Chapter 8 ENVIRONMENTAL MANAGEMENT IN INDIAN FERTILISER PLANTS The study covered a representative group of six major fertiliser producers in the country. The methods of pollution control and environmental management adopted in respect of each of the causative factors for pollution are thoroughly reviewed. An assessment was also done as to how far existing technologies are effective in mitigating pollution from plants to the required level of standard being practiced in India as well as abroad. Areas where strengthening is required, both in the technology at the plant level and management perspective at the corporate level, are highlighted. All the units studied have specific environmental policies and are maintaining the characteristics of the emissions to atmosphere and effluents discharged to the local streams within the limits of the stipulations of the regulatory authorities. This is achieved by treating pollutants in effluent streams in suitably designed pollution control plants following the end-of-pipe treatment approach. New plants such as those belonging to Tata Chemicals and Indo Gulf Fertiliser Corporation, have modem process technologies where considerable integration have taken place at the inception stage itself to see that pollution prevention is a part of the process design itself. In the case of units that came to existence long back, pollution control facilities were built and attached later as and when legislation in this area became effective. In fact, the study revealed that the pollution and environment control departments of these units exhibit meticulous care to see that the above objective is achieved. Thus now-a-days
Transcript
Chapter 8
ENVIRONMENTAL MANAGEMENT IN
INDIAN FERTILISER PLANTS
The study covered a representative group of six major fertiliser producers in
the country. The methods of pollution control and environmental management
adopted in respect of each of the causative factors for pollution are thoroughly
reviewed. An assessment was also done as to how far existing technologies are
effective in mitigating pollution from plants to the required level of standard being
practiced in India as well as abroad. Areas where strengthening is required, both in the
technology at the plant level and management perspective at the corporate level, are
highlighted.
All the units studied have specific environmental policies and are maintaining
the characteristics of the emissions to atmosphere and effluents discharged to the local
streams within the limits of the stipulations of the regulatory authorities. This is
achieved by treating pollutants in effluent streams in suitably designed pollution
control plants following the end-of-pipe treatment approach. New plants such as those
belonging to Tata Chemicals and Indo Gulf Fertiliser Corporation, have modem
process technologies where considerable integration have taken place at the inception
stage itself to see that pollution prevention is a part of the process design itself. In the
case of units that came to existence long back, pollution control facilities were built
and attached later as and when legislation in this area became effective. In fact, the
study revealed that the pollution and environment control departments of these units
exhibit meticulous care to see that the above objective is achieved. Thus now-a-days
199
states of art control facilities exist in these units and they are operated effectively.
The stipulations of the Pollution Control Boards are with in the achievable limits of
the available technology at hand. Sometimes excursions occur in the analysis of
certain parameters on account of start up, shut down of plants or may be due to
accidental situations. Existing facilities are ensured capable of handling such
situations also.
Table 8.1.1 and 8.1.2 provides a comparIson of pollution control and
environment management techniques being adopted by the various units studied vis~a~
vis the best available technology in the field. It indicates the methods of pollution
control adopted in the various plants in respect of each of the pollutants. In
comparison with the currently available best practices for efficient pollution control in
the industry, projections for further improvement of existing control measures in
these plants are identified.
Table 8.2 show the average effluent and emission characteristics of the
discharged streams from the units studied. In the fertiliser industry key parameters
being monitored universally are pH, ammoniacal nitrogen, nitrates, fluorides,
phosphates, total suspended and dissolved solids and chemical and biological oxygen
demand, toxic metals such as hexavalent chromium, vanadium etc., in the effluent
streams, particulate matter, nitrogen oxides, sulphur oxides and carbon monoxide in
exhaust streams, and temperature at which the effluents are discharged.
Fig.S.1 which is a graphical presentation of the key effluent characteristics
from the plants vis~a~vis the mandatory standards, show that all the units have been 'r\'~." ""' .•
.... .,..,. -" successful in maintaining the respective effluent reters beIo.'W the prescribed .1 \~"
~f \"'.
standards with regard to discharge of effluents. ~\ .. r~' ~
Table 8.3 indicates the Minimum National Standards (MINAS) for discharge
of fertiliser plant effiuents and emissions stipulated by the" Central Pollution Control
Board (CpeB). These are the statutory limits within which existing operators control
pollutants in their streams. In specifying these limits the long-tenn impact of
pollutants in the environment is not given due regard, instead most often it is the level
achievable by the use of current technologies.
Table 8.4 shows the ambient air quality standards in respect of noise in
different areas including industrial zones as prescribed by the Central Pollution
Control Board. Most equipment in the plant are usually designed in such a way that
the noise level emanating from their operation is less than 85 dB at a point one metre
away from the source of the sound. Besides this design stipulation, proper enclosures
are also provided for operator stations so that the exposure to noise shall not exceed
85 dB for 8 hours.
Table 8.4
Ambient Air Quality Standards in respect of Noise
Area Limits in decibel (dB)
Code Category of Area/Zone
Day Time Night time
(A) Industrial area 75 70
(B) Commercial area 65 55
(C) Residential area 55 45
(D) Silence Zone 50 40
Source: Central Pollution Control Board, 1998.
Notes: 1. Daytime shall mean from 6.00 a.m. to 10.00 p.m. 2. Night time shall mean from 10.00 p.m. to 6.00 a.m. 3. Silence zone is defined as an area comprising not less than 100 metres
around hospitals, educational institutions and courts. The silence zones are zones which are declared as such by the competent authority.
Par
amet
ers
(1)
Tot
al S
uspe
nded
sol
ids
Tot
al D
isso
lved
Sol
ids
Tem
pera
ture
pH
Bio
logi
cal
Oxy
gen
Dem
and
Che
mic
al O
xyge
n D
eman
d
Dis
solv
ed O
xyge
n
Oil
& G
reas
e
Am
mon
iaca
l N
itro
gen
as N
Fre
e A
mm
onia
Tot
al K
jada
hl N
itro
gen
as N
Nit
rate
Nit
roge
n
Sul
phat
e as
S0
4
Pho
spha
te a
s P
-
Tab
le 8
.3
Eff
luen
t C
har
acte
rist
ics
Sta
nd
ard
s
---
Min
imu
m N
atio
nal
Sta
nd
ard
s fo
r F
erti
lise
r In
du
stry
Uni
t N
itro
geno
us
Pho
spha
tic
Com
plex
(2)
(3)
(4)
(5)
mg/
I m
ax
100
100
100
mg/
I m
ax
°C
5°C
abo
ve
recy
clin
g w
ater
6.5
-8.0
7
.0-9
.0
6.5
-8.0
mg/
I m
ax
mg/
I m
ax
mg/
I m
in
mg/
I m
ax
10
10
10
mg/
I m
ax
50
50
mg/
I m
ax
4 4
100
mg/
I m
ax
20
20
mg/
I m
ax
_ m
g/I m~x _
5
5 '-
----
-----
--
N -v)
0)
(2)
Sul
phid
e as
S
mg/
l m
ax
Flu
orid
e as
F
mg/
l m
ax
Chl
orid
e as
Cl
mg/
I m
ax
Cya
nide
as
CN
m
g/l
max
Lea
d as
Pb
mg/
I m
ax
Sel
eniu
m a
s Se
rn
g/l
rnax
Zin
c as
Zn
mg/
I m
ax
Cop
pera
s C
u m
g/l
max
Nic
kel
as N
i m
g/l
rnax
Cad
miu
m a
s C
d . r
ng/I
max
Hex
aval
ent
Chr
omiu
m a
s C
r m
g/l
max
Mer
cury
as
Hg
rng/
l rn
ax
Ars
enic
as
As
mg/
l m
ax
Sod
ium
as
Na
%m
ax
Iron
as
Fe
mg/
l m
ax
Fre
e C
arbo
n di
oxid
e C
O2
rng/
I m
ax
Phe
nol
as C
6Hs
OH
m
g/I
max
Res
idue
} C
hlor
ine
as C
l m
g!l
max
Bar
ium
as
Ba
mg/
I m
ax
Van
adiu
m a
s V
m
g/I
max
(3)
(4)
to
0.2
,
0.1
0.1
0.2
0.2
---
--
(5) to
0.2
0.1
0.2
0.2 --_
.-
t...l
~
215
Table 8.5 provides European Emission Standards as prescribed by the
European Fertiliser Manufacturers' Association (EFMA). European and North
American emission and effluent standards for fertiliser industry are more or less
similar to the Indian standards in the respective areas.
Analysis of the above results show that all the units are successful in
controlling major pollutants below the specified standards. Certain plants have put up
recovery or treatment facilities so that effective reduction of pollutants takes place
well below the stipulations. All the plants studied have extensive facilities for end-of
pipe treatment of all effluents. Attempt to reduce the effluent generation at source in
these plants largely depend on the teclmologies adopted. In all units management
infrastructure exist for regular monitoring and reporting to authorities.
The specific consumption of energy, which measures the energy requirement
per tonne of ammonia, a major intermediate input and urea, a finished fertiliser
product, from plants have shown a continuous trend of reduction over these years.
(Fig. 8.2 and 8.3).
Reduced energy consumption invariably contribute to achieving better
environmental standards and result in gradual reduction in emissions, effluents and
solid waste per tonne of product manufactured.
Major design changes will be required for further improvements and hence
efforts in this line are limited unless it brings about economic incentive by way of
increased productivity, lowering of energy consumption etc.
Em
issi
on L
imit
Val
ues
to w
ater
P
lant
(lJ
Am
mon
ia
Ure
a
Am
mon
ium
Nit
rate
N
PK
-Nit
roph
osph
ate
NP
K M
ixed
Aci
d E
mis
sion
V
alue
s to
A
ir
(EF
MA
) P
lant
Am
mon
ia
Nit
ric
Aci
d S
ulph
uric
Aci
d
Tab
le 8
.S
Eur
opea
n E
mis
sion
Sta
ndar
ds
Em
issi
on
mgl
l kg
/ton
ne o
f pro
duct
(2)
(3)
(4)
(5)
(6)
New
E
xist
ing
New
E
xist
ing
NH
3-N
0.
1 0.
1 U
rea-
N
1 IS
O
0.00
05
0.1
NH
3-N
5
150
0.00
25
0.1
N
100
100
0.2
0.2
P20S
30
28
0.
06
0.11
N
H4-
N
60
120
0.12
0.
5 N
03-N
IS
15
0 0.
03
0.3
Flu
orid
e 26
13
0.
05
0.2
N
0 10
0 0
0.2
Em
issi
on
mg/
Nm
3 kg
/ton
ne o
f pro
duct
New
E
xist
ing
New
E
xist
ing
NO
X
150
300
0.45
0.
9 S
02
as f
or c
ombu
stio
n pl
ants
N
02
30
0 80
0 1.
6 4.
2 S
02
2--4
10
S03
0.
15
0.6
I
t..)
0'1
(1)
(2)
(3)
(4)
(5)
Pho
spho
ric
Aci
d F
luor
ide
5 30
0.
4 O
fP20
S D
ust
10
150
Ure
a G
ranu
lato
r U
rea
Dus
t 50
70
-80
0.25
N
H3
50
130-
165
0.25
P
rill
Tow
er
Ure
a D
ust
50
100-
150
0.5
NH
3 50
65
-100
0.
5 V
ents
N
H3
0.6
Am
mon
iwn
Nit
rate
G
ranu
lato
rlP
rill
tow
er
NH
3 "'1
0 "'1
0 P
arti
cula
tes
"'15
"'15
Neu
tali
ser/
Coo
ler/
Dri
er
NH
3 50
50
P
arti
cula
tes
30
30
CA
N
NH
3 50
50
P
arti
cula
tes
50
50
NP
K (N
itro
phos
phat
e)
NH
3 50
25
0 0.
3 N
02
500
500
0.2
Flo
urid
e 5
5 0.
02
Dus
t 50
50
0.
3 N
PK
(m
ixed
aci
d)
NH
3 50
50
0.
2 N
02
70
70
0.3
Flo
urid
e 5
5 0.
02
Dus
t 50
50
0.
2 --
-
'" 50
whe
n in
solu
ble
soli
ds a
re p
rese
nt
Sou
rce:
Eur
opea
n F
erti
lise
r M
anuf
actu
rers
' Ass
ocia
tion
, B
est A
vail
able
Tec
hniq
ues,
199
5.
(6)
0.35
-0.4
0.
65-0
.83
1-1.
5 ..;
0.65
-1
I
0.75
, ,
part
icul
ates
0.5
~
NB
] 0.
2 , I
1 0.2
0.02
0.
3 0.
2 0.
3 0.
02
0.2
t.J
-.J
218
- 15 -
10 -
5 1 2 3 4 5
Year 1987 1991 1995 1998 2000
Energy MKCallMT 12.54 11.66 11.02 10.18 9.59
Year
----- ---- .. ----.--- _._--
Fig. 8.2: Energy Consumption Trends-Ammonia Plants
