilochanpur Denka Vill. Pratappur Vill Bagdia Vill. Mangrajpur Vill
Musadia Vill. Nuragrah Vill.
µg/
m³
NOx (Season Dec 2013-Mar 2014)
Max Min Mean 98 Percentile
0
5
10
15
20
25
30
35
40
Min
Max
Mea
n
98
Per
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tile
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Max
Mea
n
98
Per
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Max
Mea
n
98
Per
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Max
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n
98
Per
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Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
cen
tile
Min
Max
Mea
n
98
Per
cen
tile
A1 A2 A3 A4 A5 A6 A7 A8
µg/
m³
NOx (Season Mar-May 2018)
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noise measurements were undertaken at Eight (8) locations for season Dec, 13 to Feb,14
and season March-May, 2018, represented in Table 3.17.Location wise result for day time
and night time forseasonDec, 13 to Feb,14 and season March-May, 2018 are presented in
Table 3.18 and 3.19 respectively.
The monitored levels were compared against the Noise Pollution (Regulation and Control)
Rules 2000, as amended through the Noise Pollution (Regulation and Control) Amendment
Rules 2010 dated 11th January 2010. The project site falls in designated industrial area and
the noise levels at all the locations were found within the ambient noise standards.
Table 3.17 : Ambient Noise Quality Monitoring Locations (Dec, 2013-Jan,2014)
Code Location Distance (Km) Coordinates Zone N01 Project Site near ETP
- 20°16'50.17"N
86°38'29.23"E Industrial
N02 Trilochanpur 2.6, SW 20°15'28.38"N 86°34'48.03"E
Residential
N03 Denkia 2.5, SW 20°14'37.88"N 86°35'19.48"E
Commercial/ Mixed use area
N04 PratapPura 4.24, W 20°16'14.85"N 86°33'50.03"E
Residential
N05 Mangrajpura 5.5, NW 20°18'53.06"N 86°33'27.09"E
Residential
N06 Nuagarh 4.7, N 20°19'58.54"N 86°36'46.98"E
Commercial/ Mixed use area
N07 Bagdia 2.0, W 20°16'42.31"N 86°35'8.38"E
Commercial/ Mixed use area
N08 Musadiha 3.84,NE 20°18'41.99"N 86°39'1.95"E
Commercial/ Mixed use area
(March-April, 2018) N01 Project Site (Plant
Gate) 00 20°16'36.93"N
86°38'3.30"E Industrial
N02 Near PPL Township 00 20°15'46.96"N 86°36'40.26"E
Residential
N03 NH 5A 3.47,N 20°18'38.31"N 86°37'27.26"E
Commercial/ Mixed use area
N04 Niharunikandha 1.84,N 20°17'37.79"N 86°36'58.78"E
Residential
N05 Abhayachandapur 1.97,SW 20°14'34.70"N 86°36'40.6"E
Residential
N06 Paradeep Rly. Station 0.31,N 20°16'57.11"N 86°36'51.25"E
Commercial/ Mixed use area
N07 Paradeep /SH-12 3.48,N 86°36'51.25"E 86°37'27.26"E
Commercial/ Mixed use area
N08 Coast Guard/Connecting NH-
5A
0.74,SE 20°15'58.46"N 86°38'55.42"E
Commercial/ Mixed use area
Table 3.18 : Ambient Noise Quality Results (Post monsoon Season, 2013-14)
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EQMS INDIA PVT. LTD. 179
Location Code
Surveyed Location
Present Category Day Time Leq dB(A)
Night Time Leq dB(A)
National Standard Day Time Leq dB(A)
National Standard Night Time Leq dB(A)
N-1 Project Site
near ETP
Industrial 62.8 45.9 75 70
N-2 Trilochanpur Residential 55.9 42.2 55 45
N-3 Denkia Commercial/ Mixed use area 51.5 39.9 65 55
N-4 PratapPura Residential 50.8 39.9 55 45
N-5 Mangrajpura Residential 52.9 40.9 55 45
N-6 Nuagarh Commercial/ Mixed use area 52.9 40.7 65 55
N-7 Bagdia Commercial/ Mixed use area 53.0 41.4 65 55
N-8 Musadiha Commercial/ Mixed use area 54.9 41.6 65 55
Table 3.19 : Ambient Noise Quality Results (Pre monsoon Season, 2018)
Location Code
Surveyed Location
Present Category Day Time Leq
dB(A)
Night Time Leq
dB(A)
National Standard Day Time Leq dB(A)
National Standard
Night Time Leq
dB(A)
N-1 Project Site (Plant Gate)
Industrial 65.0 58.3 75 70
N-2 PPL Township Residential 53.8 43.2 55 45
N-3 NH 5A Commercial/ Mixed use area
70.6 63.2 65 55
N-4 Niharunikandha Residential 52.5 45.2 55 45
N-5 Abhayachandpur Residential 52.6 42.5 55 45
N-6 Paradeep Rly. Station
Commercial/ Mixed use area
63.6 59.7 65 55
N-7 Paradeep /SH-12 Commercial/ Mixed use area
68.2 57.9 65 55
N-8 Coast Guard/Connecting NH-5A
Commercial/ Mixed use area
65.5 57.2.0 65 55
Source: Primary Data Collection and analysis, EQMS
3.9.2. Observation on Ambient Noise Quality:
The noise level at all residential locations in both the seasons were found lower than the
ambient noise standards except PPL township where day time noise level was slightly high
than the standard this may be due to its closeness to Plant. Only at NH-5A
(commercial/mixed use area), the equivalent day noise level was found higher than the
standard noise level day equivalent, which may be due to heavy vehicular movement and
road traffic.
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 180
3.10. Water Quality
3.10.1. Ground Water Quality
Eight ground water samples and five surface water sample were collected from different
locations around the site during study period. The water samples were examined for
physico-chemical parameters and bacteriological parameters. The samples were collected
and analysed as per the procedures specified in Standard Methods. Samples for chemical
analyses were collected in polyethylene carboys. Samples for bacteriological analyses were
collected in sterilized bottles. Temperature, pH, conductivity and dissolved oxygen were
measured at site itself. Surface water sample were analyzed for various parameters and
assessed using the CPCB‘s BDU Criteria.
The ground water sampling locations is presented in Table 3.20. The analysis results of
groundwater are presented in Table 3.21 and Groundwater monitoring locations with
analysis results from Dec, 2013-March, 2014 are presented in Annexure 17.
Table 3.20 : Ground Water Sampling Locations
Ground Water(March, 2018-April, 2018) GW1
Project Site 00 20°16'36.93"N
86°38'3.30"E GW2
PPL Township 00 20°16'18.54"N
86°37'36.16"E GW3
Denkia 2.5, SW 20°14'41.32"N
86°35'6.64"E GW4
Chaukimatha 1.85,NW 20°16'58.23"N
86°35'58.68"E GW5
Paradeep Port Trust 1.62,SE 20°16'39.15"N
86°39'55.65"E GW6
Musadia 3.84,NE 20°18'59.69"N
86°39'30.29"E GW7
Fatehpur 4.78,W 20°16'50.24"N
86°33'57.42"E GW8 Trilochanpur 3.66,W 20°15'37.86"N
86°34'26.48"E
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Table 3.21 : Physical and Chemical Characteristics of Ground Water Samples (Post monsoon season 2018)
S.No. Parameters GW1
GW2
GW3
GW4
Method Desired Limit /Permissible Limit
1 pH Value 6.51 7.52 6.48 7.30 APHA-4500 6.5-8.5/ No relaxation
2 Temperature 0C 25.8 26.0 25.6 25.9 IS:3025:Part 9
--
3 Conductivity,
mhos/cm
1046 980 563 1164 APHA-4500 --
4 Turbidity (NTU) <1 <5 <1 <1 APHA-2030B
1-5
5 Total Dissolved solids mg/l
680 637 366 756 APHA-2540B
500/2000
6 Total Suspended solids mg/l
<2 <2 <2 <2 APHA-2540D
--
7 Total Hardness as CaCO3 mg/l
256 218 160 338 APHA-2340C
200/600 8 Residual Free
Chlorine as RFC mg/l
<0.2 <0.2 <0.2 <0.2 IS:3025: P26 0.2-1
9 Chloride as Cl mg/l
152 122 126 356 APHA-4500B
250/1000
10 Total Alkalinity mg/l
282 246 156 300 IS:3025:Part -23
200/600
11 Sulphates as SO4 mg/l
132.0 52.8 70.4 110 APHA-4500E
200/400
12 Nitrates as NO3 mg/l
7.2 5.0 2.7 9.0 APHA-4500 45/No relaxation
13 Fluoride as F mg/l 0.42 0.39 0.32 0.48 APHA-4500D
1/1.5
14 Iron as Fe mg/l 0.29 0.32 0.24 0.32 APHA-3111B
0.3/No relaxation
15 Zinc as Zn mg/l 1.32 1.10 0.86 1.48 APHA-3111B
5/15
16 Calcium as Ca mg/l
78.4 74.4 57.6 86.4 APHA-3500B
75/200
17 Magnesium as Mg mg/l
14.6 7.8 3.9 29.6 APHA-3500B
30/100
18 Sodium as Na mg/l
57 49 43 70 APHA-3500 --
19 Potassium as K mg/l
15 11 7.0 19 APHA-3500 KB
--
20 Cadmium as Cd mg/l
<0.01 <0.01 <0.01 <0.01 APHA-3111B
0.003/No relaxation
21 Copper as Cu mg/l
<0.01 <0.01 <0.01 <0.01 APHA-3111B
0.05/1.5
22 Nickel as Ni mg/l <0.02 <0.02 <0.02 <0.02 APHA-3111B
0.02/No relaxation 23 Lead as Pb mg/l 0.018 <0.01 <0.01 <0.01 APHA-
3111B 0.01/No relaxation
24 Mercury as Hg mg/l
<0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001
25 Chromium (Total as Cr) mg/l
<0.05 <0.05 <0.05 <0.05 APHA-3111B
0.5/No relaxation
26 Arsenic as As mg/l
<0.001 <0.001 <0.001 <0.001 APHA-3114 0.01/0.05
27 Phenolic compound mg/l
<0.001 <0.001 <0.001 <0.001 IS:3025:Part 43
0.001/0.002
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28 Phosphate as PO4 mg/l
0.64 0.48 0.57 0.82 APHA --
29 Manganese as Mn mg/l
<0.01 <0.01 <0.01 <0.01 IS:3025:Part 59
0.1-0.3
30 Cyanide as CN mg/l
<0.01 <0.01 <0.01 <0.01 IS:3025:Part 27
0.05/ No relaxation
31 Boron mg/l <0.5 <0.5 <0.5 <0.5 IS:3025:Part 57
0.5-1
32 Aluminum as Al mg/l
<0.03 <0.03 <0.03 <0.03 IS:3025:Part 55
0.03-0.2
33 Anionic Detergents mg/l
<0.1 <0.1 <0.1 <0.1 APHA 0.2-1
34 Total Coliform MPN/100ml
<2 <2 <2 <2 APHA-9230B
Shall not be detectable in any 100 ml sample
35 E-coli MPN/100ml Absent Absent Absent Absent APHA-9230B
Shall not be detectable in any 100 ml sample
Physical and Chemical Characteristics of Ground Water Samples (May 2018) Contd...
S.No. Parameters GW5
GW6
GW7
GW8
Method Desired Limit /Permissible Limit
1 pH Value 7.99 7.45 7.36 7.27 APHA-4500 6.5-8.5/ No relaxation
2 Temperature 0C 25.6 25.8 26.0 25.6 IS:3025:Part 9
--
3 Conductivity,
mhos/cm
1526 788 1175 656 APHA-4500 --
4 Turbidity (NTU) <1 <5 <1 <1 APHA-2030B
1-5
5 Total Dissolved solids mg/l
992 512 763 426 APHA-2540B
500/2000
6 Total Suspended solids mg/l
<2 <2 <2 <2 APHA-2540D
--
7 Total Hardness as CaCO3 mg/l
212 236 344 228 APHA-2340C
200/600
8 RFC <0.1 <0.01 <0.01 <0.01 IS:3025: P26 0.2-1
9 Chloride as Cl mg/l
415 198 398 66 APHA-4500B
250/1000
10 Total Alkalinity mg/l
428 276 280 206 IS:3025:Part -23
200/600
11 Sulphates as SO4 mg/l
146 46.8 68.2 68 APHA-4500E
200/400
12 Nitrates as NO3 mg/l
11.0 6.8 9.0 3.8 APHA-4500 45/No relaxation
13 Fluoride as F mg/l 0.52 0.42 0.36 0.28 APHA-4500D
1/1.5
14 Iron as Fe mg/l 0.36 0.28 0.29 0.22 APHA-3111B
0.3/No relaxation
15 Zinc as Zn mg/l 1.56 0.98 1.10 0.92 APHA- 5/15
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3111B
16 Calcium as Ca mg/l
67.2 62.2 76.8 52.8 APHA-3500B
75/200
17 Magnesium as Mg mg/l
10.7 19.4 36.9 23.3 APHA-3500B
30/100
18 Sodium as Na mg/l
78 57 57 39 APHA-3500 --
19 Potassium as K mg/l
11 5 5.9 3.7 APHA-3500 KB
--
20 Cadmium as Cd mg/l
<0.01 <0.01 <0.01 <0.01 APHA-3111B
0.003/No relaxation
21 Copper as Cu mg/l
<0.01 <0.01 <0.01 <0.01 APHA-3111B
0.05/1.5
22 Nickel as Ni mg/l <0.02 <0.02 <0.02 <0.02 APHA-3111B
0.02/No relaxation
23 Lead as Pb mg/l 0.062 <0.01 <0.01 <0.01 APHA-3111B
0.01/No relaxation
24 Mercury as Hg mg/l
<0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001
25 Chromium (Total as Cr) mg/l
<0.05 <0.05 <0.05 <0.05 APHA-3111B
0.5/No relaxation
26 Arsenic as As mg/l
<0.001 <0.001 <0.001 <0.001 APHA-3114 0.01/0.05
27 Phenolic compound mg/l
<0.001 <0.001 <0.001 <0.001 IS:3025:Part 43
0.001/0.002
28 Phosphate as PO4 mg/l
0.72 0.30 0.46 0.24 APHA --
29 Manganese as Mn mg/l
<0.01 <0.01 <0.01 <0.01 IS:3025:Part 59
0.1-0.3
30 Cyanide as CN mg/l
<0.01 <0.01 <0.01 <0.01 IS:3025:Part 27
0.05/ No relaxation
31 Boron mg/l <0.5 <0.5 <0.5 <0.5 IS:3025:Part 57
0.5-1
32 Aluminum as Al mg/l
<0.03 <0.03 <0.03 <0.03 IS:3025:Part 55
0.03-0.2
33 Anionic Detergents mg/l
<0.1 <0.1 <0.1 <0.1 APHA 0.2-1
34 Total Coliform MPN/100ml
<2 <2 <2 <2 APHA-9230B
Shall not be detectable in any 100 ml sample
35 E-coli MPN/100ml Absent Absent Absent Absent APHA-9230B
Shall not be detectable in any 100 ml sample
Observation on Ground Water Quality
The pH value of drinking water is an important index of acidity or alkalinity. pH value was
found within desired and permissible limit, neutral to alkaline in nature.
Total dissolve solids was found in the range of 426 to 992 mg/l which is found well within
permissible range (2000 mg/l) of IS 10500:2012.
Chloride was found in the range of 66 to 415 mg/l which is found well within permissible
range (1000 mg/l) of IS 10500:2012
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Total hardness values ranges between 160 to 344 mg/l which found well within the
permissible range of IS 10500:2012 except at the location Denkiya (160 mg/l).
Total Alkalinity values ranges between 156 to 300 mg/l which found within
thepermissible range of IS 10500:2012
Overall the ground water quality of the study area is found well within the permissible
limit of Indian Standard IS: 10500:2012. No metallic and bacterial contaminations were
observed in ground water samples.
3.10.2. Surface Water Quality
Santra nalla, Mahanadi River and Sea water are the source of surface water in the study
area. Eight (08) surface water samples were collected and examined for major physico-
chemical parameters and bacteriological parameters. CPCB best designated Use standards
are shown in Table 3.22. Sea water Sample was analysed for various parameters using the
Receiving Sea Water Standards for SW-II Category (ref Table 3.24). Surface water
sampling locations are presented in Table 3.23. Surface water and sea water results for
study period provided in Table 3.24 and Surface water monitoring locations with analysis
results from Dec, 2013-March, 2014 are presented in Annexure 17.
Table 3.22 : CPCB Best Designated Use Standard (Source-CPCB)
Designed Best Use Class of Water
Criteria
Drinking water Source without conventional treatment but after disinfection
A Total Coliforms Organism MPN/100ml shall be 50 or less pH between 6.5 and 8.5 Dissolved Oxygen 6mg/l or more Biochemical Oxygen Demand 5 days 20°C 2mg/l or less
Outdoor bathing (Organized)
B Total Coliforms Organism MPN/100ml shall be 500 or less pH between 6.5 and 8.5 Dissolved Oxygen 5mg/l or more Biochemical Oxygen Demand 5 days 20°C 3mg/l or less
Drinking water source after conventional treatment and disinfection
C Total Coliforms Organism MPN/100ml shall be 5000 or less pH between 6 to 9 Dissolved Oxygen 4mg/l or more Biochemical Oxygen Demand 5 days 20°C 3mg/l or less
Propagation of Wild life and Fisheries
D pH between 6.5 to 8.5 Dissolved Oxygen 4mg/l or more Free Ammonia (as N) 1.2 mg/l or less
Irrigation, Industrial Cooling, Controlled Waste disposal
E pH between 6.0 to 8.5 Electrical Conductivity at 25°C micro mhos/cm Max.2250 Sodium absorption Ratio Max. 26 and Boron Max. 2mg/l
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 185
Table 3.23 : Surface Water Sampling Locations
Surface Water (March, 2018-April, 2018)
Inland Water
SW1 Project Site discharge point 100 mtr up stream Near Abhayachandpur
5.6 km, SW 20°14'11.67"N 86°35'35.68"E
SW2 Project Site discharge point 100 mtr down stream Near Abhayachandpur
6.0 km, SW 20°13'51.29"N 86°35'36.12"E
SW3 Mahanadi River (Upstream)
5.25km,NE 20°19'30.34"N 86°39'1.23"E
SW4 Mahanadi River (Downstream)
5.32km,NE 20°18'29.05"N 86°40'52.19"E
SW5 Musadia (Pond) 4.76km,NE 20°19'8.67"N 86°39'10.74"E
Sea water & Creaks
SW6 Santra Nala (Upstream) 5.70km,W 20°16'24.89"N 86°34'31.03"E
SW7 Santra Nala (Downstream)
3.95km,SW 20°15'10.65"N 86°35'51.19"E
SW8 Paradeep (Beach) 5.34km,E 20°16'36.51"N 86°41'21.77"E
Table 3.24 : Surface Water Quality in the Study Area (Pre monsoon Season, 2018)
S.N. Parameters SW1
SW2
SW3
SW4
SW5
Method
1 pH Value 7.84 7.58 7.68 7.32 6.85 APHA-4500
2 Temperature 0C 24.6 24.8 24.8 25.0 25.6 Part 9
3 Conductivity,
mhos/cm
4156 4376 368 376 1076 APHA-4500
4 Turbidity (NTU) <5 <5 <5 <5 <5 APHA-2030B
5 Total Dissolved solids
mg/l
2701 2844 238 244 688 APHA-2540B
6 Total Suspended solids
mg/l
46 54 8 10 15 APHA-2540D
7 Total Hardness as
CaCO3 mg/l
1256 1392 146 152 166 APHA-2340C
8 Chloride as Cl mg/l 1870 1998 32 36 320 APHA-4500B
9 Total Alkalinity mg/l 246 218 122 126 346 Part -23
10 Sulphates as SO4 mg/l 322 356 12.6 14.8 106 APHA-4500E
11 Nitrates as NO3 mg/l 21 24 0.82 0.89 1.0 APHA-4500
12 Fluoride as F mg/l 0.86 0.22 0.88 0.22 0.69 APHA-4500D
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13 Iron as Fe mg/l 0.42 0.46 0.26 0.46 0.56 APHA-3111B
14 Zinc as Zn mg/l 1.52 1.68 0.12 0.16 1.12 APHA-3111B
15 Calcium as Ca mg/l 356 392.8 52 55.2 56 APHA-3500B
16 Magnesium as Mg
mg/l
88.9 99.6 3.9 3.4 6.3 APHA-3500B
17 Cadmium as Cd mg/l <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B
18 Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B
19 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B
20 Lead as Pb mg/l 1.16 1.22 <0.01 <0.01 0.69 APHA-3111B
21 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 <0.001 APHA-3112
22 Arsenic as As mg/l <0.025 <0.025 <0.025 <0.025 <0.025 APHA-3114
23 Phenolic compound
mg/l
0.012 0.016 0.008 0.010 0.006 IS:3025:Part 43
24 Phosphate as PO4
mg/l
1.68 1.74 0.38 0.32 0.87 APHA
25 Manganese as Mn
mg/l
<0.01 <0.01 <0.01 <0.01 <0.01 IS:3025:Part 59
26 Cyanide as CN mg/l <0.01 <0.01 <0.01 <0.01 <0.01 IS:3025:Part 27
27 Chromium (Total as Cr)
mg/l
<0.05 <0.05 <0.05 <0.05 <0.05 APHA-3111B
28 Aluminum as Al mg/l <0.03 <0.03 <0.03 <0.03 <0.03 IS:3025:Part 55
29 Anionic Detergents
mg/l
<0.1 <0.1 <0.1 <0.1 <0.1 APHA
30 Oil & Grease mg/l 6.7 6.8 ND ND <2 Part -39
31 Chemical Oxygen
Demand as COD mg/l
578 536 10 12 18 Part -58
32 Bio- Chemical Oxygen
Demand as BOD (for 3
Days 27 ˚C) mg/l
172 160 3.0 2.8 6.8 Part -44
33 Dissolved Oxygen mg/l 5.0 4.6 6.8 7.0 7.0 APHA
34 Total coliform
MPN/100ml
1820 1850 1660 1690 5210 APHA-9230B
Source: Primery Data Collection and analysis during study period by Laboratory
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Physical and Chemical Characteristics of Surface Water Samples (Pre monsoon Season-
2018) contd...
Sl. No.
Parameters Units SW-6
SW-7
SW-8 (Sea
Water Quality)
1 pH Value - 7.98 8.05 7.82
2 Temperature 0 C 25.8 26.0 25.2
3 Turbidity NTU 7 8 <5
4 Total Suspended Solids mg/l 54 62 42
5 Total Dissolved Solids mg/l 13698 14250 31112
6 Salinity % 24.6 25 34
7 Dissolved Oxygen mg/l 5.9 6.4 7.2
8 B.O.D (27 0C, 3 days) mg/l 3.2 3.4 3.0
9 C.O.D. mg/l 12 15 10
10 Oil & Grease mg/l ND ND ND
11 Nitrite as N mg/l 0.26 0.28 0.42
12 Nitrate as N mg/l 0.14 0.16 0.18
13 Phosphates mg/l 0.12 0.14 0.32
14 Silicates mg/l 2.2 2.5 2.8
15 Total Coliform MF Count./100ml
120 165 180
Observation on Surface Water Quality
Surface water (SW1-SW5) in therds. pH value for all the surface water locations is found
within 6.5 to 8.5 range. Dissolved oxygen at all the locations is found more than 4mg/l.
Biochemical oxygen demand at all the locations is more than 3 mg/l except region has been
compared with respect to CPCB Best Designated Use Standard and Receiving Sea Water
Standa Mahanadi river. Overall the Mahandi water quality is meeting Class C i.e fit for
drinking water source after conventional treatment and disinfection. Other surface water
(SW-1, SW-2 and SW5) is meeting Class D of CPCB BDU criteria
Water quality of SW-6-to SW8 was assessed Receiving Sea Water Standards which is
meeting the SW-II category of receiving sea water standard
Table 3.25 : Receiving Sea Water Standards for SW-II Category
(Commercial Fishing, Contact Recreation, Bathing Water)
S. No. Parameter Criteria Rationale/ Remarks
1 pH range 6.5 – 8.5 Range does not skin or eye irritation and is
also
Conducive for propagation of aquatic lives
2 Dissolved
solids
4.0 mg/l Not less than 3.5 mg/ l at any time for
protection of aquatic lives
3 Colour and
Odor
No noticeable
color ,odor and
floating matters
Specially caused by chemical compound like
creosols Phenols, Naphtha , Benzene ,
Pyridine, Toluene etc. causing visible
coloration of water and tainting of and odor in
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fish flesh
4 Floating
matters
Nothing obnoxious or
detrimental for use
purpose
None in concentration that would impair
usages specially assigned to the class.
5 Fecal
Coliform
100 per 100 ml The average value not exceeding 200/100 ml
in 20% of the sample in the year and in 3
consecutive samples in the monsoon months
6 Biochemical
Oxygen
Demand
(BOD 5 days
at 20 ˚C)
3 mg/l Restricted for bathing (aesthetic quality of
water) Also prescribed by IS:2296-1974
7 Turbidity 30 NTU (Nephelo-
Turbidity Unit)
Measured at 0.9 depth
Source: Water quality standards for coastal waters marine Outfalls (EPA Rule 1986).
Observation on Sea Water Quality:
The sea water quality parameters are compared with water quality standards for coastal
waters marine Outfalls (EPA Rule 1986) for locations Santara Nala and Paradeep Beach.
The sea water quality is not complying with the Class SW-II of coastal waters marine
Outfalls (EPA Rule 1986) which states that sea water does not suits for Bathing, Contact
Water Sports and Commercial marine fishing.
3.11. Ecological Environment
The Botanical and wildlife species in an area depend on the availability of suitable habitat for
survival. Habitat loss and increasing habitat fragmentation are the primary causes of species
decline in these environments. This section provides an overview of flora and fauna
observed in study area during site visit.
Vegetation at proposed site: The total land identified for establishing proposed plant is
about 83.26 acres. There is no forest land is involved with the proposed project. The
identified land is barren land with seasonal grasses. No trees are present on the identified
land. Photographs of the proposed land is provided in Figure 3.29.
3.11.1. Forest/Vegetation in Jagatsinghpur District
The district has a meagre forest area. The total forest area of the district is estimated to be
132.92 Sq. Kms. Out of the total forest area, the reserve forest area is only 1.23 sq. km and
demarcated protected forest area is 4.77 sq. kms. Un-demarcated forest area is 83.06 sq.
km. Unclassified forest area is 0.02 sq. km. and other forest area is 43.84 sq. kms. The
major forest produces of the district are mango, sopeta, kendu leaves, sal leaves and
tamarind. Important minor forest produces are sunari barks, arjuna barks, karanja seeds,
neem seeds, mushroom, sal leaves etc.
3.11.2. Vegetation in Study Area (10 Km study Area)
The study area forms a part of the Mahanadi delta plain on the east coast. Alluvial and fluvio
tidal settlements cover the area. The soil cover in the study area is mostly alfisols and
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entisols formed in recent times. It has got moderate level of nutrients. The study area falls in
coast of Paradeep and vegetation type is coastal vegetation. Most of the land within 10 km
radius of the project site is under cultivation, waterbodies, open shrub and grasses and
settlement respectively. There is about 15.56% land is under open shrub & grass land. The
percentage landcover with different types of vegetations in the study area is about 8.3 %.
The vegetations include trees, as well as shrubs and herbs excluding grass cover. There is
a patch of the protected forest namely Jogidhankud P.F is present within the study area.
Jogidhankud P.F is present about 4.8 km south of the proposed plant site.
There are no protected areas of national ecological significance like Reserved Forests,
National Park, Wild Life Sanctuary, Biosphere Reserves and Ramsar Site within the study
area.
Most of the natural vegetation cover has been extensively damaged from time to time due to
natural calamities like cyclones, super cyclone in 1999, storm surge and inundation. The
vegetation in the study area is meagre and scanty. In few locations away from the coast is
extremely rich in vegetation the luxuriant green leaves covered. Different species of
pandanus species are very common by the side of village road.The dominant species found
is Albizia lebbeck (Sirish) and co-dominant species found are again Casuarina equisetifolia
(Jhau) and Anacardium Occidentale respectively. In the beach area Casuarina equisetifolia
form a beautiful green cover. The shrubs like piper betel, Calotropis, Datura, Solanum,
Acanthus, Opuntia andLantana etc.are also dominant in this areaareas.
The coastal area is few patches of mangrove were observed near Mahanadi estuary area
and Jatadhar creek. Typical among them as observed is Avicennia officinalis, Bruguiera
gymnorrhiza, Ceriops decandra etc. List of the flora observed in the study area is provided
in Table 3.26& Table 3.27.
Table 3.26 : List of Flora present in Study Area S. No. Scientific Name Family Common Name
1 Aegle marmelos Rutaceae Bel 2 Alangium salvifolium Lecythidaceae Akar Kanta 3 Albiziz libbek Mimosaceae Sirish 4 Annona reticulate Annonaceae Nona ata 5 Atrocarpus heterophyllus Moraceae Kanthal 6 Azadirachta indica Meliaceae Neem 7 Acacia euriculiformis Mimosaceae Akashmoni 8 Achrus zapota Sapotaceae Sabada 9 Ailanthus excelsa Simaroubaceae Maharukk 10 Albizia odoratissima Mimosaceae Kalo Sirish 11 A. procera Mimosaceae Safed Sirish 12 Alstonia macrophylla Apocynaceae Match Stick Tree 13 Anthocephalus cadamba Rubiaceae Kadam 14 Acacia nilotica Mimosaceae Black Babool 15 Anogeissus acuminate Combretaceae Dhaura 16 Barringtonia acutangula Lecythidaceae Hijal 17 B. racemosa Lecythidaceae Samudra 18 Bombax ceiba Bombacaceae Shimul 19 Butea monosperma Papillonaceae Palash 20 Carica papaya Caricaceae Pepe 21 Caesalpinia pulcherrima Caesalpiniaceae Krishnachura 22 Callistemon lanceolatus Myrtaceae Bottle Brush 23 Calophyllum inophyllum Clusiaceae Sultani Champa 24 Cassia biflora Leguminosae Cassia 25 Polyalthia longifolia Annonaceae Debdaru
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26 Dillenia indica Dilleniceae Chalta 27 Cassia fistula Caesalpiniaceae Bandar Lathi 28 Cassia siamea Caesalpiniaceae Holud Sandal 29 Casuarina equisetifolia Casuarinaceae Jhau 30 Crescentia cujete Bignoniaceae Calabus Tree 31 Coccoloba uvifera Polygonaceae Sea Grape 32 Diospyros kaki Ebenaceae Gab 33 D. Peregrina Ebenaceae Gab 34 Delbergia sissoo Fabaceae Shishu 35 Delonix regia Caesalpiniaceae Radha Chura 36 Delbergia spinasa Fabaceae Red Wood 37 Erythrina ovalifolia Papillonaceae Harikakra 38 Eucalyptus globules Myrtaceae Blue Gum 39 Feronia limonia Rutaceae Kad Bel 40 Ficus benghalansis Moraceae Bat Gach 41 Ficus hispida Moraceae Fig 42 Ficus racemosa Moraceae Gular 43 Ficus religiosa Moraceae Ashwatha 44 Ficus benjamina Moraceae Javan Fig 45 Grewia asiatica Tiliaceae Phalsa 46 Holarrhena antidysenterica Apocynaceae Kurchi 47 Jacaranda mimosifolia Bignoniaceae Vila Gulmohar 48 Kandelia candel Rhizophoraceae Candel Tree 49 Leucaena leucocephala Mimosaceae Subabool 50 Lagerstroemia speciosa Lythraceae Jarul 51 Lagerstroemia indica Lythraceae Pharas 52 Lumnitzera racemosa Combretaceae Kripa 53 Mangifera indica Anacardiaceae Mango 54 Moringa oleifera Moringaceae Sajne 55 Mangolia grandiflora Magnoliaceae Barachampa 56 Michelia champa Magnoliaceae Champa 57 Morinda citrifolia Rubiaceae Achamia 58 Mymusops elangi Sapotaceae Bakul 59 Nactyanthus arbor-tristis Oleaceae Sheuli 60 Polyalthia suberosa Annonaceae Barachali 61 Pongamia pinnata Papilionaceae Karanja 62 Psidium guajava Myrtaceae Amrud 63 Pterocarpus indicus Papilionaceae Malay Paduka 64 Putranjiva roxburghii Euphorbiaceae Child Life Tree 65 Peltophorum Ferrugineum Caesalpiniaceae Radha Chura 66 Plumeria acutifolia Apocynaceae Garur Champa 67 Plumeria rubra Apocynaceae Garur Champa 68 Parkinsonia aculeate Caesalpiniaceae Vilayati Babool 69 Saraca indica Caesalpiniaceae Ashok 70 Sesbania grandiflora Papilionaceae Bak Phool 71 Spondius pinnata Anacardiaceae Amra 72 Streblus asper Moraceae Sheara 73 Strychnos nuxvomica Lagamiaceae Kuchila 74 Syzygium cuminii Myrtaceae Kalo Jam 75 Swietenia mahogani Meliaceae Mehagani 76 Tamarindus indica Caesalpiniaceae Tentul 77 Trema orientalis Moraceae Jibanti 78 Trewia nudiflora Euphorbiaceae Pittuli 79 Tabebuia pallida Bignoniaceae Parul 80 Tecoma stans Bignoniaceae Chandra Prabha 81 Tectona grandis Verbenaceae Sagaun 82 Terminalia catappa Combretaceae Kath Badam 83 Terminalia arjuna Combretaceae White Murdah
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84 Thespesia populnea Malvaceae Palas Pipul 85 Ziziphus mauritiana Rhamnaceae Kul
Table 3.27 : List of Herbs & Shrubs S. No. Scientific Name Family Common Name
1 Acalypha hispida Euphorbiaceae Acalypha 2 Abelmoschus manihot Malvaceae Bon Vendi 3 Abutilon indicum Malvaceae Patari 4 Achyranthes aspera Amaranthaceae Apang 5 Bryophyllum sp Crassulaceae Patharkuchi 6 Calotropis procera Asclepiadaceae Akanda 7 Calotropis esculanta Asclepiadaceae Sweet Akanda 8 Canna indica Cannaceae Kalabati 9 Carissa carandas Apocynaceae Karamcha 10 Carissa esculanta Apocynaceae Karamcha 11 Cassia tora Caesalpiniaceae Chakundi 12 Catharanthus roseus Apocynaceae Nayantara 13 Capparis spinosa Capparidaceae Kabra 14 Cestrum nocturnum Solanaceae Hasnuhama 15 Celosia cristata Amaranthaceae Morog Jhuri 16 Datura metel Solanaceae Dhatura 17 Euphorbia leucocephala Euphorbiaceae Pheeljhuri 18 Lantana camara Verbenaceae Chotra 19 Moringa pterygosperma Moringaceae Sajna 20 Nerium indicum Apocynaceae Karobi 21 Nerium oleander Apocynaceae Rose Bay 22 Opuntia dillenii Cactaceae Phanimansa 23 Ocimum sp. Labiatae Tulsi 24 Pandanus tectorius Pandanaceae Keya 25 Pandanus foetidus Pandanaceae Keya Kanta 26 Pandanus fascicularis Pandanaceae Keya 27 T. diuaricata Apocynaceae Tagar 28 Thevetia peruviana Apocynaceae Kolkaful 29 Tephrosia purpurea Papilionaceae Ban Neel 30 Tridax procumbens Compositae Tridakshya 31 Piper betle Piperaceae Betel
3.11.3. Medicinal Plants
Ayurveda says ―There is no plant on the earth, which does not possess medicinal property‖,
this means that each and every plant is equally important for its biological activities, ecology
and environment. The conservation of medicinal plants means every species of plants in its
natural habitat should be protected and preserved. Conservation of invaluable biodiversity is
a national and international agenda. Because of continuous exploitation of medicinal plants
from their natural habitats, it is required to replant and regenerate them in other areas
having similar habitat or environment. Due to over exploitation of natural resources many
plant species have become extinct from the world.
During the field survey of the study area, it was observed that the medicinal plant species
occurred in a sporadic manner and only a few medicinal plant species could be identified.
Some of the medicinal plant species as could be recorded are Acalypha sps. (Muktajhuri).
Ocimum sanctum (Tulasi), Cassia fistula, Aegle marmelos (bel) etc are common varieties of
medicinal plant species.
3.11.4. Agricultural crop
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The study area is under the agro ecological region of hot subhumid to semi-arid eco region
with coastal alluvium derived soils. The length of growing period of corps is 90–210 days.
The normal annual rainfall is about 1,600 mm. The soil is sandy clayey with medium nutrient
level. The microbial population indicates that the soil is favourable for the growth of
agricultural crops. The principal food crop is paddy followed by pulses, potatoes, oil seeds
and vegetables etc. Fruit trees are mango, jack fruit, guava, tamarind, banana etc. The
garden vegetables are onion, cucumber, tomato, beans, pea, cabbage, cauliflower etc.
3.11.5. Mangrooves
Mangrove vegetation together with mud flats traversed through a network of tidal creaks like
Jatadhar Mohan creek etc., except some areas which are Sandy shoreline. Mangrove
vegetation provides food for fishes, prawns and other animals. The mangrove plays a vital
role in the economy of the area both for human beings as well as for the fauna. Main flora of
mangroves are fonned of Avicennia officina/es, A. alba, A. marina, Rhizophora mucronate
which are more abundant on the banks of the Mahanadi river mouth and are characterized
by reddish and jo~nted pneumatophores.
3.11.6. Threatened Plant Species
Threatened taxa are those species which are vulnerable to endangerment in the near future.
Threatened status of any taxa is not a single category but is a group of there categories,
critically endangered, endangered and vulnerable. On the application of different criteria of
IUCN for the assessment of conservation status of taxa, no taxa were found threatened in
the study area. The reported taxa have also not been enlisted in the Red Data Book of
Indian plants (Nayar and Shastry, 1988).
Rare and Endangered Plant Species in the Study Area: No rare and endangered plant
species was observed in the study area (Source: Red Data Book of Indian Plants, N.P
Nayar and A. P. K. Sastry, B.S.I. 1988).
3.11.7. Faunal Biodiversity
Most of the land within 10 km radius of the project site is under cultivation, waterbodies,
open shrub and grasses and settlement respectively. There is about 15.56% land is under
open shrub & grass land. The percentage landcover with different types of vegetations in the
study area is about 8.3%. Such scanty vegetation coupled by speedy industrial development
has left the area devoid of any significant faunal species or wildlife. A faunistic checklist of
the study area has been prepared that brings out that the study area is not a habitat for wild
lives. The fauna species as observed during field survey and reported by the local people
are mostly of Schedule IV and V categories such as Funambulus pennant (Palm Squirrel),
Hystrix indica (Procupine), Naja naja (Indian Cobra), Vipera sp (Bora Snake) etc and are
also commonly sited. List of fauna found in the study area is presented in Table.3.28. The
listed fauna has been cross-checked with Red Data Book of Indian Animals (Zoological
Survey of India). There is no endangered or critical faunal species in the study area.
Table 3.28 : List of the Fauna Recorded in Study Area
S. No. Scientific Name Common Name Conservation status as per Wildlife Protection Act
(1972) Mammals 1 Macaca mulatta Rhesus Monkey Sch-II 2 Presbytis entellus Langur Sch-II 3 Funumbulus pennant Palm Squirrel Sch-IV
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4 Hystrix indica Procupine Sch-IV 5 Vulpes bengalensis Fox Sch-II
Reptiles & Amphibians 1 Gecko gecko Tucktoo Sch-IV 2 Hemidactylus leschenumti Tree Gecko Sch-IV 3 Hemidactylus flavivirids Wall Lizard Sch-IV 4 Calotes versicolor Garden Lizard Sch-IV 5 Trimeresures gramineus Bamboo Pit Riper Sch-IV 6 Varanus sp Water Monitor Sch-IV 7 Ptyas mucosus Common Rat Snake Sch-II 8 Vipera russielli Ressell‘s Viper Sch-II 9 Naja naja Indian Cobra Sch-II 10 Bungarus Caeruleus Common Indian Krait Sch-IV 11 Bungarus Fasciatus Sakhamuti Sch-IV
3.11.8. Avifaunal Investigation
Avifauna is an important part of the ecosystem playing the various roles as scavengers,
pollinators, predators of insect, pest, etc. They are also one of the bio indicators of different
status of environment and affected by urbanization, industrialization and human
interference. They can be used as sensitive indicators of pollution and malfunction of
ecosystem. The study area is inhabited by thirty-seven species of birds. The list of avifauna
observed in the study area is given in Table 3.29.
Table 3.29 : List of the Birds Surveyed / Recorded in the Study Area
S. No. Scientific Name Common Name Conservation status as per Wildlife Protection Act
(1972) 1 Acridotheres tristis Common Myna Sch-IV 2 Acrocephalus aedon Thick Billed Wrabler Sch-IV 3 Acrocephalus stentoreus Indian Great Red Wrabler Sch-IV 4 Apus pacifieus House Swift Sch-IV 5 Artamus tuscus Ashy Wood Swallow Sch-IV 6 C. macrorhynchos Large billed Crow Sch-IV 7 Centropus sinensis Coucal Sch-IV 8 Clamator Pied Cuckoo Sch-IV 9 Columba livia Rock Pigeon Sch-IV 10 Copsychus saularis Oriental Magpie Robin Sch-IV 11 Corvus splendens House Crow Sch-IV 12 Cuculum varius Common Hawk Cuckoo Sch-IV 13 Cypsiurus balasiensis Palm Swift Sch-IV 14 D. aeneus Bronzed Drongo Sch-IV 15 D. leucophaeus Ashy Drongo Sch-IV 16 Dendrocitta vagabunda Refous Treepie Sch-IV 17 Dicrurus macrocurcus Black Drongo Sch-IV 18 Hirundo rustica Barn Swallow Sch-IV 19 Lanius tephronotus Gray Backed Shrike Sch-IV 20 Lenchura malacca Black Headed Munia Sch-IV 21 M. flava Yellow Wagtail Sch-IV 22 Milvus migrans Pariah Kite Sch-IV 23 Motacilla alba White Wagtail Sch-IV 24 O. xanthornus Black Hooded Oriole Sch-IV 25 Oriolus oriolus Eurarian Golden Oriole Sch-IV 26 Orthotomus sutorius Common Tailored Bird Sch-IV 27 P. cafer Red Vented Bulbul Sch-IV 28 P. krameri Rose ringed Parakeet Sch-IV
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29 Passer domesticus House Sparrow Sch-IV 30 Pluvialis apricaria Golden Plaver Sch-IV 31 Psittacula cupatria Alexandrine parakeet Sch-IV 32 S. decaocta Collarded Dove Sch-IV 33 Streptopeliua chinensis Spotted Dove Sch-IV 34 Sturnus contra Asian Pied Myna Sch-IV 35 Upupa epops Common Hoopoe Sch-IV 36 V. indicus Red Wattled Lapwing Sch-IV 37 Vanellus cinereus Grey Headed Lapwing Sch-IV
Aquatic Environment
The land based water bodies in the study area occupy about 23.58 per cent comprising
ponds, standing flood water, rivers/streams and sea. The major water body is sea occupying
maximum part. The main land based water bodies present in the study area are Mahanadi
river, Santra nala, Mahanga nala, Taldanga canal, other streams and Jatadharmohan River
Creek.
Fisheries: Fishing is the main occupation of the fisherman. As per the informal consultation
with the fishermen at present more than 600 small fishing trawlers and about seventy large
fishing trawlers are engaged in coastal fishing and deep sea fishing through Paradeep Port
day in and day out. Presently, they are not directly operating through the Port but through
the Fishing Harbour connected to the Bay of Bengal through the river Mahanadi. Variety of
marine fishes catches reported from the study area. The marine fish catch comprises of
Rays, cat fishes, Clupeids, Crockers, Threadfin, Breams, Ribbon fishes, sole, Crabs,
Prawns and Stomatopod.
Inland water Fishery: The riverine resources of the study area comprises namely
Mahanadi river, Santra nala, Mahanga nala, Taldanga canal, other streams and
Jatadharmohan River Creek. Because of high salinity mostly estuarine fishes, prawn and
crabs are captured by various means of gears. The important fish varieties are Mysteus
guilio, Mugil cephalus, M. parsian, M macrolepi, Polyneuis spp. Glossogebius spp. Penaeus
indicus, P. mondon and crabs.
With reference to the fresh water culture fishes, the dominant catches are Catla catla, Lebeo
rohita, Lebeo bata, Catla catla, cyprinus carpio and cat fishes.
3.12. Socio-Economic Environment
Description of Social Environment
As per the Census Records of India 2011, the study area has a total of 84 revenue villages
including 2 towns namely, Paradeep (M) & Paradeep garh (CT) of Odisha. All revenue
villages/Towns are mainly under Six (06) Tehsils namely, Marsaghai & Mahakalapada of
Kendrapara District and Paradeep, Paradeep Lock, Kujang & Abhyachandpur of
Jagatsinghpur District in Odisha. About 60% area is under habitation and remaining 40%
part (NE to SW) is covered by Sea (Bay of Bengal).
The study area is laying mainly in two districts namely Kendrapara and Jagatsinghpur in
Odisha state. About 63 revenue villages and 2 towns belong to Jagatsinghpur District and
19 revenue villages belong to Kendrapara District of Odisha state.
Demographic & Socio-Economic Features
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Demography is one of the important indicators of environmental health of an area. It
includes population, sex ratio, number of households, literacy, population density, etc. In
order to assess the Demographic & Socio-economic features of the area, Census data of
2011, for the concerned District Jagatsinghpur, in Odisha State was compiled and placed in
the form of tabulation and graphical representation.
As per the census records4 2011, Jagatsinghpur district has a population of 1,136,971
persons. The district has a population density of 682 inhabitants per square kilometre. Its
population growth rate over the decade 2001-11 was recorded as 7.5%. Jagatsinghapur
District also has a sex ratio of 968 females for every 1000 males, and an average literacy
rate of 86.6%. In terms of population per sq.km Jagatsinghapur is 2nd densely populated
district in the state.
Population Distribution within 2.0-km radial Zone of the Study Area
As per the census records 2011, the total population of the 2.0 km radial zone of study area
was recorded as 632 persons of Five (05) revenue villages of two tehsils named Paradeep
Lock & Abhayachandapur of Jagatsinghpur District of Odisha state. Total number of
‗Households‘ was observed as 149 in the 2.0-km radius study zone. Male-female wise total
population was recorded as 319 males and 313 females respectively. Scheduled Caste
(‗SC‘) population was observed as 112 consisting of 58 males and 54 females in the 2.0km
radial study zone. Scheduled Tribes (‗ST‘s) were found only 12 persons consisting of 7
males and 5 females respectively.
Caste wise population distribution of the 2.0-km radial study zone is shown in Table 3.30 as
follows;
Table 3.30 : Caste-wise Population Distribution of 2.0-km Radial Zone
Name of the
Village
No of
Househol
ds
Total Population
Scheduled
Castes
Scheduled
Tribes
Tahsil/
District
Person
s
Male Femal
e
Male Femal
e
Male Femal
e
Niharunikandh
a 58 251 129 122 29 26 0 0
Paradeep Lock
Niharuni 72 314 160 154 27 25 0 0
Chauliapalanda 6 30 13 17 0 0 0 0 Abhayachanda
pur Abhayachanda
pur 8 28 13 15 0 0 7 5
Kansaripatia 5 9 4 5 2 3 0 0
Sub-Total
(0-2km) 149 632 319 313 58 54 7 5
Source-Census Records 2011
Population Distribution within 10.0-km radial Zone of the Study Area
4(Source-https://en.wikipedia.org/wiki/Jagatsinghpur_district)
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 196
As per the ‗Census Records of India, 2011‘ the total population of the study area is observed
as 181030 persons, the total number of Households (Families) are recorded as 41723.
Male-Female wise population in the study area was observed as 95108 (52.5%) and 85922
(47.5%) respectively. The child population of the study area is recorded as 19475 and
comprising of 10173 (52.2%) males & 9302 (47.8%) females respectively. Village-wise
details of population distribution are given in Table 3.31 and Village-wise SC/ST details of
population distribution are presented in Table3.32.
Table 3.31 : Village-wise Population Distribution of Study Area
Name of Village
No. of
Household
Total Population
Child Population
(0-6 Years)
Total Male Female Total Male Female
0-2km Radial Study Zone
Niharunikandha 58 251 129 122 39 15 24
Niharuni 72 314 160 154 44 25 19
Chauliapalanda 6 30 13 17 6 3 3
Abhayachandapur 8 28 13 15 5 3 2
Kansaripatia 5 9 4 5 0 0 0
Total (0-2km) 149 632 319 313 94 46 48
Musadia 810 2852 1625 1227 387 205 182
Paradeep (M) 17485 68585 37300 31285 7403 3984 3419
Baharatari 32 140 72 68 10 6 4
Bhutumundai 850 3933 2035 1898 422 218 204
Singitalia 170 880 457 423 81 48 33
Pipal 480 2573 1326 1247 244 132 112
Chakradharpur 180 851 432 419 94 44 50
Balidia 386 1972 989 983 228 116 112
Nuagarh 525 2565 1282 1283 309 166 143
Udayabata 449 1953 1008 945 291 150 141
Chunabelari 353 1717 878 839 195 99 96
Nimidhihi 261 1371 704 667 163 82 81
Katakulla 182 890 464 426 84 42 42
Katha-ada 107 417 243 174 35 27 8
Koladia 96 430 225 205 47 20 27
Jagati 245 1232 611 621 143 70 73
Nunukua 293 1380 696 684 148 79 69
Narendrapur 319 1442 750 692 151 82 69
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EQMS India Pvt. Ltd. 197
Kothi 425 2074 1063 1011 187 92 95
Jhimani 595 2963 1502 1461 314 150 164
Siju 303 1531 776 755 172 85 87
Pitambarpur 143 680 343 337 77 31 46
Uchhabanandpur 157 908 467 441 102 55 47
Paradeep garh
(CT) 1006 4790 2425 2365 505 268 237
Kujanga 825 3686 1914 1772 367 188 179
Baidigadi 52 227 115 112 23 12 11
Krushnachandrapur 37 162 90 72 18 9 9
Santara 338 1683 872 811 166 95 71
Talapada 80 342 182 160 36 18 18
Mangarajpur 724 3314 1674 1640 309 150 159
Hasina 509 2252 1170 1082 182 103 79
Duadia 485 2282 1155 1127 248 136 112
Pangara 98 478 249 229 33 19 14
Fatepur 581 2840 1495 1345 330 174 156
Pratappur 223 945 455 490 109 48 61
Kharigotha 210 1057 538 519 121 62 59
Barunakandha 41 190 105 85 15 8 7
Gopiakuda 962 4293 2211 2082 451 245 206
Ghodamara 121 593 309 284 58 37 21
Panpalli 372 1591 791 800 168 90 78
Mallipura 147 686 366 320 69 39 30
Baulanga 300 1429 738 691 134 77 57
Badabandha 196 889 460 429 90 46 44
Parapada 71 360 189 171 35 19 16
Mulakani 47 238 127 111 23 16 7
Bamadeipur 710 3161 1592 1569 346 172 174
Chhatarakandha 124 524 268 256 64 33 31
Kuatarakandha 17 65 35 30 10 6 4
Banapatakandha 135 631 332 299 45 18 27
Kokakhandha 35 129 65 64 24 14 10
Balitutha 297 1231 598 633 138 65 73
Badabuda 149 688 353 335 54 27 27
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Kankardia 445 2086 1050 1036 231 101 130
Sunadiakandha 90 342 183 159 44 22 22
Bagadia 544 2736 1422 1314 293 161 132
Nuagan 1248 5185 2674 2511 424 223 201
Panigadiakandha 4 12 6 6 1 0 1
Dhinkia 832 4141 2114 2027 365 172 193
Trilochanpur 554 2803 1436 1367 250 123 127
Jamukana 167 680 330 350 69 35 34
NaladiaSasan 154 648 336 312 53 24 29
Patalipanka 701 3132 1612 1520 304 153 151
Raghunathpur 122 579 300 279 60 35 25
Kodakan 131 628 337 291 77 44 33
Chhanda 214 998 517 481 109 61 48
Gararomita 454 1953 977 976 219 101 118
Rajendra Nagar 32 158 79 79 24 13 11
Nalitajori Pal 33 168 78 90 34 12 22
Dasarajapur 16 61 30 31 3 1 2
Akhadasali 35 174 89 85 26 12 14
Palli Garh 133 666 336 330 88 37 51
Bahakuda(Pitapat) 460 2159 1090 1069 339 166 173
Baraja Bahakuda 345 1690 846 844 232 118 114
Banabiharipur 1 6 3 3 0 0 0
Badatubi 230 1061 541 520 144 66 78
Nipania 69 331 168 163 46 21 25
Jogidhankud 13 63 60 3 0 0 0
Saralikud 16 146 140 6 0 0 0
Barakoli Khala 799 3697 1914 1783 488 249 239
Total (0-10km) 41729 181030 95108 85922 19475 10173 9302
Source-Census of India, 2011
Table 3.32 : Village-wise SC & SC Population Distribution of Study Area
Name of Village
Scheduled Castes Scheduled Tribes
Persons Males Females Persons Males Females
0-2km Radial Study Zone
Niharunikandha 55 29 26 0 0 0
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 199
Niharuni 52 27 25 0 0 0
Chauliapalanda 0 0 0 0 0 0
Abhayachandapur 0 0 0 12 7 5
Kansaripatia 5 2 3 0 0 0
Total (0-2km) 112 58 54 12 07 05
Musadia 186 105 81 27 21 6
Paradeep (M) 7167 3884 3283 2924 1553 1371
Baharatari 40 20 20 1 0 1
Bhutumundai 811 422 389 4 2 2
Singitalia 100 55 45 0 0 0
Pipal 854 438 416 0 0 0
Chakradharpur 198 96 102 4 3 1
Balidia 66 29 37 4 2 2
Nuagarh 236 116 120 0 0 0
Udayabata 111 61 50 11 7 4
Chunabelari 82 44 38 4 2 2
Nimidhihi 151 73 78 5 3 2
Katakulla 42 22 20 0 0 0
Katha-ada 41 21 20 0 0 0
Koladia 352 186 166 0 0 0
Jagati 187 86 101 0 0 0
Nunukua 339 184 155 0 0 0
Narendrapur 478 256 222 0 0 0
Kothi 361 194 167 0 0 0
Jhimani 502 245 257 3 2 1
Siju 219 110 109 0 0 0
Pitambarpur 32 17 15 0 0 0
Uchhabanandpur 72 37 35 0 0 0
Paradeep garh (CT) 1807 913 894 48 25 23
Kujanga 312 160 152 4 1 3
Baidigadi 5 3 2 29 17 12
Krushnachandrapur 18 9 9 0 0 0
Santara 437 218 219 0 0 0
Talapada 41 20 21 0 0 0
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Mangarajpur 1647 838 809 0 0 0
Hasina 1260 650 610 2 2 0
Duadia 1294 661 633 7 4 3
Pangara 182 90 92 0 0 0
Fatepur 928 485 443 0 0 0
Pratappur 15 7 8 0 0 0
Kharigotha 61 35 26 0 0 0
Barunakandha 16 10 6 0 0 0
Gopiakuda 3264 1676 1588 1 1 0
Ghodamara 359 188 171 0 0 0
Panpalli 179 89 90 0 0 0
Mallipura 58 37 21 0 0 0
Baulanga 196 100 96 1 1 0
Badabandha 98 55 43 6 3 3
Parapada 86 49 37 0 0 0
Mulakani 0 0 0 0 0 0
Bamadeipur 919 469 450 3 1 2
Chhatarakandha 0 0 0 0 0 0
Kuatarakandha 0 0 0 0 0 0
Banapatakandha 57 32 25 0 0 0
Kokakhandha 0 0 0 0 0 0
Balitutha 320 154 166 0 0 0
Badabuda 74 37 37 0 0 0
Kankardia 240 116 124 0 0 0
Sunadiakandha 35 19 16 0 0 0
Bagadia 887 469 418 0 0 0
Nuagan 547 294 253 0 0 0
Panigadiakandha 3 1 2 0 0 0
Dhinkia 1649 831 818 2 2 0
Trilochanpur 935 475 460 0 0 0
Jamukana 358 173 185 0 0 0
NaladiaSasan 74 43 31 0 0 0
Patalipanka 1298 688 610 0 0 0
Raghunathpur 0 0 0 0 0 0
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 201
Kodakan 480 256 224 0 0 0
Chhanda 41 24 17 0 0 0
Gararomita 507 245 262 0 0 0
Rajendra Nagar 41 18 23 0 0 0
Nalitajori Pal 0 0 0 0 0 0
Dasarajapur 3 2 1 0 0 0
Akhadasali 6 5 1 0 0 0
Palli Garh 303 145 158 0 0 0
Bahakuda(Pitapat) 673 334 339 0 0 0
Baraja Bahakuda 176 88 88 464 220 244
Banabiharipur 0 0 0 0 0 0
Badatubi 27 15 12 0 0 0
Nipania 72 33 39 0 0 0
Jogidhankud 33 31 2 0 0 0
Saralikud 95 92 3 0 0 0
Barakoli Khala 16 7 9 0 0 0
TOTAL 34871 18148 16723 3566 1879 1687
Source-Census of India, 2011
Urban and Rural Population
As per the Census Records of India 2011, the study area has a total of 84 revenue villages
including 2 towns namely, Paradeep (M) & Paradeep garh (CT) of Odisha. Out of the total
no. of household as 41729, about 44.3% & 55.7% are recorded for Urban and Rural parts of
the study area. The total population was observed as 40.5% & 59.5% for Urban and Rural
parts respectively in the study area. Detailed compiled description of Urban and Rural
population distribution (Male-female and SC/ST Wise) is presented in Table 3.33 & 3.34 as
follows;
Table 3.33 : Male-female wise Urban & Rural Population Distribution in the Study Area
S. No.
Name of the Town No. of Households
Total Population Persons Males Females
1. Paradeep (M) 17485 68585 37300 31285
2. Paradeep Garh (CT) 1006 4790 2425 2365
Total Urban (0-10km) 18491
(44.3% )
73375 (40.5%) 39725
(41.8 %)
33650 (39.2%)
Total Rural (0-10km) 23238 (55.7%)
107655 (59.5%)
55383 (58.2%)
52242 (60.8%)
Grand Total (Urban+Rural)
41729 181030 95108 85922
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EQMS INDIA PVT. LTD. 202
Source-Census of India, 2011
Table 3.34 : SC & ST Population Distribution in the Urban & Rural Parts of the Study Area
S. No.
Name of the Town Scheduled Castes Scheduled Tribes Persons Males Females Person
s Males Females
1. Paradeep (M) 7167 3884 3283 2924 1553 1371 2. Paradeep Garh (CT) 1807 913 894 48 25 23
Total Urban (0-10km) 8974 (25.7%)
4797 (26.4%)
4177 (25.0%)
2972 (83.3 %)
1578 (84.0%)
1394 (82.6%)
Total Rural (0-10km) 25897 (74.3%)
13351 (73.6%)
12546 (75.0%)
594 (16.7%)
301 (16.0%)
293 (17.4%)
Grand Total (Urban+Rural) 34871 18148 16723 3566 1879 1687
Source-Census of India, 2011
Sex Ratio
The ‗Sex Ratio‘ of the study area is a numeric relationship between females and males of an
area and bears paramount importance in the present-day scenario where the un-ethnic pre-
determination of sex and killing of female foetus during pregnancy is practiced by
unscrupulous medical practitioners against the rule of the law of the country. It is evident
that by contrast the practice of female foeticide is not prevalent in the study area.
As per the census records 2011, the entire study area is falling in Jagatsinghpur district of
Odisha. The ‗Sex Ratio‘ was observed as 968 females per 1000 males in the District. The
same was recorded as 903 females for every 1000 males in the study area. The child (0-6
year age) sex ratio of the district was observed as 914 female children per 1000 male
children. The village wise male-female population distribution for the study area is depicted
and shown by graphical representation in Figure 3.30.
Figure 3.25 : Male-Female Wise Population Distribution
SC / ST Population
0
50000
100000
150000
200000
Total Population Male Population Female Population
Total Population, 0-10km
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 203
On the basis of the village wise SC & ST population distribution of the study area during
2011, the ‗Scheduled Castes‘ population was observed as 34871 persons consisting of
18148 males and 16723 females respectively in the study area which accounts as 19.3% to
the total population (as 181030 persons) of the study area. ‗Scheduled Tribes‘ population
was observed as 3566 persons, accounting as 2.0% to the total population of the study area
consisting of 1879 males and 1687 females. It implies that the rest 78.7% of the total
population belongs to the General category. Male-female wise distribution of ‗SC‘ & ‗ST‘
population in the study area is graphically shown in Figure 3.31 as follows.
Figure 3.26 : Percentage of SC/ST Population in Study Area
Literacy Rate
Literacy level is quantifiable indicator to assess the development status of an area or region.
Male-Female wise literates and illiterates population is represented in Table 3.35. Total
literates population was recorded as 138037 persons (76.3%) in the study area. Table 3.35
reveals that Male-Female wise literates are observed as 77178 & 60859 persons
respectively, implies that the ‗Literacy Rate‘ is recorded as 76.3% with male-female wise
percentages being 42.6% & 33.6% respectively. The total illiterate‘s population was
recorded as 42993 persons (23.8%) in the study area. Male-Female wise illiterates were
17930 (9.9%) and 25063 (13.8%) respectively. The Male-Female wise graphical
representation of literates & illiterates population in study area villages/town is shown in
Figure 3.32.
Figure 3.27 : Male-Female wise Distribution of Literates & Illiterates
Table 3.35 : Male-female wise Literates & Illiterates
05000
100001500020000250003000035000
Total SC Population,0-10km
01000200030004000
Total ST Population, 0-10km
020,00040,00060,00080,000
100,000120,000140,000
Literates and Illiterates Population, 0-10km
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EQMS INDIA PVT. LTD. 204
Name of Village
Total
Population
Literates Illiterates
Person
s
Male
s
Female
s
Person
s
Male
s
Female
s
0-2km Radial Study Zone
Niharunikandha 251 196 110 86 55 19 36
Niharuni 314 221 118 103 93 42 51
Chauliapalanda 30 22 10 12 8 3 5
Abhayachandapur 28 13 7 6 15 6 9
Kansaripatia 9 7 3 4 2 1 1
Total (0-2km) 632 459 248 211 173 71 102
Musadia 2852 2205 1334 871 647 291 356
Paradeep (M) 68585 52575
3006
9 22506 16010 7231 8779
Baharatari 140 123 64 59 17 8 9
Bhutumundai 3933 3001 1676 1325 932 359 573
Singitalia 880 717 388 329 163 69 94
Pipal 2573 1991 1104 887 582 222 360
Chakradharpur 851 720 383 337 131 49 82
Balidia 1972 1506 809 697 466 180 286
Nuagarh 2565 2003 1056 947 562 226 336
Udayabata 1953 1308 719 589 645 289 356
Chunabelari 1717 1357 730 627 360 148 212
Nimidhihi 1371 1053 575 478 318 129 189
Katakulla 890 702 390 312 188 74 114
Katha-ada 417 332 194 138 85 49 36
Koladia 430 342 197 145 88 28 60
Jagati 1232 982 504 478 250 107 143
Nunukua 1380 988 538 450 392 158 234
Narendrapur 1442 1173 640 533 269 110 159
Kothi 2074 1644 909 735 430 154 276
Jhimani 2963 2166 1187 979 797 315 482
Siju 1531 1195 658 537 336 118 218
Pitambarpur 680 547 297 250 133 46 87
Uchhabanandpur 908 640 359 281 268 108 160
Paradeep garh
(CT) 4790 3709 1998 1711 1081 427 654
Kujanga 3686 3003 1631 1372 683 283 400
Baidigadi 227 167 88 79 60 27 33
Krushnachandrapu
r 162 125 72 53 37 18 19
Santara 1683 1351 731 620 332 141 191
Talapada 342 280 157 123 62 25 37
Mangarajpur 3314 2668 1432 1236 646 242 404
Hasina 2252 1674 945 729 578 225 353
Duadia 2282 1675 920 755 607 235 372
Pangara 478 388 222 166 90 27 63
Fatepur 2840 2145 1220 925 695 275 420
Pratappur 945 682 350 332 263 105 158
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EQMS India Pvt. Ltd. 205
Kharigotha 1057 810 443 367 247 95 152
Barunakandha 190 162 94 68 28 11 17
Gopiakuda 4293 3281 1821 1460 1012 390 622
Ghodamara 593 443 238 205 150 71 79
Panpalli 1591 1232 660 572 359 131 228
Mallipura 686 521 297 224 165 69 96
Baulanga 1429 1148 618 530 281 120 161
Badabandha 889 752 407 345 137 53 84
Parapada 360 288 162 126 72 27 45
Mulakani 238 199 107 92 39 20 19
Bamadeipur 3161 2362 1282 1080 799 310 489
Chhatarakandha 524 407 226 181 117 42 75
Kuatarakandha 65 53 29 24 12 6 6
Banapatakandha 631 538 296 242 93 36 57
Kokakhandha 129 95 47 48 34 18 16
Balitutha 1231 970 501 469 261 97 164
Badabuda 688 553 298 255 135 55 80
Kankardia 2086 1566 856 710 520 194 326
Sunadiakandha 342 250 146 104 92 37 55
Bagadia 2736 1985 1135 850 751 287 464
Nuagan 5185 4143 2262 1881 1042 412 630
Panigadiakandha 12 10 6 4 2 0 2
Dhinkia 4141 3181 1750 1431 960 364 596
Trilochanpur 2803 2135 1156 979 668 280 388
Jamukana 680 499 259 240 181 71 110
NaladiaSasan 648 538 299 239 110 37 73
Patalipanka 3132 2461 1348 1113 671 264 407
Raghunathpur 579 472 249 223 107 51 56
Kodakan 628 434 261 173 194 76 118
Chhanda 998 788 426 362 210 91 119
Gararomita 1953 1468 798 670 485 179 306
Rajendra Nagar 158 108 63 45 50 16 34
Nalitajori Pal 168 124 64 60 44 14 30
Dasarajapur 61 51 28 23 10 2 8
Akhadasali 174 135 75 60 39 14 25
Palli Garh 666 451 268 183 215 68 147
Bahakuda(Pitapat) 2159 1179 669 510 980 421 559
Baraja Bahakuda 1690 956 543 413 734 303 431
Banabiharipur 6 5 3 2 1 0 1
Badatubi 1061 703 411 292 358 130 228
Nipania 331 228 137 91 103 31 72
Jogidhankud 63 54 52 2 9 8 1
Saralikud 146 105 103 2 41 37 4
Barakoli Khala 3697 2598 1491 1107 1099 423 676
TOTAL (0-10km) 181030 138037
7717
8 60859 42993
1793
0 25063
Source-Census of India, 2011
Economic Structure
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 206
The majority of people in rural sector are cultivators & agricultural labors which indicates
dominant agricultural economy. A small section of people are engaged as workers in
household industries. But in urban sector the existing scenario is completely reversed as
most of the people there are engaged in non-agricultural activity especially in local
hotels/restaurants and as drivers some people also operates their vans/jeeps/cars as tourist
vehicle.
Annual income helps in identifying families below poverty line. During the field survey,
income of a household through all possible sources was recorded. Agriculture and allied
activities was reported to be the major source of income followed by non-farm wage labor,
business, Government and Private Service etc. The other important sources of income
include government pension and income from selling of fodder.
Apart from agriculture, trade & commerce, transport, storage and communication,
manufacturing, processing and repairing services engage a major chunk of population in the
district.
Major Food, Commercial &Horticultural Crops Plantation
The Major food crop grown is paddy, sugarcane; turmeric and cotton are the major
commercial crops. The district enjoys rich fertile soil of the Mahanadi, enough water
resources and receives substantial rainfall, which are conducive for raising good crops.
Workers Scenario:
‗Occupational Pattern‘ was studied to assess the skills of people in the study area.
Occupational pattern helps in identifying major economic activities of the area. The main
and marginal workers population with further classification as casual, agricultural,
households and other workers is shown in Table 3.36. In the study area the Main and
Marginal Workers population was observed as 50878 (28.1%) and 11728 (6.5%)
respectively of the total population (181030) while the remaining 118424 (65.4%) persons
were recorded as non-workers. Thus, it implies that the semi-skilled and non-skilled work-
force required in study area for the project is available in aplenty.
Table 3.36 : Village-wise Occupational Pattern in the Study Area (0-10km)
Name of
Village
MAIN
WOR
K_P
MAI
N_C
L_P
MAIN
_AL_
P
MAI
N_H
H_P
MAI
N_O
T_P
MAR
GWO
RK_P
MAR
G_CL
_P
MA
RG_
AL_
P
MAR
G_HH
_P
MAR
G_OT
_P
0-2km Radius Study Zone
Niharunikandha 88 0 14 0 74 1 0 0 0 1
Niharuni 94 1 40 0 53 0 0 0 0 0
Chauliapalanda 12 0 8 1 3 0 0 0 0 0
Abhayachandap
ur 12 0 1 0 11 2 0 0 0 2
Kansaripatia 4 0 0 0 4 1 0 0 0 1
Total (0-2km) 210 01 63 01 145 04 0 0 0 4
Musadia 1168 19 14 5 1130 20 1 6 0 13
Paradeep (M)
2217
6 56 88 426
2160
6 1948 61 17 96 1774
Baharatari 45 4 0 3 38 2 0 1 1 0
Bhutumundai 1021 514 21 15 471 108 15 67 2 24
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 207
Singitalia 257 71 7 5 174 8 0 0 0 8
Pipal 520 235 30 17 238 253 14 97 25 117
Chakradharpur 253 45 1 0 207 11 2 8 0 1
Balidia 540 141 27 7 365 103 5 73 2 23
Nuagarh 662 171 29 55 407 16 3 6 0 7
Udayabata 464 18 111 22 313 162 6 53 10 93
Chunabelari 417 86 37 53 241 114 9 56 19 30
Nimidhihi 426 42 36 38 310 16 2 2 0 12
Katakulla 235 14 117 60 44 331 85 38 60 148
Katha-ada 29 6 3 2 18 101 5 7 18 71
Koladia 72 30 2 5 35 61 4 22 12 23
Jagati 319 159 3 53 104 42 6 8 9 19
Nunukua 220 52 2 1 165 183 12 60 3 108
Narendrapur 222 26 27 32 137 342 23 31 119 169
Kothi 615 218 35 23 339 58 8 13 5 32
Jhimani 780 230 40 133 377 122 9 7 3 103
Siju 380 134 5 7 234 129 3 21 12 93
Pitambarpur 68 5 6 0 57 141 61 69 1 10
Uchhabanandp
ur 285 82 77 5 121 19 0 7 2 10
Paradeep garh
(CT) 1321 173 116 156 876 427 16 74 22 315
Kujanga 1005 177 106 15 707 74 4 24 2 44
Baidigadi 63 16 7 2 38 22 1 0 0 21
Krushnachandr
apur 50 6 3 4 37 7 0 1 4 2
Santara 716 192 69 7 448 109 7 70 3 29
Talapada 119 93 16 0 10 1 0 0 0 1
Mangarajpur 974 227 237 48 462 241 16 203 5 17
Hasina 492 216 27 13 236 206 10 34 5 157
Duadia 710 201 136 29 344 196 6 179 1 10
Pangara 82 1 1 6 74 82 20 17 5 40
Fatepur 1010 178 254 9 569 346 198 36 4 108
Pratappur 288 170 42 1 75 46 1 37 0 8
Kharigotha 271 163 38 16 54 83 14 30 13 26
Barunakandha 46 32 3 0 11 20 3 9 0 8
Gopiakuda 973 193 87 116 577 358 67 75 14 202
Ghodamara 158 27 9 2 120 90 15 39 0 36
Panpalli 439 231 81 1 126 53 1 36 4 12
Mallipura 161 96 9 4 52 23 3 3 2 15
Baulanga 226 75 86 15 50 155 120 17 1 17
Badabandha 219 173 8 1 37 7 1 0 0 6
Parapada 62 50 1 2 9 67 9 50 0 8
Mulakani 46 31 1 4 10 37 0 33 0 4
Bamadeipur 655 274 145 10 226 392 66 257 3 66
Chhatarakandh
a 93 63 1 0 29 142 2 18 2 120
Kuatarakandha 18 18 0 0 0 3 0 0 0 3
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EQMS INDIA PVT. LTD. 208
Banapatakandh
a 215 73 80 1 61 15 1 11 0 3
Kokakhandha 8 2 2 0 4 33 2 30 0 1
Balitutha 206 25 12 2 167 165 25 109 4 27
Badabuda 44 19 1 0 24 167 1 155 2 9
Kankardia 418 230 136 11 41 270 94 90 35 51
Sunadiakandha 78 75 0 0 3 40 0 0 0 40
Bagadia 528 133 11 14 370 302 23 9 7 263
Nuagan 1207 790 116 27 274 583 152 310 12 109
Panigadiakandh
a 3 1 0 0 2 1 0 1 0 0
Dhinkia 1136 603 342 12 179 176 48 58 7 63
Trilochanpur 804 506 175 12 111 80 11 29 5 35
Jamukana 179 44 85 17 33 49 0 16 29 4
NaladiaSasan 103 21 2 2 78 94 49 12 1 32
Patalipanka 720 328 171 14 207 99 14 39 3 43
Raghunathpur 164 88 4 37 35 259 1 2 2 254
Kodakan 182 76 67 3 36 5 0 3 1 1
Chhanda 267 125 6 7 129 17 0 4 0 13
Gararomita 426 221 42 26 137 118 13 9 31 65
Rajendra Nagar 45 32 10 0 3 0 0 0 0 0
Nalitajori Pal 34 31 0 0 3 0 0 0 0 0
Dasarajapur 18 17 0 0 1 1 0 1 0 0
Akhadasali 51 34 12 0 5 1 0 1 0 0
Palli Garh 185 95 62 0 28 3 1 2 0 0
Bahakuda(Pitap
at) 691 128 245 24 294 136 2 100 3 31
Baraja
Bahakuda 446 221 139 2 84 208 17 156 6 29
Banabiharipur 3 0 3 0 0 0 0 0 0 0
Badatubi 239 85 86 1 67 237 0 207 0 30
Nipania 48 10 3 0 35 114 42 68 0 4
Jogidhankud 35 35 0 0 0 16 15 0 0 1
Saralikud 101 100 0 0 1 26 26 0 0 0
Barakoli Khala 713 228 203 4 278 1032 583 379 3 67
Total (0-10km)
5087
8 9811 4279 1645
3514
3 11728 2034 3712 640 5342
Source-Census of India, 2011
ABBREVIATIONS:
MAIN WORKERS POPULATION: MAIN WORK_P : Main workers total population, MAIN_CL_P :
Main cultivated labour population, MAIN_AL_P : Main agricultural labour population, MAIN_HH_P
: Main workers population involved in household industries, MAIN_OT_P : Main other workers
population
MARGINAL WORKERS POPULATION:
MARG WORK_P : Marginal workers total population, MARG_CL_P : Marginal cultivated labors
total population, MARG_AL_P : Marginal agricultural labors population, MARG_HH_P : Marginal
workers involved in household industries, MARG_OT_P : Marginal other workers Population
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
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Distribution of work participation rate of the study area population is shown in Table 3.37 as
follows:
Table 3.37 : Distribution of Work Participation Rate
Occupation Class 2011
Main Workers 50878 (28.1%)
Male 46141(90.7 %)
Female 4737(9.3 %)
Marginal Workers 11728 (6.5%)
Male 7578(64.6 %)
Female 4150 (35.4 %)
Non-Workers 118424(65.4%)
Male 41389(35.0 %)
Female 77035(65.0 %)
Total Population 181030
Source: Census of India Records, 2011
Graphical representation of Workers Scenario is given below as Figure 3.33.
Figure 3.28 : Workers Scenario of Study Area
Composition of Main Workers:
The ‗Main Workers‘ were observed as 50878 persons (28.1%) to the total population of the
study area and its composition is made-up of Casual laborers as 9811 (19.3%), Agricultural
laborers as 4279 (8.4%), Household workers 1645 (3.2%) and other workers as 35143
(69.1%) respectively. Composition of Main workers is shown below as Figure 3.34.
Main Workers28.1%
Marginal Workers
6.5%
Non-Workers65.4%
Workers Scenario,0-10km
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 210
Figure 3.29 : Gender-wise Distribution of Workers
Composition of Marginal Workers:
The total marginal workers are observed as 11728 which constitute 6.5% of the total
population (181030) comprise of Marginal Casual Laborers as 2034 (17.3%), Marginal
Agricultural Laborers as 3712 (31.7%), Marginal Household laborers as 640 (5.5%) and
marginal other workers were also observed as 5342 (45.5%) of the total marginal workers
respectively. Details about marginal workers in the study area are tabulated in Table3.37.
Composition of Marginal workers is shown in Figure 3.35 as follows.
Figure 3.30 : Composition of Marginal Workers
Composition of Non-Workers:
MAIN_CL_P19.3% MAIN_AL_P
8.4%
MAIN_HH_P3.2%
MAIN_OT_P69.1%
Composition of Main Workers Population, 0-10km
MARG_CL_P17.3%
MARG_AL_P31.7%
MARG_HH_P5.5%
MARG_OT_P45.5%
Composition of Marginal Workers Population, 0-10km
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 211
The total Non-workers population was observed as 118424 which constitute 65.4% to the
total population (181030) of the study area. Male-female wise Non-workers population was
recorded as 41389 Males (35.0%) and 77035 Females (65.0%) respectively. Details about
Total Non-workers in the study area are compiled in Table 3.38. Graphical representation of
Non-workers population is shown in Figure 3.36 as follows;
Table 3.38 : Composition of Non-Workers
Non-Workers Population
Persons Males Females
118424 41389 (35.0%) 77035 (65.0%)
Figure 3.31 : Composition of Non-Workers
3.10.1 Basic Infrastructure Facilities Availability (as per the census records of 2011)
A review of Basic infrastructure facilities (Amenities) available in the study area has been
done on the basis of the Field survey and Census records, 2011 for the study area inhabited
revenue villages of Jagatsinghpur District in Odisha. The study area has an average level of
basic infrastructure facilities like educational, medical, potable water, power supply, and
transport & communication network. Entire study area is predominantly rural except one
town namely; Paradeep (M). Agriculture is the main occupation of the study area
inhabitants.
As per the Census Records of India 2011, the study area has a total of Eighty Four (84)
revenue villages including two (02) towns namely, Paradeep (M) and Paradeep garh (CT)
of Odisha. All revenue villages/Towns are under Six (06) Tehsils namely,Marsaghai &
Mahakalapada of Kendrapara District and Paradeep, Paradeep Lock, Kujang &
Abhyachandpur of Jagatsinghpur District in Odisha.
The study area is mainly laying in two districts namely Kendrapara and Jagatsinghpur in
Odisha state. About sixty three (63) revenue villages and two (02) towns belong to
Jagatsinghpur District and nineteen (19) revenue villages belong to Kendrapara District of
Odisha state.
3.13. Education Facilities
0
20000
40000
60000
80000
100000
120000
Total Non-Workers
Male Non-Workers
Female Non-Workers
Non-Workers Population, 0-10km
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EQMS INDIA PVT. LTD. 212
There are about ninety two (92) Primary Schools existing in the study area. Middle Schools
are forty (40 no‘s) in the study area villages. Only twenty two (22 no‘s) Higher Secondary
Schools are available in the study area. Senior Secondary School facility is available only in
two (02) revenue village named Kujanga & Jhimani village of the study area. The
educational facilities have been further strengthening now and a number of private public
schools and colleges are also functioning in the surroundings of the study area. Besides,
there are Engineering and Medical colleges available in Towns and District headquarters
only. Higher education facilities are available in Towns of the area. There is considerable
improvement in educational facility. The villages/towns of the study area have no such
facilities can reach within 5.0 to 10.0-km range.
3.14. Medical Facilities
The medical facilities are provided by different agencies like Govt. & Private individuals and
voluntary organizations in the study area. As per the district census handbook information of
2011, no primary health center exists in the study area; most of the study area villages
depend upon the towns / district HQ of the study area having such facility. Only 11 Primary
Health Sub-Centers are exists in the rural part of the study area. Mother & Child Welfare
Centre are not exists in the study area. No primary health centre (PHC) and family welfare
centre (FWC) exists in the study area. Medical dispensaries are observed in three (3)
villages of the study area. Overall study area villages are served by average type of medical
facilities. Specialized medical facilities are available only in towns and District Headquarter
(HQ) only.
3.15. Potable Water Facilities
Potable water facility is available in most of the villages/towns of the study area. The entire
study area has plenty of good potable water facilities. Most of the villages (about 82.0%
villages) having Hand Pumps (HP) as potable water facility. Out of total eighty four (84)
revenue villages including two towns named Paradeep (M) and Paradeep garh (CT), only
thirty six (36) villages (43.0%) are served with River/Canal water in the study area. As per
the census records of 2011, about fifty four (54) villages (64.3%) are being served with
Tank/Pond/Lake in the study area. In the majority of the villages, hand pumps are commonly
observed in the study area.
3.16. Communication, Road & Transport Facilities
Apart from Post &Telegraph (P & T) services, transport is the main communication linkage
in the study area. Only about ten (10) revenue villages (12.0%) out of eighty four (84) are
served with Post Office facilities in the study area, remaining villages are depending upon
these ten (10) revenue villages and towns of the study area. The study area has average rail
and road network, passes from the area. Only four (4) villages named Nimidhihi,
Mangrajpur, Badabandha and Bagadia itself are served with railway station facility in the
study area and remaining villages depend upon these villages and towns with this facility.
Nearest town/city is Paradeep (M) at about 6.0-km away from the project site. The East
Coast Railway (ECR) line also passes across the area as well as the District HQ and most
of the villages availing this facility through the nearest railway station. Nearest Railway
Station is Paradeep Railway Station located at 3.73-km away in West direction w.r.t., the
proposed project site. Bhubaneswar Airport is about 110-kms away from the proposed site
in West direction. Most of the villages (82.0%) are served with Pucca road facility in the
study area.
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 213
About twenty four (24) villages out of the total eighty four (84) villages/towns are being
served with navigable waterways facility in the entire study area. The villages in the study
area which do not have such facility can reach within 5 to 10-km range. Mainly two (02)
towns named Paradeep (M) and Paradeep garh (CT) are available within the study area.
3.17. Banking Facility
The study area has almost all the schedule commercial banks with ATM facility at urban
areas and the district HQ.
3.18. Power Supply
It is revealed from the compiled information on Amenities availability as per the census
record of 2011; most of the villages and towns (about 100%) are electrified as about 79
villages are observed electrified for domestic purpose and about thirty-five (35) villages
(41.7%) of the study area are electrified for the all, i.e. agriculture and commercial purposes.
Almost all (about 100%) villages and towns of the study area are electrified.
Village/town wise Basic Infrastructure and Amenities availabilities data for the entire study
area is compiled and presented in Table 3.39 as follows;
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EQMS INDIA PVT. LTD. 214
Table 3.39 : Village-wise details of Basic facilities in Study Area
Name of the Village Educational Medical Drinking Water Communication &
Transport
Approach to the
Village
Power Supply Nearest Town
Distance from
Village, km P M S
S
S
S
S
CHC PHSC D T W HP TW R Tk PO P
&
T
Mob
.
BS RS PR KR NW FP ED EA
g.
EC EA
0-2km Radial Study Zone
Niharunikandha 1 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 9.0km
Niharuni 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 8.0km
Chauliapalanda 0 0 0 0 0 0 0 2 2 2 2 2 1 2 2 1 2 2 2 1 2 1 2 2 2 2 Paradeep , 7.0km
Abhayachandapur 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 8.0km
Kansaripatia 0 0 0 0 0 0 0 2 2 2 2 2 1 2 2 1 2 2 1 2 2 1 2 2 2 2 Paradeep , 20km
Total (0-2km) 1 0 0 0 0 0 0 Status for Availability and Non-Availability is shown as A (1) & NA (2) respectively
Musadia 1 1 1 0 0 0 0 2 2 1 1 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 6.0km
Paradeep (M) Urban Part Paradeep (M)
Baharatari 0 0 0 0 0 0 0 2 2 1 1 1 2 2 2 1 1 2 1 1 1 1 1 1 1 1 Paradeep , 15.0km
Bhutumundai 3 1 1 0 0 1 1 2 2 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 Paradeep , 15.0km
Singitalia 1 0 0 0 0 0 0 2 2 1 1 1 1 1 2 1 2 2 1 1 1 1 1 2 2 2 Paradeep , 13.0km
Pipal 1 1 0 0 0 1 0 2 2 1 1 1 1 2 2 1 2 2 1 1 1 1 1 2 2 2 Paradeep , 13.0km
Chakradharpur 1 1 1 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 13.0km
Balidia 2 0 0 0 0 0 0 2 2 1 2 1 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 8.0km
Nuagarh 1 1 1 0 0 1 0 2 2 1 2 1 2 2 2 1 1 2 1 1 1 1 1 2 2 2 Paradeep , 8.0km
Udayabata 0 0 0 0 0 0 0 2 2 1 2 1 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 6.0km
Chunabelari 2 1 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 10.0km
Nimidhihi 1 1 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 1 1 1 2 1 1 1 1 1 Paradeep , 8.0km
Katakulla 1 1 0 0 0 0 0 2 2 2 1 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 10.0km
Katha-ada 1 0 0 0 0 0 0 2 1 1 2 1 1 2 2 1 1 2 1 1 1 1 1 2 2 2 Paradeep , 12.0km
Koladia 1 0 0 0 0 0 0 2 2 2 1 2 1 2 2 1 1 2 1 1 1 1 1 2 2 2 Paradeep , 14.0km
Jagati 1 1 1 0 0 0 0 2 2 2 1 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 15.0km
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 215
Nunukua 1 0 0 0 0 0 0 2 2 2 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 15.0km
Narendrapur 1 0 0 0 0 0 0 2 2 2 1 2 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 13.0km
Kothi 2 1 1 0 0 1 0 2 2 2 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 15.0km
Jhimani 3 1 1 1 0 0 0 2 2 2 1 1 1 1 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 13.0km
Siju 2 0 0 0 0 0 0 2 2 2 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 14.0km
Pitambarpur 1 0 0 0 0 0 0 2 2 2 1 2 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 13.0km
Uchhabanandpur 1 0 0 0 0 0 0 2 2 2 1 2 2 2 2 1 2 2 1 1 1 1 1 2 2 2 Paradeep , 15.0km
Paradeep garh (CT) Urban Part Paradeep garh (CT)
Kujanga 3 2 2 1 1 1 0 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Paradeep , 20.0km
Baidigadi 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 1 1 1 1 1 1 Paradeep , 24.0km
Krushnachandrapur 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 1 1 1 2 2 2 Paradeep , 18.0km
Santara 2 1 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 2 1 1 2 1 1 1 1 2 Paradeep , 18.0km
Talapada 1 1 1 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 2 Paradeep , 18.0km
Mangarajpur 1 1 1 0 0 1 0 2 2 1 1 1 1 1 2 1 2 1 1 1 1 1 1 2 2 2 Paradeep , 18.0km
Hasina 2 1 1 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 1 1 1 2 2 2 Paradeep , 17.0km
Duadia 2 1 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 23.0km
Pangara 1 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 31.0km
Fatepur 1 1 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 24.0km
Pratappur 1 0 0 0 0 0 0 2 2 1 1 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 26.0km
Kharigotha 2 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 24.0km
Barunakandha 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 22.0km
Gopiakuda 3 2 1 0 0 1 0 2 2 1 1 1 1 1 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 25.0km
Ghodamara 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 23.0km
Panpalli 2 1 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 25.0km
Mallipura 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 25.0km
Baulanga 1 1 1 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 25.0km
Badabandha 1 0 0 0 0 0 0 2 2 1 2 1 1 2 2 1 2 1 1 1 1 1 1 2 2 2 Paradeep , 25.0km
Parapada 1 0 0 0 0 0 0 2 2 1 2 1 1 2 2 1 2 2 1 1 1 1 1 2 2 2 Paradeep , 29.0km
Mulakani 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 28.0km
Bamadeipur 3 1 0 0 0 0 1 2 2 1 1 2 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 30.0km
Chhatarakandha 1 0 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 32.0km
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EQMS INDIA PVT. LTD. 216
Kuatarakandha 0 0 0 0 0 0 0 2 2 2 2 2 1 2 2 1 2 2 2 1 2 1 2 2 2 2 Paradeep , 32.0km
Banapatakandha 1 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 31.0km
Kokakhandha 1 0 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 32.0km
Balitutha 1 1 1 0 0 1 0 2 2 1 2 1 1 1 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 30.0km
Badabuda 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 30.0km
Kankardia 2 1 1 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 2 1 1 2 2 2 Paradeep , 30.0km
Sunadiakandha 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 30.0km
Bagadia 3 1 0 0 0 0 0 2 2 1 1 1 1 2 2 1 2 1 1 1 1 1 1 2 2 2 Paradeep , 10.0km
Nuagan 4 2 1 0 0 1 1 2 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 1 1 1 Paradeep , 40.0km
Panigadiakandha 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 1 1 2 1 1 2 2 2 Paradeep , 25.0km
Dhinkia 3 1 1 0 0 1 0 2 2 1 1 2 1 1 2 1 2 2 1 1 2 1 1 1 1 1
Jagatsinghpur,
40.0km
Trilochanpur 1 1 0 0 0 0 0 2 2 1 1 2 1 2 2 1 2 2 1 1 2 1 1 1 2 2 Paradeep , 20.0km
Jamukana 0 0 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 1 1 2 1 1 2 1 2 Paradeep , 35.0km
NaladiaSasan 1 1 1 0 0 1 0 2 2 1 2 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 17.0km
Patalipanka 1 1 0 0 0 1 1 2 2 1 2 1 2 1 2 1 2 2 1 1 2 1 1 1 1 1
Kendrapara,
30.0km
Raghunathpur 1 1 0 0 0 0 0 2 2 1 2 1 2 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 17.0km
Kodakan 1 0 0 0 0 0 0 2 2 1 2 1 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 16.0km
Chhanda 1 1 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 21.0km
Gararomita 2 1 1 0 0 0 0 2 2 1 2 1 1 2 2 1 2 2 1 1 2 1 1 1 1 1 Paradeep , 18.0km
Rajendra Nagar 0 0 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 2 1 2 1 1 1 1 1
Kendrapara,
32.0km
Nalitajori Pal 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 2 1 2 1 1 1 1 1 Paradeep , 11.0km
Dasarajapur 0 0 0 0 0 0 0 2 2 1 2 1 1 2 2 1 2 2 2 1 2 1 1 1 1 1 Paradeep , 9.0km
Akhadasali 1 0 0 0 0 0 0 2 2 1 2 1 2 2 2 1 2 2 2 1 2 1 1 1 1 1 Paradeep , 12.0km
Palli Garh 1 1 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 2 1 2 1 1 1 1 1 Paradeep , 16.0km
Bahakuda(Pitapat) 3 0 0 0 0 0 0 2 2 1 2 2 1 2 2 1 1 2 1 1 1 1 1 1 1 1 Paradeep , 9.0km
Baraja Bahakuda 2 1 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 1 1 1 1 1 1 1 1 Paradeep , 10.0km
Banabiharipur 0 0 0 0 0 0 0 2 2 1 2 1 2 2 2 1 2 2 2 2 1 1 1 1 1 1 Paradeep , 6.0km
Badatubi 1 0 0 0 0 0 0 2 2 1 2 2 1 2 2 1 2 2 2 1 2 1 1 1 1 1 Paradeep , 10.0km
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 217
Nipania 1 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 2 1 1 1 1 1 1 1 Paradeep , 11.0km
Jogidhankud 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 2 1 1 1 1 1 1 1 Paradeep , 12.0km
Saralikud 0 0 0 0 0 0 0 2 2 1 2 2 2 2 2 1 2 2 2 1 1 1 1 1 1 1 Paradeep , 14.0km
Barakoli Khala 3 2 2 0 0 0 0 2 2 1 2 2 2 1 2 1 2 2 2 1 1 1 1 1 1 1 Paradeep , 10.0km
TOTAL
9
2
4
0
2
2
0
2 01 11
0
3
Status for Availability and Non-Availability is shown as A (1) & NA (2) respectively
Source-http://www.censusindia.gov.in/2011census/dchb/DCHB.html Abbreviations:
Educational Facilities:P-Primary School, M-Middle School, SS-Higher Secondary Schools, SSS- Senior Secondary School
Medical Facilities:CHC- Community Health Centre, PHC-Primary Health Centre, PHSC-Primary Health Sub-Centre, MCWC-Maternity and Child Welfare Centre, H-Hospital, D- Dispensary, FWC-Family Welfare
Centre
Drinking Water Facilities:T-Tap Water, W-Well Water, HP-Hand Pump, TW-Tube Well Water, R-River Water, Tk-Tank Water, O-Other Drinking Water Facility
Communication and Transport Facilities: PO-Post Office, SPO-Sub-Post Office, PTO- Post & Telegraph Office, Tel. - Telephone Connection, Mob.- Mobile Phone Coverage, BS-Bus Services, RS-Railways
Services
Approach to Village:PR- Paved Roads, KR-Kuchha Road, FP-Foot Path
Power Supply:ED-Power Supply for Domestic use, E Ag.- Power Supply for Agricultural use, EC- Power supply for Commercial use, EA-Electricity for All Purposes
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS INDIA PVT. LTD. 218
Brief Description of Places of Religious, Historical or Archaeological Importance and
Tourist interest in Villages and Towns of the District:
Sarala Pitha (Jhankad): Jhankad is the sanctum sanctorum of Goddess Sarala, regarded
as one of the most spiritually elevated expressions of Shaktism. Believed as a synthesis
of divine figure of Durga and Saraswati, the culture of Sarala is an amalgamation of three
principal Hindu cults namely Vedic, Tantrik and Vaishnavite. It is one of the eight most
famous Shakta shrines of Odisha. It is also associated with the first epic poet of Odisha,
Adikavi Sarala Dasa of 15th Century AD.
Gorakhnath Temple: Gorakhnath Temple is of among the famous Lord Shiva Shrines in
Odisha.
Paradeep: It is a major sea port of India for trade activities. The enchanting beauty of the
sea, a wonderful sea beach & marine drive, beautiful creeks, estuaries and evergreen
forests of estuarine islands of the river Mahanadi, make the place a major tourist
attraction.
Gada Kujanga: Famous for its presiding deity Kunja Behari, Garh Kujanga is also known
as Subhadra Kshetra, the Raghunath Jew Matha located near the temple of Kunja
Behari is an added attraction of this place.
Chandapur: At the end of the Village Mahilo in a typical rural atmosphere, the famous
temple complex of Lord Raghunath Jew and Lord Chandrasekhar stands around 30
years back. One can find a rare combination of Sri Ram known as Raghunath Jew and
Lord Siva known as Chandrasekhar in a single compound.
Jagatsinghpur: Alaka Ashram, better known as the Shabarmati of Odisha is located here.
Temples, beaches and sculptures of historic importance are the major drivers behind
tourist influx to Jagatsinghpur. The Somanath temple is famous for the Shiva Shrine. The
Shiva Linga was placed by Sri Muchukunda Swami and hence the image is popularly
called as Muchukunda Somanath.
Salajanga Ashram: This Ashram is located nearly 7.0-km from Naugaon hat.
Siali Beach: Siali Beach is about 20-km away from Balikuda block and the most
attracting beach of Jagatsinghpur district. It is a very good picnic spot and can be visited
during any seasons of a year.
Tulasi Gadi: Tulsi Gadi temple is located at Diasahi, approx 6.0-km from Jagatsinghpur
towards Balikuda is another place of attraction for public or family parties.
Jagannath Temple: Jagannath temple is considered as one of the oldest temples of
odisha and located in Ambasal which is about 2.0-km away from Balikuda Block.
Kunja Bihari Temple: Kunja Bihari Temple is located in Sadeipur at about 9.0-km away
from Jagatsinghpur.
Sidha Baranga Pitha: ‗Sidha Baranga Pitha‘ is located at Punanga and about 2.0-km
away from Jagatsinghpur town. It is famous for temples of Lord Janannath and Lord
Hanuman. It is also a good picnic spot of the district.
3.19. Traffic Study:
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
EQMS India Pvt. Ltd. 219
The main transportation of raw material and finished goods is via jettys and rail route.
Transportation route and sources for raw materials and the products is mentioned below:
Table 3.40 : Transportation route at Project Site
Sl.No. Raw Material Route Via
1 Sulphur Sea Jetty To B/L through Conveyor
2 Rock Phosphate Sea Jetty To B/L through Conveyor
3 MOP Sea Jetty To B/L through Conveyor
4 Sulphuric Acid Sea Jetty To B/L through Pipeline
5 Phosphoric Acid Sea Jetty To B/L through Pipeline
6 Alumina Road To B/L by Truck
7 Flurosilicic Acid - In-house
8 Ammonia Sea Jetty To B/L through Pipeline
9 Coal Sea + Rail Jetty/Rail To B/L through Conveyor
Product Route Via
1 NPK/DAP Rail/Road From B/L through Rail/Truck
2 Ammonia Road From B/L through Tanker Truck
3 Ammonium Nitrate Road/Rail From B/L through Rail/Truck
4 Nitric Acid Road From B/L through Tanker Truck
5 Alu. Fluoride Road From B/L through Truck
6 Urea Rail/Road From B/L through Rail/Truck
7 Sulphuric Acid Road From B/L through Truck
8 Phosphoric Acid Road From B/L through Truck
As the import and export of material at the PPL plant is demand based, so traffic study
can be taken tentative but not fixed. Monthly quantitative analysis for shipment, rail and
trucks was performed at site in the month of May, 2018 as mentioned below:
Table 3.41 : Quantitative Details of vehicle used for export and Import
Route No. (per month)
Shipment 4-6
Rail 30-40
Trucks 1200-1500
As the site is located close to NH-5A and all the material movement shall be done
through this highway. The NH-5A is multilane (6-lane) of very good design. Considering
total material transport from Paradeep Phosphates Limited i.e. one truck/month, the
existing highway is adequate to bear the additional load without any issue.
Traffic study was performed for minor road of PPL plant (~50 ft, 2 lane) connecting NH5A
(six lane), route for transportation and two and four wheeler of employees of PPL plant.
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Table 3.42 :Traffic study at PPL Plant road
Date of
Monitoring
:
01.05.2018
Road Lane: 2
Lane 50 ft.
Location: PPL Plant Road
Time (Hrs.) Two
wheelers
Four wheelers Light
vehicles
Heavy
vehicles
Total
6:00 95 72 29 39 235
7:00 122 104 52 78 356
8:00 159 121 43 89 412
9:00 229 233 72 121 655
10:00 197 222 73 86 578
11:00 231 130 68 150 579
12:00 228 147 70 105 550
13:00 225 112 60 122 519
14:00 187 255 55 182 679
15:00 147 231 90 142 610
16:00 134 196 68 124 522
17:00 230 218 82 157 687
18:00 165 148 102 140 555
19:00 200 188 143 135 666
20:00 169 153 111 148 581
21:00 130 133 93 107 463
22:00 128 112 68 123 431
23:00 67 77 55 100 299
0:00 38 81 68 92 279
1:00 30 52 36 63 181
2:00 14 44 30 52 140
3:00 13 34 34 26 107
4:00 29 21 54 41 145
5:00 36 28 39 52 155
Total 3203 3112 1595 2474 10384
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CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND
MITIGATION MEASURES
4.1. General
The possible impact on various components of environment due to the proposed
expansion of plant can be assessed in terms of:
Physical and Biological Environment and
Demographic and Socio-economic Environment.
For proper assessment of significance and magnitude of environmental changes due to
construction and operational phases of the plant, the impacts are analyzed on the 10 km
radius study area around the proposed plant site for each environmental parameter.
Impact assessment study for the existing PPL unit is carried out by predicting net
contribution of pollutants (qualitative as well as quantitative) on overall qualitative
assessment of various environmental indicators. Prediction of impacts is an important
component in environmental impact assessment process. Several techniques and
methodologies are in vogue for predicting the impacts due to existing and proposed
industrial development on physico-ecological and socio-economic components of
environment. Such predictions delineate contribution in existing baseline data for the
operational project and superimpose over the baseline (pre-project) status of
environmental quality to derive the ultimate (post-project) scenario of the environmental
conditions due to the proposed project. The quantitative prediction of impacts lead to
delineation of suitable environmental management plan needed for implementation
during the construction, commissioning and operational phases of the proposed project
in order to mitigate the adverse impacts on environmental quality.
Mathematical models are the best tools to quantitatively describe the cause- effect
relationship between source of pollution and different components of environment
4.2. Air Environment
4.2.1. Construction Phase
The activities of proposed expansion program will be confined to the project site within
the boundary of Plant complex. Actually the expansion site is a piece of vacant land with
no tree cover and does not come under any forestry and agricultural activities. As such
no major excavation involved except foundation and all debris/ muck either will be
utilized for leveling and landscaping purposes within the plant. Core zone of project area
is not the habitat of any significant faunal species i.e. nests, dens etc. This area does not
constitute any specific ecosystem and does not support specific floral and faunal
species. Present primary study revealed the presence of very common species of
shrubs/herbs and seasonal grasses in the core area. These plant species are not
specific for this core zone area and also vigorously distributed in the buffer zone and
therefore, the present expansion activities will not cause any significant loss of any
important flora.
Gaseous pollution
Due to different vehicular movement and project operation activities, the concentration of
air pollutants can be increased. These pollutants can affect the surrounding vegetation
and nearby agricultural crops.
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Dust Generation
Terrestrial flora can be affected by the dusty environment to be created due to vehicular
movement during construction and operation phase. Increment in the density of the dust
particles (SPM) in the atmosphere can affect the surrounding plant/crop vegetation in
following ways:
a) Blockage and damage to stomata
b) Reduction in chlorophyll content
c) Abrasion of leaf surface or cuticle
All these disturbances ultimately affect photosynthesis process and plant metabolism
which leads to reduction in plant growth up to some extent.
Noise Pollution
Noise level of the project area will be increased during construction and operation phase.
Although there is no specific noise-sensitive fauna has been recorded near to project site
but avifauna and small animals can be affected by increased noise level. In such cases
they can change their habitat.
Congregation of Labour
Construction activities often require a considerable workforce and associated support
services. The livelihood activities of this increased human population may contribute to
local environmental impacts in terms of collecting firewood and food as well as
enhancing recreational activities.
Mitigation Measures:
RET Species
Since there is no RET species recorded- no need to apply any mitigation measure.
Gaseous pollution
The SO2 in ambient air is reported in this study is low and the levels of other air
pollutants are also low. Development of multi-layer plantation (green belt) around the
proposed project area will help to mitigate gaseous pollution within and around the
project area.
Dust Generation
Dust generation will be managed through:
A periodic plantation of fast growing, evergreen, broad leaved, dust-resistant indigenous
plant species (proposed under Greenbelt Development Programme)
Effluent discharge
There will be a negligible discharge of effluent from the proposed plant which will be
directly treated inside the plant. Safe guard for rainy season runoff will be taken to
prevent any direct discharge from the plant to nearby water body. As such the river
ecology will not be affected.
Congregation of Labour
The impacts will be managed through:
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No permanent camping in vegetation rich area and riverside
A provision of fuel for laborers engaged in construction activities
Restriction on poaching/hunting and removal of any vegetation
Restriction on fishing
Based on the field observations and interaction with local people and forest officials, it
was noticed that the project area does not associated with any National Park/Wildlife
Sanctuary/Conservation Reserve and there is no wildlife migratory routes present in the
project area. Primary study also confirmed that there is no removal of any significant
flora from the project area, no removal of praying with pray of predatory animals and no
noises disrupting breeding behavior or use of breeding grounds. Improvement in the
green cover under a regular plantation program (Greenbelt Development Program) will
not only increase the plant diversity in the area but also enhance the habitat for wildlife
especially for avifauna.
4.2.2. Operation Phase
Prediction of impacts of the proposed de-bottlenecking on air environment i.e. ambient
air quality was carried out using computer-based air quality simulation model known as
ISCST3 View 6.2 model of Lakes Environment.
In the present study, the mathematical model that has been used for predictions on air
quality includes steady state Gaussian Plume Dispersion model designed for multiple
point sources.
The impacts on air quality from any project depend on various factors like design
capacity, configuration, process technology, raw material, fuel to be used, air pollution
control measures, operation and maintenance. Apart from the above, other activities
associated with any project, viz., construction phase (fugitive emission), operation phase,
transportation of raw materials and finished products, storage facilities and material
handling within the plant premises may also contribute to air pollution.
The major air pollutants expected to be emitted from PPL proposed expansion project
are Nitrogen oxides (NOx), sulphur oxides (SOx), particulate matter less than 10 microns
(PM10), particulate matter less than 2.5 microns (PM2.5), acid mist, ammonia (NH3) and
Hydrogen Flouride (HF). The major sources of continuous emissions are from the
proposed project are Stacks attached to Auxilliary Boiler, Sulphur Recovery Unit, Urea
PT, Nitric Acid process, Ammonium Nitrate process, DAP process and granulation,
GSSP Ball Mill, Scrubber outlet and Hot Air Generator, Aluminium Flouride process and
new sulphuric acid plant.
The main sources of air pollution due to the operation of the existing plant are the stacks
attached to DAP process (4 stacks), PAP process, SAP process (2 stacks), Zypmite
plant cooler, dryer and granulator. PM10, PM2.5, SOx, acid mist and HF are the main air
pollutants generated from the existing plant.
4.2.2.1 Model Details
Air dispersion modeling can be used to predict atmospheric concentrations of pollutants
at specific locations (receptors) over specific averaging times (i.e. annual, daily, and
hourly). An atmospheric dispersion model accounts for the emissions from a source;
estimates how high into the atmosphere they will go, how widely they will spread and
how far they will travel based on temporal meteorological data; and outputs the pattern of
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concentrations that will occur for various exposure periods, thereby providing the
exposure risks for different receptors.
In the proposed project, prediction of impacts on air environment has been carried out
employingmathematical model based on a Steady State Gaussian Plume Dispersion
Model designed formultiple point sources for short term. In the present case, AERMOD
dispersion model based on steady state Gaussian Plume Dispersion, designed
formultiple point sources for short term and developed by United States Environmental
Protection Agency (USEPA) has been used for simulations from point sources.
The major air pollutants expected to be emitted from PPL proposed expansion project
are Nitrogen oxides (NOx), sulphur oxides (SOx), particulate matter less than 10 microns
(PM10), particulate matter less than 2.5 microns (PM2.5), ammonia (NH3) and Hydrogen
Flouride (HF). The major sources of continuous emissions are from the proposed project
are Stacks attached to Auxilliary Boiler, Sulphur Recovery Unit, Urea PT, Nitric Acid
process, Ammonium Nitrate process, DAP process, GSSP Ball Mill, Scrubber outlet and
Hot Air Generator.
The options used for short-term computations are:
The plume rise is estimated by Briggs formulae, but the final rise is always limited to
that of the mixing layer
Stack tip down-wash is not considered
Buoyancy induced dispersion is used to describe the increase in plume dispersion
during the ascension phase
Calms processing routine is used by default
Wind profile exponents is used by default
Flat terrain is used for computation
Pollutants do not undergo any physico-chemical transformation
No pollutant removal by dry deposition
Universal Transverse Meter (UTM) coordinates have been used for computation
A uniform polar grid was used for the computation and extended to 10 km from the
center of the proposed project. In addition to that, receptors were also placed at the
sampling locations.
4.2.2.2 Emissions
The emission rates and stack parameters for the proposed expansion are listed in
Tables 4.1.
In order to estimate the worst-case scenario, the ground level concentration was
computed considering the plant emissions. 24-hourly average ground level
concentrations (GLCs) were computed for 24-hour mean meteorological data (March 1
through May 31, 2018).
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Table 4.1 : Emission Data and Stack Parameters for Proposed Expansion
Plant
Stack
Stack Spec. Emission Load (kg/hr)
Stack
Height
(m)
Stack
Diameter
(m)
Exit
Temp.
(K)
Exit
Velocity
(m/s)
SPM SOx NOX F NH3
WHRU /
Auxiliary
Boiler
30 5.5 573.15 16.25 99.3 9 64.7 NA NA
Sulphur
Recovery
Unit
20 0.6 573.15 20.20 NA 0.8 NA NA NA
Urea PT 130 30 351.15 0.76 50
mg/Nm3 NA NA NA 148.40
Nitric Acid 50 1.25 380.15 44.76 NA NA 100 NA NA
Ammonium
Nitrate 40 1.8 318.15 17.17 20.25 NA NA NA 6.75
DAP-A 50 2.8 337 16.13 50 NA NA 5 50
DAP-B 50 2.8 337 16.13 50 NA NA 5 50
DAP-C 50 2.8 337 16.13 50 NA NA 5 50
DAP-D 50 2.8 337 16.13 50 NA NA 5 50
GSSP Ball
Mill 40 0.8 313.15 15.21 3.6 1.8 NA NA NA
GSSP
Scrubber
Outlet
40 1.0 313.15 12.74 4.7 NA NA 0.68 NA
GSSP—
Hot Air
Generator
30 0.6 473.15 21.28 1.87 2.06 NA NA NA
4.2.2.3 Meteorological Data
The meteorological data consists of wind speed, direction, temperature, humidity, solar
radiation, cloud cover and rainfall recorded during the months of March 1through May
31, 2018, on an hourly basis. Wind speed, wind direction and temperature have been
processed to extract the 24–hour mean meteorological data for application in AERMOD.
4.2.2.4 Receptor Locations
A total of about 728receptors – 720 receptors of which were generated with a polar grid
from the center of the proposed project and extended to 10 km. Apart from these
receptors, the sampling locations were also taken into account to assess the incremental
load on the baseline environmental scenario.
4.2.2.5 Summary of Predicted GLCs
The summary of maximum cumulative ground level concentrations (GLCs) for the
proposed expansion and its impact on the study area under the worst meteorological
scenario is listed in Table 4.2.
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In addition to the above-mentioned pollutants, HF was also modeled and the impacts
assessed in the study area. Due to the lack of NAAQS limit prescribed by CPCB and
United States Environmental Protection Agency (USEPA), prescribed standards from
North Carolina‘s Division of Air Quality (NCDAQ) Ambient Air Levels (AALs) have been
taken for HF (30 g/m3). Table 4.3 presents the summary of the GLCs for HF.
Table 4.2 : Summary of Maximum Cumulative 24 hr. GLC (Proposed Expansion Project)
Description Concentration (g/m3)
PM10 PM2.5 SOx NOx NH3
Maximum Rise in GLC 74.76 30.04 24.46 31.22 311.38
Distance of occurrence
(km)* 0.5 0.5 0.5 0.5 0.5
Direction of Occurrence NE NE WSW NW NE
Maximum Baseline
Concentration reported 105.00 49.00 20.20 38.00 45.00
Total Concentration (Post
Project Scenario) 179.76 79.04 44.66 69.22 356.38
Prescribed Standards 100 60 80 80 400
* The distance is measured from center of Plant Boundary to the receptor of
maximum GLC
Table 4.3 : Summary of Maximum 24-hour GLC for HF
Description Concentration (g/m3)
Maximum Rise in GLC 27.95
Distance of occurrence (km)* 0.5
Direction of Occurrence NE
Prescribed Standards 30
* The distance is measured from center of Plant Boundary to the
receptor of maximum GLC.
The above tables show that in the worst case scenario, the maximum GLC for the
proposed expansion will be below the prescribed standards for all pollutants modelled
except for PM10 and PM2.5. However, it should be noted that PM10background
concentration in the study area exceeds the prescribed NAAQS standard by itself.
Additionally, the cumulative impact of the proposed expansion project at the monitoring
locations within 10 km radius is provided in Table 4.4 and 4.5.
Table 4.4 : Summary of Maximum Cumulative GLC at Monitoring Locations
Location Rise in GLC
(g/m3)
Max.
Background
Concentration
(g/m3)
Impact from
Project
(g/m3)
NAAQS
(g/m3)
Project Site PM10 30.35 96.00 126.35 100
PM2.5 12.18 47.00 59.18 60
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Location Rise in GLC
(g/m3)
Max.
Background
Concentration
(g/m3)
Impact from
Project
(g/m3)
NAAQS
(g/m3)
NOx 10.96 38.00 48.96 80
SOx 8.94 20.20 29.14 80
NH3 58.49 24.00 82.49 400
PPL
Township
PM10 3.15 87.00 90.15 100
PM2.5 1.27 45.00 46.27 60
NOx 1.24 29.10 30.34 80
SOx 0.95 16.00 16.95 80
NH3 11.18 21.00 32.18 400
Chaulipalanda
PM10 5.49 84.00 89.49 100
PM2.5 2.20 39.00 41.20 60
NOx 1.98 34.10 36.08 80
SOx 1.38 17.80 19.18 80
NH3 17.73 29.00 46.73 400
Gopinath
Colony
PM10 21.21 90.00 111.21 100
PM2.5 8.54 42.00 50.54 60
NOx 5.88 26.00 31.88 80
SOx 6.09 15.30 21.39 80
NH3 96.51 21.00 117.51 400
Udayabata
PM10 4.39 93.00 97.39 100
PM2.5 1.76 46.00 47.76 60
NOx 1.62 29.80 31.42 80
SOx 1.09 19.20 20.29 80
NH3 16.45 36.00 52.45 400
Paradeepgarh
PM10 3.20 105.00 108.20 100
PM2.5 1.28 49.00 50.28 60
NOx 0.95 36.40 37.35 80
SOx 0.68 19.50 20.18 80
NH3 11.08 19.00 30.08 400
Musadia
PM10 2.25 81.00 83.25 100
PM2.5 0.91 41.00 41.91 60
NOx 0.77 21.50 22.27 80
SOx 0.52 17.80 18.32 80
NH3 8.98 45.00 53.98 400
Jogidhankud
PM10 4.90 75.00 79.90 100
PM2.5 1.97 37.00 38.97 60
NOx 1.45 18.40 19.85 80
SOx 1.06 14.00 15.06 80
NH3 17.27 20.00 37.27 400
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Table 4.5 : Summary of Maximum GLC at Monitoring Locations for HF
Location Rise in GLC
(mg/m3)
NAAQS
(g/m3)
Project Site HF 5.68 30
PPL Township HF 1.06 30
Chaulipalanda HF 1.60 30
Gopinath Colony HF 8.90 30
Udayabata HF 1.49 30
Paradeepgarh HF 1.01 30
Musadia HF 0.81 30
Jogidhankud HF 1.57 30
Discussion of the Cumulative Impacts at monitoring locations:
• PM10: The total impact from the proposed expansion indicates maximum PM10
concentration of 126.35µg/m3 at Project Site with project impacts of 30.35µg/m3 and
baseline contribution of 96.00µg/m3.The total impact from the project exceeds the
stipulated standard of 100 µg/m3 for industrial as well as residential areas. However, it
should be noted that the GLC for PM10 from just the proposed expansion is 30% of the
NAAQS standard and the baseline concentration in the study area is very close to the
NAAQS Standard. The high PM10 in the study area is contributed mainly by industrial
emissions, vehicular emissions, re-suspected dust from paved/unpaved roads and open
areas as well as from industrial activities.
• PM2.5: The total impact from the proposed expansion indicates maximum PM2.5
concentration of 59.18 µg/m3 at Project Site with project impacts of 12.18 µg/m3 and
baseline contribution of 47.00µg/m3.The total impact from the project is within the
stipulated standard of 60 µg/m3for industrial as well as residential areas.
• NOx: The total impact from the proposed expansion indicates maximum NOx
concentration of 48.96 µg/m3 at Project Site with project impacts of 10.96µg/m3 and
baseline contribution of 38.00µg/m3.The total impact from the project is within the
stipulated standard of 80 µg/m3 for industrial as well as residential areas.
• SOx: The total impact from the proposed expansion indicates maximum SOx
concentration of 29.14µg/m3 at Project Site with project impacts of 8.94µg/m3 and
baseline contribution of 20.20µg/m3.The total impact from the project is well within the
stipulated standard of 80 µg/m3 for industrial as well as residential areas.
• NH3: The total impact from the proposed expansion indicates maximum
NH3concentration of 117.51 µg/m3 at Gopinath Colony with project impacts of 96.51
µg/m3 and baseline contribution of 21.00µg/m3.The total impact from the project is well
within the stipulated standard of 400 µg/m3 for industrial as well as residential areas.
• HF: The total impact from the proposed expansion indicates maximum HF concentration
of 8.90µg/m3 at Gopinath Colony. The total cumulative impact from the project is well
within the stipulated standard of NCDAQ‘s AAL of 30 µg/m3.
The isopleths for the pollutants are provided in Figures 1.1 through 1.6.
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Figure 4.1 : Isoplethsfor Cumulative PM10 GLC
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Figure 4.2 : Isopleths for Cumulative PM2.5 GLC
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Figure 4.3 : Isopleths for Cumulative SOx GLC
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Figure 4.4 : Isopleth for Cumulative NOx GLC
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Figure 4.5 : Isopleth for Cumulative HFGLC
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Figure 4.6 : Isopleth for Cumulative NH3 GLC
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4.3. Noise Environment
The sources of noise during the operational phase of the plant are mainly turbines
compressors, blowers, pumps and furnaces. The other sources of noise are the
movement of vehicles along the road. The proposed expansion project will be similar but
will have advanced technology and improved equipment both in terms of energy
efficiency and less noisy.
4.3.1. Impacts due to Transportation
Noise level contributed from light medium and heavy vehicles on the roads can be
considerable depending upon the traffic density. The area around the employees and
material gates is the traffic- affected areas due to transportation activities. The light
vehicles and two wheelers pass at the shift hours only except vehicles of the visitors,
which are limited only. The heavy commercial vehicles traffic is limited depending upon
the material receipt and dispatch of fertilizer through road transport. The large quantity of
fertilizer will be dispatched through railway rakes also.
4.3.2. Impact on Community
Equivalent sound levels are often used to describe community exposures to noise. Noise
survey was also carried out at eight locations outside the plant but within the study area.
Equivalent noise levels were measured for residential, commercial and industrial area
and also in other places in study areas (Chapter - 3). The Leq (day time) for these areas
is found to be well within ambient noise quality standards except three locations i.e
Paradeep railway station, near SH 12 and coast guard near NH5A where the noise
levels are above standard limits and similarly Leq (night time) for all locations was within
the prescribed limit of except three above locations. This may be due to heavy traffic due
to import and export at various industries located nearby.
The noise level norms in villages of study area are being met with respect to the norms
of ‗Ambient Air quality Standards in Respect of Noise‘.
The operation of PPL proposed expansion project will have some noise level and as
such will not have any adverse impact on the human settlement around it. The noise will
not be audible beyond its boundary limit, particularly due to natural green belt and other
attenuators.
4.4. Water Environment
Impact on water environment due to PPL proposed expansion project scheme will be in
terms of additional water consumption {water demand} and waste water / effluent
generation and discharge to environment.
4.4.1. Water Demand
4.4.1.1 Construction Phase
Since the PPL proposed expansion project will have water requirement both during
construction period as well as during operation through Canal Pump house is located at
canal side near village Bijay Chandrapur at a distance of 3 to 4 kms by road from the
plant. The requirement during construction period will be much less as compared to that
during operation. Also, water cess is being paid to Irrigation department regularly. As
such there will not be any additional water requirements for construction.
4.4.1.2 Operational Phase
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Water during operational phase is normally required for:
Dust suppression in Coal Handling
Cooling Water
Boiler Feed Water
Process Water (DM water, scrubbing/washing etc.)
Domestic and Green Belt
Existing raw water requirement of the PPL is met from the Taladanda Canal flowing in
the west – north – north east direction of the project site.
Raw water intake pump house called as Canal Pump house is located at canal side near
village Bijay Chandrapur at a distance of 3 to 4 kms by road from the plant.
Water so drawn is pumped to a reservoir of capacity around 17 lac KL which then taken
to Water Treatment Plant, treated water then pumped to the plant side as well as to the
township area by two different distribution systems. Water cess is being paid to Irrigation
department regularly.
Permitted withdrawal of water from the Taladanda Canal is 5,000,000 Gallons per Day.
(22730 m3/day)
As per notice on demand dated 16/10/2012, water withdrawn was 16949 m3/day quite
lower than the permission level.
New SAP, CPP & DM Plant would require an extra volume of approximately 7260m3/day.
The total water requirement of the proposed expansion project is 1800.43 m3/hr, will be
made available from the existing source i.e. Taladanda canal.
Extra water required if any for the proposed upcoming plants will be clarified & resolved
and approvals and permissions would be taken for the same.
4.4.2. Effluent Generation and Discharge
Industrial wastewater after it is discharged into surface water body should not produce
significant deterioration in its water quality. The effects on surface water depend on
wastewater characteristics and quantity. The impact on surface water depends on the
characteristics and also on quantity of water in the receiving water body. Awareness
programs on EMS.
PPL will follow the philosophy of treating the effluents in the well designed ETP plant and
recycling the same in the process {process condensates/ cooling/ dust suppression etc.;
Refer water balance in Ch. 2}. PPL Proposed project will be nearly is zero effluent plant.
Treated domestic water is utilized in green belt development.
4.5. Land Environment
Essentially, the two major problems normally faced in impact on land environment due to
any development project are:
Diversion of land from designated use to the ‗project use‘.
Deterioration of land / soil in terms of soil fertility and toxicity.
4.5.1. Land Diversion
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PPL expansion project is being located within the existing premises and as such no
additional land is required. Since there is no additional land required for PPL expansion
project, no soil erosion or diversion of land is involved.
4.5.2. Land Deterioration
Low soil fertility is attributable to either to low levels of nutrients {e.g. nitrogen,
phosphorus, potassium etc.} in the soil or their being made unavailable for plant intake in
some way. High levels of elements or compounds being present in the soil cause soil
toxicity. Some elements, which are essential and beneficial for crops at low
concentrations, become toxic to crops at higher concentrations. There can be slight
increase in phosphorus/sulphur/ nitrogen content of the soil due to limited plant emission
from DAP/Urea/GSSP plants and this elevated phosphorus / sulphur content will have
positive impact on the on the plant growing in the area. Proposed expansion project will
improve the Phosphorus availability in the area and consequently better crop yield.
The solid wastes (coal ash) generated in the plant will have intrinsic values and will be
sold to interested parties. The plant operations after PPL expansion project will be similar
emission and solid waste and as such not have any impact which is likely to affect soil,
or effluents release likely to affect soil. As such soil chemistry is not going to be affected
with PPL proposed expansion project.
4.6. Biological Environment
4.6.1. Flora
The quality of soils in the premises of the PPL shows that there is no adverse effect of
air, water and solid effluents on the soil system. A special thrust has been given right
from the beginning to develop the premises into a live green belt. Process effluents after
treatment are recycled back in process. The treated domestic effluent will be used for the
irrigation purposes to the maximum extent within the PPL premises in order to conserve
water.
The development of green belt will provide habitat, food and breeding areas to birds,
small animals and insects. No rare or endangered species of fauna are reported to exist
in the area. Thus, no impacts on rare / endangered species are envisaged due to normal
operations. The PPL expansion project would not affect the soil and so the plant growth
in the study area.
4.7. Socio – Economic Environment
PPL plan to carry out lots of social work (as a part of its ‗CSR‘ objectives) through with
objectives of:
Natural Resource Management
Infrastructure Development for nearby inhabitants
Health and Hygiene of nearby inhabitants
With these objectives PPL is carrying out study with regard to:
Assessment of local needs within the study area and identification of focus areas
Preparation of phase wise and year wise action plan in consultation with local bodies based on identified needs
Appointment of community development officer and organize periodic meet with local people
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Establishing open and transparent communication channel with locals
Work out modalities for sustainability of activities/programs
Establishing a well-designed grievance redressal / feedback forum
PPL expansion project will have some impacts also on socio – economic environment of
the study area- some are as given below:
4.7.1. Positive Impacts
Proposed expansion project of the plant would result in handling of more product and raw material, which will increase manpower requirement at some stages directly, or indirectly resulting in more income of people.
PPL expansion project would increase requirement from ancillary and auxiliary industries in the vicinity e.g. bagging units.
With more load on infrastructure facilities – roads and rails; these facilities would be improved.
More income to Government through more taxes on higher amount of production.
4.7.2. Negative Impact
Increased traffic on road due to more raw material requirement and more production
results in deterioration of road and increase likelihood of accidents.
However these can be handled and safety on roads can be ensured through increased
awareness and better management of resources.
4.8. Traffic Study
The site is located in planned notified industrial area having a good network of internal
roads which is further joining NH 5A highway. So, during construction phase, impact due
to movement of vehicles at the project site will be temporary and not significant.
During operation phase, the movement of vehicles from and to the site will be such that,
considering total material transport from PPL plant i.e. 1200 to 1300 trucks/month, and
other movement vehicles, the existing highway is adequate to bear the additional load
without any issue, so impact of vehicular traffic due to proposed expansion will not be
significant at the study area.
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CHAPTER 5. ENVIRONMENTAL MANAGEMENT PLAN &
ENVIRONMENTAL MONITORING PROGRAM
5.1. Introduction
Prediction of the potential adverse environmental and social impacts arising from
development interventions is at the technical heart of EIA process. An equally essential
element of this process is to develop measures to eliminate, offset, or reduce impacts to
acceptable levels during implementation and operation of projects. The integration of
such measures into project implementation and operation is supported by clearly
defining the environmental requirements within an Environmental Management Plan
(EMP).
Normally, potential impacts are identified early during the initiation of project, and
measures to avoid or minimize impacts are incorporated into the alternatives being
considered. In this respect, some of the most important measures to protect the
environment and local communities become integral to the project design, and may not
be reflected in a formal EMP.
PPL by way of EIA study propose to identify all the likely potential impacts, collect data
information and incorporate all the measures necessary to avoid or minimize impacts on
surrounding environment. Many of the mitigation measures are already in place as this is
the case of expansion of the plant. It is desirable to collect even such information in the
EMP to facilitate better assessment and communication as well as improve the systems
and technologies to improve mitigation for environmental components having moderate
residual impacts.
5.2. Objectives of EMP
Overall objective of EMP:
Prevention: Measures aimed at impeding the occurrence of negative environmental impacts and/or preventing such an occurrence having harmful environmental impacts.
Preservation: Preventing any future actions that might adversely affect an environmental resource or attribute.
Minimization: Limiting or reducing the degree, extent, magnitude, or duration of adverse impacts.
5.3. Components of EMP
EMP for PPL to enhance the fertilizer production capacity through expansion project
considers the following aspects:
Description of mitigation measures
Description of monitoring program
Institutional arrangements
Implementation schedule and reporting procedures
Institutional framework includes the responsibilities for environmental management as
well as responsibilities for implementing environmental measures.
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5.4. Central Pollution Control Board {CPCB} Guide Lines for Fertiliser
Industry
CPCB in its publication “Probe/97/2002 - 03”- ‗Environmental Management in Selected
Industrial Sectors Status / Needs‘, which also includes fertilizer sector has brought out
suggestions / recommendations and norms for fertilizer units. The suggestions /
recommendations and norms as applicable to PPL and their compliance status is
detailed below:
5.4.1. Emission and Effluent Standards
5.4.1.1 Emission
Emission from PT:
For units commissioned after January 01, 1986: 50 mg/Nm3 or 0.5 kg/t of product;
PPL Emission from existing PT‘s
50 (max.) mg/Nm3.‘
5.4.2. Charter on Corporate Responsibility for Environmental Protection (CREP)
PPL has adopted the Charter on Corporate Responsibility for Environmental Protection
(CREP). The compliance of recommendation by charter for fertilizer industries has been
presented in detail in Chapter 2 (Section 2.3.15):
CPCB in its publication ―Probe/97/2002-03‖- ‗Environmental Management in Selected
Industrial Sectors Status / Needs‘, which also includes fertilizer sector has brought out
suggestions/recommendations and norms for fertilizer units. The
suggestions/recommendations and norms as applicable to proposed project and their
compliance status is detailed below in Table 5.1:
Table 5.1 : Compliance Status
S.No. Action Point Status / Proposed Plan
1. Conservation of water: PPL propose to implement with ―zero liquid‖
effluent for the proposed expansion project.
2. Conservation of
material:
The manufacturing process will generate gypsum
coal ash and effluents comprising of recovery of
Hydroflourosilicic acid, which will be sold and
recycled back into the process to produce
Aluminum Flouride.
3. Toxic substances:
All safety measures would be taken for
elimination of toxic substances, but the present
production process doesn‘t have any such toxic
substances.
4. Wastewater treatment: The generated wastewater will be treated and
recycled back in the process.
5. Management of Storm
water:
No wastewater generated would be directly
discharged in to the drains.
6. Emission Control: Emission control is met by installation of three
level control equipment that includes venturi
scrubber with three different working efficiencies.
7. Management of Management of the hazardous substances would
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S.No. Action Point Status / Proposed Plan
hazardous chemical be made according to the MSIHC Rules 1989 &
Hazardous waste management rules 2008.
8. Solid Waste
management
All the solid waste generated would be
processed with proper disposable techniques
and proper monitoring and management plan.
9. Monitoring of Effluent,
Emission and Ambient
air quality
A detailed environmental monitoring plan already
exist and modified plan (due to proposed
expansion project) will be implemented
10. Environmental
Management Cell
Already Exists
5.4.3. Air Environment
The emission from PPL proposed expansion project shall be mainly from the various
stacks (in Ammonia plant, Urea plant, Acid Plants, DAP/GSSP, HRG and Auxiliary Plant)
and will be limited. Fugitive emissions while handling solid/ granular product will be
recovered and recycled (as PPL has experience of DAP dust collection and recovery
system in bagging plant) or leakages in the plant. In order to mitigate the adverse
environmental impact due to the operation proposed GSSP plant followingmeasures are
recommended:
The control measures (through proper up keep / maintenance) and good housekeeping will considerably reduce the fugitive emission.
AAQ monitoring system of air pollutants SOx, NOx, ammonia, acid mist, fluorides and SPM should be regularly carried out.
Regular monitoring of shop floor environment is to be carried out to control the fugitive emission as well as shop floor safety.
Leakages {of gases / liquids/ dust} should be checked and promptly attended.
5.4.4. Noise Environment
The statutory national standards for noise levels at the plant boundary and at residential
areas near the plant are being and are to be met. The following mitigation measures are
proposed to meet the objectives:
The selection of any new plant equipment is to be made with specification of low noise levels. Noise suppression measures such as acoustic enclosures / cabins, buffers and / or protective measures are be provided (wherever noise level is around +80 dB (A) and exposure limits to workers is likely to be more than 8 hours a day) to limit noise levels within occupational exposure limits. Areas with high noise levels are to be identified and segregated where possible and will include prominently displayed caution boards.
However, in areas where noise levels are high and exposure time is less, employees will be provided with ear protection measures like earplugs or earmuffs. Earplug should be provided to all workers where exposure level is > 85 dB (A). The exposure of employees working in the noisy area should be monitored regularly to ensure compliance with the regulatory requirements.
The existing practice of regularly monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures.
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The green belt around the plant to attenuate the noise level but instead of block plantation there should be variability in tree height and shape, as this would disperse the sound waves more efficiently. Plant that attenuate should be planted at the noise zone.
5.4.5. Water Environment
PPL plant should take ample precautions to reduce water consumptions and tackle
effluents problem. The philosophy of segregation of effluent streams and treatment near
the source and recycle back to the system will help in reducing the water consumptions
and effluent generation considerably. Efforts should continue and new efforts should
be directed to:
Possibility of increased use of treated effluents in horticulture and green belt developments.
Recycle of treated effluents in the system as far as possible.
The treated sewage should be effectively utilized in the plant or for irrigation in green belt.
The use of any chemical to check microbial activity should be avoided, as it would harm the human health and fauna.
Use of pesticide and herbicide should be avoided as they can cause ground water contamination.
PPL should install three or more piezo metric wells at selected places (one near treated effluent pond) to see and check the ground water contamination.
Water is a precious commodity and it should be conserved.
Rain water harvesting. [Since it is coastal area the sub soil water may be saline and rain water harvesting may not be useful].
5.4.6. Biological Environment
Greenbelt Development Programme
Increasing vegetation in the form of greenbelt is one of the preferred methods to keep
the pollution under control. Plants serve as a sink for pollutants, act as a barrier to break
the wind speed as well allow the dust and other particulates to settle out there. It also
helps to reduce the noise level up to some extent. The main objective of the green belt is
to provide a buffer/barrier between the sources of pollution and the surrounding areas.
The green belt helps to capture the fugitive emissions and attenuate the noise apart from
improving the aesthetics quality of the region. Of the total area of the proposed project
site (core zone) 33% area shall be developed as a green belt along the periphery of the
plant. The goal of installation a greenbelt would also be to maximize both ecological
functionality and scenic beauty of the project area. Some greenery is already existed in
the project area. The present greenbelt area will cover the 33% of the total project area
and this greenbelt of different thickness will be established systematically. Ideal size of
greenbelt shall be between 10 and 50 meter wide and run the length of roads, major
structures and open spaces. Width depends on the availability of land.
Selection of species
Local or indigenous species will be preferred under this programme and the species
those have dust & noise tolerant capacity, enhance aesthetics and develop a habitat for
wildlife especially for avifauna will be introduced. A plantation of sound and dust receptor
as well as aesthetically valuable species is proposed which will help in reduction of
pollution (both atmospheric & noise), reduction of stress and beautification of the area.
Hardiness, longevity, a minimum of wind through and breakage, attractiveness and
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minimal maintenance requirement are some qualities of species which are to be taken
into consideration during selection. A standard spacing of 3m and 2m for tree and shrub
species respectively will be taken into consideration.
Selection of the plant species will also be based on the growth and morphological
characters i.e. height, crown cover and also on the basis of their adaptability in the
region. Following types of species are proposed under greenbelt development:
Native Plant Species- drought resistance
Species that can minimize noise level
Species that can absorb dust
Habitat Improvement Species
Fruit Species to enhance the Food Availability for Wildlife
By reviewing the various literatures, following plant species has been chosen for
greenbelt development listed in Table 5.2.
Table 5.2 : List of Plant species to be planted
Sl.
No.
Scientific Name Name Characteristics
Tree
1 Albezia lebbek Siris Habitat Improvement, Dust Removal, Drought
Resistant
2 Azadirachta indica Neem Noise Barrier, Drought Resistant, Dust Removal
3 Bahunia variagata Kachnar Habitat Improvement
4 Butea monosperma Dhak Noise Barrier, Drought Resistant, Dust Removal
5 Cassia fistula Amaltas Avenue Plant, Drought Resistant, Dust Removal
6 Dalbergia sissoo Shisham Noise Barrier, Drought Resistant, Dust Removal
7 Delonix regia Gulmohar Avenue Plant
8 Emblica officinais Amla Medicinal Plant, Habitat Improvement
9 Ficus glomerata Goolar Habitat Improvement
10 Ficus religiosa Peepal Habitat Improvement, Drought Resistant, Dust
Removal
11 Syzygium cumini Jamun Drought Resistant, Dust Removal
12 Polyalthia longifolia Ashoka Avenue Plant, Indicator Plants (to monitor pollution
level), Dust Removal
13 Holoptelia integrifolia Kanju Drought Resistant, Dust Removal
Shrub
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1 Bougainvillea sp Bougainvillea Avenue Plant, Dust Removal
2 Dodonea sp Dodonea Avenue Plant
3 Hibiscus rosasinenis Gudhal Avenue Plant
4 Nerium odorum Nerium Avenue Plant
(Source: Edited from Hocking 1993, Saxena 1991, Phytoremediation of particulate matter from ambient environment through dust capturing plant species. Published 2007 by Central Pollution Control Board, Ministry of Environment & Forests, Govt. of India in Delhi)
Greenbelt around the Project area
In the context of air pollution attenuation, greenbelts will be developed around the project
in a manner so as to effectively reduce the pollution caused by project activities. Design
of effective greenbelts involves consideration of meteorological, physico-chemical,
biological, and horticultural aspects relevant to pollutant source and the area where
greenbelt has to be established. Such plantation will be carried out in three different
layers. Species like Cassia fistula and Beutia monosperma will be planted inner side of
the greenbelt (Ist row), Albezia lebbek, Ficus species, Holoptelia and Jamun will be
planted in the middle of the greenbelt (II row) whereas species like Dalberzia sissoo, and
A. indica species will be planted outside layer (III row) of greenbelt.
Roadside plantation
The roadside plantation will be carried out with the species having the properties of
control dust pollution and maintain the aesthetic value. Butea monosperma, Holoptelia
integrifolia, Syzygium cumini and Albezia lebbek will be planted under this plantation.
Avenue plantation in adjacent residential colony
Tree species like Cassia fistula, Delonix regia, Emblica officinais, and Polyalthia
longifolia will be used for such type of plantation along with shrubs Bougainvillea sp,
Dodonea sp, Hibiscus rosasinenis, and Nerium odorum. The purpose of such plantation
is to fill the blank areas with greenery and strengthen scenic beauty.
5.4.7. Land Environment
The proposed expansion project will generate the solid wastes (coal ash and gypsum)
similar (in quality as well as increase in quantity) to the existing system. Mostly the waste
will be sold to actual users. However some wastes (oily sludge from machines/ empty
bags/ paper/cotton wastes etc.) will be similar and the proposed handling philosophy for
the same is to continue. No additional measures are required.
5.4.8. Socio-economic Environment
As a good corporate citizen and major industry PPL may consider adopting few more selected villages in developing them as model villages.
Awareness program are to be initiated in immediate neighbouring villages about PPL plant activities and the various EHS measures undertaken to make the plant safe and environment friendly.
PPL should finalise the study and start carrying out CSR activities in coordination with district authorities.
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5.4.9. Environmental Management Cell
PPL already have an environment management cell headed by a senior executive
supported by Manager (EC) and other supporting staff. The laboratory is equipped with
necessary sophisticated instruments including:
Fine Particulate sampler (PM2.5)
Respirable dust sampler (PM10)
Digital Hygrometer
Stack Monitoring Kit
Personal dust sampler
Sound level meter
Multi Gas meter
On line weather monitor
Spectrophotometer
Electronic Balance
Electric oven
DO meter
PH meter
BOD incubator
COD digester
Oil & grease digester
Water bath
Water double distillation system
Multi parameter analyzer for water analysis A team of well-trained and experienced staff carries out tests in the laboratory.
EMP Budget:
It is necessary to include the environmental cost as a part of the budgetary cost
component. PPL proposes a 5 % (Rs 473 crores) of total capital cost of project to be
earmarked for environmental management plan as mentioned in section 2.11 of chapter
2.Funds is earmarked exclusively for environmental works. It is proposed to take up
protective measures like regular monitoring, storm water drain cleaning before monsoon,
plantation, etc. The management propose to undertake environmental works to achieve
the environmental quality as desired. A budgetary cost is allocated for conducting the
environmental works on a continuous basis. For the expansion phase, the same will be
followed.
5.4.10. Post – Operational Monitoring Program
PPL should carry out environment monitoring and with necessary equipment and
associated facilities. The monitoring plan proposed is as follows:
Table 5.3 : Environmental Monitoring Program
Discipline Location Parameter Frequency
Meteorology one Temp.{max.; min.}; Relative humidity; Rain fall; Wind speed and direction.
Daily
Ambient Air Quality
Four SPM,SOX, NOx, acid mist, Flourides, RPM and CO
Twice a week
Stack All continuous SPM, Once a
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Discipline Location Parameter Frequency
Emission stacks NOx,SOx,NH3& CO (as applicable0
week; SOx is continuous
Effluents
Final effluents discharge point
pH, Free NH3, TAN; TKN; NO3;SS; PO4, Oil-grease; COD; BOD
As & when dischargeot Arabian sea or utilized for irrigation.
Sanitary TSS; BOD Weekly
Ground Water Quality
{PeizometricWells / Hand pumps}
pH, NO3, Floride,NH3& PO4
Monthly
Noise Plant area & neighbouring villages
Day & Night time noise level
Plant area – Monthly Villages - Annually
Health Check Up
All Plant Personnel
Disease of eyes, ears and chest
Annually
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CHAPTER 6. Hazards Evaluation and Risk Assessment
6.1. Introduction
PPL would be handling all materials at the proposed plant. The storage of raw material is
planned at the site location itself, so, in an unlikely event of release emergencies, there
would be a potential risk to life and properties. Hence, the risk assessment study has
been conducted for various parameters that include identification of hazards, to calculate
consequence distances, to evaluate safety at the plant and to spell out risk mitigation
measures to enhance safety at the plant.
6.2. Hazard Identification
Hazard is defined as a chemical or physical conditions those have the potential for
causing damage to people, property or the environment. In this chapter the hazards
associated with only the proposed expansion project have been discussed.
The primary step of the Hazard identification is the risk analysis and entails the process
of collecting information on:
the types and quantities of hazardous substances stored and handled at the plant,
the location of storage tanks & other facilities, and
potential hazards associated with the spillage and release of hazardous chemicals.
6.2.1. Hazardous Materials to be Stored at the Plant
The major hazardous chemical to be stored at the PPL site will be dilute sulphuric acid
and Sulphuric Acid 98.5% with specific gravity 1.84,
The acid is stored in two separate tanks, with each tank capacity of 5000 T. Total acid
storage capacity will be 10000 MT.
6.2.2. Characteristics of Hazardous Materials
Table 6.1 : Characteristics of Hazardous materials
Material Storage Capacity (MT) Remarks
Ammonia 10000X 5+=50,000 Existing Ammonia Storage
Tanks (details in Ch-2)
Sulphuric Acid 4X10000+1X5000=45000
1X10000=10000
Existing
Proposed
Phosphoric Acid 6X10000=60000
2X5000=10000
Existing
Under commissioning
Nitric Acid
(conc.)
5000
Sulphuric Acid 10000 X 5 + 5000X1
Ammonium
Nitrate
3000 Bagged Storage
HFO /LSHS 18000X2= 36000KL
HSD 15X1=15KL Chlorine
Tonners
930X2= 1860 Kg
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Important characteristics of the hazardous material (i.e. Ammonia, Chorine etc.) has
been presented below:
PPL will be using a number of raw materials but only few are stored in bulk and few
chemicals are listed under ―List of hazardous and Toxic Chemicals‖ category under
MSIHC Rules, 1989. The raw materials coming under hazardous category as specified
by MSIHC Rules, 1989 (including subsequent amendments) is given in Table below:
LPG 102
153
Industrial Cylinders
Domestic Cylinders
Sulphur 45000
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Table 6.2 : Environmental Monitoring Program
S. No.
S. No & Threshold Quantity (TQ in MT) as per MSHIC Rules
Chemical Hazards Remarks
Schedule-1, Part-II
Schedule-2, Part-I
Schedule-3, Part-I
Hazards Toxic
1 Ammonia CAS No:7664-41-7
UN No:1005
31 2 TQ-1: 60 MT TQ-2: 600 MT
105 TQ-1: 50 MT TQ-2: 500 MT
Fire Hazards: Mixing of ammonia with several chemicals can cause severe fire hazards and/or explosions. Ammonia in container may explode in heat of fire. Health Hazards: Vapors cause irritation of eyes and respiratory tract. Liquid will burn skin and eyes. Poisonous; may be fatal if inhaled. Contact may cause burns to skin and eyes. Contact with liquid may cause frostbite.
ERPG-1: 25 ppm
ERPG-2: 150 ppm
ERPG-3: 750 ppm
IDLH: 300 ppm
2 Sulphuric Acid CAS No: 7664-93-9 UN No: 1830
591 --- Flammability: Will not burn Health Hazard: Extremely hazardous - use full protection; Reactivity: Violent chemical change possible
ERPG-1: 2.0 mg/m
3
ERPG-2: 10 mg/m
3
ERPG-3: 30 mg/m
3
IDLH: 15 mg/m
3
3 Nitric Acid
CAS No: 7697-37-2
Non-flammable Colorless to light yellow.Liquid; Odor: Acrid.
423 --- --- Very hazardous in case of skin contact (corrosive, irritant, permeator), of eye contact (irritant,corrosive), of ingestion, . Slightly hazardous in case of inhalation (lung sensitizer). Liquid or spray mist may produce tissue damage particularly on mucous membranes
NFPA:
Health: 4 Flammability: 0 Reactivity: 0
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S. No.
S. No & Threshold Quantity (TQ in MT) as per MSHIC Rules
Chemical Hazards Remarks
Schedule-1, Part-II
Schedule-2, Part-I
Schedule-3, Part-I
Hazards Toxic
Disagreeable and choking. (Strong.)
BP: 121 C
of eyes, mouth and respiratory tract. Skin contact may produce burns. Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing, 4choking, or s5hortness of breath. Prolonged exposure may result in skin burns and ulcerations. Over-exposure by inhalation may cause respiratory irritation. Severe over-exposure can Result in death.
4 Phosphoric Acid
CAS No.:7664-38-2
497 -- -- Non-flammable viscous colourless, odourless liquid
Oral (LD50): 1530 mg/kg [Rat]. Dermal(LD50): 2740 mg/kg DUST (LC50):;850 mg/m 1 hours
5 Chlorine
CAS No:7782-50-5
UN No:1017
A greenish yellow gas with a pungent suffocating odour. Toxic by inhalation.
119 5 TQ-1: 10MT TQ-2: 25 MT
108 TQ-1: 10MT TQ-2: 25 MT
(Gas); Non Combustible; May ignite other combustible materials (wood, paper, oil, etc.). Mixture with fuels may cause explosion. Health Hazards: Poisonous; may be fatal if inhaled. Contact may cause burns to skin and eyes. Bronchitis or chronic lung conditions
ERPG-1: 1.0 ppm ERPG-2: 3.0 ppm ERPG-3: 20 ppm IDLH: 10 ppm
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S. No.
S. No & Threshold Quantity (TQ in MT) as per MSHIC Rules
Chemical Hazards Remarks
Schedule-1, Part-II
Schedule-2, Part-I
Schedule-3, Part-I
Hazards Toxic
6 Ammonium Nitrate
CAS No: 6484-52-2
White odourless prills, with strong disagreeable acrid taste. Ammonium nitrate is not flammable.
Gr. 3-Highly Reactive Substance
Decomposes from 170 °C before boiling
water
33 --- 126 TQ-1: 350 MT TQ-2: 2500 MT
Ammonium nitrate is moderately toxic if large amounts are swallowed; Highly Reactive When heated to decomposition (unconfined) ammonium nitrate produces nitrous oxides, white ammonium nitrate fumes. Ammonium nitrate is incompatible with copper, zinc, or their alloys (i.e., bronze, brass, galvanised metals, etc.), aluminium powder and mil
;
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The petroleum products used in PPL plant and their hazardous nature are as below:
Table 6.3 : Petroleum Products in PPL and hazardous nature
Item Physical Impact on Man, Animal & Eco-System
Physical Chemical
HSD UN No.-1202 Flammable Liquid-Class-3 Hazardous Waste ID No.-17 Hazchem Code-3Y* NFPA Hazards Signals Health-0 Flammability-2 Reactivity/ Stabilty-0
BP- 150 – 400°C Vapour Pressure (35°C)- <1 mm at 38°C Specific Gravity-0.81 – 0.91 at 20°C
LEL -0.6% (V/V) UEL – 7.5% (V/V) Flash Point > 32°C Auto ignition Temp.-256°C Stable compound
Entry throughinhalation, ingestion and skin; Inhalation Effects:Dizziness and headache, Aspiration – Rapidly developing, potential fatal chemical pneumonities Ingestion Effect: Nausea and Vomiting; Contact Effects: Irritation, Eyes- Irritation; Dermatitis may develop on prolonged contact.
Solubility in water- Insoluble
Incompatible with oxidizing agents.
LD50 (oral rat)- 2800 mg/kg; LD50 -200;TLV(ACGIH)- 5 mg/kg; STEL- 10 mg/kg
LSHS/FO UN No.-1270 Flammable Liquid-Class-3 Hazardous Waste ID No.-17 Hazchem Code-3Y*E NFPA Hazards Signals Health-0 Flammability-2 Reactivity/ Stabilty-0
BP- 185 – 5000C
Vapour Pressure (35
0C)- <1 mm at
200C
Specific Gravity-0.8 – 0.9 -- 1.05 at 15.5
0C
LEL - 1% (V/V) UEL – 5% (V/V) Flash Point > 66
0C
Auto ignition Temp.-263
0 C
Stable Compound
Entry through inhalation, and skin; Inhalation: Dizziness and headache. Ingestion: Nausea and Vomiting Contact: Irritation, Eyes: Irritation. Dermatitis may result from prolonged contact.
Solubility in water- Insoluble in water
Incompatible with oxidizing agents.
Vapour Density (Air-1)-3 - 5
6.2.3. Associated Hazards
Hazards associated with the use and storage of hazardous new product namely
Ammonium Nitrate has been presented in the following sub sections:
As detailed in the above table out of 6 liquid materials stored in bulk all comes within
Schedule I part II (List of Hazardous and Toxic Chemicals) of MSIHC Rules but three
materials (Ammonia, Chlorine and Ammonium Nitrate) of them comes under Schedule 3
(list of hazardous chemicals for application of rules 5 and 7 to 15). Total Ammonia stored
in PLL is 50,000 Mt, much more than the threshold quantity and such PPL is coming
under "major accident hazards (MAH) installations" as per MSIHC rules. PPL has to
follow all norms as stipulated in MSIHC rules for MAH installtions.
Two material (Ammonium Nitrate, Ammonia) and fuel are inflammable. Ammonium
Nitrate is explosive also. Eight of these hazardous liquid materials are toxic. Two
materials namely Ammonia and Chlorine are toxic.
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6.2.3.1 Ammonium Nitrate
Ammonium Nitrate is highly reactive substance. Though it has not been put as Explosive
substance in MSIHC Rules, it has been used as explosive by terrorist in making bombs.
Considering this Government of India has declared this as ‗Explosive‘. Hazardous nature
of Ammonium Nitrate is given below in brief.
Government Notification New Delhi: Concerned over the increased use of ammonium
nitrate by terror groups in making bombs, the government has finally declared the
chemical as an "explosive". But given the widespread use of the mixture as fertilizer, the
government notification came with a rider that its possession and use would invoke penal
action only if the composition had 45% or more ammonium nitrate content.
"The central government hereby declares that ammonium nitrate or any combination
containing more than 45% of ammonium nitrate by weight including emulsions,
suspensions, melts or gels shall be deemed to be an explosive," the commerce and
industry ministry said in a notification issued last week.
Hazardous Nature: Ammonium nitrate is not flammable under normal applications and
is not considered a fire risk, but will support combustion in an existing fire by liberating
oxygen – even if smothered. It is for this reason that fires involving ammonium nitrate
cannot be extinguished by the prevention or air ingress
Ammonium nitrate has a melting point of 1700C and decomposes from 170 °C before
boiling.. It is not in itself combustible but, as it is an oxidising agent, it can assist other
materials to burn, even if air is excluded.
Ammonium nitrate will not explode due to the friction and impact found in normal
handling, but it can be detonated under heat and confinement or severe shock. For
example, in a fire, pools of molten ammonium nitrate may be formed and if the molten
mass becomes confined (e.g. in drains, pipes, plant or machinery) it could explode,
particularly if it becomes contaminated.
In a fire, all types of ammonium nitrate may melt and decompose with the release of
toxic fumes (mainly oxides of nitrogen) which may be yellow or brown. Most types do not
continue to decompose once the fire has been extinguished. However, when some types
of ammonium nitrate fertilizers (cigar burners) are heated they undergo a smouldering
(self-sustaining) decomposition that can spread throughout the mass to give substantial
toxic fumes, even when the initial heat source is removed. The risk of fire or explosion is
greatly increased if ammonium nitrate is mixed with combustible or incompatible
materials, such as powdered metals, alkali metals, urea, chromium or copper salts,
organic and carbonaceous materials, sulphur, nitrites, alkalis, acids, chlorates and
reducing agents (consult data sheets to establish if a substance has reducing
properties).
The risk of an explosion is increased by a combination of the following:
Heating ammonium nitrate (e.g. in a fire);
Contamination;
Serious confinement (e.g. in drains or enclosed parts of equipment).
To minimise the risk of explosion it is therefore important to take precautions against
each of these situations.
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6.3. Effect & Consequence Analysis
As a part of risk assessment study, maximum credible accident analysis (MCA) is carried
out to determine the maximum loss scenario from this analysis. It is an eventuality, which
is possible and will have maximum consequential distances for the particular hazardous
chemicals under evaluation.
The selection of the accident scenarios is based on the engineering and professional
judgment, accident descriptions of the past in similar type of plants & the expertise in risk
analysis studies.
6.3.1. Likely Scenarios
Few likely failure scenarios have been selected after critical appraisal of raw materials
and products properties and storage inventories. Failure scenarios selected are as given
in Table 6.4 below:
Table 6.4 : Different Failure Scenarios
S. No. Scenario Remark
Scenario – 1 Ammonia Tank [ 200 m Puddle]
Scenario -2 Heavy Ammonia Leakage and Spillage
Scenario -3 Nitric (conc.) Acid Tank
Scenario – 4 Chlorine Cylinder/Pipe Line Leakage
6.3.2. Weather Effect
The effect of ambient conditions on the impact of fire / heat radiation and GLC of
hazardous / toxic material can be beneficial as well as harmful. A high wind (turbulence)
can dilute the toxic material while stable environment can extend the reach of IDLH or IT
(inhalation LC50 rats for products) or AEGL (in absence of IDLH data) concentration to
long distance. Any inflammable gas / vapour release in turbulent weather will soon dilute
the hazardous gases below LEL and thus save the disaster.
Incidents Impacts
The identified failure scenarios (Table 6.4) have been analysed (Using ALOHA Module)
for the impact zones considering damage due to thermal and toxic impacts. Each
incident will have Impact on the surrounding environment which in extreme case may
cross plant boundary. The impact zones for various scenarios are given in Table 6.5.
Table 6.5 : Hazards Scenario Impact
Scenario
No.
Scenario Impact Zone (m) Remarks
Material
Scenario-1 Ammonia Tank [200 m
Puddle]
IDLH~>10000
IDLH~>10000
Stability Class D Template
1
Stability Class F Template
2
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Scenario
No.
Scenario Impact Zone (m) Remarks
Material
Scenario-2 Heavy Ammonia Leakage
and Spillage
IDLH>10000
IDLH>10000
Stability Class D Template
3
Stability Class F Template
4
Scenario-3 Nitric (conc.) Acid Tank
Leakage
IDLH ~ 188 Stability Class D Template
5
Scenario-4 Chlorine Cylinder/Pipe
Line Leakage
IDLH ~ 75
IDLH ~159
Stability Class D Template
6
Stability Class F Template
7
Figure 6.1 : Ammonia Tank [200 m Puddle]
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Figure 6.2 : Ammonia Tank [200 m Puddle]
Figure 6.3 : Heavy Ammonia Leakage and Spillage
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Figure 6.4 : Heavy Ammonia Leakage and Spillage
Figure 6.5 : Nitric (conc.) Acid Tank Leakage
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Figure 6.6 : Chlorine Cylinder/Pipe Line Leakage
Figure 6.7 : Chlorine Cylinder/Pipe Line Leakage
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6.3.3. Consequence Analysis
6.3.3.1 Toxic Hazards
Toxic hazards are mainly due to Ammonia, chlorine gases and Nitric Acid leakage.
Ammonia leakage impact can cross the plant boundary (> 10 km; if not controlled in
time). The impact due to chlorine and Nitric Acid is limited to 159 / 188 m (within plant
only.) products will go up to 7.7 km in worst case (Scenario 1).
The other hazards in the plant include (but not limited to):
Other toxic hazards due to acids / other toxic spillages (mainly limited to
spillage area only.).
Mechanical hazards due to machines / equipment‘s.
Hazards due to individual soft spots like walking casually and noticing a pit and falling or
colliding/ stumbling or slipping (not noticing a wet place etc.).
Acid spillage-its impact will be limited to spillage area. The spillage if comes in contact
with metal parts will produce hydrogen which is highly flammable gas. Any person
moving in area and getting splash will get the injury. In addition the spillage will cause
pollution problem. The spillage is to be collected and neutralized for toxic contents before
disposal.
6.3.3.2 Fire Hazards
Fire hazards in the proposed expansion project are much less (Fuels-coal, FO/LSHS,
HSD (limited storage only)). These fuels are not highly combustible and their impacts
are limited only (within short distance). However process has fire hazards due to
hydrogen.
6.4. Recommendations
Based on the outcome of the risk assessment, following recommendation has been
made to avoid any risk associated with the storage and use of acids and other liquid
materials in the plant:
6.4.1. LDAR program :--
Chemicals are manufactured in multi-stages in batch/continuous mode. In the
manufacture of chemicals, various unit processes/operations/equipment are used in
industries.
The chemical industries are using pipelines, pumps, valves/ vessels and other fittings in
the transfer of materials from reactors and other ancillary facilities to other equipment. To
reduce fugitive emissions in the plant, proper Leak Detection &Repair (LDAR) program is
required in the industry.
The proposed LDAR program is as follows :--
Identification of sources: Valves, pipes, joints, pump seals, flanges etc.
Monitoring of gases/fluids is to be carried out regularly. Monitoring frequency
should be once in a quarter is required.
The industries handling small/large quantities of hazardous chemicals like
chlorine, SOx/NOx/Hydrogen (process) etc. can use simpler methods like
gas/vapour sensors.
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Focus should be for prevention of fugitive emissions by having preventive
maintenance of pumps, valves, pipelines etc. A preventive maintenance
schedule should be prepared and it should be strictly adhered to
When monitoring results indicate hazardous gases/vapors/VOC above permissible limit
repairing should be done immediately. The repair should be conducted in such a way
that there is no fugitive emission from the particular component.
6.4.2. Fugitive Emission Control Guidelines :--
The following guidelines will be strictlyfollowed :--
Fugitive emissions over reactors, formulation areas, rotory machines,
chemical loading, transfer areas etc. will be collected through hoods and
ducts by induced draft and controlled by scrubber/ dust collector.
Scrubbers installed for channelized emissions are used for fugitive emissions
control also and sometimes dedicated scrubbers will be used.
Hazardous gaseous emissions (toxic and odorous) will be routed to activated
carbon beds or to incinerator, and for dust emissions cyclones/bag filters will
be provided.
Enclosures to chemical storage area, collection of emissions from loading of
raw materials, in particular, solvents through hoods and ducts by induced
draft, and control by scrubber/ dust collector will be ensured.
Vapour balancing, nitrogen blanketing, iso tanks etc, will be provided. Special
care will be taken for odorous chemicals.
6.4.3. Acid Spillage
Double drain valve will be provided to sulphuric acid storage tank.
Full body protection will be provided to operator.
Caution note and emergency first aid will be displayed
All employees will be trained for use of emergency first aid.
Safety shower and eye wash will be provided in storage tank area and plant
area.
Total close process will be adopted for Sulphuric acid handling.
Dyke wall will be provided to storage tank
Tanker unloading procedure will be prepared.
SOP will be prepared for sulphuric acid handling.
Training programme will be conducted for safe handling and emergency
handling of Sulphuric Acid
In Storage Tank Area, reaction with water generating fumes should be
displayed and avoided
Suitable extinguishing media-Extinguish with dry powder / sand. Do not use
water.
Fire and explosion hazards-Not flammable. May evolve toxic fumes in fire
(sulphur oxides).
Personal protective equipment-Fire fighter must use fresh-air helmet and
chemical protection suit
Personal protection: complete protective clothing including self-contained
breathing apparatus. Do Not let this chemical enter the environment.
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Evacuate danger area do not absorb in saw-dust or other combustible
absorbents.
6.5. Occupational Exposure Mitigation Planning
To control any occupational health and safety impact a detailed planning for mitigation
measures has been done in the design stage of the project. Apart from the occupational
exposure mitigation plans for various activities and work areas of hazards, following
administrative control measures will be followed:
All the employees will be trained for EHS policies.
Health check-up for OSHA– Yearly
Health check-up for Employees- Yearly
All the OSHA peoples have been trained for Basic life support, first aid, Basic
fire safety and emergency preparedness.
Ambient air quality monitoring in every month at 3 locations
Monthly monitoring of environmental parameters.
Safety display boards provided throughout the plant.
Monthly fire extinguisher audit.
Work permit system
PPE adherence
Waste management and hazardous waste handling
Safe lifting operation
Industrial hygiene
6.6. Other Recommended Measures for Safe Operation of the Plant
In addition to the specific recommendations made in the above section for storage and
handling of sulphuric acid within the plant premises, for safe operation of the plant and
risk reduction, following suggestions and recommendations are made:
Personnel especially contractor workers at the plant should be made aware
about the hazardous substance stored at the plant and risk associated with
them.
A written process safety information document may be compiled for general
use.
The document compilation should include an assessment of the hazards
presented including (i) toxicity information (ii) permissible exposure limits. (iii)
physical data (iv) thermal and chemical stability data (v) reactivity data (vi)
corrosivity data (vii) information on process and mechanical design.
The process design information in the process safety information compilation
must include P&IDs/PFDs; process chemistry; maximum intended inventory;
acceptable upper and lower limits, pressures, flows and compositions and
process design and energy balances.
The adequate numbers of heat, smoke, detectors may be provided at
strategic locations in the plant and indication of detectors/sensors should be
provided in main control room.
Predictive and preventive maintenance schedule should be prepared for
equipment, piping, pumps, etc. and thickness survey should be done
periodically as per standard practices.
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Safe work practices should be developed to provide for the control of hazards
during operation and maintenance.
Personnel engaged in handling of hazardous chemicals should be trained to
respond in an unlikely event of emergencies.
The plant should check and ensure that all instruments provided in the plant
are in good condition and documented.
Safety measures in the form of DO and Don‘t Do should be displayed at
strategic locations especially in Hindi and English language.
The present DO‘s and DON‘T‘s followed in their other units/ factories is
checklist in the form of do‘s and don‘ts of preventive maintenance,
strengthening of HSE, manufacturing utility staff for safety related measures.
6.6.1. Personal Protective Equipment
Personal protective equipment (PPEs) are devices that are fitted and issued to each
worker personally for his or her exclusive use. They are intended for temporary use and
emergency response action only. If a worker must enter a contaminated area, he must
wear adequate protective equipment. Employees should be taught when and how to use
respiratory apparatus (SCBA) provided, and how to recognize defects in the equipment.
Without SCBA entry into the contaminated area should not be attempted.
Keep personal protective equipment where it can be accessed quickly,
outside the hazardous material storage area and away from areas of likely
contamination.
Each employee should maintain his personal protective equipment in clean,
working condition at all times.
All equipment should be used and maintained in accordance with the
manufacturer‘s instructions.
Equipment installed for body and eye wash should be checked properly for
round the clock operation.
6.6.1.1 Handling of Hazards
Some of the measures employed in handling of hazards:
Personal protective equipment used by the workers during handling of
hazardous chemicals, should be replaced after getting defective.
If any spillage of hazardous chemicals, it should be cleaned and disposed as
per standard practiced.
Empty drums of hazardous chemicals should neutralize immediate.
Workers engaged in handling of hazardous chemicals should be made aware
of properties of hazardous chemicals.
6.6.1.2 General Working Conditions at the Proposed Plant
House Keeping
The House Keeping practices employed would be:
All the passages, floors and stairways should be maintained in good
conditions.
The system should be available to deal with any spillage of dry or liquid
chemical at the plant.
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Walkways should be always kept free from obstructions.
In the plant, precaution and instructions should be displayed at strategic
locations in Hindi and English Languages.
All pits, sumps should be properly covered or securely fenced.
Ventilation
The Ventilation measures that would be employed:
Adequate ventilation would be provided in the work floor environment.
The work environment would be assessed and monitored regularly as local
ventilation is most effective method for controlling dust and gaseous
emissions at work floor.
Safe Operating Procedures
Other operation procedures followed would be:
Safe operating procedures will be available for mostly all materials,
operations and equipment.
The workers will be informed of consequences of failure to observe the safe
operating procedures.
Work Permit System
Work permit system will be followed at the plant during maintenance.
Fire Protection
For fire protection the measures taken are:
The fire fighting system and equipment will be tested and maintained as per
relevant standards.
Smoke detectors will be provided at the plant and shall be calibrated and
maintained properly.
Static Electricity
The general instructions for working with static electric are:
All equipment and storage tanks/containers of flammable chemicals shall be
bounded and earthed properly.
Electrical pits shall be maintained clean and covered.
Electrical continuity for earthing circuits shall be maintained.
Periodic inspections shall be done for earth pits and record shall be
maintained.
Material Handling
For material handling the regulatory measures that are taken for workers handling
various materials would include:
The workers shall be made aware about the hazards associated with manual
material handling.
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The workers shall be made aware and trained about the use of personal
protective equipment (PPE) while handling hazardous chemicals.
Communication System
Communication facilities shall be checked periodically for its proper functioning.
Safety Inspections
The system shall be initiated for checklist based routine safety inspection and internal
audit of the plant. Safety inspection team shall be formed from various disciplines and
departments.
Predictive and preventive maintenance schedule shall be followed in religious manner.
Electrical Safety
For electric safety provisions to be taken care of are:
Insulation pad at HT panels shall be replaced at regular interval.
Housekeeping in MCC room shall be kept proper for safe working conditions.
Colour Coding System
Colour coding for piping and utility lines shall be followed in accordance with IS:
2379:1990.
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CHAPTER 7. Additional Studies
7.1. Introduction
A detail report based on study regarding Risk assessment prepared covering
objective, methodology of HIRA, Identification of Hazards, details of Hazardous
material, bulk storages with QRA approach rules sets and assumptions, effect due to
incident radiation Intensity damage due to overpressure. Likely failure scenarios
have been given in Onsite Emergency Plan report attached as Annexure 29.
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CHAPTER 8. SUMMARY AND CONCLUSIONS
8.1. Prelude
The present study was aimed at identifying the potential environmental impacts due to
the various project activities, assessment of impact with and without mitigation
measures, and at developing an environmental management and monitoring plans for
proper mitigation of any adverse environmental impact. In this study, the various
activities likely to take place during the construction and operation phases of the project
have been analysed in relation to the baseline condition of different environmental
components. The mitigation measures proposed for the contractors and the project
proponent have also been reviewed and the potential residual impacts discussed. The
key points considered in this study are described in the following sections:
8.2. Regulatory Compliance
The project is yet at its technical investigation stage. Prior to its implementation, it will be
necessary to acquire all the necessary clearance from the Government of India, as per
the applicable national regulations. Key clearances include obtaining the No Objection
Certificate from the Odisha PCB under The Water (Prevention and Control of Pollution)
Act, 1974 and Rules, 1975; The Air (Prevention and Control of Pollution) Act, 1981 and
Rules, 1982; and Environmental Clearance from the MoEF, under the EIA Notification,
2006, The Environment (Protection) Act, 1986 and Rules, 1986. In addition to that
Authorization for Hazardous Waste Management will also be required under the
Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008
from OSPCB.
8.3. Baseline Conditions
The monitoring of the existing environmental conditions of the proposed project site and
of its close vicinity have been established with respect to physical, biological and human
environment. The air quality of the area meets the prescribed National Ambient Air
Quality Standards applicable for the industrial, residential and rural Areas. The
background noise levels were also found within the standards as at present most of the
area is not developed.
The water quality also meets all standards for use in domestic and industrial
applications. The geology of the project area is of varied nature; however it is not prone
to floods. In addition to that there is no sensitive ecosystem in the vicinity. No
rehabilitation and resettlement issue is emerging with the selected project site.
8.4. Environmental Impacts and Mitigation Measures
The project entails various impacts on the study area, some negative and some positive.
The impacts will be caused by the construction activities as well as by the other industrial
activities during the construction and operation phases, respectively. Various impacts
identified during the study have been provided mitigation measures for a better
environmental management. In addition to that the roles and responsibilities of the
developers have also been given in the Environmental Monitoring Programme to monitor
the implementation of the environmental management plan to ensure the mitigations of
adverse impacts.
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8.5. Recommendations
Based on the environmental impact assessment conducted, the following
recommendations are made:
Systems of periodic auditing and reporting shall be adopted during the
construction period to ensure that the contractors adhere to the
Environmental Management Plan.
The project proponent and its team of consultants and contractors are urged
to develop a strategy for effective communication with local people.
The construction team/ developer should effectively follow the suggestions
made in the EMP and/ or any other environmental measures so as not to
damage the environment of the project area.
The industry shall have to adhere the conditions stipulated in the
environmental clearance as well as in consent/ authorization from OSPCB.
Since regulations are fast changing in India, the project proponent must keep hemselves
updated with respect to applicable laws and take appropriate actions in case the
provisions in some regulations undergo change.
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CHAPTER 9. DISCLOSURE OF CONSULTANTS
Declaration by Experts contributing to the EIA/EMP Report of Proposed Expansion
project of DAP and Proposal of Coal Handling Plant, Ammonia, Ammonium Nitrate,
Urea, GSSP, Ammonium Fluoride, Nitric Acid at Paradeep in Jagatsinghpur District,
Orissa by Paradeep Phosphate Ltd.
―I, hereby, certify that I was a part of the EIA team in the following capacity that validated
this Report‖.
EIA Coordinator:
Signature
Name: Yashwant bordia
Period of involvement August 2016 to to finalization of report
Contact Information: 8890836012
Functional Area Experts
Functional Areas Name of the
Expert
Involvement (Period and Task**)
August 2016 to
finalization of report
Signature
Air Pollution
Monitoring &
Control (AP)
Y. Bordia
Site visit, assistance in
selection of monitoring
locations, checking air
quality data, evaluation
of results of Ambient
Air Quality Monitoring
(AAQM)
Air Quality Modeling
and Prediction (AQ)
Sanjeev Sharma
Assistance in air
quality modeling and
prediction: met file
generation and model
run
Noise Sanjeev Sharma
Site visit, assistance in
selection of sampling
locations for noise
level sampling,
interpretation of
monitoring results for
the project and
contribution to EIA
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
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Functional Areas Name of the
Expert
Involvement (Period and Task**)
August 2016 to
finalization of report
Signature
documentation
Water Pollution
(WP) Y. Bordia
Site visit, assistance in
selection of sampling
locations for surface
water sampling, water
balance for the project
and contribution to EIA
documentation
Ecology and Bio-
diversity
Conservation (EB)
Ratnesh Kotiyal
Site visit, assistance in
selection of sampling
locations and
contribution to EIA
documentation
Solid and
Hazardous Waste
Management
(SHW)
Y. Bordia
Identification of waste
generated from the
industry, studying
adequacy of mitigation
measures for
management of
hazardous waste
Socio-Economics
(SE)
Anil Kumar
Site visit, contribution
to Baseline
environment and
contribution to EIA
documentation
Landuse (LU) Anil Kumar
Development of
landuse maps of study
area using GIS /
related tools, site visit
for ground truth survey,
finalization of landuse
maps
Risk and Hazards
(RH) S K Jain
Site visit, Identification
of modeling scenarios,
consequence modeling
using PHAST,
finalization of DMP,
contribution to RA /
DMP Documentation
and contribution to EIA
EIA/EMP Report of Proposed Expansion Project of Paradeep Phosphate Limited
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Functional Areas Name of the
Expert
Involvement (Period and Task**)
August 2016 to
finalization of report
Signature
documentation
*Following category ‘B’ FAEs have worked as support FAE to category ‘A’ FAEs.
Mr.Om Prakash for Air Environment (AP) ; Ms.Shweta Gupta FAE (B) for Noise &Water
Environment, and FAA for Solid and Hazardous Waste Management&Air Quality Modeling
and Prediction (AQ)
Declaration by the Head of the Accredited Consultant Organization:
I, S K Jain, hereby, confirm that the above mentioned experts validated the EIA / EMP
Report for Expansion of existing plant of DAP and Proposal of Coal Handling Plant,
Ammonia, Ammonium Nitrate, Urea, GSSP, Ammonium Fluoride, Nitric Acid located at
Jagatsinghpur, Orissa by M/s Paradeep phosphate Ltd.
Signature :
Name : S K Jain
Designation : Technical Director
Name of the EIA Consultant Organization : EQMS India Pvt Ltd.
NABET Certificate No. and Date : NABET/EIA/1619/SA 070; July 17, 2018