Indian Oil Corporation Limited Barauni Refinery EIA Report on ...

Indian Oil Corporation Limited

Barauni Refinery

EIA Report on

Projects at IOCL Barauni Refinery

May 2015

Contents :

1) TOR for Replacement of Reactors & Allied modernization jobs of Coker A and Installation of Biturox Unit at IOCL Barauni Refinery.

2) TOR for BS-IV Project : MS Quality Up-gradation & HSD Quality Up-gradation at IOCL Barauni Refinery.

3) Updated Chapters of EIA report.

4) Previous EIA report.

TOR (30th Reconstituted Expert Appraisal Committee (Industry-2) Proposal No. IA/BR/IND/24783/2014 File No. J-11011/318/2014 IA II (I) Subject : Replacement of reactors & allied modernization jobs of Coker A and Installation of Biturox Unit in the existing Barauni Refinery in District Begusarai, Bihar by M/s IOCL Barauni Refinery – reg. TOR

The project authorities gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken along with the draft Term of References for the preparation of EIA-EMP report. All the Petroleum Refinery Plants are listed at S.N. 4(a) under Category ‘A’ and appraised at the Central level.

M/s IOCL Barauni Refinery has proposed for replacement of reactors & allied

modernization jobs of Coker A and Installation of Biturox Unit in the existing Barauni Refinery in District Begusarai, Bihar. PP informed that Coker revamp & Biturox project conceptualized in 2006. EC was obtained vide MEF&CC’s letter no. J-11011/491/2007. IA(II) I dated March 2008. EC expires after five years as PP did not submitted application within validity period of environmental clearance. Therefore, PP submitted fresh proposal for environmental clearance.

a) Coker A : Mainly intended for the replacement of 30 years old Coke Drums/Reactors for reliability improvement. The Coke drums will be replaced by higher metallurgy to process high sulphur feed. No capacity augmentation is envisaged. It will retain its original capacity of 0.6 MMTPA. Automation of facilities like heading un-heading devices, Coke drum level indication, coke cutting system etc. 05 nos of new heat exchangers In preheat circuit, which will lead to one furnace operation against present 02 furnace operation. Cost of project is Rs. 480.31 Crore. No additional land is required. One furnace operation is envisaged against two furnace operation, which will lead lower emission, lower fuel consumption and power consumption. SOx reduction will be 9.4 Kg/hr.

b) New BituroxUnit : Intended for production of 0.15 MMTPA of different grades of

bitumen viz. VG-10, 20, 30 & 40. It will consists of feed blending, feed-product heat exchanger, biturox reactor, process air/water supply, off gas treatment section and other related facilities. Existing incinerator of FCCU will be utilized for flue gas. Cost of project is Rs. 71.43 Crore. No additional land is required. SO2 will be increased by 0.3 kg/h due to incinerator.

Coker A will be operating with only one furnace against present two furnace

configuration. Whereas flue gas of Biturox Unit will be routed through existing FCCU incinerator. Overall the increase emission from FCCU stack will be less than 2nd furnace emission of Coker A (which will be cut off after project). Additionally, installation of more CAAQMS and analyzers is under approval for better monitoring and control of emissions. Modernization of ETP and BTP has been completed recently in 2014-15 with new facility like UF and bio-towers. Effluent water generation from Coker A will reduce due to new coke cutting system and additional effluent from Biturox Unit of 1.5 m3/hr will be taken care within high capacity modernized ETP and BTP. More over new RO plant in ETP/BTP with capacity of 510 m3/hr is likely to be commissioned in 2015-16.This will further reduce overall fresh water

consumption by recycling ETP/BTP water.

The Committee suggested to modify/update the said EIA-EMP report by taking this proposal into consideration. The Committee recommended following TOR to be incorporated in the EIA-EMP report :

1. A separate chapter on status of compliance of Environmental Conditions granted by

State/Centre to be provided. As per circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA-EMP report.

2. Project Description and Project Benefits. 3. Manufacturing process details along with the chemical reactions and process flow

diagram for the proposed project. 4. Is there additional storage required for the proposed project, if yes details thereof. 5. Baseline data for air, water and soil for last one year. 6. Ambient air quality monitoring data for PM2.5, PM10 SO2, NOx, (methane & non-

methane HC) and VOCs particularly in the downwind direction. 7. Existing status of stack emission, raw water requirement, treated effluent quantity &

quality data, noise pollution and solid waste management in the existing units. 8. Details of Sulphur balance in the existing refinery unit. 9. Additional SO2 emissions due to the proposed project. 10. A note on how SO2 and NOX will be controlled at the existing level leading to no

increase in pollution load. 11. Unit-wise air pollution control devices to be installed. For the proposed units. 12. Water Balance chart for the existing unit and due to the proposed project. Action plan

for reduction of water requirement. 13. Quantity of effluent generation and the existing effluent treatment scheme. 14. Detailed solid waste generation, collection, segregation, its recycling and reuse,

treatment and disposal. 15. Oily sludge management plan. 16. Details of membership of TSDF for hazardous waste disposal. 17. Details of proposed preventive measures for leakages and accident. 18. Environmental Management Plan 19. Risk Assessment & Disaster Management Plan

a. Identification of hazards b. Consequence Analysis c. Risk assessment should also include leakages and location near to refinery &

proposed measures for risk reduction. 20. Total capital cost and recurring cost/annum for environmental pollution control

measures.

It was decided that project proponent should submit the final EIA report for consideration of the proposal by the Expert Appraisal Committee (Industry-2). Public hearing is exempted under section 7 (ii) of EIA Notification, 2006 as public hearing was held on 25th September, 2007 and no significant pollution load increase has been envisaged.

TOR (34th Reconstituted Expert Appraisal Committee (Industry-2) Proposal No. IA/BR/IND/26336/2015 File No. J-11011/15/2015-IA II (I) Subject: Proposed modernization of BS-IV Project: MS Quality Up-gradation & HSD Quality Up-gradation by M/s. IOCL Barauni Refinery -reg TOR

The project authorities gave a detailed presentation on the salient features of the

project and proposed environmental protection measures to be undertaken along with the draft Term of References for the preparation of EIA-EMP report. All the Petroleum Refinery Plants are listed at S.N. 4(a) under Category ‘A’ and appraised at the Central level.

M/s. IOCL Barauni Refinery has proposed for modernization of BS-IV Project: MS Quality

Up-gradation & HSD Quality Up-gradation. Cost of project is Rs. 1327 crore. PP informed that there is no additional increment in Refining Capacity of 6.0 MMTPA, however capacity of following units are proposed to undergo revamp/addition of small units to meet BS-IV standard for petrol and diesel.

a) Naphtha Hydro Treating Unit (NHTU) revamp from 0.3 MMTPA to 0.47 MMTPA. b) Catalytic Reforming Unit (CRU) revamp from 0.3 MMTPA to 0.47 MMTPA. c) Diesel Hydro Treating Unit (DHDT) revamp from 2.2 MMTPA to 3.3 MMTPA. e) Additional new Naphtha Splitter Unit (NSU) to enhance present capacity of 0.464

MMTPA to 0.76 MMTPA. f) Additional new Cracked Gasoline De-sulphurisation Unit to enhance present capacity

of 0.4 MMTPA to 0.76 MMTPA It was noted that no additional land requirement ( Project will be implemented within

existing Refinery Boundary Limit). RO plant is coming up in ETP and likely to be commissioned in FY 2015-16, post commissioning of RO plant & BS:IV project the overall water consumption will come down from present 690 m3/hr to 651 m3/hr. Additional requirement of power is 8.5 MWH ( Will be fulfilled from existing Power Plant Capacity of 90 MWH, which is presently running at a load of 42.25 MWH ). 1.25 MT/hr of Hydrogen Gas will be fulfilled from existing Hydrogen generating units ( HGU, CRU & DOG PSA ) of 9.08 MT/hr, which is presently running at load of 6.05 MT/hr. SO2 emission expected to increase by approx. 200 kg/hr. Total refinery SO2 emission after project = approx. 900 kg/hr. Limit for Barauni Refinery is 1035 kg/hr. No impact on water, as post project overall water consumption will come down due to commissioning of RO plant in ETP for recycling of treated effluent.

It was noticed that project namely replacement of reactors & allied modernization jobs

of Coker A and Installation of Biturox Unit in the existing Barauni Refinery was considered in the 30th EAC meeting held during 22nd – 23rd December, 2014 and the Committee suggested to modify/update the said EIA-EMP report by taking this proposal into consideration. After detailed deliberation, the Committee suggested them to club the new proposal with the existing proposal to evaluate the cumulative impact. The existing ToR will remain same. Public hearing is exempted under section 7 (ii) of EIA Notification, 2006 as public hearing was held on 25th September, 2007 and no significant pollution load increase has been envisaged.

Indian Oil Corporation Limited

Barauni Refinery

Updated Chapters of EIA report

May 2015

Indian Oil Corporation Limited Barauni Refinery

High Sulphur Maximization Project & BS-IV Project

Updated Chapters of EIA report Chapter Index

Contents

Chapter -1 : Project Description and Project Benefits 1.1 High Sulphur Crude maximization Project. 1.2 BS-IV Project. 1.3 Present & Post Project Scenario. 1.4 Project Cost. 1.5 Project Benefits. Chapter – 2 : Process Details with Chemical Reactions 2.1 Biturox Unit. 2.1.1 Introduction. 2.1.2 Design Basis & Chemical Reactions. 2.1.3 Process Description. 2.2 Coker A Revamp. 2.2.1 Introduction. 2.2.2 Design Basis & Chemical Reactions. 2.2.3 Process Description. 2.3 NSU, NHTU & CRU. 2.3.1 Introduction. 2.3.2 Design Basis & Chemical Reactions. 2.3.3 Process Description. 2.4 Prime G+ 2.4.1 Introduction. 2.4.2 Chemical Reaction. 2.4.3 Process Description. 2.5 DHDT. 2.5.1 Introduction. 2.5.2 Design Basis & Chemical Reactions. 2.5.3 Process Description.




Chapter-3 : Process Flow Diagrams (PFD’s)

3.1 Coker-A Unit PFD. 3.2 Biturox Unit PFD. 3.3 Catalytic Reforming Unit (CRU) PFD. 3.4 FCCU Cracked Gasoline Desulphurization Unit (Prime G+) PFD. 3.5 Naphtha Splitting Unit (NSU) PFD. 3.6 Diesel Hydro treating Unit (DHDT) PFD. Chapter-4 : Baseline data & Monitoring

4.1 One Year baseline data for Air. 4.2 One Year baseline data for Water. 4.3 Stack Emission Monitoring. 4.4 Raw Water Requirement. 4.4.1 Present raw water requirement. 4.4.2 Post Project raw water requirement. 4.5 Treated Effluent Quality & Quantity. 4.6 Noise Pollution Monitoring. 4.7 Present Solid Waste Management. 4.8 Sulphur Balance 4.9 Note on SO2 emission and NOX emission. 4.10 Air Pollution Control Devices. Chapter-5 : Water Balance

5.1 Water Balance Chart of existing. 5.2 Water Balance Chart due to proposed project. 5.3 Action Plan for reduction of water requirement. Chapter-6 : Effluent Management

6.1 Quantity of Effluent generation. 6.2 Effluent Treatment Scheme.




Chapter-7 : Solid Waste & Oily Sludge Management

7.1 Solid Waste Management. 7.2 Oily Sludge Management. Chapter-8 : Environment Management Plan 8.1 Water Management. 8.2 Effluent Management. 8.3 Emission Management. Chapter-9 : Expenditure on Environment Pollution Control measures 9.1 Total Capital Cost for environment pollution control measures. 9.2 Total recurring cost per annum for environment pollution control measures.



Updated Chapters of EIA report Chapter-1 Project Description & Benefits

Chapter -1

Project Description & Benefits




Currently IOCL Barauni Refinery has taken up below listed projects

1. High Sulphur Crude maximization Project 2. BS-IV Project

1. High Sulphur Crude maximization Project

The subject project is intended for the replacement of coke drums/reactors for reliability improvement in Coker A Unit along with inclusion of new Biturox Unit. It is also one of the projects proposed under High Sulphur Crude maximization plan of Barauni Refinery in 2006 in which one Crude tank of 40000 m3 was also envisaged.

1.1. Coker A revamp project:

Existing reactors/coke drums have been in operation for the last 30 years and already outlived its life. In this project, the coke drums will be replaced with higher metallurgy to process high sulphur feed. It may be mentioned that no capacity augmentation is envisaged in the project however certain automation facilities like automatic heading-un heading devices, coke drum level indication, coke cutting system etc are proposed. In addition, energy optimization measures are also proposed by adding 5 numbers of new heat exchangers in preheat circuit and one furnace will be decommissioned out of total two furnaces.

1.2. New Biturox Unit

Installation of Biturox plant at Barauni Refinery is intended for the production of 150TMTPA Bitumen to meet the region’s demand. Different grades of Bitumen viz VG-10, 20, 30 & 40 shall be produced from this unit. The subject unit is licensed by M/s Poerner Inc, Austria. This project also comes under High Sulphur Crude maximization plan of the Barauni Refinery

2. BS-IV Project

Total BS-IV MS/HSD supply being statutory requirement, low cost option has been explored with maximum utilization of the existing assets i.e, revamp of existing units has been considered instead of new units to the extent feasible. An in-house study has been performed by exploring various means of achieving 100 % BS-IV MS & HSD. The study is based on Licensor's input, literature survey/ in-house expertise and information. The study indicated, capacity revamp of DHDT and NSU, CRU revamp or New CCRU, Prime G+ Revamp and additional RFCC gasoline de-sulphurisation Unit is required to meet 100 % HSD and MS of BS-IV specifications.




Unit Capacity Augmentation

Envisaged, MMTPA Remarks Present Proposed

NSU 0.464 0.76 Revamp / New Unit : New NSU as existing NSU revamp not feasible

NHTU 0.30 0.472 Revamp: Revamp or New unit

CRU 0.3 0.47 Revamp: Revamp or New unit

PRIME-G+

0.32 (SHU) 0.22 (HDS)

0.76 (SHU) 0.56 (HDS)

New Unit : PG+ Revamp or Parallel new RFCC gasoline treatment unit

DHDT 2.2 3.3 Revamp: BS IV Revamp to 3.3 MMTPA

For revamp units, the necessary hardware modifications shall be performed in the existing available plot plan of the corresponding units. In case of additional new units, the area currently rendered vacant which is adjacent to existing ISOM unit (MSQ block) location is proposed.

With the above facilities, at current crude processing capacity of 6.3 MMTPA the refinery can produce about 1.3 MMTPA and 3.2 MMTPA of BS-IV MS & HSD respectively along with flexibility to produce 25 % of Euro V specifications. Comparison of units T'put in BS-IV scenario vis- a- vis current actual operating /design capacity is compiled below. Attribute Design BS-III Scenario

(Actual for 2013-14) BS-IV Scenario

MMTPA MMTPA MMTPA Crude Tput 6.0 6.47 6.3 HS% 13-15 8.98 19.7 Coker A T ‘put 0.6 0.38 0.26 Coker B T ‘put 0.5 0.12 0.00 RFCCU T ‘put 1.43 1.69 1.7 Biturox T ‘put 0.15 - 0.15 DHDT T ‘put 2.2 CRU T ‘put 0.3 0.36 0.47 NHDT T ‘put 0.18 0.25 0.24




ISOM T ‘put 0.13 0.23 0.25 SHU 0.32 - 0.46 Prime G+ (HDS) 0.22 0.27 0.48 SRU 80 MTPD 28.4 MTPD 59.54 MTPD F&L - 8.99 9.0 Margin $/bbl - 5.45 6.84 BS-III MS 700 1190 Nil BS-IV MS Nil Nil 1312 BS-III HSD - 3249 Nil BS-IV HSD 2156 Nil 3210 SKO 750 820 250

2.1. MS Quality Up-gradation Path-forward

MS pool consist of mainly three streams namely Heavy Reformate, Isomerate and treated RFCC gasoline. Thus meeting final MS pool specifications depends the combined performance of the units i.e CRU (including NHTU) , ISOM (including NHDT) and Prime G+ unit.

2.2. HSD Quality Up-gradation Path-forward

With back-blending of about 25 wt % (BS IiI scenario), DHDT is currently operated at about 2.6-2.7 MMTPA against the design capacity of 2.2 MMTPA, but with bottlenecks. Execution of Low cost DHDT revamp along with replacement of advance catalyst variant is scheduled in Nov'14 S/D, will ensure operation of DHDT up to 2.9 MMTPA. Major modifications envisaged in the low cost revamp include augmentation of feed filter, replacement of feed & Product pumps, control valves etc' Moreover the new catalyst charge is designed to handle 3.3 MMTPA scenario as well. Following modifications are essential for operation of DHDT at 3.3 MMTPA. Envisaged major modifications include: Additional MUG compressor Additional Feed pump 2 additional heat exchangers Wash water pump, coalscers & Piping modifications.




2.3. Present and Post Project Scenario

Attribute ( Figures in MMTPA )

Design BS-III Scenario (Actual 2013-14)

BS-IV Scenario (Post Project)

Crude T’put 6.00 6.47 6.30 High Sulphur Crude % 13-15 8.98 19.70 Coker A : T’ put 0.60 0.38 0.26 Coker B : T’ put 0.50 0.12 0.00 RFCCU : T’ put 1.43 1.69 1.70 Biturox : T’ put 0.15 - 0.15 DHDT : T’ put 2.20 2.49 3.30 CRU : T’ put 0.30 0.36 0.47 NHDT : T’ put 0.18 0.25 0.24 ISOM : T’ put 0.13 0.23 0.25 Prime G+ 0.4

(0.32+0.08) 0.27 0.76

SRU 80 MTPD 28.4 MTPD 59.54 MTPD

3. Project Cost

3.1. High Sulphur Crude maximization Project

Total cost of Rs 480.31 Cr for Coker A revamp & Rs 71.73 Cr for New Biturox Unit 3.2. BS-IV Project

Total capital expenditure has been estimated to be Rs 1327 Cr (with + 30 % accuracy), inclusive of 81 Cr. financial cost component, calculated on a period of four years of Phasing.

4. Project Benefits

4.1. High Sulphur Crude maximization Project :

a) Coker A Revamp Project : Reliability Improvement High Sulphur Maximization

b) New Biturox Unit :

Production of International Grade Bitumen Product High Sulphur Maximization




4.2. BS-IV Project

a) 100% production of BS IV specification MS (commonly known as Petrol) b) 100% production of BS-IV specification HSD (commonly known as Diesel)



Updated chapters of EIA report Chapter -2

Process Details with Chemical Reactions

Chapter -2






2.1 Biturox Unit

2.1.1 INTRODUCTION The Biturox unit shall be designed for production of viscosity graded paving bitumen VG10, VG20, VG30 and VG40 using Biturox process by oxidation of the Vacuum Residue and VGO obtained from the Vacuum Unit of the refinery.

The Design Basis includes the basis for the unit design, the basic information about utilities and side conditions.

2.1.2 DESIGN BASIS & CHEMICAL REACTIONS

Duty and Capacity

The unit is designed for a design capacity of 150000 TPA considering

the specification of the design product grade VG30 and the alternative grades VG10, VG20 and VG40.

continuous production of 24 hours per day and 8000 operating hours per year.

Based on this the design throughput related to the design product grade VG30 is 18.750 MTH.

The Biturox unit is designed for continuous production. The turn down rate for production of the design product grade VG30 is 75%.

Feed material

The feed components for bitumen production are the vacuum residue and the vacuum gas oil obtained from the VDU by processing of the high sulphur crudes as Basrah Light, Arab Mix (a mixture of 20% Arab Light and 80% Arab Heavy), Upper Zakum, Kuwait, Iran Mix (a mixture of 25% Iran Light and 75% Iran Heavy) or a blend thereof.

Vacuum Residue

The main feedstock for bitumen production is the Vacuum Residue produced in the vacuum unit of the refinery with the following specification.





VACUUM RESIDUE (MAIN FEED COMPONENT)

CHARACTERISTICS UNIT Sample Analysis 1) LKNr. 2013/002218 Range 2)

Penetration @ 25°C 0.1 mm 177 150-200 Softening Point °C 37.8 36-40 Density @ 15°C g/cm3 1.0298 1.028 – 1.032 API Gravity API° 5.8 5.5 – 6.1 Kin. Viscosity @ 100°C mm2/s 1357.00 1200 - 1700 Kin. Viscosity @ 135°C mm2/s 203.10 180 – 240 Kin. Viscosity @ 150°C mm2/s 110.40 100 - 125 Dynamic Viscosity @ 60°C Pa.s 53.4 40 - 65 Flash Point COC °C 342 min. 300 Asphaltenes (nC7-insoluble) mass % 7.66 6.5 – 8.5 Paraffin Content (EN 12606-1) mass % 1.90 max. 2.2 Sulfur Content mass % 4.5580 4.0 – 5.0

Heating Test RTFOT

Change of mass % 0.05 max. 0.07 Retained Penetration @ 25°C 0.1 mm 113 - Retained Penetration @ 25°C % of origin 63.8 min. 60 Softening Point after RTFOT °C 42.4 - Increase of Softening Point °C 4.6 max. 5 Viscosity @ 60°C after RTFOT Pa.s 87.2 - Viscosity Ratio @ 60°C - 1.63 max. 2 Distillation Analysis ASTM D 7169, ASTM D 6352

0 mass% (IBP) °C 415.8 - 10 mass% °C 516.8 500 - 520 20 mass% °C 548.0 - 30 mass% °C 571.4 - 40 mass% °C 591.8 - 50 mass% °C 612.0 - 70 mass% °C 656.6 - 90 mass% °C 714.0 -

Vacuum Gas Oil

Below shows the specification of the VGO that will be used as a flux component if required to fulfil the requirements on the feed material.





Product Specification

The Biturox unit shall be capable of producing the grades VG10, VG20, VG30 and VG40 with the specifications shown below.

VGO (FLUX COMPONENT)

CHARACTERISTICS UNIT Sample Analysis 1) LKNr. 2013/02221

Range 2)

Density @ 15°C g/cm3 0.9285 0.925 – 0.930 Kin. Viscosity @ 40°C mm2/s 127.80 90 – 150 Kin. Viscosity @ 60°C mm2/s 36.41 30 – 50 Kin. Viscosity @ 80°C mm2/s 17.39 15 – 20 Kin. Viscosity @ 100°C mm2/s 9.80 8 - 11 Flash Point °C 188.5 min. 185 Sulfur Content mass% 2.8620 2.3 – 3.4 DISTILATION ANALYSIS: ASTM D 7169, ASTM D 6352 0 mass% (IBP) °C 294.2 10 mass% °C 387.8 370 – 400 20 mass% °C 414.2 30 mass% °C 432.0 40 mass% °C 448.0 50 mass% °C 463.4 60 mass% °C 478.6 70 mass% °C 494.8 80 mass% °C 513.4 90 mass% °C 539.2 530 - 550 100 mass% °C 637.4

PRODUCT SPECIFICATION PAVING GRADES

CHARACTERISTICS UNIT TEST METHOD VG10 VG20 VG30 VG40

Absolute Viscosity @ 60°C Poise IS-1206 (Part II) 800-1200 1600- 2400- 3200-Kinematic Viscosity @ 135°C, (min.) cSt IS-1206 (Part III) 250 300 350 400 Flash Point COC, (min.) °C IS-1209A 220 220 220 220 Solubility in Trichloroethylene, (min.) mass % IS-1216 99.0 99.0 99.0 99.0 Penetration @ 25°C, 100g, 5s, (min) 0.1 mm IS-1203 80 60 45 35 Softening Point (R&B), (min.) °C IS-1205 40 45 47 50 Tests on residue after RTFOT (Rolling Thin Film Oven Test): Viscosity Ratio @ 60°C, (max.) 1) - IS 1206 (Pt II) 4.0 4.0 4.0 4.0 Ductility @ 25°C, (min.) cm IS-1208 75 50 40 25





2.1.3 PROCESS DESCRIPTION Biturox is a process for production of blown bitumen. Various qualities of bitumen can be made out of different residues - with or without blending components - under atmospheric conditions or with elevated pressure.

Biturox process is oxidation of feed material at an operating temperature between 240 - 270°C and pressure up to 2.0 kg/cm2 g.

To reach high efficiency of the reaction between feed stock and oxygen a large reaction surface of the air bubbles is required. For that reason the Biturox reactor is equipped with a three - stage agitator to break up the incoming air bubbles. To ensure a small bubble size through the whole length of liquid column in the guiding cylinder the air bubbles are collected by coalescing plates under each agitator disc to break them up again whereby the reaction surface is renewed.

On the other hand, due to the large size of the air pipes the process air is introduced into the liquid product in a form of big bubbles with a small reaction surface. This prevents a fast start of the reaction between fresh feed and oxygen and prevents coke formation. So the Biturox reactor has low servicing needs and this effects minimum operating costs.

This technique replaces the conventional air pipes with small openings which are closed due to coke formation within short time.

Biturox Reactor

The reactor section, where the Biturox Process occurs, consists of three main components:

Biturox Reactor

Agitator, with three stages of disc mixers.

The guiding cylinder, located concentric to the shell and containing two coalescing plates, one is located under the middle disc mixer and the other under the upper disc mixer.

Controlled amount of feedstock, air and water are simultaneously fed into and processed within the reactor unit.





2.2 Coker-A 2.2.1 INTRODUCTION

The Coker-A unit of Barauni Refinery is designed for processing 600,000 MT per year of reduced crude from atmospheric/ vacuum distillation units. The unit can process vacuum residues from a wide variety of crude oils including Bonny Light and Arab Mix crudes. It can also process a number of low value streams such as extracts and de-waxed oils from Lube plants and decant oil from the bottom of FCC units in addition to the vacuum residues. The unit is designed to produce unstabilised Naphtha, LPG rich off gas, Reduced Petroleum Coke (RPC) and components for HSD, LDO and Fuel Oil pools. The unit upgrades heavy residual oil converting it to above products. A delayed Coker unit mainly consists of a furnace, coke chambers (reactors), fractionator and light ends recovery system. The associated facilities include coke cutting/ handling and water re-use system. Coker-A unit is to be designed to process 0.6 MMTPA of feed in 7200 on-stream hours per year. 2.2.2 DESIGN BASIS & CHEMICAL REACTIONS The unit is designed for the following three cases :

CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit, while processing 0.6 MMTPA high sulphur crude (50:50 wt Arab mix)

CASE-II Feed corresponding to future refinery configuration without Resid Desulphurisation, while processing 0.6 MMTPA low sulphur crude (Bonny light).

CASE-III Feed corresponding to future refinery configuration without Resid Desulphurisation, while processing 0.42 MMTPA low sulphur crude (Bonny light).

Coker A Feed : a) Vacuum Residue from AVU’s. b) Phenol Extract from Phenol Extraction Unit. c) VGO from AVU’s d) CLO

Coker A Products : a) Off gas : To be routed to existing LPG recovery unit for LPG recovery. b) Coker Naphtha : To be routed to existing LPG recovery unit for stabilization/ LPG recovery. c) Coker Kero : Suitable for routing to DHDS unit (Cases 1&2)/ blending into HSD pool. d) Coker LDO : To be routed to FCC Unit (Cases 1&2) / LDO pool (Case-3). e) Coker fuel oil : Suitable for blending into ‘Fuel Oil’ Pool. f) Coker residue : Suitable for blending into Fuel oil pool. g) Coke





Chemistry behind coking: Delayed Coking is a thermal conversion process by which a residual stock or crudes’ “bottom of the barrel” material is upgraded to more valuable distillates. This process also produces a solid carbonaceous matter called coke. This coke, depending upon its quality can be used for the manufacture of electrodes for aluminum production (called anode grade), for electrodes in the electric arc furnace for steel making (this grade is known as needle coke) or other miscellaneous applications e.g. Titanium-di-oxide manufacture, coke ovens, silicon carbide etc. Cokes required for such applications requires “Calcination” which essentially means driving off the water and the oily volatile matters from the coke. The quality of the coke mainly depends on the feedstock. If the feedstock is not of good quality, the coke (called the fuel grade) can be used as a fuel in the cement industry or power plant. The mechanism for the formation of coke is rather complicated. However, two independent mechanisms exist. First mechanism involves the polymerization and condensation of the aromatics portion in the feed. The aromatics ring cross link to such a degree to form coke. The formation of this so called “thermal coke” is the most desired one for a good quality coke (e.g. needle coke). In the second mechanism the colloidal asphaltene and the resin gets distorted and precipitate out of the solution to form a highly cross linked structure. This is known as “asphaltene coke” and undesired for a good coke quality. Formation of these two types of coke are governed more by the feedstock quality than by the operating parameters. These reactions proceed in following three distinct phases : Partial vaporisation and mild cracking of the charge stock as it passes through the heater. Successive cracking and polymerisation of the liquid in the drum until it is converted to

vapor and coke. Cracking of the vapor as it passes through the coke drum.

2.2.3 PROCESS DESCRIPTION

The Quench column K-6 has been provided to further condense the heaviest fraction of the Coke chamber vapor by LDO quench on temperature control of Column overhead cascaded with flow control. The internals of the column consist of a Disc and doughnut arrangement. The bottom material i.e. residue is pumped using residue pumps, H-22/22A on flow cascaded with level control of the Quench Column bottom to the main fractionator bottom as recycle to the furnace. To avoid coking of Quench Column bottom, a portion of fresh preheated feed from 604-EE-00-003 A/B is used as quench and is routed on temperature control to the Quench Column bottom.

Provision to route a part of the residue as product to storage is also kept. For this, residue

from H-22, apart from being routed to fractionator, a part will be cooled in the residue cooler 604-EE-00-008 (T-13 Box cooler). A part of this cooled residue will be routed back to Quench Column as Quench, instead of fresh feed, during this mode and the rest is sent as product to storage.





Delayed Coker unit is divided into following sections : Feed handling and preheat Furnace Coke chambers Quench column Fractionator and Strippers Quench, flushing & Instrument Purge Oil system





2.3 NSU, NHTU & CRU

2.3.1 INTRODUCTION To get motor spirit of low lead and high octane it was proposed to have a Catalytic Reformer Unit (CRU) in Barauni Refinery in 1990. The plant is having following facilities: 1. Naphtha Splitter Unit – NSU. 2. Naphtha Hydro-Treater Unit - NHTU. 3. Catalytic Reformer Unit – CRU. 2.3.2 DESIGN BASIS & CHEMICAL REACTIONS SL. NO. NAME CAPACITY TURN DOWN (MT/YR) RATIO 01. Naphtha Splitter Unit (NSU) 0.54 40% 02. Naptha Hydro-Treater Unit (NHTU) 0.30 50% 03. Catalytic Reformer Unit (CRU) 0.30 50%

PURPOSE The purpose of Reformer is to enhance the octane number by changing the hydrocarbon structure in the presence of catalyst and hydrogen. It is not advantageous to operate reformer with lighter hydrocarbons. So splitter was required to get suitable cut of feed for reformer. Since reforming reaction is to be carried out in presence of catalyst, but impurities/water act as catalyst-poison, so we need hydro-treater to remove impurities and water. NAPHTHA SPLITTER UNIT (NSU) FEED : IBP-140 0C cut naphtha from storage tanks PRODUCTS : IBP 70 0C cut naphtha is sent to Hydrogen Generation Unit as their feed.

IBP 70-140 0C cut naphtha is sent to NHTU and storage tank. NAPHTHA HYDRO-TREATER UNIT (NHTU) FEED : Feed to NHTU comes from Naphtha Splitter Unit(NSU) bottom.

PRODUCTS : NHTU stripper bottom is fed to CRU or sent to storage for subsequent start up. Specific Gravity: 0.765.





Catalytic Reformer Unit – CRU FEED : NHTU stripper bottom is feed for CRU. PRODUCTS :

A) Reformate: Component SOR EOR Specific Gravity 0.788 0.787 RON 95.0 95.0 MW 93.0 92.8 RVP at 380C - 0.40 Max.

B) Hydrogen Rich Gas : Component SOR (Mole %) EOR (Mole %) H-2 93.0 88.8 C-1 2.9 5.1 C-2 1.5 2.5 C-3 0.7 1.3 C-4 0.5 0.8 C-5 + 1.4 1.5 MW 4.6 5.6

C) LPG Absorber off Gas : This LPG absorber off gas goes to fuel gas network. Component SOR (Mole %) EOR (Mole %) H-2 52.6 46.7 C-1 10.6 16.9 C-2 19.7 22.5 C-3 13.6 9.5 C-4 1.7 2.5 C-5 + 1.8 1.9 MW 17.3 17.7

D) Stabilizer over head liquid : This liquid goes to LPG Recovery Unit for LPG recovery. Component SOR (Wt. %) EOR (Wt. %) C-1 0.0 0.2 C-2 7.7 9.6 C-3 62.5 44.1 C-4 29.8 45.9 C-5 0 0.2 MW 45.5 46.9 Specific Gravity 0.504 0.510 Octane No. 95.0 95.0





CHEMICAL REACTIONS: NHTU : To protect the reformer catalyst, the feed is to be pretreated in order to eliminate the following poisons: Sulfur, Nitrogen, Water, Diolefins, Olefins, Arsenic and Metals. Elimination of these poisons are achieved in Naptha Hydro-treater Unit (NHTU) by the use of specific catalyst and operating conditions, except for water which is eliminated in the stripper, though bulk amount of water is separated in hydrotreater separator. A) HYDROREFINING REACTIONS : a) Desulfurisation:

Mercaptans, sulphide and disulphide easily react, leading to the corresponding saturated hydrocarbons.

R-SH + H2 RH + H2S R-S-R' + 2H2 RH + R'H + H2S R-S-S-R' + 3H2 RH + R'H + 2H2S

Example: CH3-CH2-CH2-CH2-CH2-SH + H2 C5H12 + H2S

d) Amyl Mercaptan N-Pentane

Sulfur combined into cycles of aromatic structure like thiophene, is more difficult to eliminate. In that case the main reaction involves the opening of the heterocycle giving the corresponding hydrocarbon and hydrogen sulfide.





b) Denitrification:

This is the most important reaction in HTU, besides the desulfurization. It results in

Production of Ammonia. R-NH2 + H2 R-H + NH3 Example:

Its rate is lower than the desulfurization reaction, mainly in the case of hetrocyclic

compounds, having an aromatic structure.

c) De-oxygenation Oxygen dissolved or present in the compounds of the same type as the Sulphiding

Compounds or as peroxides or Phenols, is eliminated in the form of water.

B) HYDROGENATION REACTIONS:





These reactions affect the diolefins, olefins and aromatics and are highly

exothermic.

- Diolefins and olefins, if any, are converted into saturated compounds. - Aromatics hydrogenation occurs as a consequence of temperature and

hydrogen partial pressure. The use of this specific catalyst (HR 306) along with H2S partial pressure allows the limitation of these hydrogenation reactions. Less than one percent of the aromatics of the feed are hydrogenated in the hydrotreaters.

C) ELIMINATION OF ARSENIC AND METALS:

These compounds are adsorbed on the catalyst. The adsorption occurs on the

upper layers of the catalytic beds and progressively extends down to the lower part. If these compounds affect the catalyst, its activity is drastically reduced.

CRU In Catalytic Reforming Unit, the structure of hydrocarbon (low octane) is changed to hydrocarbon of higher octane number (mainly aromatics) through various reactions in the presence of specific catalyst. Main reactions :

A) DEHYDROCYCLISATION OF PARAFFINS B) DEHYDROGENATION OF NAPHTHENE C) ISOMERIZATION OF PARAFFIN

A) DEHYDROCYCLISATION OF PARAFFINS:

This reaction leads to an important increase in octane number. The hydrogen production being of 4 moles per mole of paraffin transformed.

This reaction is highly exothermic (-60 Kcal/mole) and limited by the kinetics.





Due to it's relatively low rate, operating conditions must be more severe for this reaction than for the other ones thus leading to coke formation. The volumetric yield of product from this reaction is only 70 to 80%.

B) DEHYDROGENATION OF NAPHTHENE :

This reaction also leads to an important increase in octane number, the hydrogen production being lower than from the previous reaction. This reaction is highly endothermic (-50 Kcal/mol). The conversion is almost the same as foreseen by the thermodynamics. In case of cyclopentanic naphthenes, they must be first isomerized to C5 ring naphthenes before being hydrogenated.

C) ISOMERISATION OF PARAFFINS :

This reaction leads to an increase in octane number as branched paraffin has higher octane number than the corresponding linear paraffin. There is no hydrogen production in this reaction.

C6H14 CH3-CH-CH2-CH2-CH3

I CH3 N-HEXANE ISO-HEXANE





This reaction is slightly exothermic (2 Kcal/mole) and the conversion is limited, by the thermodynamics. This later limits the gain in octane number as the branched to normal paraffin ratio at equilibrium decreases when the molecular weight increases.

Its rate is high and its volumetric yield is 100%. SIDE REACTIONS: A) CRACKING

i) Hydro cracking ii) Hydrogenolysis B) DEALKYLATION C) COKING

e) D) DISMUTATION

E) ALKYLATION

A) CRACKING:

This reaction results in the degradation of the molecules and must be, as far as possible avoided.

Two different ways of cracking takes places : i) Hydro cracking:

This degradation reactions leads to low molecular weight paraffin mainly C3 and C4. C8H18 + H2 C3H8 + C5H12 N-OCTANE PROPANE PENTENE

This is highly exothermic reaction and relatively slow reaction. Hydro cracking of straight chain paraffin result in octane improvement but hydro cracking of naphthene will reduce the naphthene potential used for conversion to aromatics.





ii) Hydrogenolysis:

This degradation reaction leads to light hydrocarbons (C1, C2, C3) and the complimentary paraffin. These reactions are of no interest in a classical reforming except when LPG production is expected. This degradation first affects the higher paraffin, which otherwise, would have been more easily dehydrocyclised to corresponding aromatics. However when naphthenes are involved in the cracking reactions potential aromatics are eliminated. Thus these reactions must be normally avoided as they result in a low reformate yield and due to the light gases formation, in a lower purity of the recycled hydrogen gas. These reactions are exothermic and non-equilibrated. Their rate is low at low temperature faster than the rate of other reactions.

B) DEALKYLATION: This reaction consumes hydrogen. It does not improve the octane of the gasoline. It could be interesting in case of aromatics production as it leads to lower aromatics at

the cost of higher aromatics.

C) COKING : Heavy polyaromatics leading to coke are formed by alkylation, dismutation and

cyclisation reactions. High temperature enhances these reactions.





D) DISMUTATION : It is basically of no interest in a normal refining operation. This is of interest for an

aromatic operation, as toluene can be transformed to pentene and xylenes.

E) ALKYLATION: This reaction has no influence on the octane number of the gasoline and takes place

without any hydrogen exchange. As it leads to heavier molecule this reaction can give products whose boiling point may be higher than the final boiling point of the gasoline cut on the other hand, high molecular weight hydrocarbons can be considered as coke precursors.

Due to their rate, the reactions will take place mainly in the following order, in

different reactors. First Reactor : Dehydrogenation : Isomerization Second Reactor : Dehydrogenation : Isomerization : Cracking : Dehydrocyclisation Third Reactor : Cracking : Dehydrocyclisation Thus the temp. drop will be high in the first reactor, less in the second and

third reactor.





2.3.3 PROCESS DESCRIPTION NAPHTHA SPLITTER UNIT (NSU): IBP-140 0C cut naphtha from storage is fed to splitter column under flow control by off site pump at tray No. 14. The feed is heated up to 95 0C in splitter feed/bottom exchanger against splitter bottom stream before it enters the column. The overhead vapors are totally condensed in air condensers. The liquid collected is pumped by splitter reflux pump and one part sent as top reflux back to the column under flow control to maintain the top temperature. The balance, which constitutes the IBP-70 0C cut naphtha is sent to HGU as their feed and rest light naphtha is sent to storage under reflux drum level control after cooling in a water cooler. Reflux drum boot water is drained in OWS manually. The pressure of splitter is controlled at reflux drum by passing a part of hot column overhead vapors around the condenser or releasing the reflux vapors to flare through a split range controller. The splitter bottom product which constitutes 70-140 0C cut naphtha is pumped to splitter feed/bottom exchanger by hydro treater feed pumps. The bottom product after exchanging heat with feed is split into two streams. One is fed to the hydro treater unit at a temp. of 65 0C and the other is sent to storage under column level control after being cooled in splitter bottom column. The heat necessary for splitter reboiling is supplied by splitter reboiler furnace and desired temperature maintained by controlling the fuel firing. Splitter reboiler pumps provide the circulation through reboiler is double pass vertical cylindrical furnace having four burners fired from the bottom. It has soot-blowing facility for convection section. NAPHTHA HYDROTREATER UNIT (NHTU): A) REACTION AND SEPARATION SECTION: The naphtha from NSU is fed to HTU by a pump. The feed flow is controlled by flow control valve. The feed then mixed with Rich Hydrogen Gas from HP separator of reformer. controls the Rich Hydrogen gas flow. Both the liquid naphtha and rich hydrogen gas are pre-heated in a series of exchangers, which are feed/reactor effluent heat exchangers. Then mixture is heated up to reaction temperature in a furnace and fed to the reactor. The furnace is four pass having three burners fired from bottom. The furnace is having facility of soot blowing. The reactor inlet





temperature is maintained by cascaded with either fuel oil or fuel gas PC's. The furnace is provided with all safety shut down inter locks. It has also provision of decoking. The desulfurisation and hydro treating reaction takes place in at almost constant temperature since heat of reaction is quite negligible. The reactor is provided with facility of steam and air for regeneration of catalyst. The reactor catalyst bed has been provided with five number of thermo couple points at various location to get the bed temperature during regeneration of the catalyst. A line has been provided to feed the naphtha to stripper, during start up, bypassing the reaction/separation section. B) STRIPPER SECTION : The separator liquid is pumped by 02-PA-001A/B under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feed/bottom exchanger 02-EE-003 A/B/C when it gets heat exchanged by hot stripper bottom stream. The stripper column consists of 28 Nos. of valve trays one to eight number of trays are single pass and the rest double pass. Feed coming from 02-EE-003 A/B/C enters at 9th tray from two sides. The overhead vapors are cooled down in 02-EA-002-air condenser and collected in 02-VV-002-stripper reflux drum. The fan load can be adjusted. The condensed hydrocarbons are returned to column top by pump 02-PA-002A/B under flow control 02-FC-1301 cascaded with 02-LC-1302 as reflux to maintain the top temp. The water accumulated in the boot is sent for disposal as sour water. 02-PC-1301 releasing excess gas in the FG system maintains the reflux drum pressure. The facility is there to inject corrosion inhibitor by pump 02-PA-005A. Stripper bottom product exchanged heat with stripper feed in 02-EE-003A/B/C and then sent to reformer as hot feed. The excess or required hydro-treated naphtha is sent to storage after being cooled in 02-EE-004 A/B under level control 02-LC-1301. 02-FF-002 reboiler heaters supply the necessary heat for stripper reboiling. 02-CC-001 products are circulated through 02-FF-002 single pass cylinders vertical furnace by 02-PA-003 A/B. Partial vaporization occurs in 02-FF-002. 02-TC-1301 at 3rd plate from the bottom of 02-CC-001 controls reboiling. Furnace is provided with all safety inter locks.





CATALYTIC REFORMER UNIT (CRU) Hydro treated naphtha from hydro treater unit is pumped to required pressure by 03-PA-001 A/B under flow control 03-FC-1101 A/B and mixed with recycle gas from the recycle gas compressor (03-KA-001). The mixed feed is pre heated in the feed-effluent exchanger 03-EE-001 followed by feed/effluent exchanger 03-EE-002. Then the mixture is brought up to the reaction temperature (480 0C) by heating in the pre-heater 03-FF-001 and then fed to 1st reactor 03-RB-001. As the reaction is endothermic, the temperature drops, so the first reactor effluent is heated in the first inter heater 03-FF-002 prior to be sent to the second reactor 03-RB-002. In the same way 03-RB-002 effluents are heated in the second inter heater 03-FF-003 prior to be fed to the third reactor 03-RB-003. The effluent from the last reactor 03-RB-003 is split into two streams and send for heat recovery parallely to feed/effluent exchanger (03-EE-002) and stabilizer reboiler (03-EE-003). The outlet from the two exchangers is combined by a these way valve 03-TIC-1101 and then cooled down successively in the Zeemann Secathen exchanger (03-EE-001), reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004. The cooled reactor effluent is flashed in the reformer separator 03-VV-001. Vapor and liquid phase are separated in separator 03-VV-001. Part of the gas phase constitutes the hydrogen recycle gas to the reactor circulated by recycle gas compressor 03-KA-001. The hydrogen rich gas compressor 03-KA-002 A/B compresses remaining amount, corresponding to the amount of gas produced. The pressure control in separator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator. Should the gas be produced in excess to 03-KA-002 A/B capacity, degassing in split range to fuel gas is performed, through 03-PC-1401 A and 03-PC-1402. The separator liquid is sent by reformer separator bottom pumps (03-PA-002 A/B) under level control 03-LC-1401 for recontacting with the gas compressed by 03-KA-002 A/B. The hot flue gases from all the three reformer furnaces are combined and sent to stream generation system for waste heat recovery to produce MP steam. Provision is there to dry the recycle gas into a dryer (03-RB-004). The dryer can later be regenerated. The unit has also been provided with facilities for continuous chloriding, water injection, DMDS/Ccl4 injection and caustic soda circulation. The separator (03-VV-001) vapor after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 A/B) and recontacted with separator





liquid. The recontacted vapor and liquid is cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003). The aim of this device is to allow for high recovery of the C5 contained in the gas phase of separator and improves the quality (H2 concentration) of the produced gas. A part of hydrogen rich vapor goes to HTU as a make up hydrogen through 02FC1202 and balance goes to the suction KO drum of HGU compressor K-05 that is run to provide H2 to DHDT after purification in a PSA unit through 3PC1601B.03PC1601 remains inline with fuel gas system at a slight higher set point than 3PC1601B.So that any excess gas can be routed to FG system through 03PC1601. The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapor distillate. The combined stream is cooled in LPG absorber feed cooler 03-EE-006 and flashed in LPG absorber. Off-gas is sent under pressure control to fuel gas system. Stabilizer feed pumps 03-PA-003 A/B pumps the liquid from 03-VV-004. After pre heating in stabilizer feed/bottom exchanger 03-EE-007 the mixture is fed to the stabilizer 03-CC-001 at tray No. 13. Stabilizer over head vapours is partially condensed in stabilizer condenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005. The vapor phase is sent to LPG absorber for C3 and C4 recovery. A part of condensed liquid is pumped as reflux to the column by stabilizer reflux pump 03-PA-004 A/B under the flow control and the balance is sent to LPG Recovery Unit under level control of reflux drum. The heat of reboiling to the stabilizer is provided by the hot reactor effluent in the stabilizer reboiler 03-EE-003 and the desired temperature maintained by controlling the flow of reactor effluent by the three way valve. The bottom product, stabilized reformate, is cooled in the feed/bottom exchanger 03-EE-007 followed by reformate cooler 03-EA-002 and reformate trim cooler 03-EE-009 before being routed to storage Tk 77 to 84.





2.4 Prime G+ Unit 2.4.1 Introduction

SHU section, treating the full range RFCC LCN gasoline, converting Diolefins to olefins and light fraction sweetened to recover a sweet desulfurized light cut to be sent to Gasoline Pool and a heavy cut sent to HDS section along with fresh HCN feed. This section allows to reach very high selectivity and to minimize the octane loss to recover a sweet desulfurized heavy cut to be sent to Gasoline pool.

2.4.2 Chemical Reactions :

SHU Reactor In this reactor, the diolefins are hydrogenated in order to avoid gum formation in the hydrotreating section where hydrodesulphurization takes place. Light mercaptans and some other light sulfur compounds are converted to heavier sulfur compounds enabling the production of a light naphtha fraction almost free of mercaptans and light sulfides. In addition, external olefins are isomerized to internal olefins.

Chemical reactions

The cracked gasoline contains the following unsaturated components:

• Diolefins (aliphatics or cyclics),

• Olefins,

• Aromatics.

Several chemical reactions can take place during the diolefin hydrogenation. The most important ones are:

• The hydrogenation of diolefins,

• The conversion of light mercaptans and some light sulfur compounds into heavier sulfur species,

• The isomerization of olefins,

• The hydrogenation of olefins.

The last reaction must be avoided as much as possible to minimize octane loss.

Hydrogenation of diolefins





Diolefins are hydrogenated into corresponding olefins and some of the olefins are hydrogenated into corresponding paraffins. The diolefins content is measured with the Diene Value (DV) or the Maleic Anhydride Value (MAV) analysis.

Diolefins:

Their hydrogenation produces several isomers, for example:

CH3 - CH = CH - CH2 - CH2 – CH2– CH3

CH3 – CH = CH – CH = CH – CH2– CH3 + H2 2 Heptene (cis and trans)

2 – 4 Heptadiene

CH3 – CH2–CH2 – CH = CH - CH2 - CH3

4 Heptene (cis and trans)

Moreover double bond migration can also occur within the newly generated olefins.

Diolefins are very unstable compounds which polymerize easily into gums. Therefore conversion of diolefins into olefins improves the product quality. These reactions are highly exothermic. The difference between the Diene Value (DV) or the Maleic Anhydride Value (MAV) of the feed and the DV or MAV of product measures the extent of these reactions and is related to the hydrogen consumption.

Isomerization of olefins

CH2 = CH - CH2 - CH2 - CH2 - CH3 CH3 - CH = CH - CH2 - CH2 - CH3

1 - Hexene 2 - Hexene

This reaction, thermodynamically enhanced by low temperatures (less than 200 deg. C) takes place when diolefins are almost completely eliminated. It offers the advantage of leading to internal olefins that are more stable towards hydrogenation than external olefins. Thus the selectivity is improved. In addition, internal olefins often have a higher octane number.

Hydrogenation of olefins

These reactions are undesirable because they reduce the octane number.

The hydrogenation of diolefins is faster than the hydrogenation of olefins. Nevertheless it is difficult to completely avoid some olefins hydrogenation.

This reaction is also exothermic.

The difference between the feed bromine number (BrN) and the product BrN measures the conversion rate of this reaction and is related to the hydrogen consumption.





Sulfur reaction

Conversion of Light Mercaptans to Heavier Sulfides

RSH + R' (C5 to C7 olefin) RS R'

Conversion of Light Mercaptans to Heavier Mercaptans

Step 1

RSH + H2 RH + H2S

Step 2

H2S + R' (C5 to C7 olefin) R'SH

Conversion of Sulfides to Heavier Mercaptans

CH3 – S – CH3 or + H2 CH4 and C2H6 + H2S C2H5 – S – CH3


Conversion of H2S to Heavier Mercaptans


HDS Reactor

Chemical reactions

Sulfur removal reactions are the desired chemical reactions and are accompanied by Olefin saturation reactions. In addition, denitrogenation reactions can take place but in a much lower extent.

All these reactions are exothermic.

Desulfurization

The typical sulfur compounds in cracked gasoline are of the thiophenic and benzothiophenic types.

The desulfurization of the sulfur compounds occurs in several steps:

Thiophene Thiophane Mercaptans H2S





The desulfurization reactions are exothermic, but given the relatively low concentration of reactant involved, these reactions do not significantly contribute to the overall reactor exotherm.

Benzothiophenes are essentially converted and the residual sulfur is essentially in the form of thiophenes and mercaptans.

Hydrogenation of olefins

Hydrogenation or olefin saturation is the addition of a hydrogen molecule to an unsaturated hydrocarbon to produce a saturated product. Olefinic hydrocarbons are found in high concentrations in cracked gasolines. The olefin saturation reaction is highly exothermic and is controlled by the process. The comparative reactivity of olefins (from more reactive to less reactive) is as follows:

n alpha - olefins / n internal olefins / alpha branched olefins / cyclic olefins / internal branched olefins.

This reaction is exothermic (delta H = 30 kcal/mol) and most of the heat release in the reactor is due to the heat of reaction of the olefins hydrogenation. Under the selected operation conditions, the olefin hydrogenation level is lower than that of hydro-desulfurization. Therefore, good selectivity is achieved. In order to desulfurize the FCC naphtha while maximizing octane retention, the olefin saturation must be minimized. The catalyst selectivity is defined as the hydrodesulfurization rate divided by the olefin saturation rate.

Typical olefins hydrogenation reactions are:

+ H2

CH3 - CH2 - CH2 -CH2 -CH2 - CH = CH2 �� CH3 - CH2 - CH2 - CH2 - CH2 -CH2 -CH3

1-heptene (n olefins) n-heptane + H2

CH3 - CH - CH = CH –CH3 CH3 - CH - CH2 - CH2 - CH3

CH3 4 methyl 2 pentene CH3 2 methyl pentane

(branched internal olefins)





Denitrification or Denitrogenation

Nitrogen is removed in catalytic hydrotreating by breaking the C-N bond producing-nitrogen free aliphatic hydrocarbons and ammonia. Breaking the C-N bond is more difficult to achieve than the C-S bond in desulfurization. Consequently, denitrification occurs to a lesser extent than desulfurization.

Nitrogen compounds typically found in cracked gasolines are methylpyrrol and pyridine types.

NH

CH CH

CH C - CH 3

+ 4H C 5 H 12 + NH

3 2

Methylpyrrol n-pentane ammonia

+ 5 H2 C5 H12 + NH3

n- pentane ammonia

Npyridine

The heat released by the denitrification reactions is also negligible owing to the small amount of nitrogen compound involved.

H2S Influence

H2S is a strong inhibitor of the hydrodesulfurization reactions and favors recombinant mercaptans formation. However, it does not decrease the olefin hydrogenation level. As a result, H2S decreases both catalyst activity and selectivity.

For this reason, the H2S is removed from the recycle gas through an amine absorber.

Relative rates of reaction

Under the selected operating conditions and the choice of catalyst, these reactions are classified in decreasing order of reaction extent:





hydrodesulfurization > olefins hydrogenation > > > aromatic hydrogenation

2.4.3 PROCESS DESCRIPTION

SHU : Reaction Section

The unit feed is Light Cracked Naphtha (LCN) gasoline coming directly from the RFCC unit or mixed with a limited quantity of feed from storage tank-31/32. The feed is first routed to LCN feed filters 803-G-01, in order to remove scale particles and gummy ingredients.

Feed from storage will be limited to 10% of total feed.

The RFCC LCN gasoline (IBP - 140°C Cut) feed is then charged to the SHU Feed Surge Drum, 803-V-01. The SHU Feed Surge Drum pressure is maintained @ 2.3 by split range control of hydrogen and venting to flare. The unit feed is pumped to the SHU (Selective Hydrogenation Unit) section by SHU Feed Pumps, 803-P-01 A/B, under flow control. The hydrogen make-up is coming from HGU (Hydrogen plant) or CRU (Unit 03) via the first stage of hydrogen make-up compressors of Isomerization unit (Unit 802), 802-K-01 A/B@ 35 kg/cm2g. These H2 make-up compressors allow working at 26.0 kg/cm²g at SHU Reactors inlet. The flow of hydrogen is mixed with the feed to SHU reaction section under flow control to the LCN gasoline feed.

The mixture of gasoline feed and hydrogen make-up is preheated in the SHU feed / Splitter bottom exchanger, 803-E-01 and then by exchanging heat with the SHU reactor effluent in the SHU Feed / Effluent Exchanger, 803-E-02. The mixture is then heated to the proper reactor inlet temperature 150-200°C in SHU Preheater, 803-E-03, by desuperheated Medium High Pressure steam (MHS) under flow control reset by temperature control at the SHU reactor inlet.

To allow a good control of the SHU reactor inlet temperature, a minimum temperature increase of 5 deg. C must be achieved in the SHU Preheater, 803-E-03. For that purpose, a bypass of SHU Feed / Splitter bottom exchanger, 803-E-01, and SHU Feed / Effluent Exchanger, 803-E-02 cold side is installed. This bypass line is only required for the start-up operation, as both exchangers are designed for the EOR conditions.

During start-up, the heat exchangers are clean, potentially oversized and the catalyst may be very active. In order to maintain the inlet temperature of the splitter close to the normal operating conditions, a bypass of the SHU Feed / Effluent Exchanger, 803-E-02, hot side is provided to limit high fluctuations at the splitter inlet and avoid an overload of the splitter bottom section.





The SHU Reactors 803-R-01 A/B are two identical single bed downflow reactors. Both reactors are designed to operate in the lead/lag position or in a single reactor configuration to enable on-line catalyst replacement. The piping arrangement and valves allow the flexibility to take one reactor off line for isolation and catalyst change out, while the other reactor remains in operation. After catalyst change out, the isolated reactor is then put back on line in tailing position. This reactor arrangement provides the operating flexibility to ensure a continuous operation.

The fluid entering the SHU Reactors is mostly liquid. The vaporization in the reactor is kept to a minimum in order to achieve the required reactor performances.

The reactor effluent is cooled down by exchanging heat with the feed in the SHU Reactor Feed / Effluent Exchanger, 803-E-02. Then the effluent flows to the SHU Splitter, 803-C-01, under pressure control of the SHU Reactor inlet.

As the selective hydrogenation reactor is operated mainly in liquid phase, a sufficient liquid velocity shall be maintained at its inlet. Therefore, the hydrocarbon flowrate to the reactor shall be at least 75 % of the design flowrate. In case of turndown (50% of capacity), part of the HDS stabilizer bottom shall be recycled to the Feed surge drum 803-V-01, via LCN feed filters, under flow control. This recycle line is installed after cooling down by 803-E-11 A/B, 803-AC-06 and 803-E-14 in order to maintain a temperature of about 45deg. C in 803-V-01 and consequently keep the same heat recovery in the exchanger train.

SHU : Splitter Section

The SHU Splitter 803-C-01 has 51 trays and the feed enters the column at tray 38. The purpose of the SHU Splitter is to fractionate the selective hydrogenation reactor effluent to produce a Light Light Cracked Naphtha (LLCN), a Heart Cut and a Heavy LCN stream. The LLCN / Heart Cut cut-point is adjusted to produce LLCN with low sulfur content and minimal thiophene carry-over, while simultaneously recovering a large portion of olefins. This is possible since the heavier boiling components contain a disproportionate amount of sulfur relative to olefins. The Heart Cut / Hy. LCN cut-point is adjusted to produce a rich C5-C6 cut to send to Isomerization Unit after further hydrotreatment.

The SHU Splitter overhead is partially condensed in the SHU Splitter overhead air condenser 803-AC-01A/B.Then it flows to the SHU Splitter Reflux Drum, 803-V-02, where the vapor phase and liquid phase are separated. The vapor phase (excess of hydrogen and light ends in the hydrogen make-up) is further cooled in SHU Splitter Post-Condenser, 803-E-05. Liquid condensates are routed to the SHU Splitter Reflux Drum, 803-V-02 while sweet vapor phase is routed to the refinery Fuel Gas system under pressure control to maintain





the Splitter overhead pressure. In case of total hydrogen consumption in SHU Reactors, hydrogen injection maintains the pressure in the Splitter.

The liquid from the SHU Splitter Reflux Drum, 803-V-02, is pumped by the SHU Splitter Reflux Pumps 803-P-02 A/B, and sent to the top of the Splitter as reflux of the column, under flow control reset by SHU Splitter Reflux Drum level control.

The LLCN product is drawn from a partial-draw off chimney tray located on tray 6 of the Splitter, on flow control reset by Splitter tray 10 temperature control. The LLCN product is cooled down in LLCN Air Cooler, 803-AC-02, pumped by LLCN Product Pumps, 803-P-03 A/B and cooled down in LLCN Cooler, 803-E-06, in order to meet the battery limit conditions. LLCN product is directly sent to Gasoline MS Pool.

The Heart Cut product is drawn from a partial-draw off chimney tray located on tray 26 of the Splitter, on flow control reset by Splitter tray 29 temperature control. The Heart Cut product is cooled down in Heart Cut Air Cooler, 803-AC-03, pumped by Heart Cut Pumps, 803-P-04 A/B and cooled down in Heart Cut Cooler, 803-E-07, in order to meet the battery limit conditions. A part of Heart Cut product is sent to NHDT Feed Surge Drum, 801-V-01, of NHDT unit (Unit 801) while the remaining part is sent to the Gasoline MS Pool.

The splitter is reboiled with desuperheated Medium High Pressure steam (MHS) in a thermosyphon reboiler, SHU Splitter Reboiler, 803-E-04. The MHS steam rate is under flow control. The SHU Splitter bottom product is cooled down in SHU Feed / Splitter bottom exchanger, 803-E-01.

The SHU splitter bottoms product is mixed with Heavy Cracked Naphtha (HCN) gasoline feed from the RFCC unit (RFCCU), and routed to HDS Feed Surge Drum, 803-V-03. Part of this SHU Splitter bottoms product can be sent to NHDT Feed Surge Drum, 801-V-01, of NHDT unit (Unit 801) after cooling down in HCN to NHDT Air Cooler, 803-AC-07, and HCN To NHDT Trim Cooler, 803-E-16.

If there is no HCN gasoline feed to process, part of the Splitter bottoms (after SHU Feed / Splitter bottom exchanger) can be cooled down through HCN to NHDT Air Cooler, 803-AC-07, to maintain the operating temperature in the HDS Feed Surge Drum, 803-V-03.

HDS Section

Before mixing with Splitter bottoms in the HDS Feed Surge Drum, 803-V-03, the Heavy Cracked Naphtha (HCN) gasoline feed from the RFCC unit (RFCCU) is first routed to HCN feed filters 803-G-03, in order to remove scale particles and actual gums.





The HDS Feed Surge Drum, 803-V-03, pressure is maintained by split range control of hydrogen and venting to flare. The HDS feed is pumped to the HDS reaction section by HDS Feed Pumps, 803-P-05 A/B, under flow control.

HDS liquid feed is combined with the recycled hydrogen and is preheated in the HDS Feed/Effluent Exchangers, 803-E-08 A/B/C/D/E before entering HDS Reactor, 803-R-02.

The HDS Reactor operates downflow in totally vaporized phase. The HDS reactor is divided into 2 beds: each bed contains HR-806 catalyst. The overall temperature rise in the reactor is controlled by injection of liquid quench between the first and second bed. The liquid quench is coming from HDS Separator drum, 803-V-04, via HDS Quench Pumps, 803-P-06 A/B, under flow control in cascade with the inlet temperature control of the second catalytic bed.

The HDS effluent is further heated in the HDS Heater, 803-F-01. The heater is located downstream the reactor so that the effluent entering is fully vaporized. The HDS reactor inlet temperature is controlled with the heater outlet temperature by the duty of the fired heater via fuel gas regulation control.

The effluent from the HDS heater is then cooled by the HDS Feed / Effluent Exchangers 803-E-08 A/B/C/D/E and HDS Effluent Air Condenser, 803-AC-04, and flows to the HDS Separator drum, 803-V-04, in which two phases are separated.

The reactor effluent is water washed to dissolve any precipitation of ammonium salts prior to cooling in the HDS Effluent Air Condenser. Salt formation, especially ammonium chloride (NH4Cl) and ammonium bisulfide (NH4HS) in a lesser extent may precipitate depending on the partial pressures of H2S, NH3 and Cl in the vapor phase. Wash water is coming from condensates from NHDT unit 801-P-08 pump and is injected intermittently, when required, upstream the HDS Effluent Condensers. A water phase containing H2S plus some NH3, is removed and sent to the Sour Water Stripper Unit under interface level control.

The liquid hydrocarbon phase is routed to the Stabilizer section, under flow control reset by HDS Separator Drum level control, and the remaining part to the HDS Quench Pumps, 803-P-06 A/B.

The vapor hydrocarbon phase is cooled down in Amine Absorber Feed Cooler, 803-E-09, and flows to the Amine Absorber KO Drum, 803-V-05, to remove any entrained liquid droplets responsible of foaming in the amine absorber. Then the vapor phase flows to the Amine Absorber, 803-C-02, where H2S is substantially removed from the gas.





2.5 DHDT 2.5.1 INTRODUCTION Diesel Hydrotreater (DHDT) is installed to improve the diesel quality with respect to Cetane No. & other specification.





The design feed is a blend containing Straight run Gasoil from low sulphur imported crude (SRGO-LS), Straight run Gasoil from high sulphur imported crude from middle east (SRGO-HS), Total Cycle Oil from FCCU (TCO), Light Coker Gasoil from Coker unit (LCGO) with below mentioned properties. UNIT CAPACITY

1) Design Capacity : 2.2 MMTPA 2) Stream Factor : 8,000 hours per year 3) Turndown : 40% of design capacity

2.5.2 BASIS OF DESIGN & CHEMICAL REACTIONS Feedstock properties Depending on the case, the feed is a blend of different gasoil streams with the following properties:

LS GO HS

GO LS LVGO

HS LVGO

CK CGO HCN LCO

Density@150C 0.8640 0.8544 0.8862 0.875 0.8436 0.9050 0.8293 0.9519 Total Sulphur, wt% 0.15 2.2 0.21 3.0 2.31 3.84 0.53 2.5 Total Nitrogen, ppmw 70 60 500 400 700 1550 400 1500 Bromine Number 2 2 2 2 25 50 40 25 Flash Point, 0C 75 80 114 112 35 85 37 80 Pour Point, 0C Specific 3 9 -3 12 15 0 0 Viscosity@40 0C, cSt 4.5 4.0 7.0 6.5 30. 7.0 - 6.0 Cetane Number 44 50 42 46 36 38 18 20 Metals Ni + V, ppmw Fe, ppmw Chliride, ppmw Silicon, ppmw

0.04 0.3 0.3 -

0.2 0.3 0.3 -

0.2 0.3 0.5 -

0.2 0.3 0.5 -

0.1 0.3 10 3.0

0.07 0.3 12 3.0

2.0 0.3 - -

4.0 0.3 10 0

Distillation Temp,% D-86 D-86 D-1160

D-1160

D-86 D-86 D-86 D-86

IBP 192 190 242 225 140 181 130 173 5% 235 230 268 252 164 193 139 202 10% 252 249 274 265 173 220 142 214 30% 276 272 295 287 202 250 149 247 50% 292 296 312 302 226 275 157 275 70% 315 318 340 330 252 315 171 307 90% 362 364 380 360 279 340 192 354 95% 375 370 400 375 290 365 202 367





EBP 395 390 420 395 316 380 213 372 Each feed throughput is as follows: Feed 1 Feed 2 Feed 3 Feed Rate, kg/hr 275000 275000 275000 LS GO, wt% 56.0 45.0 36.5 HS GO, wt% 5.0 8.0 21.0 LS LVGO, wt% 5.0 5.0 0 HS LVGO, wt% 1.0 2.0 5.5 CK, wt% 6.0 (1) 6.0 (1) 9.0 CGO, wt% 3.5 (1) 4.0 (1) 4.5 HCN, wt% 9.0 (1) 10.0 (1) 10.5 LCO, wt% 14.5 (1) 20.0 (1) 13.0 Total Cracked Components, wt% 33.0 40.0 37.0 (1) Sulphur content of 0.32%, 0.42%, 0.14% and 1.19% wt% respectively in CK, CGO, HCN and LCO considered for Feed 1 and Feed 2. The specified properties of the feed stocks are as follows: Feed 1 Feed 2 Feed 3 Specific Gravity 0.871 0.876 0.869 Sulphur, wt% 0.454 0.602 1.443 Nitrogen, wtppm 421 513 430 Bromine Number, g/100g 11.8 13.7 13.2 Mono aromatics content, wt% 19.0 20.0 18.0 Di aromatics content, wt% 12.8 13.7 10.3 Tri aromatics content, wt% 3.0 3.4 3.2 ASTM D86 Distillation Temperatures IBP, 130 130 130 10%, 197 193 190 30% 252 249 246 50% 280 278 276 70% 307 306 305 90% 355 354 353 EBP 402 402 400

The product specifications required to be met are as follows: Unit Feed rate, kg/hr 275000 Total pressure drop across catalyst beds in three reactors, kg/cm2 8.5 max Product Diesel total Sulphur max, ppm 40 Product Diesel Density @ 150C, kg/m3 0.840 max





Product Diesel Cetane Number 51.5 Product Diesel 95 vol% distillation ( D86 ), 0C 360 Diesel yield at 400C Flash Point, wt% 92.0

HYDROTREATING CHEMISTRY WITH REACTIONS

The following chemical steps and/or reactions occur during the hydro treating process: Sulfur Removal Typical feed stocks to the Union fining unit will contain simple mercaptans, sulfides and disulfides. These compounds are easily converted to H2S. However, feed stocks containing heteroatomic aromatic molecules are more difficult to process. Desulfurization of these compounds proceeds by initial ring opening and sulfur removal followed by saturation of the resulting olefin. Thiophene is considered 15 times more difficult to process compared to diethyl sulfide. a. Mercaptan

b. Sulfide

c. Disulfide

d. Cyclic Sulfide





e. Thiophenic

Nitrogen Removal

Denitrogenation is generally more difficult than desulfurization. Side reactions may yield nitrogen compounds more difficult to hydrogenate than the original reactant. Saturation of heterocyclic nitrogen-containing rings are also hindered by large attached groups. The reaction mechanism steps are different compared to desulfurization. The denitrogenation of pyridine proceeds by aromatic ring saturation, ring hydrogenolysis, and finally denitrogenation. a. Pyridine

b. Quinoline

c. Pyrrole

Oxygen Removal

1.1





Organically combined oxygen is removed by hydrogenation of the carbon-hydroxyl bond forming water and the corresponding hydrocarbon.

a. Phenols

Olefin Saturation Olefin saturation reactions proceed very rapidly and have a high heat of reaction. a. Linear Olefin

b. Cyclic Olefin

Aromatic Saturation Aromatic saturation reactions are the most difficult. The reactions are influenced by process conditions and are often equilibrium limited. Unit design parameters would consider the desired degree of saturation for each specific unit. The saturation reaction is very exothermic.

Halides Removal Organic halides, such as chlorides and bromides, are decomposed in the reactor. The inorganic ammonium halide salts which are produced when the reactants are cooled are then dissolved by





injecting water into the reactor effluent or leave with the stripper off-gas. Decomposition of organic halides is considered difficult with a maximum removal of ~90%.

Reaction Rates

The approximate relative heats of reaction per unit of hydrogen consumption for these reactions are:

Desulfurization 1 Olefin Saturation 2 Denitrification 1 Aromatics Saturation 1

All of the reactions discussed above are exothermic and result in a temperature rise across the reactor. Olefin saturation and some desulfurization reactions have similarly rapid reaction rates, but it is the saturation of olefin which generates the greatest amount of heat. The temperature rise expected for a given charge stock along with the desired product quality will play a very important role in determining the number, size, and arrangement of the reactors, heat exchange, and hydrogen circulation rate.

2.5.3 PROCESS DESCRIPTION The exact arrangement of lines, vessels, etc. may vary from unit to unit, but basically all units will consist of a reaction section and a fractionation section. These two sections are described below in general terms. REACTION SECTION Fresh Feed System The feed to the unit can be either cold (40 deg C) and hot (100 deg C). Feed obtained from





offsite storage tanks at 40 deg C is pumped into a Feed coalescer for the removal of potential free water. The feed is further heated to 100 deg C in a preheater exchanger. Hot feed is sent from offsite and pumped by Hot feed pumps. The combined feed is sent through a Feed Filter for removal of suspended solids to the feed surge drum which is blanked with nitrogen to prevent gum formation resulting in possible equipment fouling.

The feed pumps take suction from the feed surge drum and pumps the raw oil to reactor loops and the feed is preheated via process exchangers with reactor effluent.

The feed pumps are high head machines capable of pumping large volumes of oil at pressures of over 120 kg/cm2. The manufacturer’s instructions must be consulted before operating the charge pumps since special care must be taken to avoid damage due to low flow, high temperatures, vibration, etc. Proper lubrication and cooling must be assured at all times both for the pump and its driver if serious damage is to be avoided. This type of pump should never be operated against a blocked discharge, nor at flow rates below the minimum recommended by the manufacturer. A spillback to the surge drum may be added to maintain minimum flow at reduce throughput. Feed Heat Exchange

In a more commonly used heat recovery scheme, the reactor charge is preheated by the reactor effluent in a series of feed-effluent exchangers before entering the reactor charge heater This attempts to recover as much heat as possible from the heat of reaction. Liquid feed is preheated separately with reactor-effluent exchanges before combining with the recycle gas which is also preheated with reactor-effluent exchanges. The combined feed stream enters a mixed phase heater to reach the desired reactor inlet temperature (340-370℃). A fresh feed bypass around one or more exchangers is used to provide better control of the charge heater outlet temperature. Austenitic stainless steel materials are normally used in the hottest heat exchangers. These materials provide the best resistance to the corrosive atmosphere and severe operating conditions. However, they are subject to stress corrosion when exposed to air and moisture. This type of corrosion can be avoided by neutralizing the sulfide scale on the tube walls and by avoiding the condensation of moisture in the tubes. Makeup Hydrogen System

Make-up H2 is obtained from Hydrogen unit at a pressure of 19.5 kg/cm2g. Since the reactor section pressure is 90-95 kg/cm2g, the make-up gas must be compressed before it can join the system. The compression system consists of two identical makeup compressors. Reciprocating compressors are used to raise the pressure of the gas, with two stages of compression varying in accordance with the difference between the supply and reaction section pressures. From the discharge of the last stage of compression, the makeup gas joins the recycle gas just before Effluent condenser. The point of entry into the reactor circuit depends on whether or not a stage of compression can be saved by entering the circuit at a lower pressure location. On multi-stage compressors the gas from the first stage must be cooled to about 45 deg C





before it can enter the second stage. The spillback gases, used to control the inter-stage suction from and make up suction drum pressures also need to be cooled in First stage discharge cooler and First stage discharge trim cooler before being returned to the first suction drum. Reciprocating compressors are driven by electric motors. The manufacturer’s instructions for the startup, shutdown and care of these units must be studied and well understood. In general, close attention must be paid to the compression ratio across each cylinder as well as the suction and discharge temperatures. Excessive compression ratios must be avoided since they will lead to high cylinder discharge temperatures, rapid wear, low compressor efficiency, and a possible overloading of the drive.

The cylinder discharge temperatures give a very good indication of the performance of the machine and should be recorded on a regular basis. Higher than normal temperatures show that cylinder or inter stage cooling may be inadequate, or that the compressor valves are faulty. In such cases, quick remedial action must be taken in order to avoid overheating and damaging the cylinders. It must be remembered that higher than design compression ratio and high molecular weight gases (as indicated by a reduction in H2 purity) will increase the load on the driver.

The flow of makeup gas through the compressor and into the unit is controlled by a complex system of pressure controllers on the high pressure separator and the first stage suction drum. The basic philosophy of the control scheme is to control the flow of gas as the demand for hydrogen dictates (as determined by the pressure in the high pressure separator). As hydrogen is consumed in the reactors, the pressure in the high pressure separator will start to decrease. This will in turn call for more makeup gas by closing the control valve in the spillback line from the final stage discharge to suction.

In the event that the unit is calling for more makeup gas than is available (hydrogen consumption is too high), the pressure control system essentially works in reverse. The first stage suction drum pressure will start falling because there is not sufficient gas available from the hydrogen plant to replace what is being pumped out of the suction drum. When this happens, the pressure controller on the first stage suction drum senses the decrease in pressure and, in order to protect the first stage of the compressor from excessive compression ratio, forces the first stage spillback valve to open. This spill backs more gas back to the first stage suction drum to build the pressure back up. The high pressure separator pressure will start decreasing. At this point the operator will recognize that hydrogen consumption is exceeding supply and must be reduced either by decreasing reactor temperatures or feed rate or both. Alternatively, the hydrogen supply may be increased.

It is very important for operating personnel to become familiar with the mode of control used so that pressure beyond the capability of the equipment may be avoided. The maximum allowable compressor temperatures and compression ratios should be obtained from the manufacturer and posted in the control room or near the compressors. Recycle Hydrogen System After separation of the gas and liquid phases in the high pressure separator, the gas leaves from the top of the high pressure separator and flows to the suction of the recycle gas compressor via Recycle gas K.O drum. The recycle gas will be sent to an amine scrubber to remove H2S in the





future. Non-condensable gases are removed from the condensate receiver by means of steam jet ejectors. The condensate is removed from the receiver and pumped to the refinery condensate header or H2 Plant in OSBL. Note that condensate should never be allowed to enter the turbine since it would seriously damage the rotor and other internals. Whenever the compressor is out of service the turbine casing drains should be kept open and sufficient steam flow should be maintained to keep the turbine warm. Lube oil circulation should also be maintained when the compressor is down, and only shut off when required for maintenance. After the recycle compressor discharge, some recycle gas will be split off the main stream for use as quench gas between catalyst beds in the reactor. Separate quench gas streams are used to reduce reactor inter bed temperatures before each catalyst bed. Quench flow is regulated by a flow controller cascaded from a temperature controller at the top of the catalyst bed below the quench zone. The makeup gas joins the recycle gas before the recycle gas compressor in order for a makeup stage of compression to be saved. The combined makeup and recycle gas is divided into passes which are normally allow controlled into the combined feed passes going to the combined feed exchanger. The object is to maintain equal gas flow to each reactor charge heater pass at a sufficiently high rate to avoid overheating the tubes. From this point until it returns to the high pressure separator, the gas flows along with the liquid through the reactor circuit in the same manner previously described. Reactor Once the feed and recycle gas have been heated to the desired temperature, the reactants enter the top of the reactor. As the reactants flow downward through the catalyst bed, various exothermic chemical reactions occur and the temperature increases. Each bed will contain a 3 element radial thermocouple assembly at the top and at periodic levels down through the bed dependent upon bed length. Multiple catalyst beds are provided depending upon the heat of reaction and unit capacity. Reactor skin thermocouples will be provided at the bottom of each bed and on the bottom reactor head, for monitoring the reactor wall temperature. Specific reactor designs will depend upon several variables. Reactor diameter is typically set by the cross-sectional liquid flux. As the unit capacity increases, the reactor diameter increases to the point where two parallel trains would be considered. Reactor height is a function of the amount of catalyst and number of beds required. Other local factors may also influence the reactor design including seismic activity and weight limitations. Crane, bridges and road capacities are also factors. The reactors are typically divided into individual catalyst beds supported on a beam and grid support system. The support system is separated from the next bed of catalyst by a quench gas distributor, reactant mixing internals and a vapor/liquid re-distributor tray. The reasons for separating a reactor into separate beds are the following:





a. If the gas and liquid flows become poorly distributed part way through the reactor, the

catalyst will not be effectively utilized, by separating a reactor into multiple beds with redistribution trays in between, the reactants existing one bed are redistributed evenly across the cross-sectional area of the next catalyst bed. In this way, should there be a problem with distribution in a bed; the catalyst in the lower beds will still be effectively utilized.

b. If the radial temperature profile becomes skewed part way through a reactor, the reaction rates will be different in different parts of the catalyst bed. This overworks the part of the catalyst that is hotter and under-utilizes the part of the catalyst bed that is cooler. It is also potentially hazardous if the hotter portion becomes significantly higher than the bulk temperature and forms a hot spot, especially if the hot spot is next to the reactor wall. Mixing of the reactants reestablishes thermal equilibrium and thus, after every quench zone, assures that all the catalyst is efficiently utilized.

c. In certain situations the heat of reaction will be large enough that the temperature increase across a reactor will be greater than the design. If this were allowed to happen, a reaction could become unstable and result in a temperature runaway. Therefore, cold recycle gas about 40-65deg C is brought into the reactor at the inter bed quench points in order to cool the reactants and thus control the reaction rate.

Good distribution of reactants at the reactor inlet and at the top of each subsequent catalyst bed is essential for optimum catalyst performance. UOP's proprietary reactor internals are used to accomplish this distribution. FRACTIONATION SECTION The function of the fractionation section is to separate sour gas and naphtha from the diesel product. This can be accomplished with a column fractionation scheme. The hydrocarbon liquid collected in the Flash drum is sent to a stripper column on level control. The feed is preheated by reactor effluent. Stripping steam (MP steam) is used under flow control to re boil the stripper. Steam added to the bottom of the tower helps strip light ends from the bottoms. Light ends and H2S gather at the top of the stripper and are partially condensed in stripper overhead condenser and Stripper overhead trim cooler. Corrosion inhibitor is injected into the stripper overhead line ahead of the overhead condenser. Three phases are separated in the stripper overhead drum. Sour water is combined with the sour water from the Flash drum and sent to waste water stripping unit at battery limit. The liquid hydrocarbon are pumped through the stripper reflux pumps and split into three streams. First one is reflux which is returned to top of the stripper under level control and second is other reflux routed to the 7th tray of the stripper under the flow control after being heated by the diesel product – hot naphtha recycle exchanger . And third stream is liquid distillate (un stabilized naphtha) which is routed to Naphtha stabilizer commissioned in August 2010 under DHDT revamp (Earlier it was sent to FCCU). Vapor stream is sent to the absorber knockout drum. This stream is mixed with gas from the





Flash drum and gas from naphtha stabilizer & MSQ (Under DHDT revamp in 2010) before it enters Absorber knockout drum. The gas from absorber knockout drum is routed to the bottom of the LP absorber. Lean amine is fed directly from battery limit into the absorber under flow control. After washing the H2S in the hydrocarbon gas the amine gets collected in the bottom of the absorber. Rich amine is sent under level control to the amine treating unit at battery limit. The overhead gases from the absorber are routed to the Stripper gas amine knockout drum to remove the traces of amine in the carryover. The sweet gas is routed to fuel gas header under the pressure control of the stripper receiver. The stripper bottom product exchanges against the returned naphtha reflux to 7th tray of the stripper and undergoes further cooling in the feed preheat exchanger, the diesel product cooler and the diesel product trim exchanger. Water is removed from the diesel product in the diesel product coalescer and the diesel product is sent under flow control to the storage tank at battery limit.

Chapter 3 PFD’s

Legends:Revamp RedExisting Blue

Cold Feed from Storage Tank

Hot Feed from AVUs

Surge Drum

604-EE-001A&B 604-EE-002A/B

604-EE-003A/B/C/D 604-EE-0051

604-EE-52A/B/C/D 604-EE-53 604-EE-54

Feed Pump 604-PA-001A/B

Cold CLO from RFCCU

K - 2(T)

Coker kero Run Down

EE-002A/B EA-003

EE-006A/B LDO Product Run Down EE-010A/B PA-004A/B

PA-003A/B EE-001A/B Feed preheat

exchanger

EA-002 EE-005A

EA-00-001 Air Cooler EE-00-004

Condenser E - 01

Coker Off gas to LRU

PA-002A/B

PA-14A/B

K - 7

Stripping Steam

PA-007A/B

EE-52A/B/C/D

Furnace F-01(M) B

Steam Steam

CW CW

COKE COKE

Anti Foam Anti Foam

LDO quench

Naptha to LRU

Reactor/ Coke drum

RA -51A

CFO Stripper

Stripper

Feed CFO Product -II

PA-005A/B

PA-006A/B(M)/C(N)

Air Cooler

CFO Product Run Down

To C - 1/ Slop

HC recovery Vessel (E - 9A)

OWS

To C -1/ Slop

C -7

PA-025A/B

E -9 Water

Scrubber Oil

Scru bber

H -7 / H -5

Reactor Chamber Drain

C -1(M)

Main Fraction

ator

Reflux Drum

Filter Filter

BLOCK DIAGRAM OF COKER - A

VV-00-001

Fuel Oil / Fuel Gas

Stripping Steam

Stripping Steam

LDO CR

LDO

Kero

CF

O

Reflux

LDO CR

Fra

cti

on

ato

r B

ott

om

Reactor Blow Down Vapour

Fractionator Bottom

Pri

ma

ry F

ee

d

Hot kero to DHDT

Hot LDO to DHDT Feed Preheat Exchanger

Reactor/ Coke drum

RA -51B

PA-61A/B

K - 2(B)

Feed CFO Product -I

EE-13

CFO Product MP Steam Generator

EE-51 EE-53 EA-005

Lean Kero to Sponge Absorber (LRU)

PA-063A/B

PA-11A/B(M) Sour Water to Existing SWS Unit

Air Cooler

Trim Cooler

Feed preheat exchanger BFW Heater

Air Cooler

EE-0055

LDO Quench Cooler

Trim Cooler

TO V-04

Feed preheat/LDO CR Exchanger-II

EE-03A/B/C/D

Feed preheat/LDO CR Exchanger-I

VV-00-003

FO IR Surge Drum

CFO CR

604-EE-54

FO IR/CR 604-PA-69A/B

CFO IR

LDO quench

Reactor overhead vapour

Furnace F-01 A

DECOMMISSIONED

BLOCK DIAGRAM OF BITUROX UNIT

Slop Oil

Vaccum Residue

Vaccum Gas Oil

603-E-501A/B/C 603-EE-507

603-R-501 Reactor

Air KOD

Fuel Gas

INCINERATOR/ CO INCINERATOR

MP steam

BFW

DM water

603-V-501 Steam Drum

Wash water

Preheat exchangers

Bitumen to tanks

Scrubber

Scrubbed water to ETP

Stack

NaoH

Gyan

Rectangle

Gyan

Text Box

PRIME G+

803-V-01

803-G-01

4.0

45

803-P-01A/B

PIC

SPLIT-RANGE

4329

803-E-01

803-R-01A 803-R-01B

4.6

122132

188

803-C-01

803-V-02

803-P-02A/B

803-E-02

803-E-03

26 150200

164209

23.5

123

135140

15.7

7.7

56

157

MHSSTEAM

COND.

904.3

803-AC-01

803-AC-02

974.3

65123

40 4.0

CWS

LCN TOMS POOL

803-P-03A/B803-E-06

803-AC-03

65

803-P-04A/B

CWR

CWSCWR

40803-E-07

4.0 40

HEART CUTTO MS POOL

5.9HEART CUT

TO NHDT

803-E-04

185

MHSSTEAM

188

803-V-03

280340

21

803-G-02

HCN TONHDT

HCN FROMRFCCU

803-P-05A/B

803-R-02

332405803-F-01

300370

78

803-V-04

803-P-06A/B

803-V-07

803-C-02

207

803-C-03

5.6

6.7

207

803-AC-05

803-P-08

803-E-13

6.7

40

803-V-05

5.3

14.3

803-V-06

TO FG

24.1

803-E-08A/B/C

803-E-08C/D

803-E-11A/B

803-E-12

TO MSPOOL

803-AC-06 803-E-1424.3

803-KA-01A/B

LEANAMINE

14.6

RICHAMINE

803-P-07

P-1.4T-45

H2 FL

H2 MAKEUP

LCN FROMRFCCU

TC

P-3.9T-55

P-2.2T-76

TC

P-4.6T-40

803-P-09A/B

STEAM

CWS CWR

CWS

CWR

14.7

14.4

H2MAKE-UP

PC

S-11

TC P-15T-55

803-AC-04

CHILESE

Zone de texte

STREAM N°2 ON BLOCK FLOW DIAGRAM

CHILESE

Zone de texte


CHILESE

Zone de texte


CHILESE

Zone de texte


CHILESE

Zone de texte


Gyan

Text Box

Gyan

Text Box

Chapter -4

Baseline Data & Monitoring

Content

4.1 One Year baseline data for Air.

4.2 One Year baseline data for Water.

4.3 Stack Emission Monitoring.

4.4 Raw Water Requirement.

4.4.1 Present raw water requirement.

4.4.2 Post Project raw water requirement.

4.5 Treated Effluent Quality & Quantity.

4.6 Noise Pollution Monitoring.

4.7 Present Solid Waste Management.

4.8 Sulphur Balance

4.9 Note on SO2 emission and NOx emission

4.10 Air Pollution Control Devices.

4.1 One Year Baseline Data for Air

IOCL - BARAUNI REFINERY AMBIENT AIR QUALITY MONITORING RESULTS (MONTHLY AVG. VALUES)

Table 1.0- LOCATION: TIME OFFICE

Month RPM(<10) RPM <2.5 SO2 NO2 NH3 Pb CO (1 hour)

CO (8 hours)

Ozone (1 hour)

Ozone (8 hours)

HC Benzene Benzo(a) pyrene

Arsenic Nickel

Unit (µg/m3) (µg/m3) (µg/m3) (µg/m3) (µg/m3) (µg/m3) (mg/m3) (mg/m3) (µg/m3) (µg/m3) (ppm) (µg/m3) (ng/m3) (ng/m3) (ng/m3)

Limits

100 (24 Hr)

60 (Ann)

60 (24 Hr)

40 (Ann)

80 (24 Hr)

50 (Ann)

80 (24 Hr)

40 (Ann)

400 (24 Hr)

100 (Ann)

1.0 (24 Hr)

0.5 (Ann)

4.0 2.0 180 100 NA 05 (Ann)

01 (Ann)

06 (Ann)

20 (Ann)

Apr-14 72.71 30.29 9.29 20.86 15.00 0.28 0.96 1.01 30.14 30.33 1.06 3.89 BDL BDL BDL

May-14 72.89 27.33 10.11 20.33 14.89 0.26 0.96 0.97 29.67 30.19 1.01 3.77 BDL BDL BDL

Jun-14 71.33 29.22 9.33 20.56 14.44 0.27 0.93 0.97 29.56 30.00 1.00 3.86 BDL BDL BDL

Jul-14 70.63 27.50 9.63 19.00 14.38 0.28 0.90 0.95 30.50 29.96 0.95 4.14 BDL BDL BDL

Aug-14 73.75 26.63 11.25 20.00 15.63 0.30 1.00 0.95 30.75 29.96 0.94 4.23 BDL BDL BDL

Sep-14 73.22 26.33 11.11 20.89 15.78 0.28 0.94 0.93 30.56 30.04 0.91 4.38 BDL BDL BDL

Oct-14 77.86 30.00 11.29 19.86 16.43 0.30 1.01 0.96 30.86 30.57 0.89 3.81 BDL BDL BDL

Nov-14 80.13 32.38 10.25 20.00 16.00 0.30 1.00 0.96 31.13 30.63 0.9 4.1 BDL BDL BDL

Dec-14 74.63 29.38 9.63 19.88 16.25 0.31 0.99 0.98 30.88 30.92 0.9 4.3 BDL BDL BDL

Jan-15 78.13 31.00 9.88 18.38 16.00 0.30 0.99 0.99 30.50 30.88 0.83 3.79 BDL BDL BDL

Feb-15 75.75 28.13 9.25 17.88 15.25 0.29 0.96 0.99 30.00 30.96 0.84 3.56 BDL BDL BDL

Mar-15 74.63 28.13 8.88 17.25 15.38 0.29 0.99 1.01 30.00 30.21 0.81 3.54 BDL BDL BDL


Table 2.0- LOCATION: LPG Substation 16


CO (8 hours)

Ozone (1 hour)

Ozone (8 hours)


Arsenic Nickel


Limits

100 (24 Hr)

60 (Ann)

60 (24 Hr)

40 (Ann)

80 (24 Hr)

50 (Ann)

80 (24 Hr)

40 (Ann)

400 (24 Hr)

100 (Ann)

1.0 (24 Hr)

0.5 (Ann)

4.0 2.0 180 100 NA 05 (Ann)

01 (Ann)

06 (Ann)

20 (Ann)

Apr-14 73.25 29.13 9.88 23.63 16.75 0.30 1.03 1.03 31.13 30.88 1.21 3.96 BDL BDL BDL May-14 75.38 29.00 10.50 23.13 16.38 0.29 1.03 1.01 30.75 30.58 1.14 4.10 BDL BDL BDL Jun-14 73.63 30.50 10.75 22.38 16.13 0.29 1.00 0.99 31.38 30.38 1.13 4.06 BDL BDL BDL Jul-14 72.78 28.67 10.67 21.22 15.89 0.30 1.02 0.97 31.44 30.74 1.11 4.61 BDL BDL BDL Aug-14 76.14 30.86 12.71 20.29 14.71 0.33 0.96 1.01 31.29 30.86 1.03 4.77 BDL BDL BDL Sep-14 75.75 29.25 13.13 21.50 15.88 0.33 1.01 1.03 31.38 30.96 1.00 4.85 BDL BDL BDL Oct-14 78.63 30.25 13.25 21.38 16.13 0.32 1.05 1.04 31.50 30.71 0.96 4.63 BDL BDL BDL Nov-14 80.63 31.75 11.63 22.50 16.38 0.32 1.00 0.95 31.00 30.79 0.9 4.5 BDL BDL BDL Dec-14 76.78 29.22 11.11 21.67 16.67 0.32 1.04 0.98 31.56 30.93 0.9 4.0 BDL BDL BDL Jan-15 79.22 33.33 11.33 20.56 16.56 0.30 1.00 0.99 31.11 31.30 0.86 3.91 BDL BDL BDL Feb-15 77.13 29.25 10.50 19.63 16.13 0.30 1.01 1.01 30.25 30.71 0.89 4.14 BDL BDL BDL Mar-15 75.38 30.88 10.75 19.88 15.75 0.30 1.03 1.00 29.63 30.33 0.90 3.93 BDL BDL BDL


Table 3.0- LOCATION: CRU CONTROL ROOM


CO (8 hours)

Ozone (1 hour)

Ozone (8 hours)


Arsenic Nickel


Limits

100 (24 Hr)

60 (Ann)

60 (24 Hr)

40 (Ann)

80 (24 Hr)

50 (Ann)

80 (24 Hr)

40 (Ann)

400 (24 Hr)

100 (Ann)

1.0 (24 Hr)

0.5 (Ann)

4.0 2.0 180 100 NA 05 (Ann)

01 (Ann)

06 (Ann)

20 (Ann)



Table 4.0- LOCATION: BTP


CO (8 hours)

Ozone (1 hour)

Ozone (8 hours)


Arsenic Nickel


Limits

100 (24 Hr)

60 (Ann)

60 (24 Hr)

40 (Ann)

80 (24 Hr)

50 (Ann)

80 (24 Hr)

40 (Ann)

400 (24 Hr)

100 (Ann)

1.0 (24 Hr)

0.5 (Ann)

4.0 2.0 180 100 NA 05 (Ann)

01 (Ann)

06 (Ann)

20 (Ann)



Table 5.0- LOCATION: BR REFINERY TOWNSHIP (ESTATE OFFICE)


CO (8 hours)

Ozone (1 hour)

Ozone (8 hours)


Arsenic Nickel


Limits

100 (24 Hr)

60 (Ann)

60 (24 Hr)

40 (Ann)

80 (24 Hr)

50 (Ann)

80 (24 Hr)

40 (Ann)

400 (24 Hr)

100 (Ann)

1.0 (24 Hr)

0.5 (Ann)

4.0 2.0 180 100 NA 05 (Ann)

01 (Ann)

06 (Ann)

20 (Ann)


IOCL - BARAUNI REFINERY

TABLE - 6.0 METEOROLOGICAL OBSERVATIONS AT BR COMPLEX

LOCATION: TIME OFFICE (RECORDED ON THE DAYS OF AAQM)

(MONTH: JANUARY,2014)

Date of Monitoring Temperature Atmospheric Relative Wind Predominant Rainfall (DEG C) Pressure Humidity Speed Wind Direction (mm) (mm Hg) (%) (Km/h) (FROM) MAX MIN MAX MIN MAX MIN

(02-03) .01.2014 21 11 743 742 68 55 1.73 ENE Nil

(06-07) .01.2014 20.5 9.5 743.5 743 75 56 2.13 NE Nil

(09-10) .01.2014 19 8.0 742 741.5 69 53 1.65 NW Nil

(13-14) .01.2014 17 7.0 742.5 742 77 62 1.32 WNW Nil

(16-17) .01.2014 18 7.5 743 742 75 59 2.77 SW Nil

(20-21) .01.2014 19 8.5 743.5 743 78 64 3.14 WSW Nil

(23-24) .01.2014 20.5 10 744 743 78 64 2.57 NW Nil

(27-28) .01.2014 21 11 743 742 75 56 4.33 WNW Nil

(30-31) .01.2014 22 11 744 743 69 54 2.19 NW Nil




(MONTH: FEBRUARY,2014)


(03-04) .02.2014 22 10 748 747 70 56 1.65 E Nil

(06-07) .02.2014 23 11 749 748 69 58 2.2 ENE Nil

(10-11) .02.2014 22.5 10.0 747 746 71 56 2.14 NE Nil

(13-14) .02.2014 23 12.0 749 748 70 56 2.1 NE Nil

(17-18) .02.2014 24 11.0 748 747 78 59 3.19 SW Nil

(20-21) .02.2014 25 12 747 746 70 57 2.68 W Nil

(24-25) .02.2014 24 10 748 747 69 58 3.61 WSW Nil

(27-28) .02.2014 25 11 747 746 72 59 3.97 SW Nil




(MONTH: MARCH,2014 )


(04-05) .03.2014 28 13 743 742 68 56 2.31 WSW Nil

(07-08) .03.2014 29.5 13 742 741 69 58 3.12 SW Nil

(11-12) .03.2014 31 14.0 742 741 67 56 4.32 W Nil

(14-15) .03.2014 32 15.0 741 740 70 56 5.13 WSW Nil

(18-19) .03.2014 33.5 15.0 742 741 69 59 3.19 SW Nil

(21-22) .03.2014 34 15.5 743 742 70 57 2.68 W Nil

(25-26) .03.2014 34.5 16 741 740 69 58 3.61 WSW Nil

(28-29) .03.2014 35 16 741 740.5 71 63 2.13 SW Nil




(MONTH: APRIL,2014)


(01-02) .04.2014 37 21 743 742 58 51 4.75 SW Nil

(04-05) .04.2014 37.5 22 744 742.5 61 53 3.01 WSW Nil

(08-09) .04.2014 37 23 742 741 59 52 2.65 ENE Nil

(11-12) .04.2014 38 22 743 741.5 62 56 5.72 WSW Nil

(15-16) .04.2014 37.5 22 744 743 55 47 3.61 WSW Nil

(18-19) .04.2014 37 21 742 741.5 69 61 5.36 ENE Nil

(22-23) .04.2014 38 23 745 744.5 62 55 2.55 WSW Nil

(25-26) .04.2014 39 25 743 741.5 62 55 4.63 NE Nil




(MONTH: MAY,2014)


(01-02) .05.2014 40 28 740 739 55 46 2.06 SW Nil

(05-06) .05.2014 38 26 739 738 59 48 4.32 NE 1.13

(08-09) .05.2014 41 27 741 740.5 54 43 2.62 ENE Nil

(12-13) .05.2014 40 26.5 739 738 59 48 1.69 NE Nil

(15-16) .05.2014 39 26 740 739 67 49 2.82 W Nil

(19-20) .05.2014 40 27 741 740 54 45 1.82 SW Nil

(22-23) .05.2014 41 27.5 742 740.5 61 46 2.06 WSW Nil

26-27.05.2014 39 23 742 740.5 85 60 6.21 NE 3.84

29-30.05.2014 40 27 739 738 59 48 2.03 ENE Nil




(MONTH: JUNE, 2014)


(02-03) .06.2014 39 27 740 739 56 45 2.1 E Nil

(05-06) .06.2014 40 26 739 738 53 45 2.4 NE Nil

(09-10) .06.2014 38.5 26 740 739 69 48 2.29 ENE 3.11

(12-13) .06.2014 38 27 739 738 56 45 1.47 E Nil

(16-17) .06.2014 38 26 739 738 67 48 2.73 SW 1.68

(19-20) .06.2014 35 25 740 739 77 62 4.68 WSW 11.88

(23-24) .06.2014 37 27 739 738 56 48 3.55 SW Nil

26-27.06.2014 39 28 739 738 59 47 2.31 NE Nil

30-01.06.2014 37.5 27 740 739 58 47 2.01 ENE Nil




(MONTH: JULY,2014)


(01-02) .07.2014 38 27 740 739 48 64 2.97 ENE Nil

(04-05) .07.2014 39 28 739 738 46 61 1.97 NE Nil

(08-09) .07.2014 36 26 738 737 85 64 3.47 NE 34.92

(11-12) .07.2014 37 27 739 738 81 54 4.58 E 11.93

(15-16) .07.2014 36 26 738 737 56 79 2.51 NE 7.24

(18-19) .07.2014 38 27 740 739 66 45 3.43 NNE Nil

(22-23) .06.2014 36 27 740 739 67 54 3.39 E 9.51

(25-26) .07.2014 37 27 739 738 74 55 3.16 ENE 23.2

(30-31) .07.2014 36 26 739 737.5 62 48 2.13 NE Nil




(MONTH: AUGUST,2014)


(01-02) .08.2014 37 26 740 739 56 72 2.73 NE Nil

(04-05) .08.2014 35 26 739 738 58 77 4.65 NE 17.54

(07-08) .08.2014 36 25 741 742 56 72 3.22 NNE 3.91

(11-12) .08.2014 37 26 740 739 70 53 5.32 SW Nil

(14-15) .08.2014 35 25 739 738 78 55 4.22 NW 13.86

(18-19) .08.2014 36 26 740 739 68 54 2.02 E Nil

(21-22) .08.2014 36.5 26 741 740 70 56 2.43 NE Nil

(25-26) .08.2014 34 24 739 738 88 67 3.78 ENE 17.99

(28-29) .08.2014 35 25 739 738.5 81 56 7.9 E 10.07




(MONTH: SEPTEMBER,2014)


(01-02) .09.2014 35 24 739 738 77 58 4.53 NE 11.88

(04-05) .09.2014 36 25 740 739 72 55 5.09 E Nil

(08-09) .09.2014 37 26 741 740 69 51 2.82 ENE Nil

(11-12) .09.2014 36 24 742 741 70 53 5.11 ENE Nil

(15-16) .09.2014 37 25 740 739 74 55 2.48 NE Nil

(18-19) .09.2014 36 24 742 741 69 49 4.92 E Nil

(22-23) .09.2014 35 24 740 739 70 52 2.35 NE Nil

(25-26) .09.2014 34 23 741 740 72 55 2.98 ENE Nil

(29-30) .09.2014 33 23 739 738.5 79 52 2.84 NE Nil




(MONTH: OCTOBER,2014)


(01-02) .10.2014 32 22 747 746 68 59 2.46 E Nil

(07-08) .10.2014 33 23 749 748 64 59 2.8 ENE Nil

(10-11) .10.2014 31 21 748 747 65 58 2.06 ENE Nil

(14-15) .10.2014 32 21 747 746 69 62 2.14 NE Nil

(17-18) .10.2014 31 20 746 745 65 61 1.62 NE Nil

(21-22) .10.2014 30 19 747 746 69 64 1.44 NE Nil

(24-25) .10.2014 31 20 748 747 67 62 1.8 ENE Nil

(28-29) .10.2014 30 18 749 748 71 65 1.74 NE Nil




(MONTH: NOVEMBER,2014)


(03-04) .11.2014 30 17 748 747 67 55 1.32 NE Nil

(06-07) .11.2014 29 15 749 748 69 57 1.81 ENE Nil

(10-11) .11.2014 31 15 748 747 72 59 2.06 ENE Nil

(13-14) .11.2014 30 13 749 748 69 62 1.22 E Nil

(17-18) .11.2014 30.5 13 747 746 73 65 1.64 NE Nil

(20-21) .11.2014 30 14 748 747 70 62 1.29 NE Nil

(24-25) .11.2014 29 14 747 746 68 57 1.05 NE Nil

(27-28) .11.2014 28 13 748 747 71 65 1.76 NNE Nil




(MONTH: DECEMBER,2014)


(01-02) .12.2014 27 12 751 750 67 55 2.12 NE Nil

(04-05) .12.2014 26 12 752 751 67 58 2.51 E Nil

(08-09) .12.2014 24 11 751 749.5 62 55 2.23 NE Nil

(11-12) .12.2014 22 10 750 749 62 53 1.31 ENE Nil

(15-16) .12.2014 21 9 751 750 78 64 1.47 NE 0.93

(18-19) .12.2014 20 8 752 750 67 52 3.05 ENE Nil

(22-23) .12.2014 18 6.5 751 750 69 59 1.28 NE 1.36

(29-30) .12.2014 21 8 750 749 62 56 1.77 NE Nil




(MONTH: JANUARY,2015)


(01-02) .01.2015 20 9 748 747 73 57 1.4 NE Nil

(05-06) .01.2015 19 8 747 746 72 62 2.19 ENE Nil

(08-09) .01.2015 20 9 747 746.5 73 62 2.17 E Nil

(12-13) .01.2015 20.5 10 749 748 73 63 2.39 NE Nil

(15-16) .01.2015 21 11 748 747 72 59 2.43 WSW Nil

(19-20) .01.2015 19 9 747 746 72 66 2.43 SW Nil

(22-23) .01.2015 18.5 8 748 747 72 62 3.02 WSW Nil

(29-30) .01.2015 21 10 747 746 69 56 2.53 WSW Nil




(MONTH: FEBRUARY,2015)


(02-03) .02.2015 22 11 748 747 70 55 2.62 NNE Nil

(05-06) .02.2015 23 11 749 748 68 53 3.26 NE Nil

(09-10) .02.2015 22 12 750 749 69 56 2.18 WSW Nil

(12-13) .02.2015 24 12 749 748 71 59 4.21 SW Nil

(16-17) .02.2015 28 12 748 747 67 52 3.03 ENE Nil

(19-20) .02.2015 30 13 749 748 70 58 3.64 NE Nil

(23-24) .02.2015 29 13 748 747 68 51 2.62 SW Nil

(26-27) .02.2015 30 14 747 746 69 56 2.17 WSW Nil




(MONTH: MARCH,2015)


(02-03) .03.2015 31 15 748 747 70 62 2.1 NE Nil

(09-10) .03.2015 33 17 746 745 71 55 2.27 E Nil

(12-13) .03.2015 34 18 747 746 65 56 2.8 SW Nil

(16-17) .03.2015 32 16 746 745 72 65 3.19 WSW 1.55

(19-20) .03.2015 34 19 747 746 68 55 2.61 W Nil

(23-24) .03.2015 35 19 748 747 65 54 2.26 ENE Nil

(26-27) .03.2015 34 18 747 746 63 56 2.46 NE Nil

(30-31) .03.2015 32 17 746 745 77 59 4.37 WSW 3.27

4.2 One Year Baseline Data for Water

GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 1.0- Well at Govindpur (0.5 km East of BR)

SN Parameter Unit Jun-14 Sep-14 Dec-14 Mar-15 1 Temperature oC 31.5 31.9 24.6 26.2 2 pH 7.69 7.84 7.69 7.56 3 Turbidity NTU < 2 < 2 < 2 < 2 4 Conductivity µmhos/cm 872 859 819 786 5 Total Hardness mg/L 343 356 362 372 6 Ca Haednrss as CaCO3 mg/L 172 157 159 162 7 Magnesium Hardness as CaCO3 mg/L 42 48 39 51 8 M-Alkalinity as CaCO3 mg/L 377 342 347 362 9 BOD mg/L BDL BDL BDL BDL

10 COD mg/L BDL BDL BDL BDL 11 Ammoniacle N mg/L BDL BDL BDL BDL 12 Kejaldhal N mg/L BDL BDL BDL BDL 13 Sulphides as (S) mg/L BDL BDL BDL BDL 14 Sodium as Na mg/L 41 49 43 43 15 Potasium as K mg/L 10.1 10.7 10.2 13.6 16 Total Dissolved Solids mg/L 516 504 498 473 17 Total Suspended Solids mg/L 4 6 5 6 18 Total Sulphides mg/L BDL BDL BDL BDL 19 Oil and Grease mg/L BDL BDL BDL BDL 20 Dissolved Oxygen mg/L 7.6 7.9 7.4 7.6 21 Chloride mg/L 93 82 76 88 22 Nitrate mg/L 9.6 8.8 8.3 8.2 23 Sulphate as SO4 mg/L 36 41 44 36 24 Total Silica as SiO2 mg/L BDL BDL BDL BDL 25 Phosphate as PO4 mg/L BDL BDL BDL BDL 26 Fluoride mg/L 0.62 0.67 0.58 0.63 27 Iron mg/L 0.52 0.59 0.39 0.51 28 Lead mg/L BDL BDL BDL BDL 29 Phenol mg/L BDL BDL BDL BDL 30 Nickel mg/L BDL BDL BDL BDL 31 Arsenic mg/L BDL BDL BDL BDL 32 Zinc mg/L 0.29 0.32 0.31 0.32 33 Mercury mg/L BDL BDL BDL BDL 34 Cadmium mg/L BDL BDL BDL BDL 35 Selenium mg/L BDL BDL BDL BDL 36 Cynide mg/L BDL BDL BDL BDL 37 Chromium (Hexavalent) mg/L BDL BDL BDL BDL 38 Chromium (Total) mg/L BDL BDL BDL BDL 39 Copper as Cu mg/L BDL BDL BDL BDL 40 Vanadium as V mg/L BDL BDL BDL BDL 41 Phosphorous mg/L BDL BDL BDL BDL 42 Benzene mg/L BDL BDL BDL BDL 43 Benzo (a) pyrene mg/L BDL BDL BDL BDL

GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 2.0- Hand Pump at Kesabe (1.5 km South East of BR)


10 COD mg/L BDL BDL BDL BDL 11 Ammoniacle N mg/L BDL BDL BDL BDL 12 Kejaldhal N mg/L BDL BDL BDL BDL 13 Sulphides as (S) mg/L BDL BDL BDL BDL 14 Sodium as Na mg/L 56 69 63 56 15 Potasium as K mg/L 7.9 7.1 7.4 11.6 16 Total Dissolved Solids mg/L 406 390 384 396 17 Total Suspended Solids mg/L 3 4 5 7 18 Total Sulphides mg/L BDL BDL BDL BDL 19 Oil and Grease mg/L BDL BDL BDL BDL 20 Dissolved Oxygen mg/L 7.2 7.5 7.3 6.9 21 Chloride mg/L 75 83 79 88 22 Nitrate mg/L 6.2 6.6 26 6.2 23 Sulphate as SO4 mg/L 21 28 29 32 24 Total Silica as SiO2 mg/L BDL BDL BDL BDL 25 Phosphate as PO4 mg/L BDL BDL BDL BDL 26 Fluoride mg/L 0.51 0.56 0.51 0.58 27 Iron mg/L 0.48 0.52 0.32 0.51 28 Lead mg/L BDL BDL BDL BDL 29 Phenol mg/L BDL BDL BDL BDL 30 Nickel mg/L BDL BDL BDL BDL 31 Arsenic mg/L BDL BDL BDL BDL 32 Zinc mg/L 0.19 0.22 0.19 0.26 33 Mercury mg/L BDL BDL BDL BDL 34 Cadmium mg/L BDL BDL BDL BDL 35 Selenium mg/L BDL BDL BDL BDL 36 Cynide mg/L BDL BDL BDL BDL 37 Chromium (Hexavalent) mg/L BDL BDL BDL BDL 38 Chromium (Total) mg/L BDL BDL BDL BDL 39 Copper as Cu mg/L BDL BDL BDL BDL 40 Vanadium as V mg/L BDL BDL BDL BDL 41 Phosphorous mg/L BDL BDL BDL BDL 42 Benzene mg/L BDL BDL BDL BDL 43 Benzo (a) pyrene mg/L BDL BDL BDL BDL

GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 3.0- Hand Pump at Raichiahi (2.0 km South of BR)

SN Parameter Unit Jun-14 Sep-14 Dec-14 Mar-15 1 Temperature oC 32.6 32.1 26.1 26.6 2 pH 7.38 7.62 7.65 7.42 3 Turbidity NTU < 2 < 2 < 2 < 2 4 Conductivity µmhos/cm 712 788 7.79 792 5 Total Hardness mg/L 266 289 279 285 6 Ca Haednrss as CaCO3 mg/L 119 126 121 163 7 Magnesium Hardness as CaCO3 mg/L 36 40 38 30 8 M-Alkalinity as CaCO3 mg/L 162 177 172 232 9 BOD mg/L BDL BDL BDL BDL

10 COD mg/L BDL BDL BDL BDL 11 Ammoniacle N mg/L BDL BDL BDL BDL 12 Kejaldhal N mg/L BDL BDL BDL BDL 13 Sulphides as (S) mg/L BDL BDL BDL BDL 14 Sodium as Na mg/L 51 59 56 74 15 Potasium as K mg/L 7 9 8 13.2 16 Total Dissolved Solids mg/L 374 489 467 436 17 Total Suspended Solids mg/L 3 5 4 6 18 Total Sulphides mg/L BDL BDL BDL BDL 19 Oil and Grease mg/L BDL BDL BDL BDL 20 Dissolved Oxygen mg/L 7.1 7.5 7.2 7.6 21 Chloride mg/L 68 78 73 87 22 Nitrate mg/L 6.2 5.6 5.2 6.2 23 Sulphate as SO4 mg/L 25 31 32 49 24 Total Silica as SiO2 mg/L BDL BDL BDL BDL 25 Phosphate as PO4 mg/L BDL BDL BDL BDL 26 Fluoride mg/L 0.5 0.8 0.6 0.7 27 Iron mg/L 0.39 0.43 0.23 0.63 28 Lead mg/L BDL BDL BDL BDL 29 Phenol mg/L BDL BDL BDL BDL 30 Nickel mg/L BDL BDL BDL BDL 31 Arsenic mg/L BDL BDL BDL BDL 32 Zinc mg/L 0.22 0.29 0.25 0.37 33 Mercury mg/L BDL BDL BDL BDL 34 Cadmium mg/L BDL BDL BDL BDL 35 Selenium mg/L BDL BDL BDL BDL 36 Cynide mg/L BDL BDL BDL BDL 37 Chromium (Hexavalent) mg/L BDL BDL BDL BDL 38 Chromium (Total) mg/L BDL BDL BDL BDL 39 Copper as Cu mg/L BDL BDL BDL BDL 40 Vanadium as V mg/L BDL BDL BDL BDL 41 Phosphorous mg/L BDL BDL BDL BDL 42 Benzene mg/L BDL BDL BDL BDL 43 Benzo (a) pyrene mg/L BDL BDL BDL BDL

GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 4.0- Hand Pump at Mahna (2.0 km South West of BR)


10 COD mg/L BDL BDL BDL BDL 11 Ammoniacle N mg/L BDL BDL BDL BDL 12 Kejaldhal N mg/L BDL BDL BDL BDL 13 Sulphides as (S) mg/L BDL BDL BDL BDL 14 Sodium as Na mg/L 36 41 39 62 15 Potasium as K mg/L 8.8 8.1 8.3 8.2 16 Total Dissolved Solids mg/L 444 478 471 442 17 Total Suspended Solids mg/L < 2 < 2 < 2 < 2 18 Total Sulphides mg/L BDL BDL BDL BDL 19 Oil and Grease mg/L BDL BDL BDL BDL 20 Dissolved Oxygen mg/L 7 7.5 7.2 8.3 21 Chloride mg/L 84 89 87 66 22 Nitrate mg/L 6.9 6.2 5.7 6.4 23 Sulphate as SO4 mg/L 29 33 31 37 24 Total Silica as SiO2 mg/L BDL BDL BDL BDL 25 Phosphate as PO4 mg/L BDL BDL BDL BDL 26 Fluoride mg/L 0.51 0.55 0.52 0.57 27 Iron mg/L 0.58 0.63 0.25 0.66 28 Lead mg/L BDL BDL BDL BDL 29 Phenol mg/L BDL BDL BDL BDL 30 Nickel mg/L BDL BDL BDL BDL 31 Arsenic mg/L BDL BDL BDL BDL 32 Zinc mg/L 0.18 0.22 0.19 0.25 33 Mercury mg/L BDL BDL BDL BDL 34 Cadmium mg/L BDL BDL BDL BDL 35 Selenium mg/L BDL BDL BDL BDL 36 Cynide mg/L BDL BDL BDL BDL 37 Chromium (Hexavalent) mg/L BDL BDL BDL BDL 38 Chromium (Total) mg/L BDL BDL BDL BDL 39 Copper as Cu mg/L BDL BDL BDL BDL 40 Vanadium as V mg/L BDL BDL BDL BDL 41 Phosphorous mg/L BDL BDL BDL BDL 42 Benzene mg/L BDL BDL BDL BDL 43 Benzo (a) pyrene mg/L BDL BDL BDL BDL

GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 5.0- Hand Pump at Nurpur (1.0 km West of BR)



GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 6.0- Hand Pump at Papraur (2.0 km North West of BR)



GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 7.0- Hand Pump at Masadpur (1.0 km North of BR)

SN Parameter Unit Jun-14 Sep-14 Dec-14 Mar-15 1 Temperature oC 31.7 32.2 24.3 26.7 2 pH 7.62 7.42 7.56 7.82 3 Turbidity NTU < 2 < 2 < 2 < 2 4 Conductivity µmhos/cm 872 855 8.46 986 5 Total Hardness mg/L 341 354 343 377 6 Ca Haednrss as CaCO3 mg/L 215 185 179 159 7 Magnesium Hardness as CaCO3 mg/L 31 41 38 53 8 M-Alkalinity as CaCO3 mg/L 259 274 271 287 9 BOD mg/L BDL BDL BDL BDL


GROUND WATER QUALITY MONITORING RESULTS AROUND BR Table 8.0- Well at Harpur (1.0 km North East of BR)


10 COD mg/L BDL BDL BDL BDL 11 Ammoniacle N mg/L BDL BDL BDL BDL 12 Kejaldhal N mg/L BDL BDL BDL BDL 13 Sulphides as (S) mg/L BDL BDL BDL BDL 14 Sodium as Na mg/L 62 65 61 72 15 Potasium as K mg/L 17 22 19 24 16 Total Dissolved Solids mg/L 681 685 598 723 17 Total Suspended Solids mg/L 5 4 5 5 18 Total Sulphides mg/L BDL BDL BDL BDL 19 Oil and Grease mg/L BDL BDL BDL BDL 20 Dissolved Oxygen mg/L 7.2 7.15 7.36 8.20 21 Chloride mg/L 109 113 124 118 22 Nitrate mg/L 8.1 7.6 6.7 6.9 23 Sulphate as SO4 mg/L 43 37 32 38 24 Total Silica as SiO2 mg/L BDL BDL BDL BDL 25 Phosphate as PO4 mg/L BDL BDL BDL BDL 26 Fluoride mg/L 0.49 0.41 0.36 0.34 27 Iron mg/L 0.81 0.66 0.22 0.56 28 Lead mg/L BDL BDL BDL BDL 29 Phenol mg/L BDL BDL BDL BDL 30 Nickel mg/L BDL BDL BDL BDL 31 Arsenic mg/L BDL BDL BDL BDL 32 Zinc mg/L 0.26 0.31 0.33 0.22 33 Mercury mg/L BDL BDL BDL BDL 34 Cadmium mg/L BDL BDL BDL BDL 35 Selenium mg/L BDL BDL BDL BDL 36 Cynide mg/L BDL BDL BDL BDL 37 Chromium (Hexavalent) mg/L BDL BDL BDL BDL 38 Chromium (Total) mg/L BDL BDL BDL BDL 39 Copper as Cu mg/L BDL BDL BDL BDL 40 Vanadium as V mg/L BDL BDL BDL BDL 41 Phosphorous mg/L BDL BDL BDL BDL 42 Benzene mg/L BDL BDL BDL BDL 43 Benzo (a) pyrene mg/L BDL BDL BDL BDL

4.3 Stack Emission Monitoring

STACK EMISSIONS MONITORING (2014-15) TABLE 1.0 : SO2 EMISSIONS (Conc.)

S.N. Source Fuel Limit Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

Name

% of Gas Firin

g

Conc (mg/Nm3

)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3) 1 AVU - I 50 871 221.7 227.6 231.7 219.7 237.6 243.7 2 AVU - II 50 871 269.7 277.6 273.8 288.6 293.4 277.6 3 AVU - III 60 705 273.4 289.4 314.2 309.4 298.1 286.3 4 CRU - R 85 296 61.2 63.4 66.2 63.8 61.5 63.2 5 CRU - S 85 296 59.4 57.9 59.8 56.4 54.2 52.9 6 COKER - A 80 378 63.8 61.8 63.4 65.2 62.7 59.8 7 COKER - B 80 377 8 BOILER -I DUCT -A 30 1201 317.2 321.5 352.6 374.2 377.2

DUCT - B 30 1201 293.6 313.2 329.2 337.6 343.7 9 BOILER -II DUCT -A 30 1201 287.4 311.5 324.5 336.2 357.5 351.2 359.1

DUCT - B 30 1201 279.6 296.7 314.9 347.8 329.4 333.6 341.5 10 BOILER -III DUCT -A 30 1201 293.2 329.7 349.1 361.1

DUCT - B 30 1201 288.6 341.5 355.8 359.4 11 BOILER -IV DUCT -A 30 1201 317.2 321.6 331.6 352.4 349.6 DUCT - B 30 1201 305.1 317.5 349.6 341.2 357.1

12 BOILER - V 30 1201 337.9 13 FCCU NA 1700 87.3 84.7 82.9 79.4 77.3 73.6 14 HGU 75 461 57.1 59.6 61.8 63.2 59.7 57.7 15 DHDT 100 50 49.3 53.4 56.3 54.1 52.3 51.8

16 GT - I 0 1700 49.8 51.4 53.9 49.9 51.3 49.6 17 GT - II 0 1700 53.2 54.3 51.7 47.9 46.1

18 SRU NA NA 1447.3 1321.6 1405.9 1355.6 1432.8 1327.6 1396.3 1289.6 1278.8 1266.2 1196.4 1296.5 19 MSQ (NHDT) 100 50 14.6 14.9 15.3 15.9 16.2 15.4 20 Prime G 100 50 13.7 15.3 16.7 17.1 17.9 16.7

21 Boiler 6 30 1201 321.70 329.2 356.4 328.4 317.2 321.6

STACK EMISSIONS MONITORING (2014-15) TABLE 2.0 : NOx EMISSIONS (Conc.)


Name

% of Gas

Firing

Conc (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/Nm

3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3) 1 AVU - I 50 400 129.6 133.4 139.1 143.6 149.2 153.9

2 AVU - II 50 400 123.5 91 129.4 143.2 146.3 143.9

3 AVU - III 60 390 141.2 153.7 163.7 169.4 173.6 177.4

4 CRU - R 85 365 83.5 12.3 83.4 81.4 79.8 77.5

5 CRU - S 85 365 78.7 11.9 75.3 73.1 71.6 69.7

6 COKER - A 80 370 81.5 79.7 83.2 81.1 79.7 77.3

7 COKER - B 80 370

8 BOILER -I

DUCT -A 30 420 143.2 107 163.2 167.9 162.5

DUCT - B 30 420 136.5 103 169.4 163.4 169.2

9 BOILER -II

DUCT -A 30 420 136.2 149.3 156.3 159.4 159.6 162.3 166.2

DUCT - B 30 420 131.9 157.4 167.4 161.3 138.6 147.2 152.7

10 BOILER -III

DUCT -A 30 420 129.8 143.2 148.3 153.4

DUCT - B 30 420 133.4 139.4 145.9 148.6

11 BOILER -IV

DUCT -A 30 420 161.6 166.8 156.7 162.3 168.5

DUCT - B 30 420 145.3 159.1 162.5 143.8 159.3

12 BOILER - V 30 420 145.2

13 FCCU NA 450 66.1 19.2 61.6 58.7 61.6 59.8

14 HGU 75 375 41.5 43.1 41.9 43.7 41.8 39.6

15 DHDT 100 350 71.6 73.6 77.4 74.2 77.2 74.9

16 GT - I 0 450 139.4 13.4 147.6 139.5 133.6 131.2

17 GT - II 0 450 133.9 11.8 141.9 139.4 136.7

18 SRU NA 350 147.2 83.4 152.3 17.6 157.4 79.4 166.9 77.2 163.5 73.2 161.8 71.9

19 NHDT 100 250 23.4 21.7 23.6 21.6 23.1 21.9

20 Prime G 100 250 31.2 33.6 34.9 29.9 31.2 29.7

21 Boiler 6 75 275 147.6 93 153.7 149.6 166.4 169.4

STACK EMISSIONS MONITORING (2014-15) TABLE 3.0 : CO EMISSIONS (Conc.)


Name

% of Gas

Firing

Conc (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/Nm

3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3) 1 AVU - I 50 175 8.66 8.89 9.01 9.23 9.46 9.23

2 AVU - II 50 175 9.01 8.78 8.89 8.66 8.44 8.66

3 AVU - III 60 170 9.35 9.58 9.80 10.03 10.15 9.92

4 CRU - R 85 157 7.41 7.18 7.30 7.18 6.95 7.07

5 CRU - S 85 157 7.18 6.95 7.07 6.95 6.73 6.61

6 COKER - A 80 160 8.21 8.32 8.66 8.44 8.55 8.32

7 COKER - B 80 160

8 BOILER -I

DUCT -A 30 185 0.00 24.28 22.34 24.28 22.46 21.55

DUCT - B 30 185 0.00 23.83 21.55 22.57 20.29 22.91

9 BOILER -II

DUCT -A 30 185 23.14 24.40 23.83 25.42 24.28 22.46 23.14

DUCT - B 30 185 24.74 25.31 24.28 23.60 22.57 20.75 22.69

10 BOILER -III

DUCT -A 30 185 24.40 23.60 21.32 20.41

DUCT - B 30 185 22.91 22.12 23.14 21.09

11 BOILER -IV

DUCT -A 30 185 23.83 24.05 23.83 21.32 22.00

DUCT - B 30 185 24.40 25.42 21.89 23.14 23.60

12 BOILER - V 30 185 0.00 24.28

13 FCCU NA 400 8.89 9.46 10.03 10.15 10.60 10.37

14 HGU 75 162 6.38 6.16 6.38 6.50 6.38 6.50

15 DHDT 100 150 7.30 7.64 8.21 8.09 8.32 8.66

16 GT - I 0 200 7.52 7.07 7.52 7.30 7.52 7.30

17 GT - II 0 200 7.30 7.30 7.18 0.00 7.07 6.95

18 SRU NA 150 7.52 8.09 7.64 8.21 7.41 8.09 7.75 7.87 7.52 7.64 7.30 7.52

19 NHDT 100 100 4.10 4.33 4.10 4.22 4.33 4.45

20 Prime G 100 100 4.33 4.79 4.67 4.79 4.90 4.67

21 Boiler 6 75 113 23.60 24.28 23.60 21.20 22.46 23.71

STACK EMISSIONS MONITORING (2014-15) TABLE 4.0 : PM EMISSIONS (Conc.)


Name

% of Gas

Firing

Conc (mg/Nm3)

Actual (mg/Nm

3)

Actual (mg/Nm

3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/Nm

3) 1 AVU - I 50 55 87 89 91 97 103 97

2 AVU - II 50 55 83 91 89 93 103 107

3 AVU - III 60 46 93 95 103 107 109 107

4 CRU - R 85 23 13.8 12.3 13.4 12.2 13.6 12.7

5 CRU - S 85 23 13.1 11.9 12.6 11.9 12.1 11.9

6 COKER - A 80 28 41 43 47 49 53 51

7 COKER - B 80 28

8 BOILER -I

DUCT -A 30 73 91 107 103 106 103

DUCT - B 30 73 94 103 112 96 109

9 BOILER -II

DUCT -A 30 73 103 101 107 109 107 109 102

DUCT - B 30 73 98 96 98 94 96 101 105

10 BOILER -III

DUCT -A 30 73 101 105 93 105

DUCT - B 30 73 105 97 89 112

11 BOILER -IV

DUCT -A 30 73 105 97 105 101 105

DUCT - B 30 73 103 106 96 104 98

12 BOILER - V 30 73 102

13 FCCU NA 100 17.1 19.2 21.4 21.8 29.7 23.4

14 HGU 75 32 12.9 13.1 12.4 13.2 12.7 13.6

15 DHDT 100 10 14.3 12.9 13.7 15.1 14.5 14.9

16 GT - I 0 100 14.3 13.4 12.7 14.2 11.8 12.4

17 GT - II 0 100 12.9 11.8 13.4 12.1 13.1

18 SRU NA NA 15.7 15.7 14.7 17.6 15.7 15.8 14.9 13.7 13.2 12.9 12.4 11.8

19 MSQ (NHDT) 100 5 13.1 12.9 11.7 12.1 11.8 11.3

20 Prime G 100 5 12.9 13.3 12.4 12.9 12.3 12.1

21 Boiler 6 75 16 89 93 96 98 91 98

STACK EMISSIONS MONITORING (2014-15) TABLE 5.0 : Ni+V EMISSIONS

S.N. Source Limit Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

Name

Conc (mg/Nm3)

Actual (mg/Nm

3)

Actual (mg/Nm

3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/N

m3)

Actual (mg/Nm

3) 1 AVU - I 5 BDL BDL BDL BDL BDL BDL

2 AVU - II 5 BDL BDL BDL BDL BDL BDL

3 AVU - III 5 BDL BDL BDL BDL BDL BDL

4 CRU - R 5 BDL BDL BDL BDL BDL BDL

5 CRU - S 5 BDL BDL BDL BDL BDL BDL

6 COKER - A 5 BDL BDL BDL BDL BDL BDL

7 COKER - B 5

8 BOILER -I

DUCT -A 5 BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

DUCT - B 5 BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

9 BOILER -II

DUCT -A 5 BDL BDL BDL BDL

DUCT - B 5 BDL BDL BDL BDL

10 BOILER -III

DUCT -A 5 BDL BDL BDL

DUCT - B 5 BDL BDL BDL

11 BOILER -IV

DUCT -A 5

DUCT - B 5

12 BOILER - V 5 BDL BDL

13 FCCU 5 BDL BDL BDL BDL BDL BDL

14 HGU 5 BDL BDL BDL BDL BDL BDL

15 DHDT 5 BDL BDL BDL BDL BDL BDL

16 GT - I 5 BDL BDL BDL BDL BDL BDL

17 GT - II 5 BDL BDL BDL BDL BDL BDL

18 SRU NA BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

19 MSQ (NHDT) 5 BDL BDL BDL BDL BDL BDL

20 Prime G 5 BDL BDL BDL BDL BDL BDL

21 Boiler 6 5 BDL BDL BDL BDL BDL BDL

STACK EMISSIONS MONITORING (2014-15) TABLE 6.0 : EMISSIONS (Load)

S.N. Source Limit Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

Name Kg/hr

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

Actual (Kg/hr)

1 SO2 1035 698 712.00 703.00 702.00 695.00 697.00 701.00 707.00 692.00 709 702 697

2 NOX NA 175.23 181.74 179.20 191.47 193.41 213.92 233.09 202.86 207.14 219.28 213.36 190.42

3 CO NA 17.37 18.33 17.24 19.55 18.71 22.83 24.77 22.50 22.17 22.40 21.50 19.33

4 PM NA 75.12 75.85 73.05 83.21 81.79 97.65 109.44 103.13 104.51 108.74 103.51 87.91

4.4 Raw Water Requirement

4.4.1 Present Raw Water Requirement

SN Parameter UOM Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 2014-15

1 Crude T'put MT 531597 570550 549074 568562 511890 390533 531149 404104 346526 546766 457608 535474 5943832

2 Fresh Water Consumption (Refinery + Domestic)

M3 514800 529728 514080 528984 529728 497520 527496 411120 438960 513360 462336 512616 5980728

3 Fresh Water Consumption Rate (Refinery + Domestic)

M3/HR 715 712 714 711 712 691 709 571 590 690 688 689 683

4 Specific Freshwater Consumption

M3/MT CRUDE 0.968 0.928 0.936 0.930 1.035 1.274 0.993 1.017 1.267 0.939 1.010 0.957 1.006

4.4.1 Post Project Raw Water Requirement

S.N Consumption Centre Present (m3/hr)

Post Project (m3/hr)

1 DM Water 320 77 2 Cooling Tower Make up 194 396 3 Service Water 168 171 4 Drinking Water 7 7 5 Total 689 651

4.5 Treated Effluent Quality & Quantity

Treated Effluent Quality : April 2014 till Sept 2014

SN Parameter Limit Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 (mg/l

except pH)

MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG

1 pH 6.0 – 8.5 7.9 6.6 7.31 8.2 6.8 7.29 7.4 7 7.19 7.3 6.8 7.14 7.60 6.90 7.38 8 7.4 7.60 2 Oil & Grease 5 5 3 3.98 5 3 4.45 5 3.6 4.63 5 3 4.44 4.20 2.40 3.08 3 2.2 2.47 3 BOD 15 15 12 14.63 15 6 12.85 15 12 14.20 15 8 13.80 15.00 8.00 12.10 15 8 12.73 4 COD 125 125 72 98.00 120 80 96.27 110 46 80.24 124 48 93.95 80.00 24.00 54.63 110 20 51.95 5 TSS 20 22 18 19.42 21 12 18.85 22 18 19.00 21 5.2 13.41 5.90 3.80 4.59 10.4 4.4 5.43 6 Phenols 0.35 0.3 0.02 0.05 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.03 0.02 0.02 0.032 0.017 0.02 7 Sulphides 0.5 0.5 0.26 0.39 0.5 0.26 0.38 0.5 0.26 0.40 0.5 0.26 0.41 0.39 0.26 0.31 0.39 0.26 0.33 8 CN 0.2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9 Ammonia as

N 15 2.7 1.9 2.3 2.9 2.4 2.7 2.7 2.2 2.45 2.6 1.5 2.1 3.3 2.2 2.8 2.1 1.5 1.8

10 TKN 40 26.6 20.5 24 24.5 20.8 22.7 23.2 20.1 21.65 26.4 21.5 24.0 28.6 24.1 26.4 25.5 20.6 23.1 11 P 3.0 1.1 1.7 1.4 1.6 1.2 1.4 1.7 1.1 1.4 1.6 1.3 1.5 1.8 0.9 1.4 1.5 0.6 1.1 12 Cr

(Hexavalent) 0.1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

13 Cr (Total) 2.0 1.4 1.2 1.3 1.2 0.9 1.1 1.4 0.5 0.95 1.2 0.9 1.1 1.2 0.7 1.0 1.1 0.8 1.0 14 Pb 0.1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15 Hg 0.01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 16 Zn 5.0 2.2 1.6 1.9 2.2 1.6 1.9 1.8 1.3 1.55 2.1 1.5 1.8 2.1 1.4 1.8 1.8 0.9 1.4 17 Ni 1.0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 18 Cu 1.0 0.21 0.14 0.18 0.18 0.15 0.17 0.16 0.12 0.14 0.16 0.09 0.13 0.13 0.11 0.12 0.13 0.00 0.07 19 V 0.2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 Benzene 0.1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 21 Benzo (a) -

Pyrene 0.2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Treated Effluent Quality : Oct 2014 till March 2015

SN Parameter Limit

Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

(mg/l except

pH) MAX MIN AVG MA

X MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG

1 pH 6.0 – 8.5 7.80 7.40 7.61 8 7 7.23 7.8 7.0 7.30 8.2 7.1 7.34 7.20 6.80 7.03 7.90 6.60 7.10

2 Oil & Grease 5 5.00 2.00 3.32 5 3 4.08 5.0 3.3 4.30 5.0 3.6 4.85 5.00 2.30 4.28 5.00 3.20 4.30

3 BOD 15 15.00 10.00 13.64 15 7 12.28 15.0 4.0 8.00 15.0 3.0 11.39 15.00 8.00 13.17 15.00 9.00 13.00

4 COD 125

124.00

27.50 92.80 125 32 87.64 112.0 40.0 58.40 121.0 16.0 63.67 72.00 24.00 50.71 120.00 24.00 54.00

5 TSS 20 6.80 4.20 4.75 20 4.8 12.92 20.0 7.2 13.10 20.00 3.00 12.47 20.00 12.00 18.21 20.00 9.00 17.00

6 Phenols 0.35 0.30 0.02 0.04 0.2 0.03 0.07 0.3 0.03 0.06 0.20 0.05 0.12 0.25 0.05 0.12 0.15 0.05 0.11

7 Sulphides 0.5 0.39 0.26 0.30 0.5 0.13 0.24 0.5 0.13 0.21 0.50 0.13 0.37 0.50 0.26 0.42 0.50 0.13 0.40

8 CN 0.2 0 0 0 0 0 0 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00

9 Ammonia as N 15 1.9 1.2 1.6 1.6 1.1 1.4 1.9 1.66 1.8 0.055 0.066 0.061 6.80 8.50 7.65 8.8 6.80 7.800

10 TKN 40 23.5 20.3 21.9 24.1 20.8 22.5 25.7 21.8 23.8 35.10 39.20 37.15 26.60 30.80 28.70 33.6 29.6 31.60

11 P 3.0 1.8 1.2 1.5 1.6 1.5 1.6 1.6 1.4 1.5 0.551 0.642 0.061 0.431 0.521 0.476 0.500 0.431 0.466

12 Cr (Hexavalent)

0.1 0 0 0 0 0 0 0 0 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

13 Cr-Total 2.0 1.5 1.3 1.4 1.3 0.8 1.1 1.3 0.90 1.1 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

14 Pb 0.1 0 0 0 0 0 0 0 0.00 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

15 Hg 0.01 0 0 0 0 0 0 0 0.0 0

<0.001

<0.001

<0.001

<0.001 <0.00

1 <0.00

1 <0.001

<0.001

<0.001

16 Zn 5.0 2.4 2.1 2.3 2.8 2.1 2.5 2 1.9 2 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

17 Ni 1.0 0 0 0 0 0 0 0 0 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

18 Cu 1.0 0.16 0.11 0.14 0.22 0.11 0.17 0.14 0.09 0.12 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

19 V 0.2 0 0 0 0 0 0 0 0 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

20 Benzene 0.1 0 0 0 0 0 0 0 0 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

21 Benzo (a) -Pyrene

0.2 0 0 0 0 0 0 0 0 0 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Treated Effluent Quantity : Oct 2014 till March 2015

SN Parameter

Quantum value

(kg/TMT of Crude

processed)

Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14

Limit MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG 1 pH -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 2 Oil & Grease 2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3 BOD 6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 4 COD 50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 5 TSS 8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 6 Phenols 0.14 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 7 Sulphides 0.2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8 CN 0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 9 Ammonia as

N 6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

10 TKN 16 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 11 P 1.2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 12 Cr

(Hexavalent) 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

13 Cr (Total) 0.8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 14 Pb 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 15 Hg 0.004 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 16 Zn 2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 17 Ni 0.4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 18 Cu 0.4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 19 V 0.8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 20 Benzene 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 21 Benzo (a) -

Pyrene 0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Treated Effluent Quantity : Oct 2014 till March 2015

SN Parameter

Quantum value

(kg/TMT of Crude

processed)

Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

Limit MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG MAX MIN AVG 1 pH -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 2 Oil & Grease 2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3 BOD 6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 4 COD 50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 5 TSS 8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 6 Phenols 0.14 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 7 Sulphides 0.2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8 CN 0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 9 Ammonia as

N 6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

10 TKN 16 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 11 P 1.2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 12 Cr

(Hexavalent) 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

13 Cr (Total) 0.8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 14 Pb 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 15 Hg 0.004 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 16 Zn 2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 17 Ni 0.4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 18 Cu 0.4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 19 V 0.8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 20 Benzene 0.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 21 Benzo (a) -

Pyrene 0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

4.6 Noise Pollution Monitoring

1) Noise pollution at various loacations is being monitored twice in a year.

2) Noise monitoring at 35 locations are being carried out in Field Control room and DCS Control Room.

3) Noise monitoring at 35 identified loactions, defined as High Noise Area (Plant Area) is being carried out.

4) Noise monitoring at 10 loactions near boundary wall of refinery is being carried out.

5) Noise monitoring datas for the year 2014-15 are given below.

S.N. LOCATIONS

Min dB(A) Max dB(A) LeqdB(A)1 AVU – I - FIELD CONTROL ROOM 64 66 64.82 AVU – II – FIELD CONTROL ROOM 65 67 66.13 AVU-III FIELD CONTROL ROOM 67 69 65.94 AVU-I, II/ COKER DDCS CONTROL ROOM 52 57 58.25 AVU – III/ CRU DDCS CONTROL ROOM 56 59 55.76 COKER-A FIELD CONTROL ROOM 62 65 63.87 COKER-B FIELD CONTROL ROOM 60 63 62.98 CRU FIELD CONTROL ROOM 64 67 64.79 BXP CONTROL ROOM 63 65 65.110 RFCCU FIELD CONTROL ROOM 66 69 64.811 DHDT FIELD CONTROL ROOM 59 63 60.212 HGU-1 FIELD CONTROL ROOM 62 65 63.713 HGU-2 FIELD CONTROL ROOM 58 64 60.914 SRU FIELD CONTROL ROOM 65 67 65.715 MSQ CONTROL ROOM 57 61 58.316 OM&S CONTROL ROOM 59 63 61.217 CRUDE OIL STATION 60 63 62.418 FINISHED PRODUCT CONTROL ROOM 58 64 62.719 LPG CONTROL ROOM 59 62 60.820 ETP FIELD CONTROL ROOM 57 60 59.621 UTILITY CONTROL ROOM 56 59 58.122 OLD DM PLANT CONTROL ROOM 62 64 63.823 TPS - CONTROL ROOM 61 63 61.924 TPS FIELD CONTROL ROOM 68 70 68.925 BOILER 6 CONTROL ROOM 65 68 68.426 RO DM PLANT CONTROL ROOM 61 63 62.127 BXP DM PLANT CONTROL ROOM 72 74 65.228 INSIDE THE MECHANICAL WORKSHOP 79 83 78.929 QUALITY CONTROL LABORATORY 57 63 58.730 M&I BUILDING 59 62 57.331 STORES 60 66 62.832 FIRE STATION 61 64 62.633 FIRE WATER PUMP HOUSE 80 84 81.934 INSTRUMENTATION BUILDING 56 59 58.335 ELECTICAL PLANNIG BUILDING 57 61 56.8

Eight Hourly Basis

Month: SEPTEMBER,2014 Table 1: FIELD AND DCS CONTROL ROOM

IOCL - BARAUNI REFINERYNOISE LEVEL MONITORING RESULTS FOR BR

S.N. LOCATIONS

Min dB(A) Max dB(A) LeqdB(A)1 AVU – I NEAR FURNACE F-02 71 74 72.32 AVU – I NEAR FURNACE F-03 74 76 75.13 AVU – II NEAR FURNACE F-02 72 75 75.74 AVU – II NEAR FURNACE F-03 72 75 75.75 AVU-III NEAR FURNACE F-01 75 77 76.96 AVU-III NEAR FURNACE F-02 74 76 75.87 AVU-III NEAR FURNACE F-03 75 78 77.28 COKER - A PUMP NEAR P – 06 A/B 81 83 79.99 COKER A NEAR FURNACE 70 74 70.9

10 LRU COMPRESSOR 1st FLOOR PLATFORM

80 84 81.811 LRU COMPRESSOR GROUND FLOOR 80 83 81.5

12 LRU SUCTION KOD BESIDE COMPRESSOR (08-P-013 A/B) 82 84 82.3

13 LRU BOTTOM FRACTIONATORS PUMP (07-P-008 A/B) 81 83 82.3

14 COKER - B REACTOR FEED PUMP 68 70 69.315 COKER - B FURNACE GROUND FLOOR 66 69 68.816 COKER - B FURNACE FIRST FLOOR 68 70 69.717 COKER - B OLD PUMP HOUSE 69 72 71.218 CRU RECYCLE GAS COMPRESSOR 80 83 82.019 RFCCU COMPRESSOR HOUSE 78 81 80.820 HGU COMPRESSOR HOUSE 75 77 76.221 DHDT COMPRESSOR HOUSE 82 85 83.222 BXP AIR COMPRESSOR HOUSE 76 78 75.923 MSQ COMPRESSOR HOUSE 74 77 74.524 FIRE PUMP HOUSE - Sector - 7 80 82 81.825 TPS AIR COMPRESSOR - INSIDE 81 84 83.626 TPS AIR COMPRESSOR - OUTSIDE 74 76 75.627 TPS NEAR BOILER 1 79 81 80.728 GT-1 73 77 75.929 GT-2 74 78 74.130 MSQ NITROGEN PLANT 78 81 80.731 OLD NITROGEN PLANT 77 80 79.632 FLUE GAS RECOVERY COMPRESSOR 79 81 80.833 RUP PUMP HOUSE 80 83 80.334 AERATOR AIR BLOWER 82 85 82.935 DAF AIR BLOWER 84 87 85.6

Eight Hourly Basis


Table 2: HIGH NOISY AREAMonth: SEPTEMBER,2014

S.N. LOCATIONS

Min dB(A) Max dB(A) LeqdB(A) Min dB(A) Max dB(A) LeqdB(A)1 GATE NO. 1 69 72 69.9 55 57 56.72 GATE NO. 2 70 74 72.9 61 65 63.93 BIO –TREATMENT PLANT GATE 77 80 78.9 71 75 73.84 BIO –TREATMENT - CONTROL ROOM 68 70 69.2 62 65 63.6

5 OIL INDIA GATE (NEAR GOVINDPUR VILLAGE)

62 65 63.6 51 55 54.2

6 GATE NO. 10 66 70 65.3 56 59 57.4

7 RFCCU SITE CLOSE TO THE BOUNDARY

62 64 63.6 58 62 60.7

8 SRU SITE CLOSE TO THE BOUNDARY 63 66 65.3 60 63 61.69 CISF COLONY 56 60 60.2 48 52 50.9

10 NEAR BURROW PIT 57 62 61.1 55 61 58.1

DAY NIGHT

IOCL - BARAUNI REFINERYNOISE LEVEL MONITORING RESULTS FOR BRTable 3: BOUNDARY OF THE REFINERY AREA

Month: SEPTEMBER,2014

S.N. LOCATIONS

Min dB(A) Max dB(A) LeqdB(A)1 AVU – I - FIELD CONTROL ROOM 63 65 63.72 AVU – II – FIELD CONTROL ROOM 64 67 65.93 AVU-III FIELD CONTROL ROOM 66 68 66.44 AVU-I, II/ COKER DDCS CONTROL ROOM 51 56 56.15 AVU – III/ CRU DDCS CONTROL ROOM 54 58 54.36 COKER-A FIELD CONTROL ROOM 61 64 62.97 COKER-B FIELD CONTROL ROOM 63 65 63.48 CRU FIELD CONTROL ROOM 65 67 64.99 BXP CONTROL ROOM 62 64 65.210 RFCCU FIELD CONTROL ROOM 67 69 64.811 DHDT FIELD CONTROL ROOM 60 63 60.312 HGU-1 FIELD CONTROL ROOM 62 64 63.513 HGU-2 FIELD CONTROL ROOM 59 63 61.614 SRU FIELD CONTROL ROOM 66 69 66.315 MSQ CONTROL ROOM 58 61 58.916 OM&S CONTROL ROOM 60 63 61.517 CRUDE OIL STATION 59 62 62.118 FINISHED PRODUCT CONTROL ROOM 61 64 62.919 LPG CONTROL ROOM 58 62 60.620 ETP FIELD CONTROL ROOM 59 61 59.821 UTILITY CONTROL ROOM 57 59 58.122 OLD DM PLANT CONTROL ROOM 63 65 64.123 TPS - CONTROL ROOM 62 64 62.324 TPS FIELD CONTROL ROOM 67 70 68.725 BOILER 6 CONTROL ROOM 64 67 68.126 RO DM PLANT CONTROL ROOM 62 64 62.727 BXP DM PLANT CONTROL ROOM 71 74 65.128 INSIDE THE MECHANICAL WORKSHOP 77 83 78.229 QUALITY CONTROL LABORATORY 56 61 57.830 M&I BUILDING 58 61 57.731 STORES 61 66 62.832 FIRE STATION 60 64 62.433 FIRE WATER PUMP HOUSE 81 84 81.934 INSTRUMENTATION BUILDING 56 58 58.135 ELECTICAL PLANNIG BUILDING 57 59 56.2

Eight Hourly Basis

Month: MARCH,2015 Table 1: FIELD AND DCS CONTROL ROOM


S.N. LOCATIONS

Min [dB(A)] Max [dB(A)] Leq[dB(A)]1 AVU – I NEAR FURNACE F-02 70 73 71.82 AVU – I NEAR FURNACE F-03 72 75 74.33 AVU – II NEAR FURNACE F-02 73 76 75.94 AVU – II NEAR FURNACE F-03 71 74 74.65 AVU-III NEAR FURNACE F-01 74 76 75.96 AVU-III NEAR FURNACE F-02 72 75 74.67 AVU-III NEAR FURNACE F-03 74 77 76.88 COKER - A PUMP NEAR P – 06 A/B 80 83 79.49 COKER A NEAR FURNACE 71 74 70.7

10 LRU COMPRESSOR 1st FLOOR PLATFORM

81 84 81.911 LRU COMPRESSOR GROUND FLOOR 78 81 79.8

12 LRU SUCTION KOD BESIDE COMPRESSOR (08-P-013 A/B) 82 84 82.3

13 LRU BOTTOM FRACTIONATORS PUMP (07-P-008 A/B) 80 82 81.7

14 COKER - B REACTOR FEED PUMP 68 70 69.315 COKER - B FURNACE GROUND FLOOR 67 69 68.916 COKER - B FURNACE FIRST FLOOR 68 70 69.717 COKER - B OLD PUMP HOUSE 70 72 71.518 CRU RECYCLE GAS COMPRESSOR 81 83 82.219 RFCCU COMPRESSOR HOUSE 79 81 80.820 HGU COMPRESSOR HOUSE 76 78 76.821 DHDT COMPRESSOR HOUSE 80 83 82.122 BXP AIR COMPRESSOR HOUSE 77 79 76.323 MSQ COMPRESSOR HOUSE 73 75 73.624 FIRE PUMP HOUSE - Sector - 7 81 83 82.225 TPS AIR COMPRESSOR - INSIDE 82 84 83.726 TPS AIR COMPRESSOR - OUTSIDE 73 75 75.127 TPS NEAR BOILER 1 78 80 80.128 GT-1 73 77 75.929 GT-2 74 78 74.130 MSQ NITROGEN PLANT 76 79 78.831 OLD NITROGEN PLANT 77 80 79.632 FLUE GAS RECOVERY COMPRESSOR 79 81 80.833 RUP PUMP HOUSE 81 83 80.534 AERATOR AIR BLOWER 83 85 83.335 DAF AIR BLOWER 84 87 85.6

Eight Hourly Basis


Table 2: HIGH NOISY AREAMonth: MARCH,2015

S.N. LOCATIONS

Min [dB(A)] Max [dB(A)] Leq[dB(A)] Min [dB(A)] Max [dB(A)] Leq[dB(A)]1 GATE NO. 1 67 71 68.6 55 57 56.82 GATE NO. 2 69 73 70.4 59 63 62.13 BIO –TREATMENT PLANT GATE 74 78 76.1 72 75 73.84 BIO –TREATMENT - CONTROL ROOM 70 73 70.7 64 66 64.7

5 OIL INDIA GATE (NEAR GOVINDPUR VILLAGE) 61 64 63.2 52 55 54.2

6 GATE NO. 10 67 70 65.3 57 59 57.9

7 RFCCU SITE CLOSE TO THE BOUNDARY 63 65 64.2 58 62 60.7

8 SRU SITE CLOSE TO THE BOUNDARY 64 66 65.5 61 63 61.89 CISF COLONY 57 60 60.6 48 51 50.6

10 NEAR BURROW PIT 56 64 62.3 53 57 56.3

DAY NIGHT

IOCL - BARAUNI REFINERYNOISE LEVEL MONITORING RESULTS FOR BRTable 3: BOUNDARY OF THE REFINERY AREA

Month: MARCH,2015

4.7 Present Solid Waste Management at Barauni Refinery



Updated Chapters of EIA report Chapter – 4.8 Sulphur Balance

4.8 Sulphur Balance for FY 2013-14 and FY 2014-15 (03 Quarters)

IOCL BR Input for FY 2013-14 Sl. No. Crude / Other inputs Input

(MT) Sulphur

Content (% ) Sulphur in Input (MT)

1 Labuan 758123 0.0951 721.14 2 Bonny Light 341913 0.1537 525.59 3 Nemba 447464 0.2126 951.52 4 Usan 69670 0.2300 160.24 5 Forcados 263725 0.1884 496.96 6 White Rose 83189 0.2800 232.93 7 Bombay High 401417 0.1200 481.70 8 EA 345859 0.0887 306.62 9 Girrasol 597915 0.3241 1937.96 10 Bonga 453 0.2460 1.11 11 Seria Light 274880 0.0696 191.34 12 Brass River 62979 0.1782 112.22 13 Miri Light 38356 0.0851 32.62 14 Quaiboe 957859 0.1324 1268.25 15 Quarter Land 42490 1.2120 514.98 16 Plutino 1722 0.3860 6.65 17 KIKEH 15161 0.0601 9.11 18 Saxi 193716 0.3030 586.96 19 Hungo Blend 223512 0.5796 1295.40 20 Jubli Blend 615 0.2558 1.57 21 Palanca 65482 0.1956 128.11 22 MURBAN (LS) 410365 0.8101 3324.56 23 Kissanje 144692 0.3689 533.70 24 OKORO 153636 0.1810 278.08 25 Arab Mix 130755 2.1600 2824.51 26 Kuwait 249 2.7400 6.82 27 DUBAI 1768 1.9400 34.30 28 Umm Shif 2404 1.3210 31.76 29 Basra Light 174475 2.8370 4949.29 30 MURBAN (HS) 202613 0.8101 1641.46 31 Lower Zakum 33101 1.0370 343.26 32 Upper Zakum 37459 1.8200 681.75

Total Crude 6478017 33 ISD 42125 0.8100 341.21 34 GR Reformate 2715 0.0100 0.27 35 LVFO from AOD 5432 0.0100 0.54 36 Py Gasoline from Panipat 2332 0.0100 0.23 37 Other Inputs 40 0.0150 0.01

Total Input 6530661 Total Sulphur 24954.75




IOCL BR Output for FY 2013-14 Sl. No. Products / Other outputs Output

(MT) Sulphur content

S in Output (MT)

1 LPG 316882 135 ppm 42.78 2 S R N 124689 180 ppm 22.44 3 M S(BS-III) 1190518 135 ppm 160.72 4 M S(BS-IV) 0 50 ppm 0.00 5 Superior Kerosene 820005 0.10% 820.01

6 High Speed Diesel ( B S - III) 3249279 300 ppm 974.78

7 High Speed Diesel (BS - IV) 0 50 ppm 0.00 8 L S H S / I F O -116 950 ppm 0.11 9 R P C 124199 2.00% 2483.98 10 FO 67204 950 ppm 63.84 11 B i t u m e n -1465 1.80% 26.37 12 C B F S 47043 1.30% 611.56 13 SULFUR 10253 99.95% 10253.00 Fuel (Liquid)

14 Fuel Oil 120339 950 ppm 114.32 15 Naphtha 111090 180 ppm 20.00 16 HSD 99 300 ppm 0.03 17 FCCU Coke 126416 7.40% 9326.97 18 Fuel (Gas) 207990 150 ppm 31.20 19 Losses 16236 150 ppm 2.44

Total Output 6530661 Total Sulphur 24954.55




IOCL BR Input for FY 2014-15 (03 Quarter)

Sl. No. Crude / Other inputs Input

(MT) S %

in input S in input

(MT) 1 Kissanje 70475 0.3689 259.95 2 Kimanis 24959 0.0560 13.98 3 Saxi 36373 0.3030 110.21 4 Bombay High 56581 0.1200 67.90 5 White Rose 3447 0.2800 9.65 6 Kikeh 91804 0.0601 55.16 7 Quaiboe 495388 0.1324 655.92 8 Zafiro 203612 0.2700 549.75 9 D-Jeno 67750 0.4200 284.55

10 Koley 61075 0.3700 225.98 11 Bonny Lt 443765 0.1537 682.16 12 Plutino 140990 0.3860 544.22 13 MURBAN(LS) 568777 0.8101 4607.93 14 Usan 0 0.2300 0.00 15 OKORO 0 0.1810 0.00 16 Girrassol 370478 0.3241 1200.79 17 Labuan 379769 0.0951 361.24 18 Saturno 77099 0.8300 639.92 19 Nemba 280223 0.2126 595.89 20 Amenum 130794 0.0900 117.71 21 Agbami 123910 0.0400 49.56 22 Seria Light 305387 0.0696 212.57 23 EA 150134 0.0887 133.10 24 Hungo Blend 139274 0.5796 807.19 25 Arab.Mix 95267 2.1600 2057.77 26 Arab.Mix(Ext Lt) 6741 1.1900 80.22 27 MURBAN(HS) 4390 0.8101 35.56 28 Basrah 75523 2.8370 2142.59

Total Crude 4403984 29 CFO from BGR 13040 0.0100 1.30 30 LVFO from AOD 21771 0.0100 2.18 31 Py Gasoline from Panipat 0.0100 0.00 32 Other Inputs 25 0.0150 0.00

Total Input 4438821 Total Sulphur 16504.96




IOCL BR Output for FY 2014-15 (03 Quarter) Sl. No. Products / Other outputs Output

(MT) Sulphur content

S in Output (MT)

1 LPG 217824 135 ppm 29.41 2 S R N 54253 180 ppm 9.77 3 M S(BS-III) 837090 135 ppm 113.01 4 M S(BS-IV) 0 50 ppm 0.00 5 Superior Kerosene 528313 0.10% 528.31 6 High Speed Diesel ( B S - III) 2182785 300 ppm 654.84 7 High Speed Diesel (BS - IV) 0 50 ppm 0.00 8 L S H S / I F O -1276 810 ppm -1.03 9 R P C 97068 2.00% 1941.37

10 FO 33063 810 ppm 26.78 11 B i t u m e n -30 1.80% -0.54 12 C B F S 21682 1.30% 281.86 13 SULFUR 7499 99.90% 7491.03 Fuel (Liquid)

14 Fuel Oil 93176 810 ppm 75.47 15 Naphtha 75787 180 ppm 13.64 16 HSD 204 300 ppm 0.06 17 FCCU Coke 92397 5.27% 4866.54 18 Fuel (Gas) 137895 150 ppm 20.68 19 Losses 11448 150 ppm 1.72 20 ISD 49644 0.91% 451.76

Total Output 4438821 Total Sulphur 16504.67



Updated Chapters of EIA report Chapter – 4.9 Note on SO2 and NOx emission

4.9 Note on SO2 and NOx emission

IOCL Barauni Refinery have limit of 1035 kg/hr SO2 emission (inclusive of all stacks) as per MoEF EC letter no. J-11011/491/2007-IA II (I) dated 18th March 2008.

Presently IOCL BR SO2 emission is between 690 – 720 kg/hr (refer Chapter 4.3), which is approx. 30 - 35% less than the limit of 1035 kg/hr as given by MoEF.

Due to proposed projects, approx. additional emission of SO2 will increase by 15 -20 % ( 150 - 200 kg/hr) from existing emission. This increase will lead to overall SO2 emission of refinery to 870 – 920 kg/hr, which will be still within the limit of 1035 kg/hr.

This increase in SO2 limit in post project scenario is mainly governed by increase in consumption of utility as stated below:

IOCL Barauni Refinery is presently being able to meet NOx limits for individual furnaces (Refer Chapter 4.3) w.r.t guidelines under “ The Environment (Protection) Rules, 1986 “ given by CPCB with implementation of low NOx burners in furnaces.



Updated Chapters of EIA report Chapter – 4.10 Air Pollution Control Devices

4. 10 Air Pollution Control Devices

IOCL Barauni Refinery presently has following Air Pollution Control Devices:

i) 05 AAQMS Stations.

ii) 01 CAAQMS Station with SO2, NO2, PM 10 & CO analyzers.

iii) 19 Stack monitoring stations with SO2 & NOx analyzers.

Upcoming Air Pollution Control Devices at IOCL Barauni Refinery:

i) PM 2.5, Ammonia, Ozone & Benzene analyzer in existing CAAQMS.

ii) 02 new CAAQMS Station with SO2, NO2, CO, PM 10, PM 2.5, Ammonia, Ozone & Benzene analyzer.

iii) Inclusion of CO and PM analyzer in all 19 Stacks.




Water Balance

Chapter -5

Water Balance




Water Balance

5.1 Water Balance Chart of existing configuration .

Current Water Balance




Water Balance




Water Balance

5.2 Water Balance due to proposed project at IOCL Barauni Refinery

5.3 Action Plan for reduction of water requirement.

1) Implementation of In house water conservation schemes.

2) Commissioning of ongoing RO plant at ETP/BTP for maximization of reuse in Refinery Operations.

Chapter -6

Effleuent Generation & Treatment Scheme

6.1 Qantity of Effluent generation

Current IOCL Barauni Refiney Effluent is as given below :

6.2 EFFLUENT TREATMENT SCHEME

ETP : ETP is designed for effluent flow of 600 M3/Hr (Dry weather) flow or 1000 M3/Hr (Wet weather) flow. PRELIMINARY TREATMENT

An automated mechanical screen, designed for the ultimate flow of 24 MLD, will be provided in the elevated channel for the removal of suspended matter. a manual bar screen will be provided as a bypass in the incoming channel

Two detritors, one on each side of the screened sewage channel, will be provided for the removal of dense, inorganic solids. a central bypass channel will be provided between the detritors.

Screened and degritted effluent will be collected in the raw effluent collection chamber /raw effluent pumping station A raw effluent pumping station for full capacity (24 MLD) has been provided. a total of four submersible centrifugal screw impeller

type pumps has been be provided (are able to lift the raw effluent without oil emulsification and low shear type); two will each be designed to handle the anticipated wet weather flow (24 MLD) and other to meet the standby tender requirement.

The above system is fully covered to control the emission of volatile organic compounds. PRIMARY TREATMENT.

Transfer of raw effluent via submersible effluent transfer pumps into two closed equalization tanks. Equalization of the screened effluent in an above ground equalization tank. Steam heating will be provided to the equalization tank. Collection of oil from the equalization tank to the slop oil sumps by an floating type funnel skimmers Transfer of equalized effluent to tpi separator by gravity. Routing of slop oil from tpi to wet slop oil sump. Routing of sludge from tpi to sludge collection sump. Routing of sludge (intermittently) from equalization tanks to sludge dewatering system Coagulation of tpi treated effluent in flash mixer through alum. Mixing of treated spent caustic stream to the outlet of tpi system Flocculation of coagulated effluent in flocculation mixer through deoiler polyelectrolyte. Treatment of the flocculated effluent in dissolved air floatation unit. Collection of daf treated water into a ph correction tank Transfer of treated effluent to the btp region by connecting the out of the treated water transfer pumps into the outlet of guard

ponds pipeline.

SPENT CAUSTIC TREATMENT Receipt of effluent into the newly constructed spent caustic collection sump.

PH correction as per process requirement Treatment by oxidation with H2O2 Routing of treated spent caustic to the tpi outlet. Routing of sludge (if any) to sludge dewatering system The spent caustic treatment facility is fully covered to control the emission of volatile organic compounds. Treated spent caustic stream neutralization

OILY CHEMICAL SLUDGE TREATMENT

The various oil & chemical sludge produced in the process will be treated in a isolated oily chemical sludge treatment system. Transfer of excess sludge to the sludge holding tank. Thickening of the produced sludge by a sludge thickener to increase the sludge consistency Transfer of thickened/digested sludge from the sludge thickener to the centrifuge via suitable progressive cavity centrifuge feed

pumps. Addition of polyelectrolyte to improve sludge dewatering characteristics via polyelectrolyte dosing pumps. Return of centrifuge centrate to the inlet receiving sump by gravity (depending upon plant hydraulics).

BTP : BTP is designed for the effluent flow of 1000 M3/Hr (Dry weather) flow or 1400 M3/Hr (wet weather) flow. PRELIMINARY TREATMENT

An influent receiving chamber with a mechanical coarse screen designed for the full capacity will be provided. the mechanical coarse screen will remove large debris and floating matter that could damage the downstream process pumps.

Screening of effluent prior to collection The existing horizontal centrifugal type pumps will be used to feed the effluent to the bio tower system.

SECONDARY BIOLOGICAL TREATMENT.

Secondary biological treatment by the two stage aerobic treatment. The two stage aerobic biological treatment primarily consists of bio tower filters followed by extended aeration process. The extended aeration tanks will consist of:

fine bubble diffusers external air blowers

Clarification in the secondary clarifier. Settled sludge from the bottom of the secondary clarifier will be recycled back to aeration tanks to maintain the desired mlss level. Excess sludge will be wasted to the sludge holding tank.

BIOLOGICAL SLUDGE TREATMENT

The biological sludge produced in the process will be treated in a isolated sludge treatment system. Transfer of excess sludge to the sludge holding tank. Thickening of the produced sludge by a sludge thickener to increase the sludge consistency. Transfer of thickened/digested sludge from the sludge holding tank to the centrifuge via suitable progressive cavity centrifuge feed

pumps. Addition of polyelectrolyte to improve sludge dewatering characteristics via polyelectrolyte dosing pumps. Return of centrifuge centrate to the inlet receiving sump by gravity (depending upon plant hydraulics).

DISINFECTION & FILTRATION TREATMENT

Pre chlorination by clo2 generator Constant filtration of treated effluent water via low pressure filtration system for removal of suspended impurities.( better than

Pressure sand filtration system , refer attached sheet) Backwash of filters in auto Collection of filtered water in the filter water storage tank.

TERTIARY TREATMENT BY ULTRA FILTRATION

The system is operated at 4 x 25 % capacities, for flexible operational conditions. Transfers of filtered water via basket strainer through a basket strainer feed pump. Removal of fine suspended colloidal solids via ultra filtration treatment.



Updated EIA-EMP report Chapter - 7 Oily Sludge & Solid Waste Management

Chapter -7

Oily Sludge & Soild Waste handling




7.1 Oily Sludge Management

The Oily sludge is generated mainly during cleaning of storage tanks. Due to high oil content in the sludge, it cannot be disposed off directly. Hence, the same used to be subjected to melting pit treatment wherein maximum amount of recoverable oil was extracted from the sludge and the residual oil sludge used to be disposed off through biodegradation at bio-remediation site through weathering by a special bacterial consortium. The residual oily sludge was accumulated in a synthetic lined pit of 2500 m3 before storage.

From March, 2007, the recovery of oil in the oily sludge is being done by Mechanised skid process wherein the residual oily sludge oil content is in the range of 5-10% against previous 15-20%. The residual oily sludge water content is lesser by 10-20% leading to lower sludge quantity for bio-remediation.

The residual oily sludge generated as in previous years will be harmlessly degraded into waste and carbon dioxide using a process called bio-remediation. In this process, the sludge is spread out on earmarked site and a bacterial consortium oilivorous — S is applied along with nutrients.

The designated area is tilled every fortnight using a tractor trailer. The bacteria, jointly developed by M/s TERI and IOCL (R&D) eats away the oil and sulfur present in the sludge. The added nutrients speed up the process. In a period of 10-12 weeks, the oily sludge is bio-degraded and the site is used again for a fresh phase of bio-remediation of additional new sludge.

Oily Sludge Management for regular refinery operation :




Oily Sludge Management for Tanks given for M&I :




7.2 Present Solid Waste Management at Barauni Refinery






Updated EIA-EMP report Chapter - 08 Environment Management Plan

Chapter -8

Environment

Management Plan




Environment Management Plan Barauni Refinery is an existing refinery running for more than five decades. It has a detailed Environmental Management Programme and it meets all statutory requirements. There has been continuous thrust on the reduction of energy usage by means of adopting various energy conservation (ENCON) measures. ENCON is an ongoing process and plans have been formulated to achieve a further saving in the coming years. Similar to ENCON, there is a constant thrust on loss control and resource conservation measures. There has been considerable reduction in Fresh Water consumption by diverting once through cooling water to circulating water system in various units. Treated effluent is reused for fire water cooling tower make up, coke cutting purposes, horticulture, green belt development and also in Eco ponds where adequate life flourishes. IOCL Barauni Refinery had achieved zero discharge to the river Ganga since Oct 2013, which is a significant achievement towards conservation of natural resources. Further, steam leak, pump/ valve gland leak and comprehensive loss control surveys by internal and external teams are done to reduce losses. These measures have also helped in reducing the refinery loss. A dedicated pollution control cell consisting of experienced and qualified engineers coordinates all the activities related to environmental management in the refinery. There is a full-fledged pollution control laboratory, having modern and sophisticated equipments and manned by qualified personnel to monitor performance on a day to day basis. Recently full-fledged NABL accredited lab has been added to IOCL Barauni Refinery monitoring system. Occupational health monitoring of the employees is being done since inception by the refinery hospital. However, the existing facilities have been further strengthened by setting up a full fledged Occupational Health Centre (OHC) equipped with latest clinical, pathological and work environment monitoring equipment and manned by professionally qualified and trained Doctors and paramedical staff.




1) Water Management

Fresh water from ground water is taken from Artesian Well. IOCL Barauni Refinery have 07 artesian wells with total pumping capacity of approx. 2000 m3/hr. Currently it requires approx. 689 m3/hr of fresh water from these artesian wells.

100% reuse of treated effluent. Treated effluent is recycled backed for refinery operations (Cooling Towers makeup, coke cutting water makeup etc.), Fire Water make up water, horticulture, ecological park and green belt development (inside refinery premises)

RO plant is coming up for treated effluent at ETP/BTP and likely to be commissioned by Jan 2016.

With addition of RO plant mentioned above, treated effluent quality will improve and more recycling will be done in refinery operations (like reuse in DM plants for generation of Boiler Feed Water(BFW) and DM water)

2) Effluent Management

IOCL Barauni Refinery have recently modernized Effluent Treatment Plant (ETP) , Biological Treatment Plant (BTP) & Tertiary Treatment Plant (TTP ) with capacity of 1000 m3/hr, 1400 m3/hr and 1400 m3/hr.

These plants are designed for processing of storm water collected from Refinery during monsoon seasons.

BTP is designed for processing of Township sewage and Refinery sewage.

Apart from regular full fledge IOCL laboratory, accredited 03rd party lab is

fictional since Oct 2014.




Apart from own lab, Barauni Refinery has MoEF accredited Pollution control Lab for analyzing effluents.

3) Emissions Management

IOCL Barauni Refinery have 05 Manual Ambient Air Quality Monitoring Stations (AAQMS).

01 Continuous Ambient Air Quality Monitoring Stations (CAAQMS).

All 19 stacks have stack monitoring stations.

02 Sulphur Recovery Unit with capacity of 40 MT/day.

Quarterly monitoring of VOC by LDAR.



Updated EIA report Chapter - 09 Expenditure for Environmental Pollution control measures

Chapter -9

Expenditure for Environmental Pollution control measures



Updated EIA report Chapter - 09 Expenditure for Environmental Pollution control measures

Total Capital Cost for environment pollution control measures : 1) Effluent Treatment Plant (ETP), Biological Treatment Plant (BTP & Tertiary Treatment Plant (TTP) : Rs 110 Crore 2) 04 Manual Ambient Air Quality Monitoring Stations : Rs 1.2 Crores 3) 01 Continuous Ambient Air Quality Monitoring Station : Rs 0.75 Crores 3) 19 Stack Monitoring Stations : Rs 3.5 Crores 4) Connectivity of CAAQMS & Stack Monitoring to CPCB server = Rs 66.45 Lac 6) Development of Bio-remediation site: Rs 49.83 Lac 7) RO plant for treated effluent at BTP : Rs 67 Cr 8) Rain Water Harvesting : Rs 45 Lac 9) Alternate Fuel ( 25 KW Solar Panel ) : Rs 26.75 Lac Total (approx.) = Rs 185 Crorees. Total recurring cost per annum for Environment Pollution Control measures.

1) Operation & Maintenance of ETP, BTP & TTP =Rs 150 Lac/annum. 2) Ambient Air Quality Monitoring, Stack Monitoring, Ground Water Monitoring, Noise monitoring, Work area monitoring and VOC/LDAR monitoring by accredited consultants = Rs 32.21 /annum. 3) Recovery of oily from oily sludge on Turnkey basis : Rs 1.68 Crore/annum. 4) Dedicated effluent treatment plant Lab = Rs 19.97 Lac/annum. 5) Repair & Maintenance of AAQMS & Stack analyzers = Rs 25.26 Lac/annum. 6) Bio-remediation: Rs 11.09 Lac. 7) Carbon Foot printing (via tree plantation) = Rs 15.25 Lac/annum. 8) Rain Water Harvesting = Rs 20.25 Lac/annum. 9) Eco park & Green Belt development = Rs 12.25 Lac/annum. Total (approx.) = Rs 455 Lacs / annum

For

AT

An ISO 9001:2000 & 14001:2004 CompanyBENGAL AMBUJA COMMERCIAL COMPLEX

UN-F13, 1050/1, SURVEY PARK, KOLKATA - 700 075 - (033) 2418 8127/8128/8601,

e-mail :[email protected], [email protected] : www.envirotecheast.com

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1.0 Introduction Envirotech East Pvt. Ltd.

CHAPTER-1

INTRODUCTION

1.1 BACKGROUNDIndian Oil Corporation Ltd (IOCL) is a public sector unit owned by Government of India. At present, it accounts for around 60.2 MMTPA of total installed crude refining capacity through its seven integrated plants at Guwahati, Barauni, Gujrat, Haldia, Mathura, Digboi and Panipat and also subsidiaries like CPCL-Chennai, Narimanam and BRPL/ Bongaigaon Refinery & Petrochemicals Ltd. A new refinery at Paradeep, Orissa is under construction.

1.2 BARAUNI REFINERYBarauni Refinery, one of the seven refineries under the umbrella of Indian Oil Corporation Limited, is the sole Petroleum Refinery in the State of Bihar. Since its inception in 1964 with the collaboration of erstwhile U.S.S.R., thus putting itself among the earliest major industrial projects in the public sector in India, it has, at present, attained a total installed refining capacity of 6MMTPA.

Barauni Refinery (BR) has earned ISO-9001 as well as prestigious ISO-14001 & OSHAS-18001certification, which is a manifestation of its commitment towards promoting environmental & occupational health & safety considerations with simultaneous emphasis on qualitative improvement in its product pattern.

The refined products fulfil the requirement of the eastern region by road, rail and also a product pipeline going upto Kanpur, UP via Patna, Mughalsarai, & Allahabad. A branch pipe line from Gowria (Near Kanpur) also supplies product to Lucknow. The imported crude oil from Nigeria, Malaysia and Middle East Countries is supplied to Barauni Refinery through a Haldia – Barauni crude oil pipeline.

In view of the future specification, the demand of quality petroleum products, particularly HSD and MS, will increase notably in the country. Having realised and identified the need, the management at Barauni Refinery has planned to install some additional facilities to improve the HSD & MS quality in Barauni Refinery. Besides, in order to optimize refinery product pattern and economic viability, facilities for increased processing of high sulphur crude are also envisaged.

1.3 STATUTORY CLEARANCE FOR EXPANSION PROJECT TO 6 MMTPAVarious environmental permits are required to implement the Project. Bihar State Pollution Control Board (BSPCB) has accorded its No Objection Certificate (NOC) vide letter No. T6/85 dated 03.10.1997. (Annexure-1.1)

The Ministry of Environment & Forests has issued Environmental Clearance vide letter dated 8th March, 1999. (Annexure-1.2)

The present status regarding the Compliance of Environmental Clearance Conditions is enclosed as Annexure-1.3.

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1.4 PURPOSE OF THE EIA/EMP REPORT AND SCOPE OF STUDYAs per EIA Notification 2006, published on 14th September 2006, all projects or activities, including expansion and modernization of existing projects or activities or change in Product Mix, falling under Category ‘A’ in the Schedule shall require prior Environmental Clearance from Ministry of Environment & Forests, Govt. of India.

All projects of Petroleum Refining Industry shall be treated as Category ‘A’ projects and ‘therefore, shall require prior Environmental Clearance from Ministry of Environment & Forests, Govt. of India. In this connection, Barauni Refinery submitted an application along with filled up ‘Form I’ in the prescribed format and Pre-feasibility Report to MoEF for seeking prior Environmental Clearance for its proposed project vide Letter No. EP/EC-APPL dated 08.12.2006. Subsequently, the proposal was considered by the Expert Appraisal Committee (Industry) in its 63rd meeting, held on 28th March 2007 to determine the Terms of Reference (TOR) for undertaking detailed EIA study for obtaining Environmental Clearance in accordance with the provisions of the EIA Notification 2006. Accordingly, MoEF issued a letter (Ref. F. No. J-11011/491/2006-IA II (I)) dated 7th May 2007, with mention of the finalized Terms of Reference (Annexure – 1.4). The Expert Appraisal Committee approved the TOR, as proposed by Barauni Refinery, which were:

Baseline Studies Estimation of Impact Loads Assessment of Environmental Impacts Formulation of Management Plans Preparation of Reports Period of Study: One full season other than monsoon.

The various components of environment for undertaking the EIA study should be:

Ambient Air Quality Meteorology Prediction of the impact on Air Quality Surface & Ground Water River Water Effluent Water Land Environment Biological Environment Noise Environment Occupational Safety & Health Socio-economic Environment Green belt Development Disaster Management Plan

In addition, the Committee suggested the following TORs for the preparation of the EIA/EMP Report:

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Details of Process Description The data collected for the existing refinery and near the township will form the baseline data.

The impacts due to the new units shall be predicted and super imposed on the existing baseline data to assess the incremental impacts.

Ambient Air Quality monitoring within 5 km. radius of the refinery for one full season and location of the station shall be in the down wind direction.

Impact prediction due to all the stacks in the refinery and incremental impact due to additional stacks.

Installation of continuous ambient air quality monitoring station. Fate of Disulphide in the oil. Measures for conservation and recycling of treated effluent. Action plan for disposal of Spent Catalyst. Development of Green Belt as per the CPCB Guidelines. Compliance with the proposed standards for refinery. Measures for disposal of Oily sludge. Details of Occupational Health Surveillance Programme. Risk assessment and Disaster Management Plan. The changes with respect to Socio-economic environment since 2000 till 2007.

As advised, the Draft EIA/EMP Report was prepared, accommodating all the components, based on finalized TOR for its submission to Bihar State Pollution Control Board.

Subsequently, the Public Hearing was conducted on 25.09.2007 at Officers’ Club, Barauni Refinery Township. Minutes of Public Hearing are enclosed as Annexure -1.5. Barauni Refinery has already planned to take/ has taken actions on the relevant issues raised during the meeting, which are:

Issue raised Action taken/ being taken by Barauni Refinery

A) In their perception, there is a rise in respiratory ailments in the surrounding villages. As per Management, regular survey by its Occupational Health Center does not support this.However, a survey will be conducted so as to examine and assess the health of the people of the villages.

A survey was conducted by a panel of doctors, accompanied with paramedics from the Government Hospital, Begusarai, delegated by Civil Surgeon, Begusarai. As per their report (Annexure-1.6), no adverse effects or increase in respiratory ailments were observed.

B) They also indicated Papaya plants in there residences have stunted growth. The management in its explanation assured that the study by competent horticulturist will be taken up so as to assess the actual situation.

The issue was referred to Rajendra Agricultural University, Pusa. In response, a booklet on “Technology for Growing Papayas in Bihar” (Annexure-1.7) was received which says, ‘viral disease is the major limiting factor in Papaya cultivation in all regions of Bihar and attempts are on to select papaya lines showing strong tolerance to viral diseases.”

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C) In Keshawe village, the water drawn from few of the hand pumps has odour. The management assured that during post monsoon, the issue will be investigated in consultation with the villagers.

Water samples drawn from surroundings ofKeshawe village hand – pumps were analyzed at PHE laboratory, Kolkata / Patna during Nov`07. The odor of water has been detected as a “localized problem”. This has further been substantiated based on “Ground water survey”, conducted earlier, which established “Water streams flows in North–South direction” while Kesave village is located in the eastern direction of refinery. From this, it is concluded that no contamination through seepage of refinery water in reverse direction (of stream flow) is a possibility. However, M/s NEERI Nagpur has been commissioned for a fresh survey of ground water strata.Implementation of recommendations of this study is planned.

This EIA Report is prepared on the basis of the available secondary data/ literature along with the on-site data during the period (20th March 2007 – 19th June 2007) representing the summer season, generated through on-site monitoring of relevant environmental components and parameters.

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2.0 Project Description Envirotech East Pvt. Ltd.

CHAPTER-2

PROJECT DESCRIPTION

2.1 PROJECT HIGHLIGHTSThe principal features or highlights of the proposed MS & HSD Quality Upgradation and High Sulphur Crude Maximisation Project at Barauni Refinery under study are as follows:

Location Development Block Barauni in Begusarai district of BiharLand requirement As proposed facilities will be installed within the existing refinery

premises, no additional land acquisition is necessary.Fuel and source Low "S" fuel oil, fuel gas, naphtha and diesel from internal source.

Cooling system Closed cycle cooling system with cooling towers.Source of water Own tube wells within the refinery.Effluent treatment & disposal

The existing ETP will be used for treating the effluent, generated from the proposed units. The major part of the treated wastewater will be recycled back to the refinery for various end uses and only a small quantity will be discharged to the Ganga River through the existing closed pipeline.

SO2 emission Total 1035 kg/hr including existing and proposed units.

2.2 PROJECT LOCATION AND LAYOUTBarauni Refinery (BR) is located in Development Block Barauni of District Begusarai of the State of Bihar, about 8 kms. away from the northern or left bank of Ganges. From Patna, the state capital, BR is about 125 km due east. The latitude and longitude at the Refinery site is 25o26' N and 86o04' E respectively. The district head quarters town of Begusarai is about 6 km to the east and the Refinery Township is just adjacent to Begusarai, being about 5 kms. from the Refinery as the crow flies. The block head quarter town of Barauni is about 10 km due WNW. The proposed units will be confined within the plant boundary.

Plant layout depicting the existing as well as proposed units/facilities has been presented in Figure-2.1.

2.3 CAPACITY AND EXPANSIONBarauni Refinery was commissioned in the year 1964 with a Crude Processing Capacity of 1.0 MMTPA with one Crude Distillation Unit. This capacity was increased to 3.3 MMTPA with the addition of two CDUs in the year 1966 and 1969.

Its present refining capacity is 6 MMTPA, through the revamp of the existing primary units along with the installation of the units like RFCCU, DHDT unit, LPG treating unit, Gasoline Treating Unit, Hydrogen Unit and Sulfur Recovery Unit.

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In order to meet BS-III Specifications, Barauni Refinery has planned to incorporate some new facilities in their existing Refinery System in connection with the MS Quality and HSD Quality upgradation projects.

Also, in order to optimize refinery processing economics and at the same time to enlarge the refinery product slate with production of Bitumen and ATF as finished products, maximization of high sulphur crude processing is envisaged. This will involve changes in configuration of Process units like RFCCU & Cokers along with suitable metallurgy upgradation as part of major revamp of the facilities.

The Block Flow Diagram of the existing as well as the proposed process units has been shown as Figure – 2.1(B).

2.4 EXISTING UNITS AND FACILITIES2.4.1 Main Process Units

1. Atmospheric & Vacuum Distillation Unit (AVU-I) 2. Atmospheric & Vacuum Distillation Unit (AVU-II) 3. Atmospheric & Vacuum Distillation Unit (AVU-III) 4. Delayed Coking Unit-A (DCU) 5. Delayed Coking Unit-B (DCU) 6. LPG Recovery Unit (LRU) 7. Catalytic Reformer Unit (CRU):a) Naphtha Splitter Unit (NSU) b) Naphtha Hydro-Treating Unit (NHTU) c) Catalytic Reforming Unit (CRU) 8. Residue Fluidised Catalytic Cracking Unit (RFCCU)9. Diesel Hydrotreating comprising the following units :

(i) Diesel Hydrotreating Unit (DHDT)(ii) Hydrogen Generation Unit (HGU)

10. Sulphur Recovery Unit (SRU)(i) Amine Regeneration Unit (ARU) (ii) Sour Water System (SWS)(iii) Sulphur Recovery unit - 2 trains

The units and their capacities are listed in Table-2.1.

2.4.2 Existing Offsite and Associated FacilitiesExisting offsite and associated auxiliary facilities include:- Thermal Power Station (TPS) (5 boilers, 3 TGs & 2 GTs)- Cooling Tower- DM Plant- Air Compressor- Air Drier

- Effluent Treatment Plant (ETP) (600 m3/hr capacity) & Biological Treatment Plant (1162 m3/hr capacity)- Receipt, blending and despatch facility at Offsite area- Nitrogen Generation Unit

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2.5 PROPOSED NEW PROJECTS AND FACILITIES2.5.1 MS QUALITY UPGRADATION PROJECT

The following new units are proposed under this project:1. Reformate Splitter Unit 2. Naphtha Hydro-treating & Splitter Unit (NHDT) 3. Isomerisation Unit (ISOM) 4. FCC Gasoline Selective Hydro-treating (SHU) – Prime G + Unit 5. FCC Gasoline Hydro-desulphurisation Unit (HDS) – Prime G + Unit 6. Hydrogen Generation Unit (HGU) 7. DHDT Naphtha Splitter Unit

Besides, existing Catalytic Reforming Unit will be revamped with the addition of one new reformer reactor by replacing one existing reformer reactor.

Plant layout depicting these additional facilities has been presented in Figure-2.1.

2.5.2 HSD QUALITY UPGRADATION PROJECT Installation of one additional reactor in DHDT unit.

2.5.3 HIGH SULPHUR CRUDE MAXIMISATION PROJECT The following new units are proposed under this project:1. Bitumen Unit (BBU)2. ATF Treating Unit3. Sulphur Recovery Unit (SRU)

Apart from this, the existing units i.e., Delayed Coker Unit (Coker-A) and Residue Fluidised Catalytic Cracking Unit will be revamped.

2.5.4 PROPOSED OFFSITE AND ASSOCIATED FACILITIES1. Storage Tanks [5 X 5000 m3 (for Intermediate Products), 3 X 3000 m3 (for ATF), 2 X 3000 m3 (for Bitumen)]2. Hydrogen Bullet (1 X 225 m3) 2. Cooling Tower Cells (1 X 2650 m3/hr, 1 X 3250 m3/hr capacities)3. Steam Turbine Generators (1 X 20 MW) at existing TPS4. Boiler (1 X 150 TPH) at existing TPS 4. DM Water Plant (130 m3/hr capacity)5. Air Compressor (1 X 6500 Nm3/hr capacity) + Dryer (1 X 1500 Nm3/hr capacity)6. Nitrogen Unit7. Bitumen Dispatch Facilities by TTL

All these facilities will come under MS Quality Upgradation and High Sulphur Crude Maximisation Projects. No additional auxiliary facilities have been considered under HSD Quality Upgradation Project.

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All other offsite & utility requirements would be met through the existing facilities which include Fire Fighting Facilities, ETP, Raw water etc.

Refinery Plot Plan depicting these additional facilities has been presented in Figure-2.1 (A).

2.5.5 PROCESS DESCRIPTION2.5.5.1 MS QUALITY UPGRADATION PROJECT(A) Naphtha Splitter Unit (NSU) (Existing)

Schematic / Process Flow Diagram for NSU is shown in Figure-2.2.1.

Straight run naphtha (SRN) which is a full range naphtha cut (C5-160 ASTM) is fed to NSU for separating it into two fractions. The top fraction which is called Light Naphtha (LN cut range C5-90 ASTM) is a feed to Hydrogen Generation Unit (HGU). The remaining LN is routed to new Naphtha Hydro-treating Unit (NHDT). The bottom fraction of the NSU, which is 90-160 ASTM cut is routed to existing Hydro-treating Reactor for subsequent reforming in CRU.

(B) Catalytic Reforming Unit (CRU) (Existing)Schematic / Process Flow Diagram for CRU is shown in Figure-2.2.2.

The bottom fraction of the NSU, which is 90-160 ASTM cut is routed to existing Hydro-treating Reactor wherein hydro-desulphurisation of feed naphtha takes place in order to remove the sulphur from the feed naphtha. The hydro-treated naphtha is then routed through a series of heaters & reforming reactors wherein complex reactions of Dehydrogenation & Dehydro-isomerisation of Naphthenes, Isomerisation & Dehydro-cyclisation along with mild hydrocracking of Parafins and hydrogenation of olefins take place to improve the octane number of the feed naphtha to about 94 units. This improved octane number stream is known as reformate.

As a part of revamp of existing CRU, one new reactor shall replace one existing reactor to cope with the higher severity.

(C) Reformate Splitter Unit – New UnitSchematic / Process Flow Diagram is shown in Figure-2.2.3.

Reformate from Catalytic Reformer Unit is fed to reformate Splitter Column under flow control. The overhead vapours are totally condensed in the Reformate overhead condenser and collected in Reformate splitter reflux drum. Part of the liquid collected in the reflux drum is sent back as reflux to column under flow control. The overhead product (Light Reformate), which is rich in benzene content is sent to ISOM unit for saturation of benzene.

The heat necessary for splitter reboiling is supplied by steam Rebolier. (Splitter Reboiler is a vertical thermo-syphon MP steam reboiler).

Heavy reformate (High Octane Component) from reformate splitter bottom is routed to MS pool.

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(D) Naphtha Hydro-Treating Unit (NHDT)- New UnitSchematic / Process Flow Diagram for NHDT is shown in Figure-2.2.4.

The top fraction of the NSU (LN) remaining after feeding to HGU, along with Coker Naphtha and a heart cut from Prime – G+ Unit under MSQ is fed to Naphtha Hydro-Treating Unit (NHDT). In NHDT, gum forming unsaturated components (especially di-olefins) of combined feed stream are saturated by hydrogenation of olefins, di-olefins & sulphur is removed by hydro-desulphurisation. Thus, the hydro-treated naphtha is then fed to a splitter for separating residual C7+ compounds in the Hydro-treated naphtha from splitter bottom. This bottom fraction is either fed to Reformer Unit or can also be routed to Naphtha Pool. The top fraction of the Splitter unit is fed to isomerisation Unit.

(E) Isomerisation Unit (ISOM) – New UnitSchematic / Process Flow Diagram for ISOM is shown in Figure-2.2.5.

Feed to the ISOM unit is hydrotreated naphtha. Feed is pumped by charge pump and gets dried thorugh drier. The dry feed gets mixed with dry hydrogen. Combined feed is subsequently routed to ISOM reactors after getting heated in feed/effluent exchangers. ISOM reactor effluent is routed to Stabiliser after getting cooled in feed / effluent exchangers. Heat is supplied to the stabilizer column thru stabilizer Reboiler. MP steam is used as hot medium in stabilizer Reboiler. Stabiliser column is a total reflux column with only net vapor product from stabilizer reflux drum. Reflux to the column is supplied through stabilizer reflux pumps from stabilizer receiver. Vapor from stabilizer receiver is scrubbed in caustic scrubber for removal of chloride from gas. Scrubbed fuel gas is routed to refinery fuel gas system under pressure control. Stabilizer bottoms are routed to De-isohexanizer. Top and bottom streams are mixed together (final isomerate) and routed to MS pool. The unconverted component from middle of the column is routed to reactor.

(F) Prime G+Unit-New Unit(i) Selective Hydro-treating Unit (SHU)

Schematic / Process Flow Diagram for SHU is shown in Figure-2.2.6.

The prime G+Unit consists of Selective Hydro – treating Unit (SHU) followed by the splitter unit &Hydro-Desulphurisation Unit (HDS). The feed to the Prime G+Unit is Light Cracked Naphtha (LCN) from RFCC unit. The LCN will be fed to SHU in which selective hydrotreating of di-olefins and conversion of lower mercaptans to higher mercaptans by reacting with olefins take place while removing the sulphur from the feed stream and by preventing the octane loss. That is why the name selective hydro-treating unit is given. Thus, the hydro-treated LCN stream will be fed to a splitter unit wherein the stream shall be separated into three parts namely Top Cut, Heart Cut & bottom cut. The top cut will directly be routed to MS Pool. Part of the Heart Cut will be routed to new NHDT Unit along with Coker Naphtha and Light Naphtha. Remaining part of heart cut will be routed to MS pool.

(ii) Hydro-desulphurisation Unit (HDS)Schematic / Process Flow Diagram for HDS is shown in Figure-2.2.7.

The bottom cut (Heavy Cut) will be routed to Hydro-desulphurisation unit (HDS). After the desulphurization of bottom cut, it will be routed to MS Pool. A provision is kept to route part of the FCC

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Heavy Cycle Naphtha (HCN) to HDS unit also. The remaining / whole part of the HCN shall be routed to DHDT feed pool as per the operational requirement. A flexibility of recycling of the bottom cut to new NHDT is also kept.

(G) Hydrogen Generation Unit (HGU)Schematic / Process Flow Diagram for HGU is shown in Figure-2.2.8.

To meet the make up requirement of Hydrogen for NHDT, ISOM and PRIME G+ unit of MSQ facilties, naphtha steam reforming type Hydrogen unit has been considered where Hydrogen is produced by steam reforming of Naphtha. Naphtha is first desulphurised over a desulphurisation catalyst where, inpresence of hydrogen, non-reactive sulphur compounds are hydrogenated to hydrogen sulphide which is then absorbed on Zinc Oxide beds. The desulphurised feed is mixed with preheated steam and then heated to the desired temperature before entering steam reforming furnace tubes containing a nickel based catalyst. The reformed gases leave the tubes and after exchanging heat to generate steam, pass through a CO shift convertor where most of the carbon monoxide is reacted with excess steam to produce additional hydrogen and carbon dioxide. The converted gases leave the reactor and preheat the incoming Naphtha, Boiler Feed water and Demineralised water. The impurities like carbon monoxide, carbon dioxide, methane, nitrogen and water vapour are removed by high pressure adsorption on molecular sieves in PSA (Pressure Swing Adsorption) system. All adsorbed gases are removed during desorption & regeneration of the beds and used as fuel in reformer furnace. Hydrogen with 99.5% (vol) purity is fed to MSQ units/ refinery H2 network.

2.5.5.2 HSD QUALITY UPGRADATION PROJECTDHDT MODIFICATION DHDT unit is designed to produce hydrotreated diesel of 0.20 wt% `S’ and 48.5 Cetane no. Further,the licensor has carried out the basic design for the additional facilities that will be required in future formeeting the HSD quality of 350 wt ppm `S’ and 51 Cetane no. For achieving HSD quality of 350 wtppm `S’ and 51 Cetane No., an additional reactor is required to be installed. The additional reactor (3rd

reactor) will be connected to the outlet of 2nd reactor. The hydraulic of the DHDT unit was designed taking care of the additional pressure drop across an additional (3rd) reactor and Recycle gas scrubber. Hence, the unit configuration will remain unaltered except addition of a new reactor in series. The block flow diagram with new reactor in the system is shown in the attached block flow diagram asFigure-2.3. The unit comprises the following sections:

(i) Reaction Section:� Fresh Feed System� Feed Heat Exchange System� Make-up Hydrogen system� Recycle Hydrogen system� Reactor System� Reactor Effluent Cooling System� Reactor Effluent Water Wash System� Vapour / Liquid Separation System(ii) Fractionation Section

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The brief process description of all the above section is given below.

(i) REACTION SECTION Fresh Feed System

The feed to the unit can be either cold (40°C) or hot (100°C). Feed obtained from offsite storagetanks at 40°C is pumped into a Feed coalescer for the removal of potential free water. The feed isheated to 100°C in a preheat exchanger. Hot feed is sent from offsite and pumped by hot feedpumps. The combined feed is sent through a feed Filter for removal of suspended solids to the feedsurge drum, which is blanketed with nitrogen to prevent gum formation resulting in possibleequipment fouling. The feed pumps take suction from the feed surge drum and pumps the raw oil tofeed pre-heat section, where feed is preheated via process exchangers with reactor effluent.

Feed Heat Exchange system The reactor charge is preheated by the reactor effluent in a series of feed-effluent exchangers beforeentering the reactor charge heater. This is done to recover as much heat as possible from the heat ofreaction. Liquid feed is preheated separately with reactor effluent before combining with the recycle gas which is also preheated with reactor effluent. The combined feed stream enters a mixed phase heater to reach the desired reactor inlet temperature (340 – 370°C). A fresh feed bypass around one or more exchangers is used to provide better control of the charge heater outlet temperature.

Makeup Hydrogen SystemMake-up H2 is obtained from Hydrogen unit at a pressure of 19.5 kg/cm2 g. Since the reactor sectionpressure is >100 kg/cm2 g, the make-up gas is compressed by make-up gas compressor before it joins the system. The make-up gas joins the recycle gas at the suction of recycle gas compressor.

Recycle Hydrogen SystemAfter separation of the gas and liquid phases in the high pressure separator, the gas leaves from thetop of the high pressure separator and flows to the suction of the recycle gas compressor via RecycleGas Knock out drum.

After the recycle compressor discharge, some recycle gas will be split off the main stream for use asquench gas between catalyst beds in the reactor. Separate quench gas streams are used to reducereactor inter bed temperatures before each catalyst bed. Quench flow is regulated by a flow controllercascaded from a temperature controller at the top of the catalyst bed below the quench zone.

Reactor SectionOnce the feed and recycle gas have been heated to the desired temperature, the reactants enter thetop of the reactor. As the reactants flow downward through the catalyst bed, various exothermicchemical reactions occur and the temperature increases. Each bed contains a 3 element radialthermocouple assembly at the top and at periodic levels down through the bed depending upon bedlength. Reactor skin thermocouples are provided at the bottom of each bed and on the bottom reactor head, for monitoring the reactor wall temperature. The reactors are typically divided into individual catalyst beds supported on a beam and grid support system. The support system is separated from

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the next bed of catalyst by a quench gas distributor, reactant mixing internals and a vapor/liquid re-distributor tray.

Reactor Effluent CoolingDue to the exothermic nature of the reactions taking place in the reactor, the temperature of thematerial leaving will be greater than the reactor inlet temperature. The heat of reaction as well as alarge portion of the heat contained in the reactor feed is recovered in a series of heat exchangers. Thereactor effluent is used to preheat not only the liquid feed but also recycle gas and stripper feed.

Reactor Effluent Water WashFinal cooling of the reactor effluent is obtained in air fin cooler (Effluent Condenser). Water is injectedinto the stream before it enters Effluent condenser in order to prevent the deposition of salts that cancorrode and foul the cooler. The sulfur and nitrogen contained in the feed are converted to hydrogensulfide (H2S) and ammonia (NH3) in the reactor. These two reaction products combine to formammonium salts which can solidify and precipitate as the reactor effluent is cooled. Likewise,ammonium chloride may be formed if there is any chloride in the system. The purpose of the water isto dissolve these salts before they precipitate.

Vapor / Liquid Separation This unit has the HP separator and the Flash drum. The HP separator operates at 84 kg/cm2 g and54°C where three phases are separated. The hydrocarbon liquid phase from HP separator is routedunder level control to the Flash drum through Power recovery turbine to recover the energy. The sourwater containing salts is also routed to the bottom of the flash drum. The gases are furthercompressed in recycle compressor and recycled.

The Flash drum operates at 17.6 kg/cm2 g and 54°C where three phases are again separated. Thesour water is removed under level control and sent to sour water stripping unit at battery limit. Thiswater contains a large concentration of H2S and NH3. The hydrocarbon liquid phase is routed tostripper heat exchanger train, where it is heated by reactor effluent to the required stripper inlettemperature at 260°C.

(ii) FRACTIONATION SECTIONThe function of the fractionation section is to separate sour gas and naphtha from the diesel product.The hydrocarbon liquid collected in the flash drum is sent to a stripper column on level control. Thefeed is preheated by reactor effluent. Stripping steam (MP steam) is used under flow control to reboilthe stripper. Steam added to the bottom of the tower helps stripping light ends from the bottoms. Light ends and H2S gather at the top of the stripper and are partially condensed in Stripper overheadcondenser and Stripper overhead trim cooler. Corrosion inhibitor is injected into the stripper overheadline ahead of the overhead condenser. Three phases are separated in the stripper overhead drum.Sour water is combined with the sour water from the Flash drum and sent to waste water stripping unitat battery limit.

The liquid hydrocarbon are pumped through the stripper reflux pumps and spilt into three streams.First one is reflux which is returned to top of the stripper under level control and second is other reflux

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routed to the 7th tray of the stripper under the flow control after being heated by the diesel productexchanger. And third stream is liquid distillate (unstabilized naphtha) which is routed to RFCC unit atbattery limit.

Vapor stream is sent to amine absorber knock out drum. This stream is mixed with gas from the flashdrum before it enters absorber knock out drum. The gas from absorber knock out drum is routed to thebottom of the LP absorber. Lean amine is fed directly from battery limit into the absorber under flowcontrol. After washing the H2S in the hydrocarbon gas, the amine gets collected in the bottom of theabsorber. Rich amine is sent under level control to the amine treating unit at battery limit. Theoverhead gases from the absorber are routed to the Stripper gas amine knockout drum to remove thetraces of amine in the carryover. The sweet gas is routed to fuel gas header under the pressurecontrol of the stripper receiver.

The stripper bottom product exchanges heat with the returned naphtha reflux to 7th tray of the stripperand undergoes further cooling in the feed preheat exchanger, the diesel product cooler and the dieselproduct trim exchanger. Water is removed from the diesel product in the diesel product coalescer andthe diesel product is sent under flow control to the storage tank.

2.5.5.3 HIGH SULPHUR CRUDE MAXIMISATION PROJECT

(A) Delayed Coking Unit (Coker – A) The delayed Coking is a thermal cracking process. The feed to this unit is vacuum residue. Thevacuum residue from Vacuum Distillation Unit (VDU) of AVU – I / II / III is fed to Coker – A. It is heated to a temperature of about 240°C in pre-heat exchangers wherein the outgoing hot product streams coming from the unit exchange heat with the incoming feed. Thus, the pre-heated feed is introduced to the fractionating column of Coker – A. The bottom stream of the fractionating column is fed to the firedheaters at about 320°C. In the fired heaters, it is heated to a temperature of about 500°C and the hotstream is introduced to the Coke Chambers (Coke Drums) at bottom pressure of about 5.0 Kg/cm2 g.In the Coke Drums, the hot stream thus undergoes cracking and polymerization in the Coke Drumsand gets adequate residence time for condensation. The condensed coke slowly gets deposited in theCoke Drums and the hot vapor formed due to cracking in the chamber leaves the chamber top atabout 450°C. A stream of Coker Gas Oil is added into the overhead vapor line as a quenchingmedium to prevent the vapors from further cracking. The hot vapors then proceed further to a quenchcolumn where additional gas oil quench is added to condense heavy components from the hot vapors.Thus, adequately quenched hot vapors leave the quench column at about 410°C from the top andproceed further to the Coker Fractionator. The bottom stream of the quench column is removed asproduct stream known as RFO at about 400°C. In the fractionator, the hot vapors are fractionated intodifferent product streams namely off-Gas, Coker Naphtha, Coker Kerosene, Coker Gas Oil and CokerFuel Oil. The off-gas & naphtha are routed to LPG Recovery Unit for LPG recovery and stabilization ofthe naphtha respectively.

The Coke Drums, after adequately cooling by steam and water, are opened and the solid coke isremoved by cutting. While the coke cutting operation proceeds in the coke full chamber, the otherempty chamber is put in operation and this cycle goes on. The cycle length of about 24 hours is

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maintained. One cycle of the coke drum is a period from the time after putting into operation once uptoits putting into operation the second time.

(B) Residue Fluidised Catalytic Cracking Unit (RFCCU)It is a catalytic cracking process in a fluidized bed. The feed to this unit can be either Vacuum Gas Oilor Vacuum residue in the admixture. Provision is also there to route CFO from Delayed Coker Unit.The feed from the storage tanks is pumped to this unit. It is heated to a temperature of about 204°C inpreheat exchangers wherein the outgoing hot product streams coming from the unit exchange heatwith the incoming feed. Thus, the pre-heated feed is introduced to the bottom of riser – reactor. Steam is added at the bottom of the riser-reactor thru specially designed nozzles along with feed for proper atomization. The cracking of the feed takes place in presence of catalyst. The catalyst is routed to the regenerators from the top of the riser-reactor and the hot vapors are routed to the main fractionator after stripping & separation of catalyst fines in the steam stripper & cyclone separator respectively at the top of the riser-reactor. In the fractionator, the vapors are desuperheated & separated into different fractions namely off-gas, Light Cycle Oil (LCO) & Clarified Oil (CLO) from top, side & bottom respectively. The fractionator off-gas is routed to the GASCON section wherein uncondensed Gas, LPG, LCN & HCN are separated. Sour Off gas, Sour LPG & Sour LCN after sweetening are routed to their respective storage.

(C) Bitumen Blowing Unit – New UnitSchematic / Process Flow Diagram for BBU is shown in Figure-2.4.1.

The feed to the Bitumen unit consists of the hot Vacuum Residue (VR) taken directly from the vacuum unit and cold Vacuum Residue from storage. The hot VR enters the Bitumen unit under the flow control at a temperature of about 240°C. The cold Vacuum Residue from storage is pumped by feed pumps to the furnace where the Vacuum Residue is heated to a temperature of about 241°C. The temperature of the feed is maintained at 232°C by temperature control. The combined feed is then routed to the Biturox reactor. The reactor unit, where the Biturox process occurs, consists of three main components.� The Biturox reactor� The agitator, with three stages of disc mixers� The guiding cylinder, located concentric to the shell and containing two coalescing plates, each one is located under the middle disc mixer and the other under the upper disc mixer.

Measured amounts of feedstock, air and water are simultaneously fed into, and processed within thereactor unit. Compressed air is fed into the guiding cylinder through four vertical air injection pipes andflows down through the pipes to the bottom of the reactor where it is blown into the incoming feed. Asthe air injection pipes are large in diameter, the air bubbles created at the bottom of the pipes arelarge and as such minimize the amount of available oxygen at the air inlet, which prevents overheating and coke formation at this point. To increase the amount of available oxygen and be able toachieve maximum utilization, it is necessary to reduce the size of the air bubbles, thus releasing moreoxygen to the process. As the air bubbles are introduced to the process at the bottom of the reactorthey begin to rise and are immediately broken up, become smaller, and are dispersed by the first discmixer. It is at this point that the optimum intensive reaction begins – involving the combination offeedstock, small air bubbles and steam. The small bubbles continue to rise inside the guiding cylinder,

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grow and become large, and are again broken up and dispersed by the disc mixer. The abovementioned sequence of movement is continuous, in stages, as the material is being processedcirculates rapidly upstream within the guiding cylinder and the inside wall of the reactor shell. Thiscontinued circulation, together with the dynamics of the process itself, ensures a uniform reaction andconsistently offers the best in product quality.

Offgas from the Biturox process contains N2, residual O2, water stream, CO, CO2, H2S, SO2 andhydrocarbons. To prevent the deposits in Offgas line, make-up water (BFW) will be injected into the Offgas pipe. Due to the vaporizing of BFW the temperature of the Offgas will be reduced approximately to 170-180°C. As a result of Offgas cooling a part of the hydrocarbons will condense from the Offgas and wash the pipe. The amount of injected BFW is controlled with flow controller.

The vapors and excess air at about 170-180°C are routed to the quench drum. A raw waterconnection is provided on the quench drum for reducing the temperature of the off gases from 180°Cto 80°C. The residual O2 content in the Offgas will be indicated by the Oxygen analyazer located in the Offgas line downstream of the scrubber section. An alarm will indicate the high oxygen content inOffgas before the explosion limit is reached. The offgas will be led to incinerator. The condensedhydrocarbons and water flow into a settler. The settler is a horizontal vessel with a vertical baffle. Themixture of oil and water flows into one side of the baffle, where the water and oil are separated intotwo layers. Oil is drained to OWS regularly and as and when oil accumulation is observed. Thequenched off-gas from the quench drum passes through a water seal drum where the temperature ofgas is reduced to 49°C. This drum is located on top of the quench drum. Water is injected into thedrum and a seal is maintained by a gooseneck seal. The off gas from the water seal drum is routed to the incinerator through flame arrestors. The offgas then enters the incinerator through four nozzles where it is burnt. The incinerator is a vertical cylindrical type furnace provided with one fuel gas burner.The produced product is discharged from the reactor by the product pump. A part of the productleaving the reactor is circulated on pressure control from the product pumps back to the feed line ofthe reactor. The product is led to the Steam generator and Bitumen trim cooler will be used to cool theproduct to storage temperature.

(D) ATF Treating Unit-New UnitSchematic / Process Flow Diagram is shown in Figure-2.4.2.

The Kero from downstream of existing Kero Coalescer in AVUs shall be routed to ATF Treatment Unitdirectly at a pressure of about 8.0 kg/Cm2 g. The ATF Treating Facilities include Five Sections,namely, i) Napfining Section, ii) Mericat – II Reactor Section, iii) Aquafining Section, iv) Drying Sectionand v) Cleaning / Filtration Section.

The objective of each section is explained below:

i) Napfining SectionThe Napfining Section, which is a FFC (Fibre Film Contactor) Unit, extracts the majority of thenaphthenic acid impurities by caustic.

ii) Mericat- II Rector Section

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Mericat – II Reactor Section, which is another FFC unit, oxidizes the mercaptans present in the feed stream using air in presence of caustic & catalyst.

iii) Aquafining SectionAquafining Section, which is also a FFC unit, is used for sodium removal in the form of traces of free caustic and sodium naphthenate in the treated Kero stream by water wash.

iv) Drying SectionThe Drying Section, which employs a salt-drier with sodium chloride, removes free water andsome soluble water.

v) Cleaning / Filtration SectionFinally, the cleaning/filtration section, which includes Clay Filter followed by a 10µ Cartridge Filter, completes the jet fuel treating system.

Thus, the untreated Kero from AVUs will be contacted with caustic in a series of Fiber Film Contactors (FFC) and water washed in another FFC in the ATF Treatment Unit. The Kero then will be routed to a salt drier for removal of any free/dissolved moisture and then will be passed thru clay filter for imparting color stability to the ATF. After filtration thru Basket Filter, the ATF will be routed to storage tanks.

(E) Sulphur Recovery Unit – New Unit

Schematic / Process Flow Diagram for SRU is shown in Figure-2.4.3.

The acid gas from Amine Regeneration Unit (ARU) & Sour Water Stripper (SWS) is fed to Main Combustion Chamber (MCC) in which the controlled burning of H2S to SO2 takes place at a temperature of about 1100°C. After combustion in MCC, the mixture passes through the S condenser where S gets separated from the gas mixture. The residual gas mixture is fed to Clause Reactors where in the reaction of SO2 & H2S takes place in a series of three reactors at about 230°C, 220°C & 205°C respectively. There is an S condenser after each reactor from where S separation takes place and the residual gas mixture is fed to subsequent reactor. Then, the effluent of the last reactor is mixed with air and fed to Super Clause Reactor. After condensation in the S condenser, the residual unconverted gases are burned in incinerator. The solid sulphur comes out from each of the S condenser make Sulphur Tree in the sulphur pit.

2.6 OFFSITE AND ASSOCIATED FACILITIESAuxiliary facilities/ utilities are the common requirements that are necessary for the operation of the main crude refining processes. The main utilities include water, power, steam, cooling tower, boiler feed water, fuels, compressed air, storage and despatch facilities and effluent treatment plant. The existing main auxiliary facilities/ utilities are discussed below:

(A) Steam and PowerThe refinery has a Captive Power Plant for meeting the requirement of steam and power. There are 5boilers, each of 75 MT/hr capacity. There are three Turbo Generators (TG), two of 12 MW capacity each and the third of 12.5 MW capacity. The TPS has a DM plant to meet the boiler feed water

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requirement and an independent cooling tower. In addition to 3 nos. of TGs., there are 2 nos. Gas Turbines (GTs) of 20 MW each, integrated with HRSG, each of 40 MT/hr steam genration capacity.

Peak demand of Power at the existing refinery operation is of the order of 42 MW. This is being met from the existing system by operating 5 nos. boilers (each 75 MT/hr steam generation capacity) and 3 nos. turbo generators (two of 12 MW and one of 12.5 MW capacity) and the GTs.

This will go up to around 52.5 MW after the commissioning of the new facilities. One Steam Turbine Generator (STG) of 20 MW capacity with one boiler of 150 MT/hr capacity has been proposed, which will be integrated to the existing CPP (Captive Power Plant).

STEAM & POWER SCENARIOExisting DHDT MSQ HS Crude Total

Power (MW) 42 0 6 4.5 52.5

Boiler Load (MT/Hr) 155 0 53 44 252Boiler in Operation 3 Nos 3 Nos (Exist) +

1No (New)GTTG

2 X 17 MW1 X 8 MW

2 X 18 MW1 X 16.5 MW (New TG)

After implementation of all the facilities, total 4 boilers (3 Existing + 1 New) and 2 GTs (existing) and 1 TG (new) will be in operation. With the installation of new boiler & TG, numbers of equipment in operation will be reduced.

(B) Water Intake and Cooling TowersThe fresh water requirement of the refinery is met by ground water supplied through 9 nos. of artesian tube wells installed in close proximity of the refinery boundary.

The pressurised Cooling Towers have been installed & commissioned to meet the cooling water requirements for the process plants. The hot water from the process units returns under pressure to the cooling tower inlet with the facility to skim off oil or the floating material from the cooled water sump. The cold water is then pumped back to the process units.

(C) Fuel SystemThe fuel supply for the heaters in the process plant consists of low "S" fuel oil and sweet fuel gas which is obtained from the refinery fuel gas network. In addition, naphtha / HSD is also supplied to GTs as fuel from separate tanks.

(D) Crude Oil ReceiptThe imported crude oil from Nigeria, Malaysia and Middle East Countries is supplied to Barauni Refinery through a Haldia – Barauni crude oil pipeline.

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(E) Product Despatch Facilities The finished products from the refinery are despatched by three different modes viz. Rail, Road and Pipeline. Two broad gauge tank wagon loading gantries are provided for loading white oil and black oil products.

White oil is transferred to the tanks of adjacent terminal of IOC (Marketing) to despatch to local areas.Tanks truck loading gantry (1 no.) is provided for the despatch of special products. While oil products are pumped through Barauni/ Kanpur product pipeline (1.8 MMTPA capacity) with the tap-off points at Patna, Mughalsarai, Allahabad, Kanpur and Lucknow. The products received from the Haldia-Barauni Pipeline are also despatched through the Barauni- Kanpur Pipeline.

(F) Effluent Treatment Plant (ETP)Barauni Refinery has been provided with an Effluent Treatment Plant since its inception, so that the effluent quality meets the specifications. Subsequently, facilities like Chemical Treatment, Bio-Treatment plant were added to ensure that the effluent meets the quality as per the latest and more stringent quality standards under Environment Protection Act, 1986. A separate pumping station has been provided for the recycling of the treated effluent back to the refinery for various end uses.

(G) Miscellaneous Other Off-site FacilitiesIn addition to the major facilities mentioned above, the refinery has elaborate fire protection facilities and fire water network covering all the areas, LPG bottling plant to fill LPG cylinders, bulk LPG despatch facilities, Quality Control Laboratory, various site offices and the Administrative Block.

2.7 WATER AND WASTE WATER 2.7.1 Requirement and Source of Water

In the refinery, water is required for operation of the process units, cooling towers and TPS, and also to meet the domestic demand within the refinery.

The existing water requirement for the refinery stands at 1155 m3/hr. This will go up to 1397 m3/hr after the installation of the new projects.

There will be additional 242 m3/hr requirement of water after the installation of the proposed projects. The break up of the total future make-up water requirement will be:

S.N. DESCRIPTION AMOUNT(m3/hr)

1. Cooling Water Make Up 8352. DM Plant water 3882. Service Water 1003. Drinking Water 74TOTAL 1397

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2.7.2 Types and Quantum of Waste Water2.7.2.1 Waste Water Generation

There are a number of sources where liquid effluents get generated at the refinery which ultimately are routed to the Effluent Treatment Plant to take care of the pollutants carried by these streams. These are described as below:

Oily Effluents Source: Pump houses, Tank farms, Product loading, Gantries, Floor washings, Process

units (Drainage from vessels and sample points) etc. Pollutants: Oil, Phenols, Sulfides, Suspended Solids.

Chemical Effluents Source: Caustic washing of Naptha. Pollutants: Sulphides, Phenol and Oil.

Storm Water Sources: Paved unit areas, Tank farms, Loading areas. Pollutants: Suspended Solids and oil when contaminated.

Sanitary Waste Source: Refinery toilets, Refinery township. Pollutants: Suspended Solids.

The total effluent load from the refinery after the installation of the proposed projects will be about 520m3/hr. The existing ETP has a design capacity of 600 m3/hr and that of the BTP is 1162 m3/hr. Therefore, the effluent load of around 520 m3/hr in the ETP and around 694 m3/hr in the BTP will be easily treated there.

The existing as well as the future water balance of the refinery after MS and HSD quality upgradation and High Sulphur Crude Maximisation Project have been presented as Figures - 2.5 (A) & 2.5 (B) respectively.

2.7.3 WASTE WATER TREATMENT FACILITIES2.7.3.1 Existing Treatment Facility

Segregated sewers have been provided for oily effluent, chemical effluent, storm water and sanitary wastes. Except storm water, all other liquid streams are routed to the ETP for the physical, chemical and the biological treatment. It is also observed that during heavy rains, a portion of the storm water also lands at the ETP from the tank farm area through manholes or through the valve chambers provided within the tank dykes (depending on the position of dyke Valves i.e. if open to the oily water sewer system).

All the waste water generated through various operation is taken to the treatment units by the properly designed channel / pipeline and treated adequately.

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The treatment units include two sectioned rectangular Sand Traps or Grit-Chambers, three Oil Separators and two large Guard Ponds.

The entire trade effluents, after the physico-chemical treatment are pumped to the biological treatment plant (located about 1 km to the South-East of the refinery), to be mixed with the raw sanitary sewage and subjected to the biological treatment based on the activated sludge process. The biological treated waste waters are routed through a polishing-cum-guard pond and then discharged into the river Ganga through 9 km. long outfall (Presently, the entire treated waste water is being recycled back to the refinery for various end uses).

The physico-chemical treatment units for the trade effluents are designed for a maximum flow of 600 m3/hr. Excess flow, if any, is diverted to an emergency basin from where it is taken back to the treatment units during lean period.

The Effluent Treatment Facility at the Barauni Refinery is shown in Figure-2.6.

2.7.3.2 Modernisation of Existing Treatment FacilityThe existing Effluent Treatment and Biological Treatment Plants are undergoing the process of modernisation. The capacity of the ETP will be increased from the existing level of 600 m3/hr to 1000m3/hr and that of BTP from 1162 m3/hr to 1500 m3/hr, with the modification of the existing equipmentsin both the ETP and the BTP.

2.7.3.3 Treatment of Additional Waste waterThe existing Refinery has an Effluent Treatment Plant (ETP) to treat the refinery effluents to meetMinimal National Standards (MINAS). As the waste water streams due to the proposed projects are similar to those generated in the existing refinery, the existing ETP can be used to treat the additional waste water.

2.7.4 Compliance with StandardsTreated effluent from the Refinery is to meet MINAS as notified by Central Pollution Control Board. MINAS has later been included in the Environment (Protection) Rules, 1986. At present, the treated effluent is meeting MINAS. Quality of treated effluent is monitored every day to check the compliance of the standard. Performance evaluation of the Effluent Treatment Plant & the Biological Treatment Plant is conducted on daily basis.

A comparison of MINAS and the present effluent quality will show that at present, the effluent standard is well within the MINAS regulations both qualitatively and quantitatively. After the commissioning of the additional units, pollution load will increase marginally and meet MINAS both qualitatively and quantitatively.

2.7.5 Re-use of Waste WaterBarauni Refinery is reusing the major portion of the treated effluent for:

Fire Tank/ cooling water make up

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Coke Cutting Gardening and horticulture Eco Ponds

Treated effluent reuse flow path in the BR has been depicted in Figure-2.7.

2.7.6 Management of Storm WaterStorm water gets generated during rains from various catchment areas in the refinery such as Tank farms, Loading Gantries, paved areas in various units, building roofs, roads and surrounding open areas. Presently a large fraction of storm water generated flows through the storm water open channel particularly in monsoon. The storm water from various areas gets routed through the network of open channels which are interconnected and finally the storm water flows out of the refinery to a burrow pit. The coke cutting water is also routed to the storm water channel.

At Barauni Refinery, the storm water was observed to be free from oil. Any accidental spillage of oil from tank farm dyked area (provided, the dyke valves are open for storm water channel) or pipe leaks etc might lead to oil passage to the storm water system. Every storm water stream, therefore, has passed through single and double oil catchers to arrest such accidental oil spillage. BR has provided good facilities for oil recovery from tank wagon loading leaks or floor washings by providing a number of oil / traps and separators which were found to be quite effective.

2.8 SOLID/ HAZARDOUS WASTE GENERATION AND DISPOSALMainly four types of solid wastes are generated in the Refinery and its townships; namely oily sludge, biological sludge (from the biological treatment of the wastewater), other industrial solid wastes (intermittent) and the domestic solid wastes. The oily-sludge and spent catalyst of RFCCU are the hazardous wastes generated in refinery operations.

Oily SludgeThe Oily sludge is generated mainly during cleaning of storage tanks. Due to high oil content in the sludge, it cannot be disposed off directly. Hence, the same used to be subjected to melting pit treatment wherein maximum amount of recoverable oil was extracted from the sludge and the residual oil sludge used to be disposed off through biodegradation at bio-remediation site through weatheringby a special bacterial consortium. The residual oily sludge was accumulated in a synthetic lined pit of 2500 m3 before storage.

From March, 2007, the recovery of oil in the oily sludge is being done by Mechanised skid process wherein the residual oily sludge oil content is in the range of 5-10% against previous 15-20%. Theresidual oily sludge water content is lesser by 10-20% leading to lower sludge quantity for bio-remediation.

The residual oily sludge generated as in previous years will be harmlessly degraded into waste and carbon dioxide using a process called bio-remediation. In this process, the sludge is spread out on earmarked site and a bacterial consortium oilivorous – S is applied along with nutrients.

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The designated area is tilled every fortnight using a tractor trailer. The bacteria, jointly developed by M/s TERI and IOCL (R&D) eats away the oil and sulfur present in the sludge.

The added nutrients speed up the process. In a period of 10-12 weeks, the oily sludge is bio-degradedand the site is used again for a fresh phase of bio-remediation of additional new sludge.

About 18000 MT of residual oily sludge has been biodegraded during 1998-2007. The quality of soil at the Bio-remediation site is checked regularly w.r.t. accumulation of heavy metals. Also, underground water quality is checked in the periphery of the site. So far, no adverse impact has been found.

Before Bioremediation of Oily Sludge After two months of Bioremediation of Oily Sludge

Spent Catalyst from RFCCURFCCU uses silica-alumina based catalyst for cracking of heavy Hydrocarbons. The trace heavy metals in the feed material get deposited on the catalyst in course of processing and act as a catalyst poison. To maintain the overall activity level of the catalyst, spent catalyst with metal deposits is purged from the system. The spent catalyst, hence withdrawn, is classified as hazardous waste due to its heavy metal content particularly w.r.t. nickel (Ni) and Vanadium (V) which are around 5000-6000 ppm.

The spent catalyst from the unit is stored in concrete lined pits as well as packed in empty polybags. These polybags are containers in which fresh catalyst is received at Refinery. The polybags are then stored under roof to safeguard from inclement weather.

With regards to its disposal, the same can be utilised either as filler in bituminous mixture used for road construction or as raw material for the cement industries. The use in road construction is corroborated by a research carried out by Central Road Research Institute and communicated to IOCL which says that 3% spent catalyst mixed with 2% lime in bitumen improves the road quality.

In regards to use of spent catalyst in cement industry, the same is corroborated by the report of National Council for Cement and Building Material in December'03. The report suggests the use of

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spent catalyst as a replacement of fly ash used as raw material in Cement Production. Accordingly a trial was carried out at M/s Kalyanpur Cement Limited, Banjari with 50 MT of spent catalyst in Jan-Feb'07. Based on the encouraging results disposal of spent catalyst by means of regular supply to M/s KCL, Banjari through bulk trucks is being pursued. In addition, Ambuja Cement Ltd., Darlaghat, HP, which is currently taking similar catalyst from Panipat Rerfinery, has also agreed to take the spent catalyst ex BR. The modalities & transportation arrangements are being worked out. In the meantime, the catalyst will continue to be disposed off in the concrete lined pits.

Other Solid WastesThe biological sludge from the sludge drying bed is being used as manure by the refinery in their township and the ECO Park etc.

The metallic wastes or the scraps are auctioned. There will not be any additional solid waste generation due to the new projects except tank bottom sludge in due course of tank M & I.

Disulphide in the oilThe caustic used in treatement of LPG (removal of Mercaptans and residual H2S) for meeting the quality specifications is regenerated by using oxygen. In the regeneration phase of the spent caustic, Na2S and Sodium Mercaptide (NaSR) after reacting with oxygen in presence of catalyst get converted to Sodium Thiosulphate and disufide oil.

At present, the small quantity of disulfide oil generated in the LPG treating unit of RFCCU is washed off with naphtha and mixed in the RFCCU gasoline stream which finally goes into BS-II MS pool. The marginally increased quantity of disulfide oil post commissioning of LPG treatment Unit in November'07 will continue to go in BS-II MS pool via RFCCU gasoline stream.

The disulfide oil post HS crude Maximisation project will be treated in MSQ Unit. Therein the sufur from the disulfide oil will be removed by means of Hydrotreating and the Hydrofinished oil will be routed to Euro-III MS pool. Hence, there will be no impact of the disulfide oil on the environment.

2.9 STACK EMISSIONSPresently, there are 15 stacks. There will be another 7 new stacks after the installation of the proposed projects. Major pollutant, emitted is sulphur dioxide (SO2). Other emissions are negligible.The total SO2 load after the installation of the proposed projects will be 1035 kg/hr.

2.10 PROJECT COMMISSIONING SCHEDULEThe expected date of the commissioning of the proposed project is Dec’2009.

2.11 EMPLOYMENTThere is marginal permanent employment generated by the project but during construction and erection there will be a large number of skilled and unskilled manpower requirement for the project. An additional 5-10 persons will be permanently employed in the proposed project.

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2.12 COSTThe total cost of the project will be around Rs 1550.24 Crores.

The Estimated Break-up is as under:

MS Quality Upgradation Project Rs 676.84 CroresHSD Quality Upgradation Project Rs 83.4 CroresHS Crude Maximization Project Rs 790.0 Crores

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TABLE - 2.1PLANT CAPACITY

Plant Unit Capacit(MMTPA)

Existing Unit1. Atmospheric & Vacuum Distillation Unit (AVU-I) 1.752. Atmospheric & Vacuum Distillation Unit (AVU-II) 1.753. Atmospheric & Vacuum Distillation Unit (AVU-III) 2.54. Delayed Coking Unit-A (DCU) 0.65. Delayed Coking Unit-B (DCU) 0.56. LPG Recovery Unit (LRU) 0.1857. Catalytic Reformer Unit (CRU): 0.3

a) Naphtha Splitter Unit (NSU) 0.54b) Naphtha Hydro-Treating Unit (NHTU) 0.30c) Catalytic Reforming Unit (CRU) 0.30

8. Residue Fluidised Catalytic Cracking Unit (RFCCU) 1.39. Diesel Hydrotreating Unit (DHDT) 2.210. Sulphur Recovery Unit (SRU) 0.0266

Proposed UnitsUnder MS Quality upgradation project1. Naphtha Splitter Unit (NSU)* 0.4562. Catalytic Reformer Unit (CRU)** 0.33. Reformate Splitter Unit 0.2754. Naphtha Hydro-treating & Splitter Unit (NHDT) 0.2975. Isomerisation Unit (ISOM) 0.1266. Selective Hydro-treating & Splitter (SHU) 0.3227. Hydro-desulphurisation Unit (HDS) 0.2278. Hydrogen Generation Unit (HGU) 0.0209. DHDT Naphtha Splitter Unit 0.19

Under HSD Quality upgradation project1. Diesel Hydro-treating Unit (DHTU) *** 2.2

Under High Sulphur Crude Maximisation project1. Delayed Coker Unit (Coker-A)* 0.52. Residue Fluidised Catalytic Cracking Unit (RFCCU)* 1.43. Bitumen Unit (BBU) 0.14. ATF Treating Unit 0.065. Sulphur Recovery Unit (SRU) (2 X 60 TPD) 0.034* Existing Units, to be revamped** Existing Unit, to be revamped with addition of one new reformer reactor by replacing one existing

reformer reactor.*** Existing Unit revamped with one additional reactor.

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TABLE-2.2PRODUCT PATTERN AT 6.0 MMTPA CAPACITY & MS / HSD QUALITY UPGRADATION

Present OprationProduct ‘000 Tonnes/year After MS/HSD Quality % on Crude (At 6.0 MMTPA) upgradation, 000Tonnes/year

(At 6.0 MMTPA)LPG 297 385Naphtha 235 182Motor Spirit 660 (BS-II) 650 (BS-III)

Light Distillates 1192 1217 20.28

ATF 0 60 SKO/MTO 996 660HSD 2993 (BS-II) 3051 (BS-III)

Middle Distillates 3989 3771 62.85

LDO 24 0LSHS 22 0CBFS 24 0LS-RPC 0 61HS-RPC 152 143Bitumen 0 96Sulphur 16 61

Heavy Ends 238 361 6.02

Fuel & Loss 581 651 10.85

Total 6000 6000 100.0

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.1 Study Area And General Environment

CHAPTER-3

BASELINE ENVIRONMENTAL SCENARIO

3.1 STUDY AREA AND GENERAL ENVIRONMENT3.1.1 PLANT LOCATION

Barauni Refinery (BR) is located in Development Block Barauni of District Begusarai of the State of Bihar (Figure – 3.1.1), about 8 kms. Away from the Northern or left bank of Ganges. From Patna, the state capital, BR is about 125 km due east. The latitude and longitude at the Refinery site is 25o26' N and 86o04' E respectively. The district head quarters town of Begusarai is about 6 km to the East and the Refinery Township is just adjacent to Begusarai, thus being about 5 km from the Refinery. The block head quarter town of Barauni is about 10 km due WNW.

3.1.2 COVERAGE OF STUDY AREAThe requirements of MOEF (Ministry of Environment & Forest) would imply the study area to be a circle of 10 kms radius with the refinery as the centre. The study area indicating BR is shown in Figure- 3.1.2.

3.1.3 TOPOGRAPHY, LAND-FORMS AND SOILSThe region surrounding BR is extremely plain and the variation in ground levels is mainly seen only on approaching the "diaras" between 40 and 44 m above MSL. The highest ground levels in the study area however exceed 48 m above MSL. However with recent developmental works, there has been a lot of disturbance of the topography through construction of embankments for roads, railway lines, flood control and filling up of land for various structures. Structurally the study area is a part of the flat alluvial plain between the river Ganga and the Burhi Gandak and built by them. According to the District Gazette of Munghyr, till a few centuries back, the course of river Ganga in this reach was about 10 kms to the north of the present one when at least half of study area would have been river-bed. The northern parts of the study area are level upland tracts while the southern half is the Gangetic riverain, where land was being constantly formed or washed away by the swift silt laden current. During recent years, human activities and embankments and structures built, at least apparently, stabilized the situations in this southern half. Even historically, this area had not been seriously floor-ravaged like some other areas of North Bihar including the Khagaria low lying tracts not far to the North and North-East. Soils in the study area are essentially sandy alluvium, but the particle size gradient varies considerably.

3.1.4 CLIMATEThe climate in the area is variable. From the angle of human comfort, the best seasons are during October- November and February-March. During April to May the weather changes and becomes hot while June to September experiences frequent rains. Weather becomes cold during December-January.

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The annual rainfall received in the area is about 1,110 mm. Of this, about 85% rainfall takes place during the months June to September. Temperature varies from a mean minimum of 11oC in January during winter to a mean maximum of 39oC in May during summer.

Relative humidity is high, mean monthly RH being in the range of 43-83% for most part of the year.

Wind for most of the period blows either from NE-E-SE sector (during summer and monsoon) or from SW-W-NW sector (during post monsoon and winter). The average wind speed is about 6.8 km/hr.

The nearest Indian Meteorological Dept (IMD) stations from Barauni Refinery are at Patna andBhagalpur. Patna is about 125 km West of Barauni and Bhagalpur is about 150 km East of Barauni. The latitudes and altitudes for both these are very close to those for Barauni.

3.1.5 WATER RESOURCES AND DRAINAGEWith the mighty Ganga forming its Southern boundary, the Ganga flood-plains (or "diaras") constituting at least 25% of the geographical area and a reasonable annual rainfall averaging over 1110 mm, the area is not subject to water scarcity. In fact sub-surface water in the alluvial strata is so copious that no thought has had to be given to collection, storage and transport of surface water for any beneficial uses, whether irrigation, industrial, municipal or anything else. Ground water table in the study area varies from 1-5 m below GL in monsoons to 3-10 m below GL in peak summers. Drainage wise, the entire study area drains to the Ganga through a number of drains. Due to the embankments built for flood protection, often drainage channels have to flow parallel to the river course in a south-easterly direction before they can empty into the river.

3.1.6 VEGETATION AND CROPSThe sandy alluvial soils of the study area favour wheat, maize, millets, oilseeds and pulses besides a variety of vegetables and fruits. The area, particularly Northern upland tracts has had prosperous agriculture and fruit orchards for centuries. With a shift in the course of Ganga southwards and building up of embankments, even the Southern "Diara" lands grow rich wheat, maize, oilseeds and padwal and other vegetables.

The area appears to have been rich in agriculture since long, as seen from the District Gazetteer of Monghyr. Till mid-nineteenth century, opium poppy seems to have been an important cash crop.

Indigo cultivation and processing was also important activity till indigo was pushed out by synthetic dyes in early twentieth century. Today grains, oilseeds, fruits and vegetables themselves serve as cash crops.

3.1.7 ECONOMIC ACTIVITY AND INDUSTRIALISATIONHaving seen the prosperity and glory of the earlier periods of Mahabharata, Gautam Buddha, Ashoka, Gupta dynasty and few following centuries, when the words Vaishali or Champaran were synonymous with wealth, well being and culture, the area had also seen the dark ages during the thousand years or more before independence finally arrived in 1947. At the time of independence, this area, as part of North Bihar, was one of the most backward, most troubled and least cared - for

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areas, troubled by floods, droughts, earthquakes, etc., barely surviving on its agriculture. And yet, the area had played very significant roles in India's Independence Movement. So after Independence, our great leaders turned their attention to the problems of North Bihar almost in gratitude and in compassion. It is then, during the fifties, that the Mokamah Bridge (Rajendra Setu) the broad-gauge railway line, the flood- control and irrigation works, the major industrial complex at Barauni were all planned. The projects came to the Barauni-Begusarai area and provided a real economic Breakthrough. Today the study area can be called the "industrial-hub" of North Bihar without any doubt or controversy. The Barauni Thermal Power Plant of Bihar Govt State Electricity Board became operational in 1962; the Refinery was commissioned in 1964; and the Fertilizer Plant of HFC went on stream in 1971. The development of communications and the setting up of the 3 above named major units in the public sector encouraged the setting up of several down stream and ancilliary units and even independent small - scale industries. Keeping in view that the development started very late, the pace cannot be called too slow particularly in view of the background conditions.

3.1.8 SENSITIVE AREASNo forests or wild life sanctuaries are found within the study area. There exists no protected/important historical or archaeological monument either. Neither hilly/ mountainous areas, nor defense installations/ airports are located within this area.

3.1.9 PLACE OF HISTORICAL AND TOURIST IMPORTANCEHistorical, archaeological, aesthetic and tourist spots are the important parts of the socio-economic aspects. As the study of these aspects becomes essential part of socio-economic environment, description of places of religious, historical archaeological, aesthetic and tourist interest have been given below:

BarauniBarauni is an important town in the study area. The locality has fast grown into a vital industrial pocket. It has a railway junction which links Bihar with Assam and West Bengal. The place is not without a historical interest. Several old images have been found at Barauni include one Surya image of remarkable craftsmanship. This Surya image is preserved at G.D College, Begusarai. The image is highly ornamented and holding full-blown lotus. The image is wearing a sacred thread too. The legs are booted and naturally the foreign influence is perceptible. Various items in the structure of the image weigh more in favour of its being placed in between the Gupta and the Pala periods. It has also been reported that there are some Brahmin families who possess manuscripts of "Bhrigu-Sanhita" - at Barauni, and do a lucrative business by reading horoscopes with the help of the copies of Bhrigu-Sanhita.

JaimangalgarhIt is site of historical and archaeological importance, though it does not fall under the study area. Jaimangalgarh is situated 16 kms north of Begusarai. Ancient images of Barah, Nadri Narayan, Shiva and Parvati located in the temple are worth seeing. The temple attracts a large number of worshipers on certain days of the year.

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KabartalIt is a large lake in the Northern part of Begusarai district near Cheria Bariarpur. It covers an area of about 22 sq kms. It used to attract hunters. It is swarmed with fish and is an important source of supply. There is an island in the lake known as `Monkey Island', from the number of monkeys which frequent it. The island is a sacred spot. Kabar is an ox- bow lake and recently it has been declared as international wet land. "Kabartal" is the only Beauty spot in Begusarai district.

BirpurIt is a village in Barauni block; it is situated on the Northern bank of the river Balan, 10 kms away from Begusarai. Ancient stone images of lord Vishnu and other dieties were discovered in the bed of an old tank in 1959. Believed to date back to the Gupta period, these are fine specimens of exquisite craftsmanship.

SemariaIt is a village, fast growing due to industrial activities, on the Northern bank of Ganges opposite Mokama. Huge congregations of devotees assemble here for bathing in the Ganges on "Kartik" and "Magh Purnima" days when large fairs are held.

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.2 Environmental Impact Assessment Methodology

3 .2 ENVIRONMENTAL IMPACT ASSESSMENT METHODOLOGY3.2.1 BASIC APPROACH

The project, in this case, is the installation of facilities for improvement of HSD and MS Quality along with the High Sulphur Maximisation Project at Barauni Refinery of Indian Oil Corporation Ltd (IOCL) located in Begusarai district of Bihar. The primary objective of an EIA Study includes determination of the present environmental scenario,

study of the specific activities related to the project and evaluation of the probable environmental impacts due to these specific activities, thus, leading to the recommendations of necessary environmental control measures. An EIA Study, thus, necessarily includes collecting detailed information on the existing environmental scenario or 'baseline data' and establishing related data of the proposed activity i.e., 'project data' or 'plant data'. The project data are then superimposed on the baseline data and the resultant environmental conditions are predicted with the help of effective predictive tools. The EIA is, thus, a comprehensive study on environmental impacts due to a project and also a tool to assess and mitigate the detrimental impacts on the environment due to construction and operation of the project.

The EIA is aimed at determining the environmental impacts on the study area of the project, which encompasses all areas falling within a radius of 10 km. around the project site, due to the construction and the operation of the project.

The major environmental disciplines studied in this EIA Report include soils, landuse, surface and ground water, hydrology, water use, meteorology, surface and ground water quality, air quality, noise, terrestrial and aquatic ecology, demography and socioeconomic (Please refer Chapter 1 for the finalized ‘TOR’ by MoEF).

The EIA Report presented here consists of field data, generated for soils, meteorology, water quality, air quality, noise, ecology, socioeconomics, etc. during three (three) months’ period (20th March, 2007 – 19th June, 2007), representing summer season. Relevant data collected from various agencies on the above disciplines are also included in the Report.

The report also includes an Environmental Management Plan (EMP), proposed pollution control and safety measures, solid wastes management, critical areas, other recommended mitigatory measures, post study monitoring programme, details of environmental management cell etc.

An on-site Disaster Management Plan (DMP) based on the Risk Assessment, inclusive of possibilities of disasters/ accidents, designated persons and teams and their responsibilities, identified emergency control centres and assembly points and other facilities to combat the emergencies is also included in this report.

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3.2.2 ESTABLISHING BASELINE SCENARIO 3.2.2.1 Soils and Land Use

Soil samples are collected from 5 (five) locations within the study area once during the month of May, 2007. The samples are analysed for relevant physical and chemical parameters for establishing the baseline data. For sampling and analysis of soils, IS:2720 is followed, in general.

Landuse patterns (settlements, huts, flood zone, orchards, water bodies) are established with the application of Geographical Information System.using satellite imageries.

3.2.2.2 MeteorologyMeteorological data for such parameters as temperature, relative humidity, atmospheric pressure, rainfall, cloud cover, wind speed and wind direction spanning 1931-60 were collected from the IMD station at Patna and Bhagalpur, located about 125 km west and 150 km east respectively from the project site.

An onsite sophisticated meteorological observatory is set up within the project site (on the roof top of the administrative building inside the Refinery Complex) which was operated for the period (20th

March, 2007 – 19th June, 2007) to supplement the above data. The parameters monitored on a daily/hourly basis at this observatory include temperature, relative humidity, atmospheric pressure, wind speed, wind direction and rainfall.

3.2.2.3 Water QualityA total of 8 stations, 2 stations on river Ganga, 6 stations for ground water quality for the determination of the water quality, are set up within the study area for obtaining data on water quality parameters. As river Ganga is the recipient of the treated plant effluent, its water quality is monitored at upstream as well as the downstream of the effluent discharge point to assess the impacts.

Normally, the final treated effluent generated in the refinery is recycled back to the refinery for various end uses and not discharged to the river Ganga except occasionally, in the monsoon season.

Samples are collected at a frequency of once in a month during the three months of March’07, April’07 & May’07 from all the stations and analysed for physical and chemical parameters as well as trace inorganics and heavy metals for drawing up the baseline data. Parameter selection, sampling and analysis of water samples are conducted as per established Standard Methods.

3.2.2.4 Air QualityAmbient air quality monitoring are conducted at 8 appropriate locations within the study area at a frequency of twice a week over three months’ period (20th March, 2007 – 19th June, 2007) to establish the background data on air quality. Twenty four-hour continuous monitoring is conducted at each station. The parameters monitored include SPM, RPM, SO2 & NOx. The air quality stations are located based on modelling exercise to locate the stations as close as possible to the maximum deposition areas of air pollutants.

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The equipment are placed at a height of 3 to 4.5 m above ground level to exclude the effect of wind blown ground dust. To avoid any impedence to the pollutants, the equipment are placed in such a manner that it is free from vertical obstructions within a cone of 120o from the position of the equipment. Monitoring is conducted using High Volume Respirable Dust Samplers fitted with Gaseous Sampling Impingers. For sampling and analysis of the above parameters, IS:5182 are followed in general.

3.2.2.5 NoiseThe ambient noise scenario within the study area are monitored once during the study period at several locations covering industrial, commercial, residential and sensitive areas using a suitable sound level meter. The monitoring is conducted over a 24-hour period to monitor instantaneous sound pressure levels (SPL) at uniform interval of 1 hour. The equivalent continuous sound pressure level (Leq) during day and nighttime are then computed to compare with the standards.

3.2.2.6 Terrestrial and Aquatic EcologyThe baseline data on terrestrial and aquatic ecology are derived from existing literature of Botanical Survey of India, Zoological Survey of India and on past studies conducted in the area by various other organisations and corroborated through extensive field studies.

3.2.2.7 Demography and SocioeconomicsRelevant data are compiled from the Primary Census Abstract (PCA) data of the Begusarai and Patna districts of Bihar, for obtaining the demographic and socioeconomic features and trends prevalent in the study area. The features which are analysed are population, household, population density, family size, sex ratio, SC-ST population, literacy rate, work participation rate and its distribution, work participation rate among females, industrial scenario etc.

The census data have been supplemented and corroborated by a socio economic sample survey within the study area conducted in 2007 through structured questionnaires portraying demographic and socio economic aspects of the study area population.

3.2.3 ESTABLISHING PROJECT DATA The project data consisting of the general layout and process description of the plant; its capacity and commissioning schedule; process flow paths; source, requirement and characteristics of fuels; source, requirement and characteristics of raw materials; sources of power, storage details of raw materials, products and other chemicals, material handling systems, quantity, nature and disposal of solid wastes, plant water use and water balance diagram, details of liquid wastes and its treatment facilities, particulars of atmospheric emissions, sources of noise and their levels, and other inherent details are established in consultation with the officials of the Project Authority.

3.2.4 ASSESSMENT OF ENVIRONMENTAL IMPACTS Impacts on soils and ground water regime of the area which would primarily result due to the solid waste disposal are studied through the data generated on soil characteristics.

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Impacts on the surface water quality of the receiving water bodies due to receipt of the plant effluents are studied. The possibility of groundwater contamination due to the leachate from solid waste dumping areas has been explored.

Impacts on the ambient air quality of the area due to the project that would mainly arise becouse ofstack emissions have been carefully quantified through mathematical modelling. Air quality modelling has been conducted based on Gaussian distribution model as spelt out in the latest CPCB guidelines (PROBES/70/1997-98).

Consequential impacts of the resultant air and water quality and landuse pattern on the terrestrial and aquatic flora and fauna are studied with reference to past knowledge and data on authentic research and literature.

Impacts on demographic and socioeconomic environment are drawn from the extensive data collected on employment potential, migration scenario etc.

3.2.5 POLLUTANTS’ GENERATION AND MITIGATORY MEASURESA comprehensive plan is prepared, covering sources of pollution, proposed pollution control system / measures, solid waste handling, utilisation, disposal and management, compensatory afforestation programme, green belt development plan, periphery development plan, critical areas of impacts, recommendation for additional mitigatory / remedial / control / safety measures etc. Proposed institutional setup for environmental management, and post study monitoring including parameters, locations and frequency of monitoring and their implementation programme are also detailed therein.

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.3 Land use and Land cover

3.3 LAND USE AND LAND COVER Land use pattern of an area plays an important role in conducting Environmental Impact Assessment of a project. The land use pattern within the study area of the refinery has been assessed with the application of Geographic Information System.

Geographic Information System or GIS offers a variety of analysis and modelling tools for dealing with many of the complex decisions. A GIS, as a decision support system, in this context, is a computer software technology that combines attribute data as well as spatial data - vector, raster, CAD, and TIN – with statistical analysis to evolve a variety of scenarios for interpretation, comprehension, exploration and development.

3.3.1 METHODOLOGYThe inputs for the study included four paper maps and LISS III multi – spectral digital data.

GIS routines, performed for the study, included scanning of paper maps of the area, importing the scanned maps into the GIS software, geo referencing the imported scanned maps, removing the residual errors, spatial data editing, creating the attribute databases, attaching the databases with one another and the spatial data.

The GIS routines, performed, also included importing and geo referencing digital data, creating a mosaic of the four geo referenced scanned maps, creating a subset of the mosaic to match the extents of the extract of the digital data, defining the study area, and application of numerous image processing techniques on the digital data.

3.3.2 RESULTS OF THE STUDYFour layouts have been created, comprising relevant information derived from numerous secondary sources, and the outputs of numerous image analysis techniques applied on the digital data. Briefly, the layouts are described as under:

Layout 1: Display of RGB after application of De-correlation Stretch. The increase saturation helps distinguish different features and conditions (shades of green, orange, red, brown, and lavender) (Figure-3.3.1).

Layout 2: Display of 3/2 ratio image for the study area with auto normalized contrast enhancement. A band ratio image emphasizes the inherent properties of the surface materials. In a grayscale display of a ratio image, the darkest and lightest tones identify areas with the greatest difference in reflectance for the two spectral bands. Areas with similar reflectance appear in intermediate gray tones (Figure-3.3.2).

Layout 3: Display of an image created via supervised classification carried out on the basis of the information available from the physical surveys carried out between 1975 and 1984 and the general comprehension of the available ground truth information (Figure-3.3.3).

Layout 4: Display of the land use within the study areas based on the information available from the physical surveys carried out between 1975 and 1984 and the general comprehension of ground truth information (Figure-3.3.4).

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.3 Land use and Land cover

3.3.3 DISCUSSIONSAn analysis of the land use within the study area (Figures 3.3.3 & 3.3.4) indicates a decline of 23.94% in the flood prone areas, and the areas under (orchards) horticulture and agriculture. The study indicates a growth of 66.56% in the area under settlements (towns, villages) and hutments. More specifically, the study indicates a decline of 4.17% in flood prone areas, and a decline of 38.89% in (orchards) horticulture and agriculture. The study indicates a growth of 35.42% in the area underhutments and a growth of 137.09% in the area under settlements (towns and villages).

The changes in the land use seem to be the effects of sedimentation in flood prone areas and the growth of population around the establishments that constitute the backward and forward linkages to Barauni Refinery and the Refinery itself. The study as such may help application of appropriate land use controls to ensure an environmentally suitable and sustainable existence of the refinery and its hinterland.

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.4 Soils

3.4 SOILS 3.4.1 FIELD STUDY, SAMPLING AND ANALYSIS

To examine the impacts of industrial/urban activities on the soils in the area, the physico-chemical characteristics of soils within the study area have been analysed by obtaining soil samples from selected points. Five sampling stations were selected for studying soil characteristics, the locations of which are depicted in Figure-3.4.1. Stations are well spread over the study area which would accord an overall idea of the soil characteristics within the study area.

A number of parameters were determined which were indicative of physical, chemical and fertility characteristics. The physico-chemical characteristics of the soils in the study area, as obtained from the analysis of the soil samples, collected once during May 2007 are presented in Table-3.4.1.

3.4.2 SOILS CHARACTERISTICS3.4.2.1 Physical Characteristics

The soils of all the locations shall be classified as silty or clay loam categories.

It is observed that all the locations have more or less the same bulk density in the 1.16 - 1.26 g/cm3

range. Porosity was found to vary in the range of 49.65 – 61.32 %.

3.4.2.2 Chemical CharacteristicsThe soils were observed to be slightly alkaline (pH range 8.21 – 8.70). This is probably due to excess of oxides and hydroxides of basic metals, particularly calcium and magnesium.

It is observed that the concentrations of Calcium, Magnesium, Sodium and Potassium are found to vary in the ranges of 167.5 – 276.3 mg/100 g, 49.4 – 66.3 mg/100 g, 0.98 – 2.66 ppm and 0.87 – 3.12ppm respectively. Electrical conductivity (EC) is moderate, varying between 189 - 253 micromhos/cm.

3.4.3 FERTILITY STATUS OF SOILSThe soils in the study area are slightly alkaline. The observed level of pH (range 8.21 – 8.70) is not expected to hinder the growth of agricultural crops. Further, the soils are observed to possess reasonable amount of Nitrate (67.54 – 78.65 ppm), Phosphate (1.15 – 2.45 ppm) and Potassium (0.87 – 3.12 ppm), which indicate moderate to good fertility or agricultural potential of the soils. The levels of other elements are appreciably good.

Thus, the overall fertility status of the soils within the study area is reasonably good and is not expected to be detrimental to the growth of agricultural and forest crops.

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.4 Soils

TABLE - 3.4.1

PHYSICO - CHEMICAL CHARACTERESTICS OF SOIL IN THE STUDY AREA(Period: May,2007)

S.N. PARAMETER & UNIT LOC -1 LOC - 2 LOC - 3 LOC - 4 LOC - 5

PHYSICAL CHARACTERESTICS

1 TextureClayLoam

Clay loam

Clay Loam

Clay Loam

Clay Loam

2 Bulk Density (g/cm3) 1.21 1.26 1.22 1.16 1.19

3 Porosity (%) 57.61 49.65 54.31 61.32 56.21

4Water Holding Capacity (%) 21.23 19.76 22.31 18.94 20.65

CHEMICAL CHARACTERESTICS

1 pH 8.31 8.45 8.21 8.55 8.7

2 Conductivity 234 189 217 253 197

3 Calcium ( mg/100g) 167.5 221.6 276.3 219.4 229.7

4 Magnesium ( mg/100 g) 49.4 51.5 66.3 59.1 55.8

5 Sodium (ppm) 2.66 1.84 0.98 1.45 2.12

6 Potassium (ppm) 2.86 3.12 2.53 0.87 1.54

7 Nitrate (ppm) 77.61 67.54 71.42 78.65 69.34

8 Phosphate (ppm) 2.45 1.79 1.66 1.2 1.15

LOCATIONS:Loc-1 GovindpurLoc-2 BihatLoc-3 PipradewasLoc-4 LadauraLoc-5 Pachama

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.5 Ambient Air Quality

3.5 AMBIENT AIR QUALITY3.5.1 MONITORING STATIONS

Eight sampling stations were set up for the monitoring of the ambient air quality within the study area.

The locations of the monitoring stations were based on the preliminary results of the air quality dispersion model in order to site the stations as close as feasible to the anticipated maximum pollutant deposition areas. The emission sources of the proposed plant were also given due cognizance while carrying out the modeling exercise. Logistic considerations as ready accessibility, security, the availability of the reliable power supply etc. were examined while finalizing the locations of such stations.

As such, station AQ01 is located within the Refinery Complex. Station AQ02 is located about 1.8 km. East-Southeast of the centre of the project site at Govindpur village while AQ03 is located about 3.0 km in the North East direction at Ladaura. Stations AQ04 and AQ05 are located about 2.6 and 4.8 km in the North West and West South West directions at villages Papraur and Bihat respectively. Station AQ06 is located at Mahana at about 2.4 km distance in the South West direction. Station AQ07 is located atMaharatpur which is about 3.5 Kms in the East North East direction. Station AQ08 is located at Refinery Township about 5.5 Kms in the East South East direction. The locations of the monitoring stations are depicted in Figure-3.5.1. The direction and the distances of the monitoring stations with respect to the Refinery Complex are summed up in Table-3.5.1.

3.5.2 PARAMETERS, FREQUENCY AND MONITORING METHODOLOGYMonitoring was conducted in respect of the following parameters:

- Suspended Particulate Matter (SPM)- Respirable Particulate Matter (RPM)- Sulphur Dioxide (SO2)- Oxides of Nitrogen (NOx)

The equipment were placed at a height of 3 to 4.5 metres above ground level at each monitoring station, thus negating the effects of wind blown ground dust and free from vertical obstructions within a cone of 120o from the actual position of the sampler, to avoid any impedance to the pollutants.

Ambient air quality monitoring was conducted during three months’ study period (20th March, 2007 - 19th

June, 2007) at a frequency of twice in a week at each station adopting a continuous 24-hours schedule.

3.5.3 STATISTICAL ANALYSIS OF RESULTSThe Minimum, Maximum, Arithmetic Mean (AM) values for each parameter are shown in Table-3.5.2.

The statistical analyses for the parameters SPM, RPM, SO2 & NOx for the entire study period have been represented as Figures 3.5.2 to Figures 3.5.5.

3.5.4 AMBIENT AIR QUALITY SCENARIO3.5.4.1 Suspended Particulate Matter (SPM)

The 24-hourly average arithmetic mean values of SPM vary between 191.5 µg/m3 (at Refinery Complex) and 236.8 µg/m3 (at Papraur) with overall mean of the 8 stations being 217.13µg/m3.

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3.5.4.2 Respirable Particulate Matter (RPM)The 24-hourly average arithmetic mean values of RPM vary between 56.9 µg/m3 (at Refinery complex) and 67.1 µg/m3 (at Ladaura). The overall mean for the 8 stations is 67.7 µg/m3.

3.5.4.3 Sulphur Dioxide (SO2)The overall mean of 24-hourly average arithmetic mean values of SO2 over the study area is derived to be 10.1 µg/m3 with stationwise variation between 8.66 µg/m3 (at Refinery Township) and 11.61 µg/m3

(at Mahana).

3.5.4.4 Oxides of Nitrogen (NOx)The overall mean of 24-hourly average arithmetic mean values of NOx over the entire area is 32.3µg/m3 while individual mean NOx levels computed at the 8 stations range between 28.6 µg/m3 (at Refinery Complex) and 34.7 µg/m3 (at Bihat).

TABLE – 3.5.1DETAILS OF AMBIENT AIR QUALITY MONITORING STATIONS

S.N. CODE LOCATION DIRECTION W.R.T. REFINERY

DISTANCE FROM REFINERY (KMS.)

1 AQ-01 Refinery Complex - -

2. AQ-02 Govindpur ESE 1.8

3.. AQ-03 Ladaura NE 3.0

4. AQ-04 Papraur NW 2.6

5. AQ-05 Bihat WSW 4.8

6. AQ-06 Mahana SW 2.4

7 AQ-07 Maharatpur ENE 3.5

8. AQ-08 Refinery Township ESE 5.5

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TABLE – 3.5.2 STATISTICAL ANALYSIS OF POLLUTANTS

(PERIOD: 20th MARCH, 2007 – 19th JUNE,2007)

POLLUTANT LOCATION MES MIN. MAX A.M.SPM

( µg/m3)Refinery 26 98 287 191.5Govindpur 26 169 324 229.5Ladaura 25 105 371 219.4Papraur 26 115 352 236.8Bihat 26 156 327 233.4Mahna 26 107 349 214.5Maharatpur 25 113 301 201.8RTS 26 109 289 210.1OVERALL 206 98 371 217.13

RPM( µg/m3)

Refinery 26 19 102 56.9Govindpur 26 49 89 64.38Ladaura 25 20 110 67.08Papraur 26 24 115 64.81Bihat 26 48 87 65.98Mahna 26 21 112 63.19Maharatpur 25 20 110 62.48RTS 26 17 105 58.31OVERALL 206 17 115 63.7

SO2( µg/m3)

Refinery 26 4.5 13.5 8.82Govindpur 26 8.8 17.1 11.56Ladaura 25 4.2 16.8 9.64Papraur 26 4.2 17.3 10.96Bihat 26 7.2 14.8 10.69Mahna 26 4.3 17.2 11.61Maharatpur 25 4.5 13.3 9.04RTS 26 4.2 12.5 8.66OVERALL 206 4.2 17.3 10.1

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Note : MIN: Minimum, MAX: Maximum, A.M. - Arithmetic Mean.

POLLUTANT LOCATION MES MIN. MAX A.M.NOx

( µg/m3)Refinery 26 17 43 30.1Govindpur 26 28 44 34.65Ladaura 25 16 47 33.6Papraur 26 16 44 32.85Bihat 26 18 43 33.62Mahna 26 16 44 32Maharatpur 25 21 42 32.76RTS 26 16 39 28.63OVERALL 206 16 47 32.3

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Figure - 3.5.2STATISTICAL ANALYSIS OF SPM

( 20th MARCH 2007 - 19th JUNE 2007 )

0

50

100

150

200

250

300

350

400

Refinery Govindpur Ladaura Papraur Bihat Mahna Maharatpur RTS

LOCATIONS

POLL

UTI

ON

CO

NC

ENTR

ATI

ON

S

MIN. MAX A.M.

Figure - 3.5.3STATISTICAL ANALYSIS OF RPM

( 20th MARCH 2007 - 19th JUNE 2007 )

0

20

40

60

80

100

120

140

Refinery Govindpur Ladaura Papraur Bihat Mahna Maharatpur RTSLOCATIONS

Po

lluta

nts

Co

nce

ntra

tion

s

MIN. MAX. AM.

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Figure- 3.5.4 STATISTICAL ANALYSIS OF SO2

( 20th MARCH 2007 - 19th JUNE 2007 )

0

2

4

6

8

10

12

14

16

18

20


POLL

UTIO

N CO

NCEN

TRAT

IONS

MIN. MAX A.M.

Figure- 3.5.5 STATISTICAL ANALYSIS OF NOx

( 20th MARCH 2007 - 19th JUNE 2007 )

0

5

10

15

20

25

30

35

40

45

50


POLL

UTI

ON

CO

NC

ENTR

ATI

ON

MIN. MAX A.M.

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.6 Meteorology

3.6 METEOROLOGY3.6.1 SEASONS

The climate of the project area is humid and tropical. It is characterised by a hot and dry summer from March to May, a south-west monsoon or rainy season from June to September, a pleasant post monsoon from October to November and a cold winter from December to February. Therefore, climatologically, four seasons viz. summer (pre-monsoon), monsoon, post-monsoon and winter could be deciphered comprising the following months:

Summer (Premonsoon) : March, April, MayMonsoon : June, July, August, SeptemberPostmonsoon : October, November Winter : December, January, February.

3.6.2 PAST RECORDS3.6.2.1 Data Collected

The nearest existing meteorological station maintained by India Meteorological Department (IMD) is situated at Patna, located about 125 km West of the project site and hence deemed representative for the study area. The station is observed to be well manned and equipped with thermometer, barometer, raingauge and wind monitor. Another IMD observatory is located at Bhagalpur, about 150 km East of the project site. Therefore, it may be presumed that the climate of the site will be in between of Patna and Bhagalpur. Therefore available past records are obtained from these two IMD stations regarding such meteorological features and summarised in Tables-3.6.1 to 3.6.6.

3.6.2.2 TemperatureMaximum temperatures at Patna (Table-3.6.1) are recorded during May (mean maximum 38.9oC) while minimum temperatures occurred during January (mean minimum 11.0oC).

The average mean maximum temperature during summer (pre-monsoon) is 36.5oC and average mean minimum temperature during winter is 12.0oC.

Similarly, maximum temperatures at Bhagalpur (Table- 3.6.2) are recorded during May (mean maximum 38.3oC) while minimum temperatures occurred during January (mean minimum 11.8oC). The average mean maximum temperature during summer (pre-monsoon) is 35.9oC and average mean minimum temperature during winter is 13oC.

3.6.2.3 Relative HumidityHumidity at Patna as usual is moderate to high, the annual mean being 66% at 0830 IST and 53% at 1730 IST (Table-3.6.1). Humidity is high during the monsoon months, particularly July to September (range 80-83% in the morning and 75-78% in the evening), comparatively lower during the post monsoon and winter months (range 62-71% in the morning and 43-62% in the evening) and low during the dry summer months (range 45-56% in the morning and 24-36% in the evening). As usual, humidity is higher during morning hours compared to evening hours for all the months.

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Humidity is high at Bhagalpur (Table-3.6.2) during the monsoon months, particularly July to September and ranges between 82-84% in the morning and between 74-80% in the evening. Humidity is moderate during the winter and post monsoon months including June, particularly October to January when it ranges between 68-76% in the morning and between 61-75% in the evening. Humidity is low during dry summer months, being between 47-60% in the morning and between 31-43% in the evening. As usual, humidity at 1730 IST is less than that at 0830 IST throughout the year.

3.6.2.4 Atmospheric PressureAs regards seasonal variation, it has been observed that barometric pressure at Patna is lowest in June and highest in December, the lowest and the highest values recorded being 991.7 mb and 1009.8 mb (Table-3.6.1).

Similarly, the corresponding barometric pressure is lowest in June and highest in December, the lowest and the highest values recorded being 992.6 mb and 1010.6 mb (Table-3.6.2).

Pressures at both the stations are very close, even in the seasonal variation, with slightly higher pressure observed at Bhagalpur compared to Patna.

3.6.2.5 Rainfall The average annual rainfall at Patna (Table-3.6.1) is about 1,110 mm. Rainfall peaks during August (about 307 mm) followed by July (about 266 mm) with the four monsoon months (June to September) contributing 86% (about 955 mm) of the total rainfall.

The average annual rainfall at Bhagalpur (Table-3.6.2) is about 1,143 mm being slightly higher than at Patna. Rainfall peaks during July (about 253 mm) followed by August (about 251 mm) with the four monsoon months (June to September) contributing 84% (about 957 mm) of the total rainfall.

3.6.2.6 Wind Speed and DirectionIt is observed that wind speeds at Patna (Table-3.6.1) are high throughout the year with very high during the summer and monsoon months (between 6.7-9.8 km/hr) with maximum occurring during May. Calm conditions are minimal throughout the year particularly during summer and monsoon. Calm conditions are relatively higher during postmonsoon and winter months, particularly October to December in evening hours. The annual mean wind speed is 6.8 km/hr and calm conditions are 11% at 0830 IST and 20% at 1730 IST.

From the distribution of wind direction at Patna (Table- 3.6.3 and 3.6.4), it could be observed that during monsoon months of June to September, SE-E-NE are the most frequent corridors both at morning and evening hours. However, during winter months, particularly November to March the most frequent wind corridors are NW-W-SW.

It is observed that wind speeds at Bhagalpur (Table- 3.6.2) are higher during the summer and monsoon months (between 6.0 - 10.4 km/hr) with maximum occurring during April, with calm conditions being minimal. Correspondingly, calm conditions are higher during the postmonsoon

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winter months of October to February. Annual mean wind speed is 6.5 km/hr and calm conditions are 30% at 0830 IST and 22% at 1730 IST.

Distribution of wind direction at Bhagalpur (Tables- 3.6.5 and 3.6.6) shows that during the monsoon months of June to September when wind speeds are high, the frequent corridors are SE-E-NE. During the post monsoon and winter months, particularly November to February, wind reverses itself with the NW-W-SW sectors being the principal directions. During summer (premonsoon) months of March and April, the principal directions are E, W and SE.

Though wind speeds at Bhagalpur in summer are slightly higher than those at Patna, Patna is windier than Bhagalpur in other seasons, particularly monsoon and winter. The feature of Patna being more windy than Bhagalpur is also reflected in the lower percentages of calm conditions at Patna especially in the morning hours.

3.6.3 ON SITE METEOROLOGICAL OBSERVATORYIn order to corroborate and supplement the long term meteorological data available from IMD Patna and Bhagalpur, a sophisticated meteorological observatory was installed on the roof top of the Administrative Building of BR. The observatory was located about 10 m above the ground level and ensured to be free from any obstruction to wind. Besides, this location was found to be most suitable one being close to the BR sources of emission. The meteorological instruments were housed to monitor the following parameters on hourly / daily basis for the Three months’ period (20th march,2007 – 19th june,2007) representing Summer (March, 2007, April, 2007, May, 2007 and June, 2007) .

a) Temperature b) Relative Humidityc) Barometric Pressured) Wind Speed and Direction.

Further, a monostatic SODAR was installed at the refinery township, about 5.5 Kms. away from the refinery to collect the Mixing Height data. The location was selected with a view to generatethe proper and the representative data.

The summary of the on-site data generated in respect of the above parameters for the period mentioned above is presented in Table-3.6.7.

The day-to-day detail data recorded at the on-site observatory for the three different months are presented in Tables- 3.6.8 through 3.6.11.

The wind rose diagrams for the entire three months’period are displayed as Figure- 3.6.1. The monthly wind rose diagrams have been shown as figures 3.6.2 through 3.6.5.

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3.6.4 ON-SITE METEOROLOGICAL OBSERVATIONS3.6.4.1 Temperature

The daily maximum and minimum temperatures recorded on-site during the aforesaid threemonths’ monitoring period (20th march, 2007 – 19th June, 2007) varied between 46.9.0C and 16.5C respectively. March was the coldest month with the minimum temperature, i.e., 16.5C, recorded on 22nd day of March, 2007.

3.6.4.2 Relative HumidityThe Relative Humidity for all the three months were found in the range of (42- 92.5) %. The maximum relative humidity value was 92.5 %, recorded on 23rd day and 25th day of March, 2007. The minimum value of 42 % was recorded on 10th day of April, 2007.

3.6.4.3 Atmospheric PressureThere was little fluctuation in the Maximum Barometric Pressure values recorded for entire threemonths’ period (20th March, 2007 – 19th June, 2007) (ranging between 752.5 to 758 mm Hg).

The maximum value of 758 mm Hg was recorded in the month of March, 2007, while the minimum value of 752.5 mm Hg was recorded in the month of June, 2007.

3.6.4.4 Wind Speed and DirectionDuring the said monitoring period the monthly mean wind speed measured on-site varied between 5.14 Km/hr in March, 2007 and 8.38 Km/hr in June, 2007 (Table-3.6.7). The overall mean wind speed during the study period was 7.05 km/hr.

The wind rose diagram (Figures-3.6.1) indicates that the most predominant wind direction for the summer season was East North East, when calm periods accounted for 5.5%.

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TABLE-3.6.1Temperature, Rainfall, Wind Speed, Humidity and Pressure

at Patna IMD Station (1931-1960)________________________________________________________________________Month Temperature (°C) Rain Mean Relative Barometric

_________________ fall Wind Humidity Pressure Daily Daily (mm) Speed (%) (mb)

Max Min (km/h) ______________________ 0830 1730 0830

________________________________________________________________________

Jan 23.6 11.0 21.1 5.1 71 53 1009.8Feb 26.3 13.4 20.2 6.3 62 43 1006.8Mar 32.9 18.6 6.7 7.6 45 27 1003.2Apr 37.6 23.3 8.2 8.8 41 24 999.5May 38.9 26.0 28.2 9.8 56 36 995.1Jun 36.7 27.1 139.0 9.0 71 57 991.7Jul 32.9 26.7 265.8 8.6 81 75 992.0Aug 32.1 26.6 307.1 7.5 83 78 993.8Sep 32.3 26.3 242.8 6.7 80 75 997.5Oct 31.9 23.0 62.8 4.7 70 62 1003.6Nov 28.9 16.1 5.7 3.6 62 52 1007.7Dec 24.9 11.7 2.4 4.1 67 53 1009.8________________________________________________________________Avg 31.6 20.8 - 6.8 66 53 1000.8Total - - 1109.8 - - - -----------------------------------------------------------------

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Table - 3.6.2

Temperature, Rainfall, Wind Speed, Humidity and Pressure at Bhagalpur IMD Station (1931-1960)

________________________________________________________________________Month Temperature (°C) Rain Mean Relative Barometric

_________________ fall Wind Humidity Pressure Daily Daily (mm) Speed (%) (mb)

Max Min (km/h) ______________________ 0830 1730 0830

___________________________________________________________________________Jan 24.0 11.8 34.5 5.0 76 63 1010.4Feb 27.0 14.3 3.5 6.3 61 53 1007.0Mar 33.0 19.1 5.6 7.7 53 39 1003.9Apr 37.0 23.6 8.7 10.4 47 31 999.9May 38.3 25.7 48.1 10.1 60 43 996.1Jun 35.3 26.4 207.6 8.2 76 66 992.6Jul 32.5 26.2 253.0 6.6 84 74 993.7Aug 32.3 26.3 250.9 6.0 84 80 994.5Sep 32.5 25.9 245.6 6.0 82 80 998.2Oct 32.0 23.1 78.8 4.6 75 73 1003.9Nov 29.0 16.6 5.0 3.4 68 64 1008.4Dec 25.5 12.8 1.6 3.9 76 63 1010.6________________________________________________________________Avg 31.6 21.0 - 6.5 70 61 1001.6Total - - 1142.9 - - - -________________________________________________________________

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TABLE-3.6.3Distribution of Wind Speed and Wind Direction at Patna

at 0830 IST (1931-1960)________________________________________________________________________________Month Days with Wind Percentage (%) Frequency of

Speed (km/h) Wind from Direction_______________ __________________________________________________Calm 1-19 >=20 N NE E SE S SW W NW Calm

________________________________________________________________________________

Jan 6 25 0 1 8 3 4 6 36 17 6 19Feb 3 25 0 1 8 6 5 6 38 8 7 11Mar 2 29 0 1 11 9 6 5 34 19 8 7Apr 2 27 1 2 21 20 6 2 18 18 7 6May 1 28 2 2 38 37 7 1 4 6 3 2Jun 1 28 1 2 42 30 11 2 4 3 2 4Jul 2 28 1 2 22 34 15 4 9 5 3 6 Aug 3 27 1 2 21 30 17 3 9 5 4 9Sep 3 27 0 2 21 24 16 4 10 9 5 9Oct 5 26 0 3 15 11 10 8 21 9 7 16Nov 6 24 0 2 6 2 4 6 38 13 8 21Dec 6 25 0 1 5 1 3 6 41 18 7 18_______________________________________________________________________________Avg - - - 2 18 16 8 5 22 12 6 11Total 40 319 6 - - - - - - - - -_______________________________________________________________________________

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TABLE-3.6.4Distribution of Wind Speed and Wind Direction at Patna

at 1730 IST (1931-1960)

________________________________________________________________________________Month Days with Wind Percentage (%) Frequency of

Speed (km/h) Wind from Direction_______________ _________________________________________________Calm 1-19 >=20 N NE E SE S SW W NW Calm

________________________________________________________________________________

Jan 7 24 0 2 7 3 2 1 8 38 14 25Feb 5 23 0 3 8 4 2 1 8 36 21 17Mar 4 26 1 6 10 2 1 1 5 32 32 11Apr 2 27 1 6 18 7 1 0 3 28 30 7May 2 28 1 5 37 17 3 0 1 13 18 6Jun 2 27 1 2 46 18 6 2 2 5 2 6Jul 3 27 1 2 27 32 10 3 5 6 4 11 Aug 4 26 1 3 27 29 11 1 5 6 5 13Sep 7 23 0 3 20 23 9 1 8 9 6 21Oct 12 19 0 3 16 7 4 4 14 9 6 37Nov 14 16 0 3 7 1 1 1 9 19 12 47Dec 11 20 0 2 4 0 0 1 4 38 15 36_______________________________________________________________________________Avg - - - 4 19 12 4 1 6 20 14 20Total 73 286 6 - - - - - - - - -_______________________________________________________________________________

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TABLE-3.6.5

Distribution of Wind Speed and Wind Direction at Bhagalpurat 0830 IST (1931-1960)

________________________________________________________________________________Month Days with Wind Percentage (%) Frequency of


________________________________________________________________________________Jan 16 15 0 1 1 5 2 2 15 24 3 47Feb 10 18 0 1 4 6 3 3 20 27 6 33Mar 8 22 1 2 5 17 7 5 16 20 3 25Apr 5 24 1 0 5 31 8 1 8 23 4 17May 4 26 1 1 5 30 15 4 2 8 3 12Jun 3 26 1 0 7 42 31 5 2 3 1 9Jul 7 23 1 1 3 33 25 8 6 4 1 19 Aug 7 24 0 1 3 33 28 4 5 5 1 20Sep 7 22 1 2 4 30 21 6 6 7 2 22Oct 11 19 1 3 5 18 10 3 6 15 6 34Nov 16 14 0 1 4 6 3 3 8 19 6 50Dec 16 15 0 1 2 3 1 2 13 24 3 51_______________________________________________________________________________Avg - - - 1 4 23 13 4 9 15 3 28Total 110 248 7 - - - - - - - - -_______________________________________________________________________________

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TABLE-3.6.6Distribution of Wind Speed and Wind Direction at Bhagalpur

at 1730 IST (1931-1960)________________________________________________________________________________Month Days with Wind Percentage (%) Frequency of


________________________________________________________________________________Jan 8 23 0 2 1 4 1 1 7 48 13 23Feb 6 22 0 3 4 3 1 1 6 46 19 17Mar 5 25 1 3 5 10 2 0 2 43 22 13Apr 3 25 2 2 3 12 4 2 3 40 26 8May 1 27 3 4 7 37 10 3 1 16 17 5Jun 4 25 1 2 5 51 19 4 2 2 4 3Jul 6 25 0 1 5 35 28 4 4 5 2 16 Aug 6 25 0 2 3 37 25 3 4 6 3 17Sep 9 20 1 1 2 31 18 2 4 8 5 29Oct 12 18 1 3 4 13 8 1 5 16 12 38Nov 11 19 0 5 3 4 1 0 8 29 14 36Dec 9 22 0 4 1 5 1 1 7 38 17 26_______________________________________________________________________________Avg - - - 3 4 20 10 2 4 24 13 20Total 80 276 9 - - - - - - - - -_______________________________________________________________________________

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TABLE 3.6.7

ONSITE METEOROLOGICAL DATA FOR BARAUNI REFINERY

(20th MARCH, 2007 – 19th JUNE, 2007)

MONTHS TEMPERATURERELATIVE HUMIDITY BAROMETRIC AVERAGE

( o C ) ( %)PRESSURE (mm

Hg) VELOCITYMAX. MIN. MAX. MIN. MAX. MIN. ( Km. Hr-1)

MARCH, 2007 38 16.5 92.5 53 758 754 5.14APRIL, 2007 45.5 24 89 42 757 753 8.38MAY, 2007 46.9 22 83 44.5 756.5 753 6.8JUNE, 2007 46.8 27.4 85.5 48 755.5 752.5 7.87OVERALL 46.9 16.5 92.5 42 758 752.5 7.05

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TABLE - 3.6.8

ONSITE METEOROLOGICAL DATA(MARCH, 2007)

DAYS TEMPERATURE( o C )

RELATIVE HUMIDITY( % )

BAROMETRICPRESSURE (mm Hg)

AVERAGE VELOCITY

TOTALRAIN FALL

MAX. MIN. MAX. MIN. MAX. MIN. ( Km. Hr-1) (MM)

20 31 17 91 59.5 756 754.5 2.73 Nil

21 33 17 92.5 69.5 755.5 755 4.16 Nil

22 36 16.5 83 55.5 756 755.5 3.87 Nil

23 36.5 17.5 92.5 70.5 755 754 4.65 Nil

24 37 20 87 64.5 755.5 754.5 4.85 Nil

25 36.5 19.5 92.5 70.5 757.5 756 7.53 Nil

26 37 21 86 65 757.5 756 7.28 Nil

27 37 20 83 53 756 755 4.85 Nil

28 37.5 21.5 91.5 65.5 756.5 755.5 5.48 Nil

29 36 19 87.5 65 757 756 5.18 Nil

30 36.5 19.5 78 55 758 756.5 4.81 Nil

31 38 21 79.5 54 757.5 756.5 6.3 Nil

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TABLE - 3.6.9ONSITE METEOROLOGICAL DATA

(APRIL, 2007)

DAYS TEMPERATURE( oC )

RELATIVE HUMIDITY( % )


AVERAGE VELOCITY

TOTALRAIN FALL

MAX. MIN. MAX. MIN. MAX. MIN. ( Km. Hr-1) (MM)

1 40 27 84 59 755.5 754.5 9.37 Nil

2 42 29 89 64 756 755 8.05 Nil

3 41.5 28.5 89 62 756.5 755 6.81 Nil

4 40 27 87 58 756.5 755 8.40 Nil

5 41 27 85 47 754 753 7.65 Nil

6 41.5 28.5 81 46 754.5 753 6.85 Nil

7 37.5 26.5 87 62 754.5 753.5 8.77 Nil

8 39 26 64 56 755 754 8.76 Nil

9 38 25 73 44 755.5 754 7.78 Nil

10 39 27 79 42 756 754.5 7.07 Nil

11 37 25 74 64 756 754.5 8.20 Nil

12 36 24 78 48 755.5 754 10.59 Nil

13 36.5 25 87 57 754.5 753 10.78 Nil

14 37 25 85 62 755.5 754 7.06 Nil

15 36 24 81 56 755.5 754 7.58 Nil

16 43 30 72 47 756 755 9.51 Nil

17 43.5 30.5 75 50 756.5 755.5 8.08 Nil

18 43 30 70 47 757 756 8.71 Nil

19 44 29 87 58 757 756 10.09 Nil

20 44.5 28.5 85 52 757 756.5 9.16 Nil

21 43.5 27.5 88 56 756.5 755.5 8.42 Nil

22 44 28 79 57 756 755.5 7.77 Nil

23 45 29 81 47 756 755.5 8.51 Nil

24 45.5 29 83 49 756 755 7.75 Nil

25 42 28 82 59 755 754.5 8.88 Nil

26 38 30 72 53 754.5 754 8.03 Nil

27 38.5 26.5 73 55 755 754 8.05 Nil

28 37 26 64 55 755 754 9.47 Nil

29 37.5 26.5 66 50 756 755 6.51 Nil

30 34.5 28.5 79 62 756 755 8.81 3.68

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(MAY 2007)


RELATIVE HUMIDITY(%)


AVERAGE VELOCITY

TOTALRAIN FALL

MAX. MIN. MAX. MIN. MAX. MIN. ( Km. Hr-1) (MM)1 38.1 30 70.5 54 754 753 6.53 Nil2 38.2 29.4 77 53 754 753 5.46 Nil3 39 28.5 81.5 47 755 753.5 7.4 Nil4 39.5 32 78 53.5 755 753.5 6.68 Nil5 38 27.9 81.5 48 755.5 754 4.45 Nil6 39.5 32 79.5 53.5 755 754.5 8.61 Nil7 41.3 29.4 83 47.5 754.5 754 8.77 Nil8 39 27.9 83 49 755 753.5 6.79 Nil9 41.3 28 81.5 48 754.5 754 6.97 Nil

10 40.7 29.9 75 48 754.5 753.5 5.48 Nil11 41.6 32.4 81 47.5 754.5 754 8.97 24.6212 36.4 22 79.5 50.5 756 755.5 7.45 Nil13 41.7 27.9 83 47.5 756 755.5 6.42 Nil14 40.5 28.5 73 44.5 755 754.5 7.95 Nil15 39.5 28.9 71.5 47.5 756.5 755.5 7.27 10.1816 38.7 28 73 44.5 756 754.5 9.9 Nil17 38.4 27.7 73 55.5 755 753.5 6.51 Nil18 41 28.9 72 48 756 755 6.6 Nil19 41.9 29.1 75.5 57 753.5 753 5.24 Nil20 41.8 28.5 73 55.5 753.5 753 7.23 Nil21 39.4 30.1 73 44.5 755 754.5 7.62 Nil22 45.3 28 81.5 48 754.5 754 6.74 Nil23 46.6 30.5 81.5 48 755.5 754 6.36 Nil24 46.5 30.4 81 47.5 755 754 5.97 Nil25 46.5 30.3 81.5 48 754.5 754 4.41 Nil26 43.9 30.4 73.5 54 756 755 9.62 Nil27 46.4 31.4 81.5 48 754.5 753 5.73 Nil28 46.5 29 82 61.5 755 754 5.99 Nil29 45.5 29.5 81 47.5 755 754 5.91 Nil30 46.7 29.2 81.5 48 755.5 754 5.06 Nil31 46.9 31.5 82 61.5 755 753.5 6.81 Nil

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(JUNE, 2007)


RELATIVE HUMIDITY

(%)BAROMETRIC

PRESSURE (mm Hg)AVERAGE VELOCITY

TOTALRAIN FALL

MAX. MIN. MAX. MIN. MAX. MIN. ( Km. Hr-1) (MM)1 46.8 31.4 70.5 55.5 754 753.5 5.04 Nil2 46.8 30.9 72 54 755.5 755 6.48 Nil3 44.9 32.4 80 61.5 755 754.5 10.35 Nil4 41.5 29.3 69 55 754 753.5 9.75 Nil5 41.5 30 81.5 48 755 753.5 8.69 Nil6 41.7 30.5 80 61.5 753 752.5 9.09 Nil7 37.5 31.5 73 58.5 753.5 753 9.46 Nil8 41.1 30.5 69 55 754.5 753.5 9.63 Nil9 35.9 30.9 77 60.5 754 752.5 11.88 Nil

10 32.9 29.5 73 58.5 753.5 753 9.08 Nil11 36.2 28.5 80 61.5 755.5 754 7.62 Nil12 38.2 30 85.5 65.5 754 753.5 6.5 17.513 34 27.4 80 61.5 755.5 754 6.13 Nil14 40.1 28 83 61.5 755 753.5 4.16 Nil15 33.4 28.6 84.5 65 754 752.5 5.42 69.616 39.1 28.9 73 58.5 753.5 753 9.8 Nil17 40 28.8 80 61.5 755.5 754 6.42 Nil18 42.2 32 83 62.5 754.5 753.5 6.89 Nil19 36.5 31 81.5 48 755 753.5 7.2 Nil

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Figure – 3.6.1

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Figure – 3.6.2

Figure – 3.6.3

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Figure – 3.6.5

Figure – 3.6.4

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3.0 Baseline Environmental Scenario3.7 Water Quality Envirotech East Pvt. Ltd.

3.7 WATER QUALITY3.7.1 ON SITE MONITORING STATIONS3.7.1.1 Monitoring Stations on River Ganga

The River Ganga flows from NW to SE at about 8 km south of Barauni Refinery. The Ganga, being the life-line of the region, its quality and ecology has been attracting the attention of masses and are becoming matter of concern. As the main drainage channel of the region, Ganga receives pollutional loads of domestic and industrial waste waters as also agricultural run off. The treated IOC effluent isdischarged into it through an underground pipeline at Kasha Diara, 5 km. downstream from Rajendra Bridge. Presently, very low quantity of the treated effluent is being discharged into Ganga. Most of thetreated effluent is being re-used as a make up in fire water, coke cutting water, cooling tower and for watering plants/shrubs in ecological park and as make up water to eco-ponds.

To assess the quality of water in river Ganga intercepted in the study area and the impact of Refinery discharges on the water quality, if any, 2 stations were selected and monitored. (Please refer Figure -3.7.1). The locations have been listed in Table 3.7.1

3.7.1.2 Ground Water Quality Monitoring StationsGround Water has been found as the most important source for catering the local needs of water consumption, for various purposes viz domestic, industrial, irrigation etc throughout the study area. On the other hand, the river water serves the purposes of bathing and washing to some extent with limited pumped irrigation by the inhabitants residing adjacent to the river bank. Therefore, any kind of deterioration owing to the industrial or the urban activities in the quality of ground water will pose serious threat to almost all form of water consumption requirement and an attention needs to be paid towards maintaining the quality of water using all possible tools such as regular monitoring with spontaneous remedial suggestions, if required.

With this view, 8 monitoring stations in the study area were identified for the assessment of the ground water quality (Please refer Figure – 3.7.1). The locations of the respective stations with respect to the refinery have been given in Table 3.7.2

3.7.2 METHODOLOGY AND FREQUENCY OF SAMPLINGWater samples were drawn at a frequency of once in a month during the entire sampling period of March 2007 to May 2007.

The samples were analysed for relevant parameters covering physical, chemical and biological qualities including certain heavy metals, trace elements and toxic constituents.

All the basic precautions and care were taken during the sampling to avoid contamination. Analysis of the samples was carried out as per established standard methods and procedures prescribed by the CPCB and relevant IS Codes.

3.7.3 WATER QUALITY OF RIVER GANGAGanga river water quality monitoring results for the two locations are compiled in Tables-3.7.3 and 3.7.4.

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The water temperature at both the stations falls more or less in the similar range.

The pH value of Ganga water showed its slightly alkaline nature. The conductivity value at both the stations has been observed in the range of 307 – 351 µmhos/cm respectively, falling in the healthy, moderate ranges and had hardly any impact on the ecosystem.

The values of hardness, carbonate alkalinity and bicarbonate alkalinity are within the limit and thus, will not cause any concern.

DO was found to be satisfactory at both the stations falling in the range of 7.7 – 8.2 mg/l. Vigorous algal growth could be the main cause of high DO and pH values.

Ganga water was in a pretty healthy and clean state in this stretch and was not being affected by the pollutant loads entering Ganga from Barauni industrial area as evidenced by the consistent value of pH (around 8.0) and DO (the values varying between 7.7 – 8.2 mg/l ).

BOD and COD were observed to vary in the range of 2.4 – 3.8 mg/L, and (4.9 – 6.1) mg/L respectively.

Chloride and Sulphates varied in the range of 16.4 – 21.1 mg/L and 17.2 –27.4 mg/L respectively.

Overall, no significant impact on water quality of river Ganga due to BR effluent is perceived.

3.7.5 GROUNDWATER QUALITYStatistical analysis of all the ground waters jointly is presented in Table – 3.7.5.

There has been little fluctuation in the values of pH for all the 8 locations. The Electrical Conductivity values of all the 8 locations were found in the range of (706 – 746) µmhos/cm, with the average for all the 8 locations being 723.23 µmhos/cm.

The total hardness values at the respective locations were observed in the range of (311 - 378) mg/l, with the arithmetic mean value of 343.73 mg/L.

Chloride was found to vary in the ranges of 25 – 57 mg/l, with the arithmetic mean value of 41.78 mg/L, which were well within the tolerance limit of 250 mg/l for chloride for drinking water.

The iron concentrations at all the 8 locations have been found very high, with the values crossing the tolerance limit of 0.3 mg/l for drinking water on most of the occasions. The values of iron ranged between 0.75 – 1.18 mg/L

The other analysed parameters like Nickel, Zinc, Arsenic, Mercury, Lead, Cadmium, Chromium, Selenium and Phenol have been found at below detection limit while the total suspended solids were nil on every occasion at all the six monitoring stations.

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An important conclusion can be drawn in the light of the overall analysis made so far that the ground water around the Barauni Refinery is free of any kind of industrial and urban pollution and has been found to be fit for human consumption as per IS:2296.

TABLE 3.7.1LOCATION OF GANGA WATER QUALITY LOCATIONS

SL.NO LOCATION NAME1 KASHA DIARA (100 MTR. UPSTEAM OF IOC OUTFALL )2 KASHA DIARA (100 MTR. DOWNSTEAM OF IOC OUTFALL )

TABLE 3.7.2LOCATION OF GROUND WATER QUALITY MONITORING STATIONS

SL.NO LOCATION NAME SOURCE1 GOVINDPUR WELL2 KESABE HAND PUMP3 RAICHIAHI HAND PUMP4 MAHNA HAND PUMP5 NURPUR HAND PUMP6 PAPRAUR HAND PUMP7 MASADPUR HAND PUMP8 HARPUR WELL

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TABLE - 3.7.3 STATISTICAL ANALYSIS OF GANGA WATER QUALITY

LOCATION : 100 MTS UPSTREAM OF IOC OUTFALL Samples Collected in March '07, April '07 & May '07

S.N. PARAMETER MIN MAX Average1 Temperature 24.8 25.8 25.32 pH 8.2 8.4 8.33 Conductivity (25oC) 307 317 3124 Dissolved Oxygen 7.7 8.1 7.95 BOD ( 3 days at 27oC) 2.4 3.1 2.86 COD 4.9 5.3 5.17 Total Hardness (as CaCO3) 217 227 2228 HCO3 Alkalinity (as CaCO3) 116 122 1199 CO3 Alkalinity (as CaCO3) 8.6 10.2 9.410 Chlorides (as Cl) 18.9 21.1 2011 Sulphates (as SO4) 26.6 27.4 2712 Free Carbon Dioxide (as CO2) 2.8 3.6 3.213 Boron (as B ) BDL BDL BDL14 Sodium Absorption Ratio 7.8 9.2 8.5

N.B. : MIN-Minimum, MAX-Maximum, A.M. - Arithmetic Mean, S.D.- Standard Deviation

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TABLE - 3.7.4 STATISTICAL ANALYSIS OF GANGA WATER QUALITY

LOCATION : 100 MTS DOWN STREAM OF IOC OUTFALL Samples Collected in March '07, April '07 & May '07

S.N. PARAMETER MIN MAX Average1 Temperature 23.8 25.4 24.62 pH 8.2 8.6 8.43 Conductivity (25oC) 331 351 3414 Dissolved Oxygen 7.8 8.2 85 BOD ( 3 days at 27oC) 3.2 3.8 3.56 COD 6.1 7.3 6.77 Total Hardness (as CaCO3) 312 332 3228 HCO3 Alkalinity (as CaCO3) 159 167 1639 CO3 Alkalinity (as CaCO3) 8.3 10.1 9.210 Chlorides (as Cl) 16.4 18.6 17.511 Sulphates (as SO4) 17.2 20.4 18.812 Free Carbon Dioxide (as CO2) 21.7 25.2 23.513 Boron (as B ) BDL BDL BDL14 Sodium Absorption Ratio 8.3 9.2 8.8

N.B. : MIN-Minimum, MAX-Maximum, A.M. - Arithmetic Mean, S.D.- Standard Deviation

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TABLE - 3.7.5GROUND WATER QUALITY MONITORING RESULTS AROUND

BARAUNI REFINERY (Samples Collected in March '07, April '07 & May ‘07)

PARAMETERS UNIT MIN MAX AVERAGE

Temperature oC 26.2 28.3 27.16pH 7.08 7.3 7.18Conductivity µmhos/cm 706 746 723.23Total Hardness mg/L 311 378 343.73Alkalinity mg/L 161 281 238.38Total Dissolved Solids mg/L 393 479 429.5Total Suspended Solids mg/L 1.1 1.4 1.23Total Sulphides mg/L BDL BDL BDLOil and Grease mg/L BDL BDL BDLChloride mg/L 25 57 41.76Nitrate mg/L 1.1 1.32 1.20Fluoride mg/L 0.45 0.87 0.64Iron mg/L 0.75 1.18 0.98Lead mg/L BDL BDL BDLPhenol mg/L BDL BDL BDLNickel mg/L BDL BDL BDLArsenic mg/L BDL BDL BDLZinc mg/L 0.56 1.23 0.90Mercury mg/L BDL BDL BDLDissolved Oxygen mg/L 5.1 6 5.5Cadmium mg/L BDL BDL BDLSelenium mg/L BDL BDL BDLChromium mg/L BDL BDL BDLBDL - Below Detection Limit

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.8 Noise

3.8 NOISE3.8.1 MAJOR SOURCES OF NOISE IN THE STUDY AREA

The existing refinery itself contributes to increased noise levels in the area. Besides industrial noise, vehicular movement on the roads is the one of the major sources of noise, significantly increasing the ambient noise level. There are also number of other domestic and commercial noise sources such as generator sets, sirens, television, radio, loud speakers, etc.

3.8.2 AMBIENT NOISE MONITORINGIn the present study, sound pressure levels have been measured by a sound level meter. Since loudness of sound is important due to its effects on people, the dependence of loudness upon frequency must be taken into account in environmental noise assessment. This has been achieved by the use of A-weighting filters in the noise measuring instrument which gives a direct reading of approximate loudness. Moreover, A-weighted equivalent continuous sound pressure level (Leq) values have been computed from the values of A-weighted sound pressure level (SPL) measured with the help of noise meter.

A number of relevant locations were selected for the measurement of Ambient Noise Levels covering industrial, commercial, residential as well as sensitive areas around the Barauni Refinery. The monitoring was carried out once during May, 2007.

The selected locations studied for this purpose are shown in Figure-3.8.1.

At each location, readings were taken at uniform interval over a twenty-four hours period. For a particular location, day time Leq has been computed from the SPL values measured between 6.00 A.M to 10.00 P.M and night time Leq from the SPL values measured between 10.00 P.M to 6.00 A.M, such that comparison could be made with the national ambient noise standards.

3.8.3 NOISE LEVELS AT RURAL ZONESTotal 7 (Seven) villages were selected for this purpose of noise level monitoring. The respective Leqvalues for Day and Night for the entire have been presented in Table 3.8.1.

The highest day time equivalent noise level i.e., 63.1 dB(A), was observed at Bihat. However, at alllocations, the noise levels were recorded well below 70 dB(A), and varied mostly in the ranges of (50 – 70) dB(A).

The night time noise levels were lower than those measured at day time, as usual. The values varied usually in the ranges of (40 – 55) dB(A).

3.8.4 NOISE LEVELS AT URBAN CENTRESTotal 5 (Five) locations were selected for the purpose of noise level monitoring at the urban areas. The respective Leq values for Day and Night for the entire study period have been presented in Table 3.8.2.

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The noise levels near Barauni Railway Station and Begusarai Railway stations were high, corresponding day time Leq values recorded as 71.2 and 72.6 dB(A) respectively.

However, at all other locations, the noise levels were recorded well below 90 dB(A) and varied mostly in the ranges of (60 – 80) dB(A).

The night time noise levels were lower than those, measured at day time as usual. The values varied mostly in the ranges of (40 – 60) dB(A).

3.8.5 NOISE LEVELS AT SENSITIVE AREASTotal 3 (three) locations were selected for the purpose of noise level monitoring at the sensitive areas. The locations near DAV Public School, Refinery Hospital, and Begusarai Science College were chosen as the locations under Sensitive Areas.

The respective Leq values for Day and Night for the entire study period have been presented in Table 3.8.3. The night time Leq values were found varying in the ranges of (40 – 50) dB(A).

3.8.6 NOISE LEVELS WITHIN THE INDUSTRIAL AREAThe important sources of noise in the Barauni industrial zone mainly from IOCL Refinery, BTPS andBarauni Carbon. Total 3 (three) such major noise level locations were selected for the purpose of noise level monitoring at the industrial areas for the purpose of noise monitoring with a view to having an overall assessment of the impact due to various noise generating industries in the area.

The respective Leq values for Day and Night for the three seasons have been presented in Table 3.8.4.

At every location, SPL readings were taken at uniform intervals over a period of eight hours (8 A.M. –4 P.M.) to compute Leq (8 hr).

The highest noise level was observed as 73.8 dB(A) at BTPS . Whereas at Refinery Main Gate and Barauni Carbon, such values were recorded as 71.1 and 71.8 dB(A) respectively.

3.8.7 NOISE LEVELS AT NATIONAL HIGHWAYSTotal 3 (three) locations were selected for the purpose of noise level monitoring on the National Highways. The respective Leq values for Day and Night for the entire study area have been presentedin Table 3.8.5.

The locations were (1) near Kapasya Chowk, NH-31, (2) at Zero Mile, NH-31 and (3) Over Rajendra Setu, NH-31.

The highest value was recorded as 88.2 dB(A) at Zero Mile on NH31 at Day time. However, all the values were found falling in the ranges of (90 – 70) dB(A) range.

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TABLE- 3.8.1NOISE LEVELS IN THE STUDY AREA (RURAL ZONE)

zone LOCATIONS

EQUIVALENT NOISE LEVELLeq in dB(A)

DAY NIGHT

RURAL

1 GOVINDPUR 60.6 48.422 BIHAT 65.9 52.43 PAPRAUR 60.3 49.954 MIRZAPUR 56.7 46.215 MAHARATPUR 55.95 44.046 RAICHIAHI 54.7 42.237 MAHANA 57.65 46.1

N.B. Day time is reckoned between 0600 HOURS TO 2200 HOURS Night Time is reckoned between 2201 HOURS TO 0600 HOURS

TABLE- 3.8.2

NOISE LEVELS IN THE STUDY AREA (RURAL ZONE)

zone LOCATIONS


DAY NIGHT

URBAN

1 BEGUSARAI RAIL STATION 72.6 70.42 BARAUNI RAIL STATION 71.2 69.63 BEGUSARAI MARKET 63.4 52.54 REFINERY TOWNSHIP 57.8 46.75 BARAUNI MARKET 61.2 50.0


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TABLE- 3.8.3NOISE LEVELS IN THE STUDY AREA (SENSATIVE ZONE)

zone LOCATIONS


DAY NIGHT

SENSITIVE1 Refinery Hospital 46.3 39.522 DAV School 58.3 46.73 Begusarai Science College 59.4 48.84


TABLE- 3.8.4 NOISE LEVELS IN THE STUDY AREA

(INDUSTRIAL ZONE)

zone LOCATIONS


DAY (4.00 To 16.00 Hrs. )

INDUSTRIAL 1 Refinery Main Gate 71.12 BTPS 73.83 Barauni carbon 71.8

N.B. Day time is reckoned between 0800 HOURS TO 1600 HOURS

TABLE- 3.8.5NOISE LEVELS IN THE STUDY AREA (TRAFFIC ZONE)

zone LOCATIONS


DAY NIGHT

TRAFFIC1 Kapasia Chowk 78.5 77.882 Rajendra Bridge 83.1 78.43 Zero mile crossing 88.2 82.02


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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.9 Ecology

3.9 ECOLOGYBiodiversity is actually the variety & variability among worlds’ living organisms including their genetic makeup & the communities in which they live. It has been increasingly used as conceptual focus for conservation policy and to measure species extinction and ecosystem loss in response to natural and human induced pressures. The purpose of an assessment of biodiversity is to provide the sort of information to decision-makers that will facilitate more effective environmental management. Thus, in any environmental analysis where integration of ecological thoughts into planning process is required, such kind of analysis of biological environmental status survey is very significant. It is well established that the deterioration of natural environment is a consequence of socio-economic developmental processes unless it is properly planned.So, this type of assessment includes evaluation of both the terrestrial & aquatic ecology.

3.9.1 TERRESTRIAL FLORA AND FAUNAThere is no natural forest in the area, however there are plantations developed by the forest department along road sides. Also there are self growing plants, vegetation and grasses. The bio-diversity of the self-growing and unprotected plant species would indicate environmental quality and hence were surveyed intensively.

The selected locations studied for this purpose are shown in Figure-3.9.1.

A survey conducted to assess the impact of pollution because of industrial/urban activities on the terrestrial fauna reveals that there is hardly any adverse effect of the pollution on the terrestrial fauna.

3.9.2 CULTIVATED TREESIn addition to the study conducted on self-growing and unprotected plants and vegetation, detailed studies were conducted on cultivated trees and agricultural crops to assess the extent of impact, if any, caused by industrial activities. Considering the economic value, species of Mango, Lichi, Banana, Guava, Lemon, Bamboo, Shisham, Palm and Jackfruit were selected for this study. List of fruit trees and other cultivated trees are given in Tables-3.9.1. The selected locations studied for this purpose are shown in Figure-3.9.1.

3.9.3 AGRICULTURAL CROPSThe land in the study area is well suited for different types of crops. In Kharif maize, Jawar, Paddy are main crops and pulses are grown at few pockets of the study area. In Rabi wheat, maize, oilseeds such as mustard, caster oil are cultivated. Besides these main crops different types of vegetables are grown. The main agricultural crops and vegetable in the study are given in Tables-3.9.2.

3.9.4 ECOLOGY OF RIVER GANGA3.9.4.1 Study Conducted

The biological organisms are the best indicators of environmental quality. Ecology of a stream includes different biological species, such as plankton (both phyto and zoo), benthic organisms

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and fishes. The aquatic organism may often serve as better indicators for subtle effects of pollution in the water body and also may provide early warning. The abundance or absence of certain organisms thus often serves as the indicator of a healthy or polluted aquatic environment. The nature and quality of such biological species in a particular environment depend on various physico-chemical characteristics of water such as pH, conductivity, nutrients, BOD etc.

The total number of species recorded at each station during summer season are given in Table- 3.9.3.

3.9.4.2 Bio-diversity IndexThe concept of species diversity is based on the theory that an aquatic biotal community inhabiting an environment which is pollution free is characterised by the occurrence of a wide variety of species, by a moderate number of individual of each species.

Of the numerous proposed quantitative indices of population, the index based on the information theory of Shannon-Weaver Index (1948) is being used extensively throughout the biological world, particularly amongst ecologists to assess environmental perturbations of river systems. The Shannon-Wiener Index is calculated by the formula :

SH = - > Pi.logepi

i=1

where, H = Species diversity indexS = the number of species in a samplepi = ni/NN = the total number of individuals of all the species in a sampleni = the number of individuals of a species.

Wilhm and Dorris (1968) used this Index (H) using aquatic macro-invertebrates to indicate pollution in the following range :

1 - indicate heavy pollution 1-3 - indicate moderate pollution, and3 - indicate clean water body

The value of bio-diversity index for phytoplankton, zooplankton of Benthic macro-invertebrates during summer season are given in Table-3.9.4.

3.9.4.3 PhytoplanktonPhytoplankton is the primary producers of an ecosystem and thus helps maintain DO of a water body. Any reduction in number of phytoplankton would ultimately affect the whole ecosystem. The observed value was 3.023 which is an indication of healthy water. Since the phytoplanktons are at the mercy of river current, this may not indicate exact nature of water.

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However, the BR effluent itself contains considerable number of phytoplanktons that develop in the guard pond and it clearly indicates the healthy nature of effluent.

3.9.4.4 ZooplanktonZooplankton in this reach mainly consists of rotifers, cladocera, copepodes and ostracods. Rotifers were found to be the most dominant zooplankton. The diversity index was recorded as 33 and 41 respectively.

3.9.4.5 Benthic Macro-InvertebratesThe benthic organisms are the best organisms for the biomonitoring of any water body due to its static nature in its habitat and unlike the plankton (both zoo and phyto), who’s abundance or presence mainly depend at the mercy of current. This group was represented by Polycheata, Insects, Gastropoda and Pelacypoda. The benthos was generally very low in this stretch (bio-diversity index ranged between (0.226 and 1.489). It may also be due to sandy nature of river bed which retains less organic matter as food for the benthos.

3.9.4.6 Fish FaunaFish fauna was collected and surveyed at the fish landing centre in and around Barauni Area. List of fishes observed are depicted in Table– 3.9.5. It was observed that the maximum number was that of cat fishes, which feeds upon the carcasses and dead bodies.

3.9.4.7 Bio-Productivity of River GangaSeveral hydro-biological factors such as cloudy weather, current velocity, turbidity, intensity of light penetration, density of phytoplankton have significant effect on productivity. The incidence of long hours of sunshines and the higher temperature of the tropics favour the conversion of solar energy into organic matter. The primary productivity is thus the basis of whole metabolic cycle in aquatic ecosystems.

The primary productivity was estimated on the basis of dissolved oxygen produced within the stipulated time, following Light and Dark bottle methods suggested by Garder and Gran (1927). The results obtained for gross primary productivity and net primary productivity for summer seasons are given in Table- 3.9.4.

The observed phytoplankton bio-diversity index during summer season gives an indication of healthy water. The BR effluent itself contains considerable number of phytoplanktons, whichclearly indicate the healthy nature of effluent.

Sampling TechniquesVegetation sampling is usually done either by the transect or by the quadrat method.

Transect Method In the transect method, the sampling plot or plots are transected by lines (line transect) or by belts (belt transect). Lines are drawn in the plot and sampling taken along these lines.

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Quadrat MethodEcosystems may cover very large areas and it is not always possible to study them entirely. Therefore, small sampling units or areas, called quardrats, are chosen for study. A quadrat is square or rectangular according to its usefulness and convenience. The size of the quadrat varies with the type of organism, to be studied.

For small plants like lichens, mosses and liverworts, or animals like earthworms distributed in patches, small quadrats of area 25X25 cm are useful. In grasslands, quadrats of three sizes have been found to be useful, depending upon the growth of grasses and their dispersion.These quardrats are 25X25 cm, 50X50cm and 100X50 cm.

Soil animals such as protozoa, nematodes, collembola, microarthropods, enchytraeids, circular samplers (a type of quadrat) of smaller size are chosen (usually 20-40 cm deep).

FrequencyThe frequency is expressed as a percentage and is estimated from the following relationship:

No of quadrats in which species A occursFrequency of species A = -------------- X 100

Total no. of quadrats examined

Sampling MethodThe quardrate size used for this study is 100X100 m area. Randomly chosen ten locations (viz. Govindpur, Bihat, Ladaura, Papraura, Mahana, Maharatpur, Begusari, Mallihpur, Refinary Township, Hatidah) for the study. So, the total no. of quadrat studied here is ten.

eg. 9 nos of quadrats in which mango occurs

Percentage frequency of Mango = ----------------------------------------------------- X 100Total 10 nos .of quadrats examined

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TABLE- 3.9.1FREQUENCY DISTRIBUTION (%) OF THE PLANT

LIST OF FRUIT TREES

Scientific Name Common Name Frequency Distribution (%)Mangifera indica Mango 90Artocarpus heterophyllus Jackfruit 70Eagle marmelos Bel 40Litchi chinensis Litchi 80Psidium guayava Guava 75Bugenia jambolans Black Berry 60Tamarindus indica Imli 40Boraseus flabellifer Palm 90Citrus aurantifolia Lime 80Musa Paradiasica Banana 15Cucumis melo Water melon 30Carica papaya Pappaya 30Citrus airandifolia Lemon 80

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TABLE - 3.9.2LIST OF CROPS

Scientific Name Common NameOryza sativa PaddyTriticum sativam WheatSaccharum officinarum Sugar caneCajanus indicus AraharBrassica nigra MustardRicinus communis CastorZea maiza MaizeCicer aeriatinum Bengal gramePisum sativum PeasLens esculanta MassorSolanum melongena BrinjilSolanum tuberosum PotatoLycopersicum esculentus TommatoCapsicum frutenus ChilieRaphanus Satisvus RadisBrassica olerracea CauliflowerTrichosanthes diocia ParwalCarcia papaya papayaMusa sapientum BananaMomordica charantia KarailaDaccus carota CarrotIpomea batata Sweet potataCucumis melo KakriHibiscus esculantus Ladies fingerCucurbita maxima KaddooMoringa oleigera DrumstickAllium cepa Onion

Spinacea oleracea Spinach

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TABLE- 3.9.3TOTAL NUMBER OF SPECIES RECORDED AT DIFFERENT STATIONS DURING STUDY PERIOD

(IN NO. / LITRE)

Type of Species Station on River GangaRW 1 RW 2

Phytoplankton 75 63Zooplankton 33 41Benthic Macro-invertibrates 485 144

TABLE- 3.9.4SHANNON – WEAVER SPECIES DIVERSITY INDEX OF BIOTA OF RIVER GANGA AT DIFFERENT

SELECTED LOCATIONS DURING STUDY PERIOD

Type of Species Station on River GangaRW1 RW2

Phytoplankton 3.023 2.621Zooplankton 2.221 2.541Benthic Macro-invertibrates 1.812 1.489

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TABLE- 3.9.5LIST OF FISHES RECORDED FROM GANGA NEAR BARAUNI

____________________________________________________________________________________ Scientific Name Local Name

Notopterus chitala Mio, Chital N. Notopterus Moai Gudusia chapra Chapra Setipinna phasa Phasa Chela utrahi Chelhwa Barilius bola Dhawai B. bendelisis Dhawai Catla catla Catla Cirrhinus mrigala Mirka C. reba Reba Labeo bata Bata L. calbasu Calbasu L. rohita Rohu Puntius chola Pothia P. sarana Pothia Mystus aor Aris M. cavasis Tengra Rita rita Ritha

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3.0 Baseline Environmental Scenario Envirotech East Pvt. Ltd.3.10 Demography and Socio - economics

3.10 DEMOGRAPHY AND SOCIO – ECONOMICSThe growth of industrial sectors and infrastructure developments in and around the agriculture dominant areas, village and towns is bound to create its impact on the socio- economic aspects of the local population of the area experiencing development. The impacts may be positive or negative depending upon the development activity. To assess the anticipated impacts of the project and industrial growth on the socio – economic aspects of people, it is necessary to study the existing socio-economic status of the local population, which will be helpful for making efforts to further improve the quality of life in the area under study.

The sociological aspects of this study include human settlements, demography, and social strata such as Scheduled Castes and Scheduled Tribes and literacy levels besides infrastructure facilities available in the study area. The economic aspects include occupational structure of workers.

The Baseline Demographic and Socio economic characteristics with regards to demography, literacy and occupational status have been described, based on the Primary Census abstract, 2001, while the relevant details of the Infrastructure Facilities have been gathered from the Primary Census abstract, 2001.

3.10.1 SOCIO- ECONOMIC ASPECTS OF THE VILLAGES FALLING IN TOTAL CORRIDORIOC Barauni falls in Begusarai district of Bihar. The total 10 KM radius area from the center of Barauni Refinery falls under the study area. The four blocks namely, Teghra, Barauni, Matihani and Begusarai which cover 15.67, 44.92, 17.43 and 21.92% of the study area respectively. The study area includes either partly or entirely 129 villages and 3 urban areas namely Barauni, Begusarai and IOC Township.

3.10.2 DISTRIBUTION OF POPULATIONAs per 2001 census, the population of the total villages, consisted of 6, 04,478. The distribution for these villages is shown in the Table below (refer Annexure for village-wise data):

TABLE – 3.10.1DISTRIBUTION OF POPULATION IN TOTAL STUDY AREA

Particulars Total Study AreaNo of Households 99,886Male Population 3,20,025Female Population 2,84,453Total Population 6,04,478

3.10.2.1 AVERAGE HOUSHOLD SIZEThe Study area had an average family size of 6.05 persons per household. This is considered to be a normal family size in Bihar state.

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3.10.2.2 SOCIAL STRUCTUREIn the study area, 11.99 % population belonged to Scheduled Castes (SC) and about 0.3 % are Scheduled Tribes (ST). The distribution of population in the study area by social structure is shown in Table below.

TABLE – 3.10.2DISTRIBUTION OF POPULATION BY SOCIAL STRUCTURE

IN TOTAL STUDY AREA

SL No Particulars Study Area1 Total Scheduled Castes 72,5302 Male 38,3663 Female 34,1644 Total Scheduled Tribes 1,3895 Male 7596 Female 630

3.10.3 LITERACY LEVELSThe literacy rate in the study area was 45.12% of the total population. The male literacy rate was 62.94 % (of total male population), whereas the female literacy was 37.05 % (of total female population). The details are given in Table below.

TABLE – 3.10.3

DISTRIBUTION OF LITERATES AND LITERACY RATEIN TOTAL STUDY AREA

SL No Particulars Study Area1 Total Literates 2,72,7602 Male Literates 1,71,6993 Female Literates 1,01,061

3.10.4 OCCUPATIONAL STRUCTUREThe occupational structure of people in the study area is studied with reference to main workers and marginal workers. The main workers include 10 categories of workers defined by the Census Department, which consists of cultivators, agricultural laborers, those engaged in live-stock, forestry, fishing, mining and quarrying, manufacturing, processing and repairs in household industry and other than household industry, construction, trade and commerce, transport and communication and other services.

The marginal workers are those workers, engaged in some work for a period of less than six months during the reference year prior to the census survey.

Altogether the Total workers were 28.49 % of the total population whereas the marginal workers were 6.30 % and Non-workers were 71.50 % of the total population. While 11.83 % were Cultivators and 24.09 % were Agricultural Labour of the total worker. The distribution of

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workers by occupation structure of the study area is shown in Table below (refer Annexure for village-wise data).

TABLE- 3.10.4

OCCUPATIONAL STRUCTURE IN TOTAL STUDY AREA

SL No Occupation Study Area1 Total workers 1,72,248

Male 1,40,502Female 31,746

2 Marginal workers 38,136Male 23,368Female 15,275

3 Non workers 4,32,230Male 1,79,523Female 2,52,707

CONTD… TABLE- 3.10.4

SL No Occupation Study Area1 Total Cultivators workers 20,390

Male 18,988Female 1,402

2 Agricultural Lab. Workers 41,511Male 33,771Female 7,740

3.10.5 INFRASTRUCTURE FACILITIESThe infrastructure and amenities available in the study area denotes the economic well being of the region.

A review of infrastructure facilities avaliable in the area has been done based on the information given in the Primary Census abstract for the year 2001. The infrastuctural facilities available in the study area are described in the following section.

3.10.5.1 Educational FacilitiesThe educational facilities are almost evenly distributed in the area. In all, there are 212 primary schools, 62 middle schools, 21 Secondary schools, 13 Adult Literacy Class/Centre, 4 Graduate College, 1 Industrial School, 6 Senior Secondary School and 2 other educational institutions in the study area. The available educational facilities in the area as per 2001census are given in Table below (refer Annexure for village-wise data).

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TABLE – 3.10.5

EDUCATIONAL FACILITIES IN THE TOTAL STUDY AREASLNo

Institution Total

1 Primary Schools 2122 Middle Schools 623 Secondary Schools 214 Senior Secondary Schools 65 Graduate College 46 Industrial School 17 Adult Literacy Class/ centre 13

8 Other Educational Facilities 2

3.10.5.2 Health FacilitiesDifferent types of health facilities are available in the study area. The health facilities are shown in Table below.

TABLE – 3.10.6HEALTH FACILITIES IN THE TOTAL STUDY AREA

SL No Institution Total1 Allopathic Dispensary 182 Ayurvedic Dispensary 13 Homeopathic Dispensary 14 Maternity and Child Welfare Centre 135 Health Centre 16 Primary Health Centre 237 Primary Health Sub Centre 168 Faimaly Welfare Centre 39 Regd. Pvt. Medical Practitioners 136

3.10.5.3 Transport FacilitiesThe study area is served by road transport facility. About 254 villages have NH and 149villages have paved road and all villages have Mud road connections.

As a whole, the study area has moderate level of communication network. About 31 villages of the study area are served by bus facility. And five villages have railway station.

3.10.5.4 Post and TelegraphsAll villages in the study area has post and Telegraphic services while only 61 villages are having post office and 3 villages are having Telegraph office and 641 villages are having phone connections.

3.10.5.5 Electrification 122 villages in the study area have electricity connections. Electricity is being supplied for domestic, Agriculture and public lighting purposes.

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3.10.5.6 Drinking Water FacilityWater supply in the study area is mainly from hand pump (122 villages), tube wells (33 villages), wells (118 villages) and taps (7 villages). 4 villages have river water supply system.

3.10.5.7 Banking Facility15 commercial bank, 7 Co-operative bank, 25 agricultural Credit Societies, 2 Non Agricultural Credit Societies and 5 other Societies are present in the study area.

3.10.6 Socio-Economic SurveyThe census data have been supplemented and corroborated by a socio-economic sample survey covering a sample population size of 511 within the study area conducted in 2001 through structured questionnaires portraying demographic and socio-economic aspects of the study area population. Total ten (10) numbers of villages / towns were selected for the survey. The findings of this socio-economic survey including demographic and socio-economic characteristics, income profiles, household amenities, educational status etc. They have been summarised in Tables – 3.10.7. The salient findings of this sample survey are presented below:

TABLE – 3.10.7

Total Population 983 (Male: 537, Female: 446)No. of Households 150 (Distributed over 11 villages and 1towns) Family Size 6.55Sex ratio 831 females per 1000 malesCaste SC/ST (8.13%), Others (91.87%)Literacy Level Overall (57.47%), Among Males (64.99%), & among Females

(48.43%)Build House Brick (88%), Mud (12%)Lighting source Electricity (88.67%), Kerosene (11.33%)Fuel used for Cooking

Coal (6.66%), LPG (50.66%), Bio-Gas (2%), Kerosene (13.33%), Electricity (4.66%), Wood (22.66%)

Own Transport Car (4.98%), Motor Cycle (6.2%), Bicycle (7.12%),Others (0.5%), Nothing (0.2%)

Drinking water source

Tap Water (46%), Well (19.3%), Hand pump (34.7%)

Sewer System Sewer (19.33%), Open Surface Drain (18.66%), Pit System (46.66%), Others (15.33%)

Source of Income Agriculture (16.7%), Business / Trade (18%), Service (27.3%), Labour (17.3%), Forestry/ Plantation (6%), Livestock/ Fishery (10.7%),Others (4%)

Comparison of the findings of the socio-economic sample survey with the 2001 census data has been made below:

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Particulars 2001 Census 2007 Sample SurveyFamily size (persons per household) 6.05 6.55Sex ratio (females per 1000 males) 889 831Scheduled caste /Scheduled tribe (% of total population)

12.29 8.13

Literacy (% of total population) 45.12 57.47Male literacy (% of total male population) 53.65 64.99Female literacy (% of total male population) 35.53 48.43

It is evident from the above comparison that there has been considerable increase in the literacy rate both among males and females of the area, even more than double of the 2001 census figures. On the other hand, the sex ratio (females per 1000 males) has reduced significantly from 889 to 831. The family size has increased from 6.05 persons per household to 6.55 persons per household. SC / ST population has reduced from 12.29 to 8.13.

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4.0 Anticipated Environmental Impacts & Mitigation Measures Envirotech East Pvt. Ltd.

CHAPTER-4

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 IMPACTS ON SOILS AND LANDUSE4.1.1 Phases of Impacts

The proposed project will have impacts on the environment during two distinct phases. One is the construction phase which may be regarded as temporary or short-term and the other is the operation stage which will have long term effects.

The environmental impacts in this study have, as such, been discussed separately for the construction phase as well as the operation stage.

The impacts have been assessed over the study area of 10 km. radius around the proposed project site. Overall impacts in the regional context are negligible unless stated otherwise.

4.1.2 Activities during Construction PhaseDuring the construction phase, the following activities among many are considered to be important towards the development of impact:

a) Site preparationb) Excavation and backfillingc) Hauling of the earth materials and the wastesd) Piling, cutting and drillinge) Erection of concrete and steel structuresf) Road constructiong) Painting and finishingh) Clean up operationsi) Landscaping and afforestation

Construction phase activities would have moderate impacts on landuse, demography & socioeconomics, on-site soils and onsite noise. It could also develop minor impacts on water use, air and water quality and ecology.

This work can be divided into two groups viz. substructural & super-structural work. Certain foundation would require pile driving. The pile driving machineries would pose noise and gaseous pollution.

Moreover, the construction work will involve cutting of trenches, excavation, concreting etc. All these activities will give rise to the dust pollution. The superstructural work will involve steel work, concrete work, masonry work etc. and will involve massive construction equipments like cranes, concrete mixers, hoists, welding sets etc. There may be dust, gaseous and noise pollution from these activities. Concrete work and masonry work involve considerable amount of water which generally induce certain impact on the local water source.

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Mechanical erection work involves extensive use of mechanical equipment for storage, transportation, erection and on-site fabrication work. These activities generally produce some air contaminants and noise pollution. On the other hand, the electrical work is less polluting in general.

4.1.3 Activities during Operational PhaseThe operation of the project which, in other words would imply loading, unloading, production and storage operations at the site, would have a certain impact on discreet environmental attributes, which are discussed in the following sections.

The process description including quantum of pollution loads from liquid and the gaseous effluents considering their proposed environmental control measures has been discussed earlier in detail.

4.1.4 Impacts on Soils during ConstructionAll the major construction activities tend to create certain changes in the soils of the area. Excavation denudes the top soil and makes it loose. Destruction of top soil leads to reduction of fertility and removal of vegetation cover with associated hazards of soil erosion.

During storms, some of the excavated soil and construction materials such as sand etc. would be blown up in the air and dispersed around the project site; some would also tend to be driven into the soil and clog intergranular spaces.

However, in order to minimise such impacts, appropriate soil conservation measures would be undertaken by the Project Authorities to minimise the chances of soil erosion. Vegetation cover would also be replaced by planting trees, flowering plants & turfing wherever needed. Construction materials would be stored in covered godowns or enclosed spaces. All efforts will be taken to avoid any accidental oil spillage for construction machineries and appropriate storage for paints, varnish, lubricating oil, compressed gases shall follow the prescribed safety norms. Felling of trees and their branches by construction workers shall be prevented. Construction wastes shall be burnt or properly disposed.

As such, the construction activities are proposed within the boundary of the Refinery Complex and the amount of the productive soils the proposed site includes is marginal. Therefore, the impacts will be minimum.

4.1.5 Impacts on Soils during Operation The soil conditions of the project site would be allowed to stabilise during this period after the impacts of the construction phase. The top soil in non-built-up areas would be restored and major portions of the site would be subjected to the extensive plantations which would help in bonding together of the soil, thus increasing its strength.

Soils can get seriously damaged by overflow, passage or application of the polluted waters containing acids, alkalies, salts, oil, heavy metal, toxicants, suspended matter etc.

The impact of the pollutants on the soil quality may rather be a slow process but, it can sometimes cause concern in the long run. The fall out of the heavy metals and the other pollutants present in the

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dust emitted from the industries, traffic and other sources may accumulate in the soil, ultimately affecting the trace metal balance of the soil and the plant growth. To some extent, such accumulation could also prove to be beneficial to plant growth but, beyond a certain limit, the pollutant concentration may be deleterious to vegetation. Since majority of the study area is actually under cultivation, it shall be of utmost importance to ensure that no degradation of agricultural soils shall result from the industrial or other types of pollution.

The porosity of the soil is nowhere affected by the refinery or any other industrial discharges or emissions. The flood plain area soils had less porosity due to the larger content of the sand particles.

It can be inferred that pH and conductivity are not affected by the industrial emissions in the study area.

There was no remarkable variation observed on the main plant nutrients at various locations due to the industrial or the urban activities. The higher concentration observed at a few locations, however, was due to higher fertilizer application by the farmers. These higher concentrations were in a healthy desirable range and would support plant growth rather than cause any adverse effects.

With the slightest apprehension if BR Effluent impact on the locations around out fall due to surface run off during flooding and seepages, if any, could result in serious deterioration of soil quality, a field visit was made and it was observed that there was no such impact and the interaction with farmers revealed that there was no any yield reduction or soil deterioration and they are getting their yield as ever before.

Around the refinery, there may be expected adverse impact at areas close to the burrow pit where BR coker stream and the waste water due to the small scale unit operations located at the Barauni Industrial Area, are discharged. However, around burrow pit, there was no agricultural field and hence, any adverse impact could not be ascertained. Sludge is processed through “Mechanised Skid Process”, wherein the residual oily sludge oil content is in the range of only 5-10%. The residual oily sludge generated will be harmlessly degraded into waste and carbon dioxide using a process called bio-remediation, wherein the sludge is spread out on earmarked site and a bacterial consortium oilivorous – S is applied along with nutrients. The added nutrients speed up the process. In a period of 10-12 weeks, the oily sludge is bio-degraded and the site is used again for a fresh phase of bio-remediation of additional new sludge. The quality of soil at the Bio-remediation site is checked regularly w.r.t. accumulation of heavy metals. Also, underground water quality is checked in the periphery of the site. So far, no adverse impact has been found.

In overall, one can easily infer that there is no evidence of the industrial or the urban activities in the study area having any adverse impact on the soil quality.

4.1.6 ConclusionThere was no impact observed on the physical as well as the chemical characteristics of the soil at all locations, due to industrial/urban activities.

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Interaction with the farmers too revealed that there was hardly any adverse impact on their field due to the industrial development. In overall, the industrial development had no negative role to play on the soil quality of the study area.

4.1.7 Impacts on Landuse during ConstructionPreparatory activities like use of the existing access roads with/without improvements and construction of the temporary offices, quarters and godowns, piling, storage of construction materials etc. will be confined within the project area. These will not generally exercise any significant impact except altering the land use pattern of the proposed site. There will be no impact on the adjoining land. However, dust and noise may sometimes create nuisance in the surrounding areas.

No additional land will be required as all additional plants, storage and expansion shall be confined within the existing boundary limits of the refinery land. As a result, the impact on landuse would be very insignificant and any impact due to construction will be confined within the complex and will not hamper the landuse aspects outside.

4.1.8 Impacts on Landuse during OperationAs stated earlier, the project site being within the refinery boundary is designated as the industrial land. The site, after the completion of its development, would consist of the built structures, neatly landscaped to lead to a pleasing outlook. Moreover, the piece of the land being situated in the heart of the Refinery Complex, would necessarily mingle with the immediately adjacent landuse of the area. It would be noted that the vicinity consists of various facilities of similar nature.

Following a long and hectic construction phase, the temporarily modified landuse pattern, such as the construction of the temporary tents to accommodate some construction personnel would gradually stabilise itself during the operation stage. Land released from the construction activities would be put to economic and aesthetic use to hasten recovery from the adverse impacts.

Plantation of the trees in the open spaces would add a different dimension to the existing landscape of the open vacant lands and would provide a visual comfort.

The operation of the plant already induced impacts on the land use pattern of the surrounding area. Over a period of time, as the plant and services were established for the workers' population, it has induced shift from the agricultural and the rural residential use surrounding the project to the industrial, the commercial and the urban residential use.

4.2 IMPACTS ON HYDROLOGY AND WATER USE4.2.1 Impacts on Hydrology during Construction

The piece of land to be developed is a small part of the whole Refinery Complex. Moreover, the storm water drainage of the land piece is well developed as an integral part of the total such development of the Complex. Therefore, the drainage pattern of overland water flow will not be changed due to the site preparation involving alteration of the existing profile and the slope of the land.

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4.2.2 Impacts on Hydrology during OperationAppropriate drainage facilities have been developed within the plant including the proper disposal to drains. Thus, operation of the complex is not likely to cause any impact on the surface water hydrology.

Various processes and the other activities going on in the refinery require a large amount of the fresh water. Apart from the industrial processes, there are several uses where water is required such as fire water, service and drinking requirements etc. The water requirement at BR is met by the ground water supplied through 9 nos. of the artesian tube wells installed in close proximity of the refinery boundary.

The abstraction of about 1397 m3/hr (1155 m3/hr for existing 6.0 MMTPA capacity and 242 m3/hr of the additional water for the proposed projects) for use by Barauni Refinery should not cause any concern about ground water depletion. The annual consumption by BR shall work out to be about 12million m3. If one were to assume natural local recharge to be 13 cms. from about 12% of the annual average rainfall of 1110 mm percolating to the underground water-table, all it would need is around 85sq km. area to recharge the abstracted amount which is only 27% of the study area. Also, there is considerable recharge from the river Ganga from the waste waters and from the “Terai” areas. The ground water in this area is really copious and there need be absolutely no worry of any shortage of water or lowering of the ground water table.

4.2.3 Impacts on Water Use during ConstructionThe water demand during the construction period will be met through the existing sources within the project boundary and not likely to have impacts on other users.

4.2.4 Impacts on Water Use during OperationThe additional water requirement of the project will be met through the existing tubewells developed to cater to the present demand, thus having no impact on the surrounding users as far as water use is concerned.

The regular water requirement of the project is being met through a number of the dedicated tubewells of the existing water supply scheme of the Refinery. Therefore, the impact on the other users is considered insignificant.

4.3 IMPACTS ON METEOROLOGYEmissions are not likely to alter the meteorology of the area. However, the emitted heat through the stacks may marginally raise the temperature of the atmosphere in a very localised pocket, which will not have any significant impact on the surrounding area.

During construction, the preparatory activities like excavation, backfilling and hauling operations are likely to emit the considerable amount of dust into air. In addition, some of the excavated soil, the exposed top soil and the construction material such as sand etc. would be blown up in the air by wind. These are likely to reduce the visibility of the area in a very localised pocket, which will be intangible with respect to the microclimate of the area. However, as the dust suppression methods, mainly sprinkling of water will be taken up, such impacts will be insignificant.

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4.4 IMPACTS ON WATER QUALITY4.4.1 Impacts during Construction

Large quantities of water will be used in the construction process, of which a significant portion will drain out as the wastewater.

Adequate arrangements already exist to ensure the proper drainage of the wastewater from the construction sites so that such waters neither form stagnant pools nor aggravate soil erosion.

With regards to the water quality, the wastewater from the construction activities would mostly contain suspended solids. The other pollutants, which may find their way to it will be in insignificant concentrations and may be safely ignored.

As the waste waters would ultimately be treated in the existing ETP, excess suspended solids in the waste- waters will be arrested before discharge.

4.4.2 Impacts during Operation4.4.2.1 Ground Water

The chances of the groundwater contamination under the plant site is small because most chemicals are used in the areas that are paved and water falling on those locations are subjected to treatment. The seepage of the product or the raw materials and the chemicals into the groundwater is unlikely under the normal operating condition.

As was discussed, there was no evidence of industrial / urban emissions / effluent affecting the ground water quality. The monitored wells were comparatively shallow and get easily mingled with the surface soil seepage and hence, had slightly higher conductivity.

4.4.2.2 Ganga WaterBackground water quality has been found by actual sampling and analysis. The major water body close to the project site is the River Ganga. Ganga receives the pollutional loads of domestic and industrial waste waters as also agricultural run off.

The treated effluent of the refinery is discharged into it through an underground pipeline at Kasha Diara, 5 km. Downstream of Rajendra Bridge. Presently, little quantity of the treated effluent is being discharged into Ganga. The major portion is being recycled back to the refinery for various end uses. Even after the installation of the proposed projects, this practice will continue and, hence, no impact on the Ganga water is envisaged.

4.5 IMPACTS ON AIR QUALITY4.5.1 Impacts during Construction

Particulate matter would be the predominant pollutant affecting the air quality during the construction phase. The soil of the project area, being generally silty in texture, is likely to generate the considerable quantities of dust, specially during the dry condition. Dust will be generated mainly during excavation, back filling and hauling operations along with the transportational activities. Moreover,wind in the area being high particularly during summer and monsoon, wind blown dust is expected to have the tangible effects.

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Therefore, it is recommended that access roads be given suitable surface treatment to curb dust-generation; sprinkling of water from trucks or other suitable means should be undertaken at the sites for the suppression of the fugitive dust as and when needed.

4.5.2 Emissions during Operation 4.5.2.1 Sources of Emission

The major sources of emission in a refinery are a number of heaters in the different units. Fuel oil is burnt in the heaters. Besides the heaters, the Captive Thermal Power Station also burns fuel oil to raise steam for the power generation and supply of process steam. Naphtha/ diesel is also used as fuel in GTs for power generation.

Existing Units1) AVU – I (Atmospheric & Vacuum Distillation Unit)2) AVU – II (Atmospheric & Vacuum Distillation Unit)3) AVU – III (Atmospheric & Vacuum Distillation Unit)4) DCU – A (Delayed Coking Unit)5) DCU – B (Delayed Coking Unit)6) CRU (Catalytic Reformer Unit)7) FCCU (Fluidised Catalytic Cracking Unit)8) DHTU (Diesel Hydrotreating Unit)9) SRU (Sulphur Recovery Unit)10) Hydrogen Generation Unit

Proposed UnitsThe following units are proposed to be installed which will contribute in generating the additional emission:

1. Reformate Splitter Unit 2. Naphtha Hydro-treating & Splitter Unit (NHDT) 3. Isomerisation Unit (ISOM) 4. FCC Gasoline Selective Hydro-treating (SHU)-Prime G + Unit 5. FCC Gasoline Hydro-desulphurisation Unit (HDS)-Prime G + Unit 6. Hydrogen Generation Unit (HGU) 7. DHDT Naphtha Splitter Unit8. Bitumen Unit (BBU)9. ATF Treating Unit10. Sulphur Recovery Unit (SRU)

Besides, there will be additional boiler for the power generation in the existing Thermal Power Stationto meet the future power requirement, which will result in the additional emission load.

Emissions pertaining to the existing condition/ load have also been considered in the modelling though its contribution is already reflected in the baseline air quality. This is to provide a picture of the total contribution of the refinery.

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4.5.2.2 Stack and Emission Characteristics In the process, fuel oil and fuel gas is burnt in the heaters/furnaces at high temperatures. Besides the heaters, the captive thermal power station (TPS) also burns fuel oil to raise steam in boilers for power generation and supply process steam. Naphtha/ diesel is also used as fuel in GTs.

As a result, stack emissions would be constituted of mainly sulphur dioxide (SO2) and oxides of nitrogen (NOx). Other emissions like particulates (SPM) & carbon monoxide (CO) will be much lower or negligible compared to SO2.

Considering stack characteristics pertaining to all the stacks (the existing and the future) it is evident that there are 21 stacks of various heights ranging from 40 to 80.47 m with stack exit diameter varying from 0.61 to 3.5 m. While stack gas temperature varies from 90 to 350C, the stack gas exit velocity varies between 5.27 and 21.4 m/s.

The stack and emission characteristics pertaining to the existing and the future stacks are presented in Table-4.1.

TABLE - 4.1STACK & EMISSION CHARACTERESTICS

[Existing and Future Stacks]

S.N Stack Attached ToLocation of

Stacks STACKFlue Gas Exit SO2 NOx

Co-ordinates (m)

Hei-ght

Inter-nal Temp

Velo-city

EMISS-ION

EMISS-ION

X-AXIS

Y-AXIS (m)

Dia at (°C) (m/s) (KG/HR) (KG/HR)top (m)

EXISTING STACKS

1 AVU - 1 0 0 42 2.46 200 6.94 35.17 6.85

2 AVU-2 123 0 42 2.46 200 6.94 35.17 6.85

3 AVU-3 527 153 80.47 3.2 200 5.124 73.13 8.56

4 COKER-A -138 -155 41.53 3.128 300 5.54 31.35 7.3

5 COKER-B -338 65 57.62 2.27 300 7.89 26.25 5.47

6 CRU-R 537 -34 53 3.05 200 5.35 15.14 8.12

7 CRU-S 537 -101 60 1.65 200 5.42 26.59 2.41

8 FCCU (CH & COB) 503 -217 62.5 3.6 90 7.02 215.31 19.34

9 DHDT 663 -247 50 2.2 200 5.36 41.5 4.23

10 HGU 533 -247 40 2.3 180 5.27 0.85 4.75

11 GT-I -483 -113 60 3 200 5.69 2.04 8.35

12 GT-II -356 -192 60 3 200 5.69 2.04 8.35

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S.N Stack Attached ToLocation of

Stacks STACKFlue Gas Exit SO2 NOx

Co-ordinates (m)

Hei-ght

Inter-nal Temp

Velo-city

EMISS-ION

EMISS-ION

X-AXIS

Y-AXIS (m)

Dia at (°C) (m/s) (KG/HR) (KG/HR)top (m)

13 SRU 9 826 77 1.3 300 5.47 40.24 1.24

14STACK AT TPS (EXISTING) -523 -125 60 3.5 160 11.0 127.63 22.59

15STACK OF VTH BOILER (EXISTING) -564 -125 60 1.5 160 21.4 127.63 10.58

PROPOSED STACKS

1 NHDT + SPLITTER 150 -200 60 0.97 350 7.62 1.85 0.89

2 HDS 150 -220 60 0.61 350 7.62 1.85 0.35

3 HGU 150 -300 40 2.3 180 7.62 0.5 6.87

4 NEW SRU 525 -500 60 1.37 300 7.62 51.81 1.93

5 BBU 450 0 60 1.68 350 7.62 1.29 2.66

6STACK OF NEW BOILER -550 -100 80 2.2 180 21.4 177.25 30.23

Total 1034.59 167.92

4.5.3 Methodology for Prediction of GLCs4.5.3.1 Mathematical Model and its Applicability

The refinery operation will emit gaseous pollutants from a number of stacks, which have the potential to deteriorate the air quality of the area.

In order to evaluate the impact on ambient air quality due to such releases, the ground level concentrations (GLCs) as a result of the plant emissions are evaluated through mathematical modelling using computer-aided techniques.

The emission from stationary source is subjected to transport and diffusion process, which is together termed as dispersion. The following processes govern the atmospheric dispersion of pollutants:

a. an initial vertical rise called the plume rise due to initial thermal buoyancy and momentum of discharge

b. transport by wind in its direction.c.diffusion by turbulence.

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d. a number of physico-chemical processes such as gravitational settling, dry and wet deposition which includes deposition on vegetation, chemical reactions, transformations and decomposition, adsorption on deposited vapors, coagulation of particles, etc.

The ground level concentration (GLC) of pollutants due to emissions from stationary elevated sources are computed using dispersion models, which are mathematical relations between the source strength and concentration and involves parameters related to transport and diffusion. The empirical Gaussian model is the widely used model in practice, which assumes that the parameters governing the transport and diffusion do not change in space and time. In reality attention may have to be given to several factors namely, existence of different stability classes at different heights,

change of terrain characteristics, change in the stability characteristics with time, existence of free convection regions and strong wind sheers. Cognizance of these factors was taken in the best possible way to suit the circumstances and the best possible estimates were obtained. The basic Gaussian equation represents an ideal steady state of homogeneous meteorological conditions, idealised plume geometry, uniform flat terrain, complete conservation of mass and exact Gaussian dispersion, which never occurs in real situations. The equation is as follows:

C (x,y,z) = (Q/(.u.y.z)).exp(-y2/2y2). exp(-(z-H)2/2y2). exp(-(z+H)2/2y2)

where,

C = Concentration of pollutant in g/cu m at a point (x,y,z)Q = Source strength in g/s (rate of pollutant release)

u = Horizontal wind speed in m/s at the source level

y & z = horizontal crosswind and vertical distance in meters from the plume centre line to the receptors respectively

H = The effective stack height which means the sum of stack height and plume rise above the stack.

The coordinate system is such that the origin (o,o,o) is at the source, X-axis is in the mean downwind direction, Y-axis is in horizontal crosswind direction and Z-axis is in the vertical. The quantities sigma y and sigma z are the standard deviations of the distribution of concentrations at `x' in horizontal crosswind and vertical directions respectively. The quantity sigma y and sigma z increase with increasing downwind distance `x', signifying that the dilution increases with distance. The rate at which sigma y and sigma z increases with distance depends upon the turbulence intensity and hence the stability of atmosphere. The concentration at any point downwind of the source is given by the equation.

In case of multiple sources of emission, the receptors co-ordinate would change with respect to the source of emission. In that case, a grid system is chosen which correspondingly selects the co-ordinates of the emission sources and those of the receptors. Both the Cartesian (x,y) or the Polar (r,) system can be used. Cartesian system which is more convenient has been used in following

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computations. With the change of wind direction, the downwind direction with respect to the receptor changes and the x-axis needs to be changed accordingly.

Bureau of Indian Standards (BIS) had published the "Guidelines for the micro-meteorological techniques in air pollution studies" (IS-8824, 1478) though its use was limited. Central Pollution control Board (CPCB) has also published Guidelines for Conducting Air Quality Modeling (PROBES/70/1997-98). It follows dispersion equations as stated above only specifying the equations and conditions to be followed for different parameters e.g. use of Pasquil-Gifford’s stability classes, Briggs' equation for effective stack height calculation and use of Irwin's formula to extrapolate measured wind speed to the higher altitudes.

Industrial Source Complex Short Term, version 3 (ISCST3) dispersion model of Environment Protection agency of USA is similar to CPCB's suggested model and has been used in the present study. This is a quite advanced model which can take account of complex terrain, building downwash, dry deposition, pollutant decay etc. It takes meteorological input for every hour and calculates concentration at each receptor for one hour average. The desired average e.g. 24-hour average or monthly averages can be obtained based on the hourly averages. The model does not consider any factor for one hour average though the basic dispersion coefficients are for 3-15 minutes average. There are different empirical factors suggested for correcting this base average concentration. In absence of any suggestion in CPCB's guideline, the correction suggested in IS-8824 has been included in the model.

It should always be considered that Gaussian plume dispersion models provide approximate results because of number of assumptions and empirical equations being involved in the computation. The models would predict results, which are mainly a guide for air quality decision.

4.5.3.2 Selection of Model ParametersThe dispersion coefficients in the horizontal/lateral plane (y) and vertical plane (z), as a function of the downwind distance from the source and the stability class (A to F), have been computed using Briggs' sigma functions applicable for rural conditions.

The wind speeds at stack height have been extrapolated from the wind speeds measured at 10 metres height using the Irwin's wind scaling law applicable for rural and other conditions, the exponent depending on the stability class.

The effective stack heights have been computed using Briggs' plume rise formula with necessary correction for stack tip down wash using the method suggested by Briggs.

The other crucial factor influencing the dispersion in atmosphere is the mixing height, the layer of atmosphere where the dispersion is confined. The effect of mixing height has been considered in GLC calculation in the form of plume penetration and plume trapping.

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4.5.3.3 Data Used for ModellingThe hourly meteorological data like ambient temperature, wind speed and wind direction used for air quality modelling have been taken from such data generated through continuous on-site monitoringduring the study period (March 2007 – June 2007).

The hourly mixing height data as well as the hourly occurrence of various atmospheric stability classes which are used in the modelling exercise are based on such data generated through on-site Sodar study conducted for May, 2000 representing summer season.

Various stack and emission data as presented in Table-4.1 have been used as inputs to the model. The prediction of GLCs and corresponding impacts has been made for the emission figures mentioned therein.

4.5.3.4 Modelling ProcedureAs recommended by CPCB, radial pattern of receptor locations has been implemented using the polar (r,) co-ordinate system with one of the sources as origin or Absolute Reference Point (ARP). The locations of the receptors have then been defined with respect to 16 radial directions (N to NNW) (angle of such directions measured anti-clockwise from East) and radial distance r from the ARP.

In this case, the stack attached to AVU-I has been considered as the ARP (Absolute Reference Point). In each radial direction 15 nos. of receptor locations have been selected in recommended multiples of average physical stack height. The maximum distance covered is 10 km, which has been seen adequate to cover the maximum concentrations for this particular situation.

While computing the GLCs, the transformation of polar co-ordinates of the receptors into Cartesian co-ordinates has been performed by defining a Cartesian co-ordinate (x,y) system with origin at the ARP of the polar co-ordinate system, x-axis along the East direction and y-axis along the North direction.

For multiple stack computation, the actual locations of the stacks have been defined in a Cartesian grid system with origin at the ARP, x-axis along the East direction and y-axis along the North direction. The inter-stack distances have been considered therein.

Since the contributions from different pollution sources are additive, the contributions of all sources at a given receptor have been computed separately and then added to get the total concentration.

The modelling has been done for 2 cases:

Case I – All 15 existing & 6 new stacks (Total 21 stacks)Case II – All 6 new stacks

4.5.3.5 Modelling ResultsThe absolute maximum of the predicted GLCs of SO2 & NOx for the 2 cases has been calculated as:

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Predicted Maximum GLCs of various pollutants

Case I Predicted Maximum GLC GLC (g/m3) Direction Distance (km)

SO2 66.99 ESE 1.4NOx 9.4 E 1.3Case II Predicted Maximum GLC

GLC (g/m3) Direction Distance (km)SO2 16.17 ESE 1.1NOx 2.95 E 0.7

Isopleths (iso- concentration plot) of SO2 & NOx plotted for the 2 cases are depicted in Figures – 4.1through 4.4.

4.5.4 Impacts on Air Quality during OperationThe absolute maximum of the predicted GLCs of SO2 & NOx would be about 67 & 9.4 g/m3

respectively, which will occur in future at a distance of about 1.1 – 1.4 kms, i.e., close to the plant boundary.

This also includes the contributions from the existing operation of the plant though its contribution is already reflected in the baseline ambient air quality, and thus provides a picture of the total contribution of the plant.

The predicted maximum GLCs of SO2 & NOx due to operation of the plant, in any case, are within the permissible limit of 80 g/m3 applicable for industrial areas as stipulated in the National Ambient Air Quality Standards.

It may, therefore, be concluded that the setting up and operation of the proposed units will not cause any intolerable impact on the ambient air quality.

4.6 IMPACTS ON NOISE4.6.1 Impacts during Construction

The construction phase will see the operation of light and heavy construction machineries, which are known to emit sounds with moderate to huge decibel value. Careful planning of their operation is required during this period so that minimum disturbances are caused. The construction personnel should be located away from the major road traffic. Finally, green belts round the complex would serve the dual purpose of checking fugitive dust as well as noise pollution. Moreover, residential areas being mostly far away, no impact is apprehended.

4.6.2 Impacts during OperationThe ambient noise monitored in and around the project area revealed high noise levels over a twenty four hour period, due to the extensive industrial, transportational and commercial activities in the area.

On the other hand, the operational activities are expected to generate unduly noise. The movement of cars and a few trucks in the area and blowing of their horns would contribute to the machinery noise.

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However, neither the sound intensity nor its duration is expected to be large enough to cause any undue disturbances to the habitat living inside and in close proximity to the site. As such, impact due to noise on the adjacent area would not assume any significant dimension. This projection is already evident from the baseline scenario.

Noise levels monitored within the BR Complex were lower than those monitored at urban areas, from which it could be inferred that traffic and urban activities were the main sources of noise.

At present, BR has considered low noise generating equipments for their system. Accoustic logging, accoustic barrier, accoustic shelter have already been provided to contain the noise level within the desired level. Use of adequate personal protection equipments like ear plugs, ear muffs has been

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Figure – 4.1Isopleth of SO2

(Case I – Existing & New Stacks)

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Figure – 4.2Isopleth of SO2

(Case II –New Stacks)

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Figure – 4.3Isopleth of NOx

(Case I – Existing & New Stacks)

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Figure – 4.4Isopleth of NOx

(Case II –New Stacks)

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strictly enforced. Besides, the chances of the working personnel exposed to the unwanted noise environment have been minimised by adopting the shift rotation approach for the employees.

However, impacts on persons working very close to the industrial noise sources are likely, which shall be minimised by providing with adequate protection in the form of ear plugs, ear muffs etc.

4.7 IMPACTS ON ECOLOGY4.7.1 Impacts on Terrestrial Ecology during Construction

The impact of construction activities will be primarily confined to the project site. As stated earlier, the existing site is a piece of vacant and barren industrial land confined within the boundary of the Refinery Complex with very few sparsely distributed non- commercial tree species. The site does not involve any forest land. Thus, the site development works will not lead to any significant loss of any important taxa.

Removal of top soil often leads to soil erosion. Deposition of fugitive dust on pubescent leaves of nearby vegetation may lead to temporary reduction of photosynthesis. Such impacts will, however, be confined mostly to the initial periods of the construction phase.

The entire complex would be extensively landscaped with a variety of taxa, the planning of which has started and have already resulted in some plantations at site.

Only few species of common birds are sited in and around the site. No wild life sanctuary is involved in the site and vicinity. Therefore, there is no likely tangible impacts from higher noise and emissions during construction on the common animals and birds in the area.

4.7.2 Impacts on Terrestrial Ecology during OperationThe baseline status of terrestrial flora and fauna within the study area has been drawn up earlier. As such, there is no forest or wild life santuary in the study area. The study area is dominated by industrial, commercial, agricultural and residential landuse.

Extensive landscaping involving plantations of carefully chosen trees, shrubs and herbs would be undertaken in and around the site. This would not only restore any loss in ecology of the area, but also sufficiently enhance the floral status around the site.

The harmful effects of such air pollutants as SPM, SO2, NOx in affecting growth and other similar func-tions of trees, either singularly or synergistically is well known. However, such effects are experienced only at high levels. The levels of pollutants expected to be maintained around the project site are much lower and are not envisaged to cause any such stress.

To study the impact of the Refinery on crops in the study area, a number of representative locations were surveyed, which are discussed earlier in details. From the results, one can infer that there was no visible adverse impacts on the cultivated trees due to industries. However, road side plantation showed slight dust deposition due to vehicular movement. As for crop, though SO2 had no impact, high SPM had certain impact and reduced yield. No specific impact on vegetables was found.

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It may, therefore, be concluded that, the proposed projects, which will not involve SPM emission will have no impact on the trees or crops.

4.7.3 Impacts on Aquatic Ecology during ConstructionAs the water quality of the surface water bodies is not likely to change significantly due to the construction activities, no substantial impact on the aquatic life is expected.

4.7.4 Impacts on Aquatic Ecology during OperationTo assess the nature of impact of Refinery effluent discharge on the aquatic ecology including bio-productivity of river Ganga, field studies were conducted at two relevant locations on the river. From the findings discussed earlier, one can conclude that BR discharge had negligible impact on the water quality of the river. BR has taken measures to reuse the treated effluent. At present, no effluent is being discharged into river Ganga.

As discussed earlier, no tangible effects are expected to be observed on the water quality of the river Ganga due to any industrial discharge from the project. As such, the existing aquatic biota of the river are not expected to suffer any undue stress due to the said activities.

4.7.5 ConclusionAs observed from the present status of terrestrial flora and fauna, it appears that the proposed projects will not cause any significant damage and, in no way, will reduce the diversity of terrestrial flora and fauna.

There will neither be any drastic change in number nor any health injuries of domestic animals in the vicinity due to the proposed projects.

As the additional refinery effluent will be recycled back to the refinery after proper treatment and not discharged into the Ganga, there will have no adverse impact on the ecology of the river.

The proposed projects will not have any adverse effect on the agricultural environment.

4.8 IMPACTS ON DEMOGRAPHY AND SOCIOECONOMICS4.8.1 Impacts during Construction

A sizeable workforce comprising skilled, semi-skilled and unskilled labourers will be needed at the peak period of construction phase. Significant number of semiskilled and unskilled labourers may be recruited from the nearby areas. This will create employment opportunities in the areas. Some competition for workers during construction phase is, therefore, anticipated.

Only few special categories of skilled personnel may be brought to site from outside the locality, proper housing / accommodation is possible in the established town on rent. No appreciable impact is anticipated.

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Even, if the temporary accommodation of migrant skilled and semi-skilled workers requires a construction camp, it will be located in the project area. Therefore, it may not cause any significant social stress, though some degradation in the physical environment would be unavoidable.

This activity, for the proposed project, will cover the arrangements for the construction workers. Most of the work in construction phase is labour intensive. As most of the job will be done by contractors, it will be ensured that the contractors’ workers are provided with proper facilities including sanitation and drinking water supply. Since most of labour force will be drawn from established neighbourhood, no new environmental problem is anticipated.

There are no permanent residents within the project area and as such, the project would not result in any oustees who have to be provided with adequate rehabilitation/ compensation by the Project Authorities. This is a redeeming feature of the project.

The construction materials like stone chips and sand will be procured locally. The other important materials like cement, steel will be procured through various sources. Thus there is a possibility of local employment generation, though temporary. There will be hardly any pollution problem due to this activity.

There are several ill effects of certain constructional activities towards the environment, which have already been stated. If proper and effective control measures are taken in time, these pollution potentials would be mitigated to a large extent, or neutralised. As the construction phase has a very short time span in comparison with the operation phase, it would not have any long term effect. Moreover, the different groups of people engaged in different construction activities will leave the place after specified time span, so the environmental consequences of these activities are not properly quantified.

These are the main things that all the people will need. Adequate and timely supply of drinking water will not disturb resources in the area.

4.8.2 Impacts during OperationThe labour force involved during construction phase is likely to be replaced by more skilled manpower to operate and maintain the plant.

Some additional manpower will be required during the operation of the additional plant units, most of which will be migrant in nature involving an increase in total population in the area. However, compared to the semi- urban nature and high population density in the vicinity, the impacts on the demographic fabric of the area will be negligible.

Large beneficial impacts in terms of gross economic yield shall accrue. In addition, gross economic yield shall increase through increase in agricultural produce, animal husbandry produce, high income group and through marketing multiplier effect. The benefits accrued shall be obviously tremendous in local as well as regional context.

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BR has been paying special attention to improve the socioeconomic environment in the neighbouring areas. It has contributed a lot in uplifting the standard of rural and urban areas as listed below :

- Provision of handpumps and erection of well in neighbouring rural areas.- Promotion of health care facilities in the surrounding villages. - Financial assistance to Begusarai Municipality in constructing and repairing the national high

way.- Conducting Kala - Azar prevention programme.

Medical facilities of the rural areas were observed to be unsatisfactory. It was also learnt that BR has spent money under rural development programme including medical facilities to rural areas.

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5.0 Environmental Monitoring Program Envirotech East Pvt. Ltd.

CHAPTER-5

ENVIRONMENTAL MONITORING PROGRAM

5.1 NEED FOR MONITORINGIt is imperative that the Project Authorities set up regular monitoring stations to assess the ambient levels in relevant areas of environment after the commissioning of the project. An environmental monitoring programme is important as it provides useful information on the following aspects:

i) It helps to verify the predictions on environmental impacts presented in this study.ii) It helps to indicate warnings of the development of any alarming environmental situations, and thus, provides opportunities for adopting appropriate control measures.The monitoring programme in different areas of environment, outlined in the next few sections, has been based on the findings of the impact assessment studies, described earlier.

5.2 RELATED ENVIRONMENTAL PARAMETERS5.2.1 Meteorology

Meteorology forms one of the important categories of environment in the area as it directly controls the levels of air quality parameters particularly wind speed and direction. As such, a meteorological observatory of continuous recording type should be set up at a suitable location within the plant for monitoring of relevant parameters. The observatory includes equipments for monitoring of temperature, wind speed and wind direction.

5.2.2 Ambient Air QualityMonitoring of ambient air quality should be carried out on a regular basis to ascertain the levels of harmful pollutants in the atmosphere, as air quality could represent one of the worst affected environmental disciplines due to the plant operations.

5.2.3 Stack EmissionsStack emissions should also be monitored, particularly to ascertain that emissions are within the stipulated level. Sampling techniques appropriate for stack monitoring should be employed with the monitoring being undertaken during operation at peak load with the frequency of once in a month.

5.2.4 Liquid EffluentsSamples should be collected from the effluent discharge channel of the plant once a month and analysed in accordance with the parameters stated in IS 2490 (Part- I) and MINAS, to ensure that the effluent quality meets the stipulated standards for discharge into inland surface waters.

5.2.5 Noise LevelsAmbient noise levels should be monitored within the plant at a frequency of once every season for one year, in order to compare the existing noise levels with the stipulated limits specified in the Gazzette Notification of December, 1989.

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5.0 Environmental Monitoring Program Envirotech East Pvt. Ltd.

5.3 MONITORING CONDUCTED5.3.1 Stack Emission

Existing stacks are monitored for the parameters SO2, NOx, particulates, nickel & vanadium with the frequency of once in a month (nickel & vanadium once in two months). The gaseous effluents from the additional stacks shall also be monitored similarly.

5.3.1 Ambient AirAmbient air quality is being monitored inside the plant at 5 stations and at the township at 1 locationwith the frequency of twice in a week. SPM, RPM, SO2, NOx, NH3 and CO are monitored.

Installation of Continuous Ambient Air Quality Monitoring StationAs per Bihar State Pollution Control Board directive, a continuous monitoring station is to be established for 24 hours observation of the air quality. Accordingly, a continuous air quality monitroing station is being built wherein SO2, NOx, HC, SPM and Benzene Parameters will be logged. The facility will be commissioned by September'08.

5.3.3 Liquid EffluentTreated effluent before discharge are monitored and analysed on the daily basis for the parameters required for MINAS.

5.3.4 NoiseNoise monitoring is being conducted at 40 (forty) locations inside and outside the plant with a frequency of every six (6) months.

5.3.5 Fugitive EmissionFugitive Emission Monitoring for Hydrocarbons is conducted at around fifteen hundred (1500) locations inside the plant with a frequency of every three (3) months.

5.3.6 Work Zone Monitoring The parameters like SO2, CO, H2S, benzene and Hydrocarbons are monitored at twenty one (21) locations in the work zone areas of the plant with a frequency of every three (3) months.

5.3.7 Ground Water QualityTo assess the ground water quality, around the refinery, monitoring is conducted at twelve (12) locations on monthly basis.

5.3.8 Sludge AnalysisOily sludge and bio sludge are monitored for several physical and chemical parameters with the frequency of every four (4) months.

5.4 RECOMMENDED ADDITIONAL MONITORINGAs discussed above, monitoring of emission from additional stacks should be added to the existing monitoring activities. The frequency and parameters are just discussed.

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6.0 Additional Studies (Risk Assessment & Disaster Management Plan) Envirotech East Pvt. Ltd.

CHAPTER-6

ADDITIONAL STUDIES(RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN)

6.1 INTRODUCTIONThis chapter contains the generic Disaster Management Plan (DMP) as required under item 11, Schedule II of the Environmental Impact Notification, 1994 of Ministry of Environment and Forests, Govt of India.

6.2 DEFINITION OF DISASTER/EMERGENCYThe word 'disaster' is synonymous with 'emergency' as defined by the Ministry of Environment and Forests (MOEF). An emergency occurring in the Barauni Refinery (here in after referred to as "Plant") is one that may affect several sections within it and / or may cause serious injuries, loss of lives, extensive damage to environment or property or serious disruption outside the plant. It will require the best use of internal resources and the use of outside resources to handle it effectively. It may happen usually as the result of a malfunction of the normal operating procedures. It may also be precipitated by the intervention of an outside force such as a cyclone, flood, or deliberate acts of arson or sabotage.

6.3 BRIEF DESCRIPTION OF THE PROJECTThe plant is located in Begusarai district of Bihar. The site is located at about 8 km. of the river Ganga.

As the site including its geographic location, administrative location, communication, physiographic characteristics, climate etc has been elaborated earlier, it has not been separately reproduced here.

The plant is provided with adequate fire protection system, central electronic control system, alarm and trip provisions for pumps, compressors, storage vessels etc, gas detection system with alarm and trip provision, automatic spray system for storage, bottling and filling and automatic safe shut down system.

More details regarding the project and facilities is available earlier in chapter captioned "Project Description". Layout plan of the plant is depicted in Figure-2.1. The roads inside the terminal have been depicted therein. The overall transportation system is described earlier in details.

6.4 POSSIBLE EMERGENCIES 6.4.1 Hazardous Materials Handled

The hazardous materials which are handled at the plant include among others crude oil, LPG, Naphtha, MS, Gasoline, HSD, Fuel Oil, Ammonia, Hydrogen, Chlorine etc. As per the hazard classification, following types of hazardous materials are handled:

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Flammable gases: Chemicals which in the gaseous state at normal pressure and mixed with air become flammable and the boiling point of which at normal pressure is 20oC or below.

Highly flammable liquids: Chemicals, which have a flash point, lower than 23oC and the boiling point of which at normal pressure is above 20oC.

Flammable Liquids: Chemicals which have a flash point lower than 65oC and which remain liquids under pressure, where particular processing conditions, such as high pressure and high temperature, may create major accident hazards.

Explosives: Chemicals, which may explode under the effect of flame or which, are more sensitive to shocks or friction than dinitro benzene.

6.5 RISK ANALYSISRisk is defined as the consequences of a particular activity in relation to the likelihood that this may occur. Risk measurement or analysis thus comprises of two variables:

1) Magnitude of consequences of certain accident and2) Probability of occurrence of this accident

Probability of a certain accident depends on the probability of failure of a plant component including human error/failure and failure of designed counter measures.

Probability of a certain consequence depends on the probability of weather/stability class, probability of wind direction, probability of ignition in case of a fire or explosion, and finally probability of being injured or killed which depends on the damage criteria and escape factors.

6.5.1 Risk Analysis MethodologyThe four normal components of a risk analysis study are:

1) Identification of hazards and accident scenarios 2) Calculation of physical effects and consequences3) Estimation of the probabilities and frequencies4) Risk assessment and calculation of risk levels

Major chemical hazards are generally considered to be of two types:

- Flammable (fire, explosion etc)- Toxic (toxic gas cloud)

Where there is the potential for gas/vapour releases, there is also the potential for explosions. These often produce overpressures which can cause fatalities, both through direct action on the body or through plant and building damage.

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Accidental release of flammable or toxic vapours can result in severe consequences. Delayed ignition of flammable vapours can result in blast overpressures covering large areas. This may lead to extensive loss of life and property. Toxic clouds may cover yet larger distances due to the lower threshold values in relation to those in case of explosive clouds (the lower explosive limits).

In contrast, fires have localised consequences. Fires can be put out or contained in most cases; there are few mitigating actions one can take once a vapour cloud gets released. Major hazards arise, therefore, consequent upon the release of flammable or toxic vapours or BLEVE in case of pressurised liquefied gases.

Various studies such as Hazard and operability studies, Event tree analysis, `What-if' analysis etc are normally applied for the identification of potential hazards.

Inventory plays an important role in regard to the potential hazards. Larger the inventory of a vessel or a system, larger is the quantity of potential release. A practice commonly used to generate an incident list is to consider potential leaks and major releases from fractures of pipelines and vessels containing sizable inventories of flammable/toxic materials.

The range of possible releases for a given component covers a wide spectrum, from a pinhole leak upto a catastrophic rupture (of a vessel) or full bore rupture (of a pipe). It is both time consuming and necessary to consider every part of the range; instead, representative failure cases are generated. For a given component these should represent fully both the range of possible releases and their total frequency.

In general, the following typical types of failures are considered:

- Rupture for vessels- Full bore rupture for pipes- Large leaks (mainly connection failures), 100 mm equivalent diameter- Small and Very small leaks (due to corrosion, impact and other such cases), 25 and 5 mm

equivalent diameter leaks respectively.

For this type of analysis, a screening process is also implemented. This ensures that attention is focused on events with potential to cause fatalities. All events which do not have the potential to generate consequences are eliminated at this stage.

When the appropriate inputs are defined, the software calculates the source terms of each release, such as the release rate, release velocity, release phase and drop size. These source term parameters then become inputs to the consequence modelling.

6.5.2 Selection of Accident ScenariosOnly a few different types of process plant components are of importance in hazard analysis, and only a few failure cases for each component are of importance for consequence analysis.

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The process of incident selection is to construct an appropriate and representative set of accident/incident scenarios (failure cases) for the study from the initial list that has been generated by the enumeration process. An appropriate set of incidents is the minimum number of incidents needed to satisfy the requirements of the study and adequately represent the spectrum of incidents enumerated.

6.5.3 Calculation of Physical Effects and ConsequencesIn order to undertake this study, the well-known DET NORSKE VERITAS (DNV), ISO 9000 certifying agency's computer software WHAZAN-II, version-2.1 has been used to simulate behaviours of accidental release of chemicals and its effects. Using the failure case data developed, the program undertakes consequence calculations for each identified incident or failure case.

The software initially models the dispersion of the released material irrespective of whether it is flammable or toxic. For flammable materials, the software then proceeds to determine the effect zones for the various possible outcomes of such a release. The extent of effect zone depends on the acceptable damage criteria.

6.5.4 Consequence Analysis, Results and Discussion6.5.4.1 Data And Assumptions For Consequence Analysis

Based on the guidelines provided in the WHAZAN-II Manual, DNV Technica, the following data and assumptions have been used during the process of consequence analysis and risk assessment:

- Product compositions taken for calculation of release rates and dispersion are: a) Naphtha characterised as n-Hexaneb) MS characterised as n-Heptane

For, if the hazardous material is a mixture of components, it must be characterised as a single component, erring where necessary on the conservative side.

- The calculations were carried out for following stability classes and wind velocity combinations:B - 3 m/sE - 1 m/s

The meteorological data like predominant wind direction, mean temperature & relative humidity have been taken, as discussed in Chapter-3.5.

- Damage criteria (Thermal damage criteria, Overpressure damage criteria etc.) has been adopted in this study.

- Exposure duration of 30 seconds has been adopted in case of fires, based on the assumption that the exposed persons will have found shelter or protection from the heat radiation or run away to safe distance within this time.

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- Catastrophic rupture of vessels will lead to instantaneous/rapid release of the entire inventory of the vessel. And releasing material will ignite immediately in case of catastrophic rupture or failure of storage vessel.

- Leaks in pipelines connected to vessels are assumed to occur at the base of the vessels and have been treated as same as the leaks of same size in vessels.

- A constant release rate is assumed over the entire duration. In general, a duration of 10 minutes has been taken for releases that can be isolated (DNV Technica).

- In case of boiling liquids aerosols formation due to evaporation has been assumed to be of similar amount as of aerosols formation due to and initial flash vaporisation due to boiling.

6.5.4.2 Final List of Incident Scenarios and ConsequencesBased on the hazard identification and MCA analysis, a final short list of incident scenarios is obtained, which are given in Table-6.1 below. Physical effects and consequences are calculated for these scenarios using various models available within the software package WHAZAN-II.

Table-6.1 Credible Accident Scenarios, Release Conditions and ConsequencesSN Scenario Description and Release Condition Consequences

Isomerisation Unit:1 ISOM feed surge drum outlet line failure (hydro-treated naphtha release at

40C, 3 kg/cm2g)Jet flame, VCE

2 ISOM unit hydrogen dryer outlet line failure (H2 release through assumed 3” line at 39C, 40 kg/ cm2g)

Jet flame, VCE

FCC Gasoline Selective Hydro-treating Unit (SHU)- Prime G + Unit:3 SHU feed surge drum outlet line failure (naphtha release at 45C, 1.4

kg/cm2g)Jet flame, VCE

FCC Gasoline Hydro-desulphurisation Unit (HDS)- Prime G + Unit:4 HDS feed drum outlet line failure (naphtha release at 76C, 1.6 kg/cm2g) Jet flame, VCE

Hydrogen Generation Unit (HGU):5 Naphtha Feed Surge Drum outlet line failure (Naphtha release through hole

of 2” equivalent dia at 40C, 3.5 kg/cm2g)Jet flame, VCE

6 HGU pre-reformer outlet line gasket failure (naphtha release through 2” leak at 507C, 28.3 kg/cm2g)

Jet flame, VCE

Off-site Storage Facilities:7 5000 KL MS tank on fire Tank fire8 3000 KL ATF tank on fire Tank fire9 5000 KL MS tank bottom line 4” leak Pool Fire10 3000 KL ATF tank bottom line 4” leak Pool Fire11 225 KL Hydrogen Bullet Catastrophic failure BLEVE/Fireball

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6.5.4.3 Scenariowise Consequence Analysis and DiscussionBLEVEs/FireballsHydrogen will be stored in pressurised condition at atmospheric temperature as liquids. BLEVE scenarios are considered for such boiling liquids because if any heat source is available near the storage tanks, which may increase the pressure inside the tanks and leads to catastrophic rupture of the tanks resulting in instantaneous evaporation of a substantial inventory followed by immediate fire and explosion of considerable damage potential.

Detailed computations for BLEVE scenarios for Hydrogen storage tanks involved here have been carried out. Outcomes of such consequence analysis comprising of BLEVE duration, fireball diameter and damage distances of different fatality and damage levels are presented in Table-6.2.

Table-6.2 Outcomes of Consequence Analysis- BLEVEs/FireballsScNo

Scenario Description

Flamm

able

Mass

(kg)

Fireb

all D

iamete

r (m)

Fireb

all D

urati

on (s

ec)

Thermal Damage Distance (m)

from Centre of Fireball for

99%

Fata

lity

50%

Fata

lity

1% F

atality

1stDe

gree

Safe

Diste

nce

11 225 KL Hydrogen bullet catastrophic failure 16400 149 11.5 358 429 602 967 1562

The effect distances for the different levels of heat dose have been worked out for each of the BLEVE scenarios for the following fatality and damage:

65 kW.s/m2 : no discomfort, safe distance 125 kW.s/m2 : 1st degree burn, limit for plant operators

950 kW.s/m2 : 1% fatality, limit for piloted ignition (secondary fire)2375 kW.s/m2 : 50% fatality, limit for non-piloted ignition5900 kW.s/m2 : 99% fatality, heavy damage to plant equipment

The thermal effect distances for three different levels of fatality (99%, 50% and 1%), for first degree burns and for safe distance have been worked out for each of the release scenarios from the heat dose units and the exposure duration equal to the BLEVE duration.

In case of BLEVE pertaining to Bullet, the diameter and duration of fireball are found to be 149 m and 11.5 sec respectively. The maximum thermal damage distances for 99%, 50% and 1% fatality are found to be about 358, 429 and 602 m respectively, while the maximum damage distance for first degree burns is about 967 m from the centre of the fireball.

It can be seen that people on-site as well as off-site are at risk from such devastating BLEVEs. Since duration of such events is very small hardly any time is available to mitigate the event. The only way to

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reduce risk of such potentially severe consequences is to take appropriate safety measures right at the detail design stage and preventive measures during operation and maintenance.

Tank FiresTank fire of the storage tanks may be considered as credible accident. Therefore, detailed computations of tank fire of the relevant tanks involved have been carried out. Outcomes of such consequence analysis comprising of the distances for different heat radiation levels are presented in Table-6.3.

Table-6.3 Outcomes of Consequence Analysis- Tank FiresScNo


Tank

Diam

eter (

m)

Wind

Spe

ed (m

/s)

Thermal Damage Distance (m)from Centre of Tank forHeat Radiation Level

37.5

kW/m

2

25.0

kW/m

2

12.5

kW/m

2

8.0 kW

/m2

4.5 kW

/m2

1.6 kW

/m2

7 5000 KL MS tank (containing MS) on fire 22.7

3 18 24 37 52 61 961 15 18 24 33 42 63

8 3000 KL ATF tank (containing ATF) on fire 22.7

3 12 14 14 18 33 541 12 12 12 15 23 36

The effect distances for the different levels of heat radiation have been worked out for each of the tank fire scenarios for the following fatality and damage:

1.6 kW/m2 : no discomfort, safe distance 4.5 kW/m2 : 1st degree burn, limit for plant operators 8.0 kW/m2 : limit for unprotected adjoining equipment12.5 kW/m2 : 1% fatality, limit for piloted ignition (secondary fire)25.0 kW/m2 : 50% fatality, limit for non-piloted ignition37.5 kW/m2 : 99% fatality, heavy damage to plant equipment

Based on past experience, it is found that peak level of radiation intensity will not occur suddenly. Rather 20-30 minutes time will be required before a tank fire grows into full size which is sufficient even for public to run away to safe distance. From these considerations, the limit of 4.5 kW/m2 heat radiation level for public beyond the plant boundary has been selected for such fires.

For similar fire size, the effect distances for 3 m/s wind is significantly larger than those distances for 1 m/s wind due to tilting of the flame in higher wind speeds.

In case of tank fire pertaining to the 5000 KL MS tank, the maximum damage distance for first degree burn under 3 m/s wind is found to be about 61 m. In similar condition, the maximum damage distance

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for thermally unprotected adjoining equipment is about 52 m and the maximum damage distance for 1% fatality/ secondary fire is about 37 m. Under 1 m/s wind speed the respective maximum damage distances are about 42 m, 33 m and 24 m.

In case of tank fire pertaining to the 3000 KL ATF tank, the maximum damage distance for first degree burn under 3 m/s wind is found to be about 33 m. In similar condition, the maximum damage distance for thermally unprotected adjoining equipment is about 18 m and the maximum damage distance for 1% fatality/ secondary fire is about 14 m. Under 1 m/s wind speed, the respective maximum damage distances are about 23 m, 15 m and 12 m.

The thermal damage circle diagrams for various tank fire scenarios have been shown in Figures-6.1 to 6.2.

It can be seen that only on-site people are at risk of thermal injury and burn from such tank fires. In addition, the incident heat radiation from such tank fires may cause thermal damage to neighbouring equipment, particularly control instruments.

The only way to mitigate these potential consequences is by reducing the emergency response time to a bare minimum through installation of thermal sensor triggered shut down and fire fighting system at strategic locations in the plant.

Pool/Bund FiresFlammable liquids like MS and ATF which have boiling point above ambient temperature are stored under atmospheric temperature and pressure. Continuous release of such non-boiling liquids due to leaks in the tanks or pipelines will form a flammable confined pool within the bunded area or an unconfined irregular pool in absence of any bund which may ignite to a pool/bund fire.

Should the ignition take place with sufficient delay, enough for the pool to vaporise to form some flammable vapour cloud and spread downwind, it may result in a flash fire accompanied by a pool fire.

Detailed computations for pool fire scenarios for MS and ATF have been carried out. Outcomes of such consequence analysis comprising of pool diameter and distances for different heat radiation levels are presented in Table-6.4.

The effect distances for the different levels of heat radiation have been worked out for each of the pool/bund fire scenarios for the following fatality and damage:

1.6 kW/m2 : no discomfort, safe distance 4.5 kW/m2 : 1st degree burn, limit for plant operators 8.0 kW/m2 : limit for unprotected adjoining equipment12.5 kW/m2 : 1% fatality, limit for piloted ignition (secondary fire)25.0 kW/m2 : 50% fatality, limit for non-piloted ignition

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Table-6.4 Outcomes of Consequence Analysis- Pool/Bund FiresScNo


Wind

Spe

ed (m

/s)Po

ol Di

amete

r (m)

Thermal Damage Distance (m)

From Centre of Pool forHeat Radiation Level

25.0

kW/m

2

12.5

kW/m

2

8.0 kW

/m2

4.5 kW

/m2

1.6 kW

/m2

9 5000 KL MS tank bottom line 4” leak 3 50 41 69 82 98 1471 50 32 42 59 77 109

10 3000 KL ATF tank bottom line 4” leak 3 50 22 22 31 58 921 50 19 19 23 39 64

Based on past experience it is found that peak level of radiation intensity will not occur suddenly. Rather 20-30 minutes time will be required before a bund or pool fire grows into full size which is sufficient even for public to run away to safe distance. From these considerations, the limit of 4.5 kW/m2 heat radiation level for public beyond the plant boundary has been selected for such fires.

For similar pool size, the effect distances for 3 m/s wind is significantly larger than those distances for 1 m/s wind due to tilting of the flame in higher wind speeds.

In case of pool fire spread over the entire bund area of 50 m diameter (bund fire) of the 5000 KL MS tank, the maximum damage distance for first degree burn under 3 m/s wind is found to be about 98 m. In similar condition, the maximum damage distance for thermally unprotected adjoining equipment is about 82 m and the maximum damage distance for 1% fatality/ secondary fire is about 69 m. Under 1 m/s wind speed, the respective maximum damage distances are about 77 m, 59 m and 42 m.

The thermal damage circle diagrams for various pool/bund fire scenarios have been shown in Figures-6.3 to 6.4.

It can be seen that only on-site people are at risk of thermal injury and burn from such pool fires. In addition, the incident heat radiation from such pool fires may cause thermal damage to neighbouring equipment, particularly control instruments.

The only way to mitigate these potential consequences is by reducing the emergency response time to a bare minimum through installation of thermal sensor triggered shut down and fire fighting system at strategic locations in the plant.

Jet FlamesContinuous release of flammable vapour like naphtha and gas like hydrogen from hole in a pressure vessel/pipeline will possess enough velocity to form a jet. Immediate ignition of such jet of flammable material will result in only jet flame or jet fire. However, delayed ignition will result in jet flame of the

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emerging jet of flammable vapour/gas as well as vapour cloud explosion (VCE) of the flammable vapour/gas cloud formed due to delay in ignition.

Detailed computations for jet flame scenarios for hydrogen and naphtha have been carried out. Outcomes of such consequence analysis comprising of flame length and distances for different heat radiation levels are presented in Table-6.5.

Table-6.5 Outcomes of Consequence Analysis- Jet FlamesScNo


Flame

Leng

th (m

)

Thermal Damage Distance (m)from Centre of Equipment for

Heat Radiation Level

37.5

kW/m

2

25.0

kW/m

2

12.5

kW/m

2

8.0 kW

/m2

4.5 kW

/m2

1.6 kW

/m2

1 ISOM feed surge drum outlet line failure (hydro-treated naphtha release)

36 6 8 11 14 21 36

2 ISOM unit hydrogen dryer outlet line failure (H2 release) 54 18 24 38 47 63 1153 SHU feed surge drum outlet line failure (naphtha

release)31 5 7 9 12 18 32

4 HDS feed drum outlet line failure (naphtha release) 34 6 8 10 13 20 345 Naphtha Feed Surge Drum outlet line failure (Naphtha

release)43 11 14 18 25 31 56

6 HGU pre-reformer outlet line gasket failure (naphtha release)

38 21 26 35 44 56 94

The effect distances for the different levels of heat radiation have been worked out for each of the jet flame scenarios for the following fatality and damage:

1.6 kW/m2 : no discomfort, safe distance 4.5 kW/m2 : 1st degree burn, limit for plant operators 8.0 kW/m2 : limit for unprotected adjoining equipment12.5 kW/m2 : 1% fatality, limit for piloted ignition (secondary fire)25.0 kW/m2 : 50% fatality, limit for non-piloted ignition37.5 kW/m2 : 99% fatality, heavy damage to plant equipment

The limit of 1.6 kW/m2 heat radiation level for public beyond the plant boundary has been selected for such flames.

The largest jet fire will be obtained pertaining to H2 gas release due to ISOM unit H2 dryer outlet line failure, In that case, the maximum damage distance for first degree burn is found to be about 63 m. In similar condition, the maximum damage distance for thermally unprotected adjoining equipment is

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about 47 m and the maximum damage distance for 1% fatality/ secondary fire is about 38 m. The safe distance (1.6 kW/m2) or distance of no discomfort in this case is about 115 m.

The thermal damage circle diagrams for various Jet Flame scenarios have been shown in Figures-6.5 to 6.10.

It can be seen that only on-site people are at risk of thermal injury and burn from such jet flames. In addition, the incident heat radiation from such jet flames may cause thermal damage to neighbouring equipment, particularly control instruments.

The only way to mitigate these potential consequences is by reducing the emergency response time to a bare minimum through installation of isolation valve system at strategic locations throughout the plant.

Vapour Cloud Explosions (VCE)/Flash FiresApart from direct release of flammable gas like hydrogen and vapours like naphtha, release of flammable boiling liquids (pressurised liquefied gas) like hydrogen generally generates sufficient quantity of vapour through flash and evaporation. Such flammable gas/vapour spreads out within LFL in the direction of prevalent wind. In such cases, provided ignition of the vapour cloud takes place, a vapour cloud explosion of high energy occurs, spread depending on the quantity and concentration of the vapour, and atmospheric stability conditions.

However, in case of release of non-boiling practically non-volatile liquids like naphtha, it is found that the quantity of vapour generated through pool evaporation is vary small and LFL distance of the dispersed vapour cloud practically does not stretch beyond the pool boundary. Such insignificant small vapour generated due to pool evaporation will be restricted to the area immediately over the pool and, therefore, no vapour cloud explosion will occur in such cases. However, flash fire of insignificant risk may occur due to such small amount of vapours. As these flash fires are limited within the pool boundary, neither the software can compute the damage distances nor it is of any concern.

Detailed computations for vapour cloud explosion scenarios for hydrogen and naphtha have been carried out. Outcomes of such consequence analysis comprising of vapour release rate, LFL distance, cloud width and damage distances of overpressure generated due to explosion for different damage levels are presented in Table-6.6.

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Table-6.6 Outcomes of Consequence Analysis- VCE/Flash FiresScNo


Vapo

ur R

eleas

eRa

te (kg

/s)St

abilit

y Clas

s &W

ind S

peed

(m/s)

LFL D

istan

ce (m

)

Clou

d Widt

h (m)

Over-pressureDamage Distance (m) from Release Point forPeak Over-pressure of

0.3 ba

r

0.1 ba

r

0.03

bar

0.01

bar

1 ISOM feed surge drum outlet line failure (hydro-treated naphtha release at 40C, 3 kg/cm2g)

7.12 B-3 34 23 34 51 89 243E-1 104 145 72 128 211 457

2 ISOM unit hydrogen dryer outlet line failure (H2 release through assumed 3” line at 39C, 40 kg/ cm2g)

7.03 B-3 94 1.9 86 112 234 576E-1 129 10.

8121 182 356 758

3 SHU feed surge drum outlet line failure (naphtha release at 45C, 1.4 kg/cm2g)

6.63 B-3 27 16 25 41 65 213E-1 84 119 53 96 152 338

4 HDS feed drum outlet line failure (naphtha release at 76C, 1.6 kg/cm2g)

6.92 B-3 30 19 28 46 73 231E-1 92 125 59 121 184 362

5 Naphtha Feed Surge Drum outlet line failure (Naphtha release through hole of 2” equivalent dia at 40C, 3.5 kg/cm2g)

7.47 B-3 47 32 51 73 97 284E-1 127 169 87 153 274 532

6 HGU pre-reformer outlet line gasket failure (naphtha release through 2” leak at 507C, 28.3 kg/cm2g)

7.31 B-3 138 41 105 139 241 528E-1 423 231 274 353 556 1142

The effect distances due to overpressure have been worked out for the following four different damage levels:

0.3 bar: heavy plant/building damage, 99% fatality 0.1 bar: repairable building damage, 1% fatality0.03 bar: major glass damage, threshold of injury0.01 bar: 10% glass damage, no injury (safe distance)

In case of largest VCE pertaining to naphtha release due to HGU pre-reformer outlet line gasket failure, the maximum overpressure damage distances under stable atmospheric condition (stability class E) and 1 m/s wind for different damages viz. 99% fatality, 1% fatality and threshold of injury are found to be about 274 m, 353 m and 556 m respectively from the point of release. The safe distance is about 1142 m.

The overpressure damage circle diagrams for various vapour cloud explosion scenarios have been shown in Figures-6.11 to 6.16. The corresponding LFL distances are also shown therein.

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It can be seen that some part of the plant may be damaged locally in case of such vapour cloud explosions, but the off-site effects are observed only at 0.03 bar capable of major glass damage (threshold of injury). Most damages will be confined within on-site boundaries.

Such vapour cloud explosions are so short lived that there is no time for emergency response and hence these potentially severe consequences must be prevented by appropriate safety engineering right at the detail design stage and preventive measures during operation and maintenance.

6.5.5 Conclusions and RecommendationsBased on the risk analysis results and discussions outlined above, the following conclusions including suggestions and recommendations can be drawn up:

1. Operation of the proposed project presents a risk to on-site people in the form of thermal injury from tank fires and random pool/bund fires around the storage tanks, process vessels and pipelines. There is an additional significant risk of thermal injury from jet flames to only on-site people around the storage tanks and process vessels. Moreover, vapour cloud explosions impose potentially significant risk to plant and equipment.

2. Tank fire, pool/bund fire and jet fire may be considered as credible accident and measures need to be taken to tackle them in the event of such fire.

In view of this, all the storage tanks should be thermally protected so as to prevent secondary fire on adjoining tanks due to any tank on fire. In case of a tank fire, accessibility for actuating the sprinkler system should be ensured.

In case of any storage tank on fire, the cooling of adjoining tanks should be restored promptly. It is also necessary to cool the tank on fire so that tank shell does not give away. In view of such simultaneous cooling, the fire fighting system should be designed accordingly.

All storage tanks, therefore have to be designed with safety features provided with remote operated shut-off valves which enhances the safety of storage tanks against failure.

3. In the event of a fire, an effective emergency plan will have to be worked out and rehearsed for fire fighting and to evacuate non-essential people present in the area surrounding the incident.

It is appropriate to assume that peak level of radiation intensity will not occur suddenly and 20-30 minutes time will be required before a tank fire grows to full size.

Adequacy of the fire water system including the distribution system, to cater to increased requirement of fire water such as for cooling of tank on fire and the adjoining tanks, for water sprinklers in the pump house area etc. should be checked.

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Adequate number of fire detectors are to be provided in fire prone areas. Sufficient isolation valves must be installed.

In on-site emergency plan provision should be made for adequate combination of fire fighting media located strategically along with crew of trained fire fighters so that fires as envisaged in this study could be quickly controlled. In case of fire, the adjoining area should be made inaccessible to non-essential personnel. The on-site emergency plan should be carefully implemented.

Non-essential personnel should be located away from the storage area in the zone of 4.5 kW/m2 radiation flux. Non-essential personnel will include office staff, plant management personnel, maintenance personnel, administration and accounts personnel etc.

4. The largest peril for plant and equipment is vapour cloud explosion. A disaster of a scale proportional to cloud mass would occur. No major off-site effects are observed and most of the damage will be confined to on-site only.

In case of a vapour cloud explosion there will be no time for any emergency response and hence these major hazards must be prevented by appropriate safety engineering right at the detail design stage.

The wind direction plays a vital role in dispersion in case of vapour/gas release. Hence adequate wind cocks are to be provided at strategic visible locations so that people can notice and take appropriate actions in case of an emergency.

5. The risk studies have shown that emergency response time for arresting release, fire fighting, safe evacuation of plant personnel and safety of stored inventory is critical to people's safety both on-site and off-site. If interceptive emergency response time can be made very short, risk of injury to plant, people and environment can be drastically reduced.

6. Pumps of highest available mechanical reliability should be installed so that a spill does not occur due to pump malfunction. Local enclosure around the pumps could be provided so that any leak from glands, valves or joints can be contained locally. Ground level foam nozzles round the bunded areas and near the locations of potential spills should be provided with facilities to inject foam at any location either locally or from remote control.

7. Risk of injury can be substantially reduced by pursuing good standard of operation and maintenance and by training and equipping several technicians in techniques of arresting leakage. The good standard of O&M will ensure that chance of a leakage is reduced to a minimum. One important function is monitoring of heath of equipment, storage, pipelines and machines. Preventive maintenance practices may be adopted to improve plant performance and safety.

8. In addition, the population growth around the plant is to be watched closely. Unorganised growth of colonies around the plant shall be avoided with the help of appropriate authorities.

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9. Above all, consistent and total quality assurance for engineering design, hardware selection, through construction to commissioning and subsequent operation and maintenance has to be adopted. The plant should be designed, constructed and operated in accordance with the safe engineering practices and standards, not only during installation but also throughout the life of the plant.

It is understood that the Project Authority will adopt such process safety assurance measures throughout the life cycle of the plant. Given that commitment the project should not pose a major source of risk to employees and public at large as far as the major chemical hazards are concerned.

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LEGEND RADIATION LEVEL

LEVEL OF DAMAGE RADIATION DISTANCE (M)

A 4.5 kW/m2 1st degree burn, limit for plant operators 61B 8.0 kW/m2 limit for unprotected adjoining equipment 52C 12.5 kW/m2 1% fatality, limit for piloted ignition (secondary fire) 37D 25.0 kW/m2 50% fatality, limit for non-piloted ignition 24E 37.5 kW/m2 99% fatality, heavy damage to plant equipment 18

Figure-6.1 Thermal Damage Distance of Tank Fire (Wind Speed 3 m/s) pertaining to 5000 KL MS Tank

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Figure-6.2 Thermal Damage Distance of Tank Fire (Wind Speed 3 m/s) pertaining to 3000 KL ATF Tank

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A 4.5 kW/m2 1st degree burn, limit for plant operators 98B 8.0 kW/m2 limit for unprotected adjoining equipment 82C 12.5 kW/m2 1% fatality, limit for piloted ignition (secondary fire) 69D 25.0 kW/m2 50% fatality, limit for non-piloted ignition 41

Figure-6.3 Thermal Damage Distance of Pool Fire (Wind Speed 3 m/s) pertaining to 5000 KL MS Tank Bottom Line 4” Leak

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A 4.5 kW/m2 1st degree burn, limit for plant operators 58B 8.0 kW/m2 limit for unprotected adjoining equipment 31C 12.5 kW/m2 1% fatality, limit for piloted ignition (secondary fire) 22D 25.0 kW/m2 50% fatality, limit for non-piloted ignition 22

Figure-6.4 Thermal Damage Distance of Pool Fire (Wind Speed 3 m/s) pertaining to 3000 KL ATF Tank Bottom Line 4” Leak

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Figure-6.5 Thermal Damage Distance of Jet Flame pertaining to ISOM Feed Surge Drum Outlet Line Failure (Hydro-treated Naphtha Release)

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Figure-6.6 Thermal Damage Distance of Jet Flame pertaining to ISOM Unit Hydrogen Dryer Outlet Line Failure (H2 Release)

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Figure-6.7 Thermal Damage Distance of Jet Flame pertaining to SHU Feed Surge Drum Outlet Line Failure (Naphtha Release)

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Figure-6.8 Thermal Damage Distance of Jet Flame pertaining to HDS Feed Drum Outlet Line Failure (Naphtha Release)

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Figure-6.9 Thermal Damage Distance of Jet Flame pertaining to Naphtha Feed Surge Drum Outlet Line Failure (Naphtha Release)

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Figure-6.10 Thermal Damage Distance of Jet Flame pertaining to HGU Pre-reformer Outlet Line Gasket Failure (Naphtha Release)

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LEGEND OVER PRESSURE LEVEL

LEVEL OF DAMAGE OVER PRESSURE DAMAGE DISTANCE (M)

A 0.1 Repairable Building Damage, 1% fatality 128B 0.03 Major Glass Damage, Threshold of Injury 211

Figure-6.11 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to ISOM Feed Surge Drum Outlet Line Failure (Hydro-treated Naphtha Release)

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Figure-6.12 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to ISOM Unit Hydrogen Dryer Outlet Line Failure (H2 Release)

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Figure-6.13 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to SHU Feed Surge Drum Outlet Line Failure (Naphtha Release)

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Figure-6.14 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to HDS Feed Drum Outlet Line Failure (Naphtha Release)

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Figure-6.15 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to Naphtha Feed Surge Drum Outlet Line Failure (Naphtha Release)

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Figure-6.16 LFL and Overpressure Damage Distance (Wind Speed E-1 m/s) pertaining to HGU Pre-reformer Outlet Line Gasket Failure (Naphtha Release)

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6.6 BASIS OF DISASTER MANAGEMENT PLANThis DMP has been designed based on the range, scales and effects of "Major Generic Hazards" described in the Risk Assessment just mentioned and on their typical behaviours predicted therein. The DMP addresses the range of thermal and mechanical impacts of these major hazards so that potential harm to people on-site and off-site, plant and environment can be reduced to a practicable minimum. The scenarios of loss of containment are credible worst cases to which this DMP is linked.

6.7 CAPABILITIES OF DMPThe emergency plan envisaged is designed to intercept full range of hazards specific to refinery such as fire, explosion, major spill etc. In particular, the DMP is designed and conducted to mitigate those losses of containment situations that have potentials to escalate into major perils of the plant, the effects of which have been described in the Risk Assessment Report.

Another measure of the DMP's capability is to combat small and large fire due to ignition of flammable liquid or vapour cloud escaped either from storage or from process streams and evacuate people from the affected areas speedily to safe locations to prevent irreversible injury.

Emergency medical aids to those who might be affected by incident heat flux and incident shockwave overpressures, is inherent in the basic capabilities.

The most important capability of this DMP is the required speed of response to intercept a developing emergency in good time so that disasters are never allowed to happen.

6.8 DISASTER CONTROL PHILOSOPHYThe emergency control philosophy of the plant is in line with its normal operational controls. The emergency control room will be the plant's Central Control Room, which will employ Distributed Control System (DCS). All emergency operations, which may involve shutdown of the plant, will be controlled from the Central Control Room by the same operator(s) using dedicated "shut-down consoles". The consoles will send commands to initiate the shutdown procedure. Plant shutdown system will be performed by a PLC (Programmable Logic Controller) connected to the DCS.

The principal strategy of DMP of the plant is "Prevention" of the major hazards. And since these hazards can occur only in the event of loss of containment, one of the key objectives of technology selection, project engineering, construction, commissioning and operation is "Total and Consistent Quality Assurance". The Project Authority is committed to this strategy right from the conceptual stage so that the objective of prevention can have ample opportunities to mature and be realized in practice.

The codes, standards and regulations (acts and rules) shall be followed to the extent applicable such as:

1. OISD (Oil Industries Safety Directorate) norms (Standard 144 for LPG Storage and Bottling Plant Operations, Standard 118 for Layouts for Oil and Gas Installations).

2. API standards (Standard 2510 for LPG Installations).3. SMPV(U) Rules, 1981 and Gas Cylinder Rules, 1981.

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4. NFPA 58, Storage and Handling of LPG. 5. Indian Explosives Act & Explosive Rules 6. The Petroleum Act7. ASME code for Unfired Pressure Vessels,Section VIII, Div. I 8. ANSI B31.3 Codes for refinery piping9. Applicable specifications of Bureau of Indian Standards (BIS) (IS:1893, IS:456, IS:800, IS:875,

IS:1742, IS:3370, IS:269, IS:1786, IS:226, IS:458, IS:4576, IS:5290).10. Indian Electricity Act, 1956 & Indian Electricity Rules. 11. Regulations for the Electrical Equipment of Building12. Factories Act, 1948.13. TAC recommendations and Fire Protection Manual14. Environment (Protection) Act, 1986 and state and federal rules under the Act, in particular

Manufacture Storage & Import of Hazardous Chemicals Rules, 1989.15. Public Liability Insurance Act, 1991.

The Disaster Management Plan (DMP) or Emergency Preparedness Plan (EPP) consists of:

* On-site Emergency Plan* Off-site Emergency Plan

Preparation of Disaster Management Plan under the headlines of On-site Emergency Plan and Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of Environment and Forests (MOEF), Govt of India.

As per the guidelines given by the Government, the "Occupier" of the facility is responsible for the development of the On-site Emergency Plan. The Government (District Authorities) should develop the Off-site Emergency Plan. However, a conceptual Off-site Emergency Plan is also presented in this report.

6.9 ON-SITE EMERGENCY PLAN6.9.1 Objectives

The objective of the On-site Emergency Plan should be to make maximum use of the combined resources of the plant and the outside service to

* Effect the rescue and treatment of casualties.* Safeguard other personnel in the premises.* Minimise damage to property and environment.* Initially contains and ultimately brings the incident under control.* Identify any dead.* Provide for the needs of relatives.* Provide authoritative information to the news media.* Secure the safe rehabilitation of affected areas.

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* Preserve relevant records and equipment for the subsequent enquiry into the cause and circumstances of emergency.

6.9.2 Different Phases of Disaster Warning Phase :

Many disasters are preceded by sort of warning, e.g. with the aid of satellite and network of weather stations. Many meteorological disasters like Cyclones and Hurricanes can be predicted and actions can be taken to counteract them.

Impact Phase :This is the period when the disaster actually strikes and very little can be done to lessen the effects of Disaster. The period of impact may last for a few seconds (like fire, explosion, gas leak) or may prolong for days (like fire, gas leaks, water pollution, floods, etc).

Rescue Phase :The rescue phase starts immediately after the impact and continues until necessary measures are taken to rush help to combat the situation and to evacuate people to safer places. Needless to emphasize that prompt and well organised rescue operations can save many valuable lives.

Relief Phase :In this phase apart from organising relief measures internally, depending on severity of the disaster, external help should also be summoned to provide relief measures (such as food, medical help, clothing, shelter etc). This phase will continue till normalcy is restored.

Restoration Phase :This is the final and the longest phase. It includes rebuilding damaged equipment/ Plant.

6.9.3 Action PlansThe Action Plan consists of:* Identification of Key Personnel.* Defining responsibilities of Key Personnel.* Designating Emergency Control Centres and Assembly Points.* Declaration of Emergency.* Sending All Clear Signal.* Defining actions to be taken by non-key personnel during emergency.

6.9.4 Key Personnel and ResponsibilitiesThe actions necessary in an emergency will clearly depend upon the surrounding circumstances. Nevertheless, it is imperative that the required actions are initiated and directed by nominated people, each having specified responsibilities as part of coordinated plan. Such nominated personnel are known as Key Personnel.

The Emergency Preparedness Chart is shown in Figure-6.16.

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The Key Personnel are:

* Site Controller (SC) or Chief Coordinator * Incident Coordinator (IC) or Plant Coordinator * Fire & Safety Coordinator * Engineering Coordinator * Welfare, Transport & Media Coordinator * Power/Utilities & Communication Coordinator * Medical Coordinator * Security Coordinator* Materials Coordinator* Finance Coordinator

6.9.4.1 Responsibilities & Roles of Chief Coordinator One getting information, the Chief Co-ordinator will

i) Report to the Site of emergency, assess the situation and declare the disaster.ii) Establish emergency control post at Fire Station Control Room.iii) Declare the disaster zone. Iv) Mobilise all Co-ordinators assembled at the emergency control post, assess the situation and

direct to put the disaster control plan to action. v) Activate emergency evacuation and rescue operation with the help of Engg/Security co-

ordinator.vi) Review the requirement for shutdown of units in consultation with the plant co-ordinator. vii) Review the control of traffic inside refinery with the help of security co-ordinator.viii) Monitor the situation and keep GM, DGM (HR) informed about the incidental (magnitude of

disaster, combating operation and casualties).ix) Approved information to Press, Govt Agencies through welfare and Media Co-ordinator with

the approval of GM.x) Inform:

DM & SP Begusarai and communicate to ED (O) Director (R) Chairman's Office IOCL, New Delhi Chief Secretary, Home Deptt, Govt of Bihar, Patna Member Secretary, B.S.P.C.B, Patna Factory Inspector, Begusarai Chief Inspector of Factories, Ranchi Regional Controller of explosives, Hazaribagh/ Calcutta Factory Medical Inspector, Patna Sr Division Manager, National Insurance Co, Muzaffarpur Chief Controller of Explosives, Nagpur Excise Superintendent Begusarai through Welfare & Medical Co-ordinator

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xi) Ensure that casualties are received adequate attention in consultation with medical co-ordinator.

xii) Monitor and control rehabilitation of the affected areas on cessation of the emergency.xiii) Declare that the "Disaster is over".

6.9.4.2 Responsibilities & Roles of Incident Coordinator For all Five Scenarios:

On getting the information, the plant co-ordinator will act as follows:

i) To rush to the site of occurrence and assess the situation and requirement.ii) To report at the Emergency Control Room at Fire Station and liasion between Chief Co-ordinator

and respective plant in-charges for safe operation and shutdown of plants/ equipment, as necessary.

iii) To assess the magnitude of disaster and advise security co-ordinator to cordon off the area. iv) To mobilise necessary manpower from neighboring units/ areas for fire fighting/rescue operation. v) To mobilise spare/ off duty personnel from township for relieving existing operating personnel. vi) To coordinate with Fire & Safety Co-ordinator for fire fighting operations/ emergency handling.vii)To advise Engineering Co-ordinator for suspension of all hot jobs in and around the affected area. viii) To coordinate with Engg Coordinator for repair and restoration of Plant/ facilities during and after

disaster. ix) To coordinate with other Coordinators for sustaining the Safety of the running units/ equipment in

view of the possible consequences of the disaster. x) To ensure that adequate water is made available for fire fighting.

For Toxic Gas Releasei) To coordinate for emptying the affected vessel as quickly as possible and isolation thereof.

For Oil Spilli) To arrange blockage of oil outflow through surface drains with the help of the Engineering Coordinator.

ii) To coordinate with Railways for suspension of movement of Locomotives in the Railway track passing along with Borrow-pit.

For Floodi) To arrange filling of all empty tanks in the Refinery with product/water.

ii) To advise Engineering Co-ordinator for arranging placement of sand bags at all sluice and screen gates on the boundary wall and also arrange manning at short notice. To arrange for availability of dewatering pumps.

iii) To make preparation of action plan for restoration of normally with receding of floodwater.

6.9.4.3 Responsibilities & Roles of Fire and Safety Coordinator On getting information, the Fire & Safety Coordinator will act as below:

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i) To rush to the emergency site. ii) To take charge of entire fire fighting/rescue operation & safety measures.iii) To arrange to communicate fire station for raising "Disaster Siren" on the advice of the Chief

Co- ordinator.iv) To deploy the manpower released from internally and from other sources for fire fighting and

allied operation.v) To examine critically the fire fighting activities on the scene.vi) To operate Mutual Aid Scheme with BTPS & BFS, Begusarai to strengthen the integrated

action. vii) To monitor and replenish any short fall of fire fighting chemicals in coordination with Materials

Coordinator. viii) To advise Engg. Co-ordinator for any emergency help like repair of fire engines/ equipments

etc. ix) To arrange to issue Safety equipment required for Plant emergencies/ Fire fighting.

For Oil Spilli) To provide adequate fire fighting coverage in and around oil spillage site round the clock.

6.9.4.4 Responsibilities & Roles of Engineering Coordinator

For All six scenarios:

On getting information or after hearing the disaster siren, the coordinator for Engineering will report to the crisis control room at Fire Station:

i) To provide all Engineering and Maintenance Services as required by Plant or other coordinators.

The Engineering Services include:

* Workshops (including auto & heavy Garages)* Field Services* Mechnical/Instrument jobs* Urgent fabrication* Use of gas Cutting for repair operation* Services for transportation of Material* Operation of Cranes, towing Services etc

ii) To mobilise manpower from all disciplines of maintenance (and to augment the number as needed)

iii) To arrange rescue and transport for affected persons to the site dispensary. iv) To arrange to supply Fire Fighting and safety equipments/materials to the site of occurrence.v) To take prompt action for renting/hiring equipments to meet emergency requirements. vi) To arrange maintenance and refuelling of all fire fighting engines and rescue vehicles.

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vii) To arrange salvaging of all valuable records/gadgets in the refinery.viii) To arrange adequate numbers of sand bags for any breach in the refinery boundary

wall/gupta bandh.ix) To arrange patrolling of Gupta Bunch in coordination with Security Co-ordinator and District

Authorities.x) To arrange clearing of uprooted trees, electric/ telephones poles etc. xi) To arrange for emergency illumination with the help of portable diesel generator sets. xii) For Oil Spill

* To arrange recovery of spilled oil.

xiii) For all Scenario except flood

* To arrange dewatering of fire fighting area.

6.9.4.5 Responsibilities & Roles of Welfare, Transport & Media Coordinator On getting the information on hearing the siren, he will rush to crisis control room at fire station.

For all six scenarios:i) To provide Transport to all co-ordinators as per requirement.ii) To arrange food, beverage, drinks and shelter for all personnel involved in emergency

opreationiii) To inform different statutory Bodies and Govt agencies about the nature and magnitude of

disaster in consultation with Chief Co-ordinator.iv) To communicate with relatives of injured/deceased employees. v) To arrange for Press Communication/AIR/TV.vi) To arrange photography/video recording of the incident.vii) To alert people of the nearby villages with the help of Police/CISF/District authorities.

For Flood:i) To arrange and mobilise adequate no. of boats with boatman from District Authorities.

6.9.4.6 Responsibilities & Roles of Power/Utilities & Communication Coordinator On getting information or hearing the siren he will rush to crisis control room at fire station.

For all six scenarios:

i) To be in-charge of Power/Utility & Communication Services and keep the entire communication system alive.

ii) To provide extra telephones for the Emergency control room at Fire Station.iii) To arrange supply/isolation of Power Supply as required by the Plant coordinator.

iv) To ensure availability of P.A system in serviceable condition. v) To arrange quick mobilisation of resources.

vi) To arrange quick resumption of Power/Steam/Air in case of power failure.

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vii) To keep the Plant Coordinator informed about time of resumption of Power in case it fails. viii) To ensure uninterrupted power supply to first aid, fire station, hospital, drinking water supply &

telecommunication system.ix) To make necessary arrangement for light etc to carry out emergency activities during night.

For Oil Spillx) To ensure workability for Auto Telephones as well as Fire alarm system in case of Power outage.

xi) To arrange for emergency illumination of the site of occurrence.

For Floodxii) To salvage of all critical electrical Motors during flood. xiii) To arrange sealing of water entry into township/site Telephone exchange.

6.9.4.7 Responsibilities & Roles of Medical Coordinator On getting information or hearing the siren the medical coordinator will act as below:

For all six scenarioi) To activate First-Aid Centre(s) : At existing site and (ii) at training centre, if required. ii) To reinforce manpower and emergency medicines to the First-Aid Centres.iii) To mobilise medical team internally at Hospital.iv) To arrange Ambulance to transfer casualties to First-Aid Centres and to the Main Hospital v) To main casualty register: Types of injury, number etc including hospitalisation and coordinate

with District Civil Surgeon and Police for completing the formalities, if any. vi) To make emergency purchase of required drugs/medical equipment through material

Coordinator.vii) To co-ordinate with all Hospitals in the vicinity and inform about no. of casualties with nature

of injuries and no. of beds required, etc.

6.9.4.8 Responsibilities & Roles of Security CoordinatorOn getting information or hearing siren he will report to crisis control room.

For all Six Scenario i) To arrange for Police help for control of traffic outside the refinery area.ii) To render necessary help to plant, Fire & Safety, Medical & Engineering Co- ordinators in Fire

Fighting/ rescue and evacuation operations. iii) To arrange to allow only authorised personnel/ Vehicles near the site of occurrence. iv) To arrange to regulate the traffic inside the refinery premises.v) To arrange to evacuate all contractor personnel and trucks from inside the refinery.vi) To arrange to control and disperse the crowd from the scene of fire. vii) To assist in transporting injured employees.viii) To contact outside agencies (S.P Begusarai; Police O.P. Refinery; Commandant, CISF, HFC Unit

& Commandant BMP Township for help, if required.

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6.9.4.9 Responsibilities & Roles of Materials CoordinatorOn getting information or by hearing siren he will rush to crisis control room at fire station.

For Six Scenarios

i) To arrange to position staff as necessary at Central Stores, Petrol pump and office for emergency issue of materials.

ii) To monitor the stock of all fire Fighting equipments/ First Aid items to replenish them as and when required.

iii) To arrange for emergency purchase of materials required by the coordinator.

For Flood

iv) To arrange for shifting materials, susceptible to damage in floodwater to safer locations.

6.9.4.10Responsibilities & Roles of Finance Coordinator On getting information or by hearing siren, he will report to the control room at fire station

For all Six Scenarios

i) To maintain Cash impreset of Rs.1, 00,000.00 (Rupees one lakh).ii) To arrange to release finance to all eligible Coordinators for emergency purchase on the advise of

Chief Coordinator. iii) To take care of insurance Formalities and assess the damage in consultation with Technical

Services.iv) Inform customs/excise regarding nature, magnitude and type of damage in consultation with Chief

Coordinator.

6.9.5 Responsibilities of Teamsi) Repair Team will identify source of leak and arrest it, take steps to keep rest of the plant in

safe condition, arrange safe shutdown of operations if necessary, attend to all repair jobs which are needed from emergency point of view, take steps to contain or reduce the intensity of emergency, arrange for additional equipment and give temporary connections as needed.

ii) Fire Fighting Team will rush to the incident spot and start fighting the fire, maintain adequate water pressure in the fire hydrant system, arrange fire extinguishers where needed and guide and direct outside fire fighting agencies.

iii) Communication Team will maintain the communication network inside the terminal, attend urgent repairs in the communication system, and arrange messengers for conveying urgent messages when needed, help others in their communication activities.

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iv) Security Team will man all gates, with minimum delay to permit the entry of authorised personnel and outside agencies, vehicles etc who have come to help, bar entry of unauthorised persons, allow the ambulance etc to go through the gates without normal checks.

v) Safety Team will rescue the casualties on priority basis, transport casualties to first aid post, safe places, or medical centres, account the personnel, search for missing personnel and pass information to the kith and kin of fatal or serious casualties, arrange required safety equipment, report of status to their leader , record of accidents, collect and preserve evidences in connection with accident cases, arrange for transport of casualties, arrange for transport of materials, attend to vehicle breakdowns, arrange petrol and diesel supply and withdraw and transport materials from stores.

vi) Medical Team will arrange for first aid, arrange for stretchers, arrange for immediate medical attention, arrange for sending the casualties to various hospitals and nursing homes and arrange for medicines.

6.9.6 Emergency Control CentreThe Emergency Control Centre will be the focal point in case of an emergency from where the operations to handle the emergency are directed and coordinated. It will control site activities and should be furnished with external and internal telephone connections, list of essential telephone numbers, list of key persons and their addresses.

Emergency management measures in this case have been proposed to be carried from single control Centre designated as CCR.

CCR is the place from where messages to outside agencies will be sent and mutual aids and other helps for the management of emergency will be arranged. It will be located in the safe area. It will be equipped with every facility for external and internal communication. CCR will be attended by Chief Coordinator. Location: F & S building.

6.9.7 Assembly PointIn an emergency, it will almost certainly be necessary to evacuate personnel from affected areas and as precautionary measure, to further evacuate non-essential workers, in the first instance, from areas likely to be affected, should the emergency escalate. The evacuation will be effected on getting necessary message from IC. On evacuation, employees should be directed to a predetermined safe place called Assembly Point.

Location: Security office/ Main Gate is the Assembly Point where all non-key personnel should assemble on getting direction over Public Address System.

Alternate Location: Workers Rest Room or Canteen. Outdoor assembly points, predetermined and premarked, will also be provided to accommodate evacuees from affected plant area(s). Roll call of personnel collected at these assembly points, indoor

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and outdoor will be carried out by roll call crew of safety team to account for any missing person(s) and to initiate search and rescue operations, if necessary.

6.9.8 Declaration of EmergencyAn emergency may arise in the terminal due to major leakage of containment or major outbreak of fire. In case of major leak or major outbreak of fire the state of emergency has to be declared by the concerned by sounding Emergency Siren.

Upon manual or sensor detection of a major loss of containment of volatile hazardous substance the DMP is activated by raising an audible and visual alarm through a network of geographically dispersed gas/vapour and heat detectors and also "break-glass" type fire alarm call points with telephone hand sets to inform the Central Control Room.

A separate siren audible to a distance of 5 kms range will be available for this purpose. The alarm is coded such that the nature of emergency can be distinguished as an emergency.

The Control Centre and Assembly points have been located at an area of the minimum risk or vulnerability in the premises concerned, taking into account the wind direction, areas which might be affected by fire/explosion, leakages etc.

After cessation of emergency, FSO will communicate to IC. After verification of status, IC will communicate with SC and then announce the "All Clear" by instructing the Fire & Sefety control roomto sound the "All Clear Signal".

Public address System (PAS). In case of failure of alarm system, communication should be by telephone operator who will make announcement in the complex through PAS. Walkie-Talkie system is very useful for communication during emergency with predetermined codes of communication. If everything fails, a messenger could be used for sending the information.

Two 5 km range variable pitch electric sirens (one in service and the other standby) will generate the main alarm for the entire site as well as for the district fire brigade. The alarm is coded such that the nature of emergency can be distinguished Fire and Gas alarm matrices are provided at the Central Control room, security gate, on-site fire station and main administrative office corridor to indicate location of the site of emergency and its nature.

6.9.9 Mutual Aid6.9.9.1 Need and Procedure

All factories may not be equipped with an exhaustive stock of equipment/ materials required during an emergency. Further, there may be a need to augment supplies if an emergency is prolonged.

It would be ideal to pool all resources available in and the nearby outside agencies especially factories during an emergency, for which a formal Mutual Aid scheme should be made among industries in the region.

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6.9.9.2 Essential ElementsEssential elements of this scheme are given below :

* Mutual aid must be a written document, signed by Location In charge of all the industries concerned.

* It should specify available quantity of materials/ equipment that can be spared (not that which is in stock).

* Mode of requisition during an emergency.

* It should authorise the shift-in-charge to quickly deploy available material/ equipment without waiting for formalities like gate pass etc.

* It should spell out mode of payment/ replacement of material given during an emergency.

* It should specify key personnel who are authorised to requisition materials from other industries or who can send materials to other industries.

* It should state clearly mode of receipt of materials at the affected unit without waiting for quantity/quality verification etc.

* Revision number and validity of agreement should be mentioned.

* This may be updated from time to time based on experience gained.

6.9.9.3 Installations in the NeighbourhoodHindustan Fertiliser Corporation (HFC) - Not in operation at present.Barauni Thermal Power Station (BTPS)

6.9.10 Emergency Management Training

The Key Personnel should undergo special courses on disaster management. This may preferably be an in-plant training. The Terminal Manager, Senior Officers and Staff should undergo a course on the use of personal protective equipment.

The Key Personnel belonging to various Teams should undergo special courses as per their expected nature of work at the time of emergency.

The Project Authority should conduct special courses to outside agencies like district fire services to make them familiar with the plant layout and other aspects, which will be helpful to them during an emergency.

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6.9.11 Mock Drillsi) It is imperative that the procedures laid in this Plan are put to the test by conducting Mock Drills. To

avoid any lethality, the emergency response time will be clocked below 2 min. during the mock drill.

ii) The mock drills should be carried out step by step as stated below:

First Step: Test the effectiveness of communication system.Second Step: Test the speed of mobilisation of the Plant emergency teams.

Third Step: Test the effectiveness of search, rescue and treatment of casualties.

Fourth Step: Test Emergency isolation and shut down and remedial measures taken on the system.Fifth Step: Conduct a full rehearsal of all the actions to be taken during an emergency.

iii) The Disaster Management Plan are periodically revised based on experiences gained from the mock drills.

6.9.12 Precautions During TransportationAs per the provisions in the Central Motor Vehicles Rules, 1989 (Rules 129, 130 and 134), every vehicle carrying the flammable goods leaving the Terminal will be checked for proper display of "Class Label" and "Emergency Information Panel".

6.10 OFF-SITE EMERGENCY PLAN 6.10.1 Objective

If the effects of the accident or disaster inside the terminal is felt outside its premises, it calls for an off-site emergency plan, which should be prepared and documented in advance in consultation with the District Authorities.

6.10.2 Key Personnel Table-6.7 presents the relevant details of the Off – Site Disaster Co-Ordinators (State Government).

The ultimate responsibility for the management of the off-site emergencies rests on the District Magistrate/Collector. He will be assisted by representatives from all concerned organisations, departments and services at the District level. This core group of officers would be called the District Crisis Management Group (CMG). The members of the group will include :

i) Collector/District Magistrate ii) Commissioner of Policeiii) Municipal Commissioner, if municipalities are involved iv) Deputy Director, Health v) Pollution Control Board Representative

An Operation Response Group (ORG) will then have to be constituted to implement the directives of the CMG.

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The various government departments, some or all of which will be concerned, depending on the nature of the emergency, could include: 1. Police2. Health & Family Welfare3. Medical4. Revenue5. Fire Service6. Transport7. Electricity8. Animal Husbandry9. Agriculture10. Civil Defence11. P W D12. Civil Supplies13. Panchayats

The SC and IC, of the on-site emergency team, will also be responsible for communications with the CMG during the off-site emergency.

6.10.3 Education of Public People living within the influence zone should be educated on the emergency in a suitable manner. This can be achieved only through the Local and District Authorities. However, necessary information can be extended to the Authorities.

6.11 AVAILABLE INFRASTRUCTUREThe following facilities/resources and team set up are available which are detailed in Annexure.

* List of coordinators and alternate coordinators* Address and telephone numbers of key personnel* Contact details of outside agencies* Communication facilities available at BR* Fire fighting equipments available at BR* Safety equipments available at BR* Hospital facilities in the area

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FIGURE-6.17ORGANOGRAM (ON-SITE EMERGENCY PLAN)

Coordinators to report at their designated place

CHIEF CO-ORDINATOR

MAIN :

Shri C.S. Das,GM (T)

ALTERNATE :

Shri M.K. PadiaGM (TS)

2

INCIDENT COORDINATOR 1

FIRE & SAFETY COORDINATOR 1

ENGINEERINGCOORDINATOR 1

POWER & UTILITIES COORDINATOR 1

COMMUNICATIONCOORDINATOR 1

SECURITY & TRAFFIC CONTROL COORDINATOR

1

RESCUE & EVACUATION COORDINATOR

1

WELFARE &MEDIACOORDINATOR

2

MATERIALS COORDINATOR 2

FINANCECOORDINATOR 2

TRANSPORT COORDINATOR

3

MEDICALCOORDINATOR

4

Shri B.P. Das, DGM (PN)Shri Sukumar Ray, CPNM

Shri P.K. Das, SFSMShri Mahesh Kumar, FSM COORDINATORShri G.C. Sikdar, CMNMShri P.K. Mukhopadhyay, SITM

Shri S.S.P. Singh, DGM (P&U)Shri C.K. Tiwari, CPJM

Shri S.K. Sharma, CMNM (EL)Shri G.M. Patel, SMNM (EL)

Shri S. Nedunchzhian, DC, CISFShri S.V Singh, AC, CISF

Shri S. Nath, CMNM (CL)Shri U.K. Prasad, SPJM

Shri N.K. Das, DGM (HR)Shri S. Acharya, SHRM

Shri N.K. Sharma, CMTMShri Hemant Kumar, SMTM

Shri S. Bhunia, DGM (Finance)Shri S. Banik, SFM

Shri B. Prasad, PAMShri K. Choudhary, O (A & W)

Dr. (Mrs.) N. Bose, CMODr. S.D. Dharmik, ACMO (F)-

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Position of Co-ordinators :

: AT INCIDENT SITE : AT TIME OFFICE

: AT DISASTER C/R : AT TOWNSHIP HOSPITAL

Note : 1 The alternate co-ordinator will function as the coordinator in the absence of the designated main coordinator

2 In case of declaration of Off-site Disaster by Chief co-ordinator. DGM (HR) will act as Industry Coordinator for Liaison with District Authorities

ADVISERS TOCHIEF COORDINATOR

2

Shri M.R. Sonde, DGM (TS)Shri, Birendra Kumar, CTSM(Refinery Operation related issues)

Shri S.K. Sarkar, DGM (MN)Shri S.K. Patra, CESM(Repair Modification & Maintenance issues)

Shri D. Chakraborty, CTSMShri B.S. Rajan, STSM (S&EP)(Communication with SPCB, MOE&F & Pollution & Safety related issues)

1

2

3

4

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TABLE-6.7OFF – SITE DISASTER CO-ORDINATORS (STATE GOVERNMENT)

CO-ORDINATOR NAME (S/SHRI) DESIGN TEL. NO.CHIEF CO-ORDINATOR

SANJAY KUMAR HANS

DM. BGS 212285

SECURITY CO-ORDINATOR

AMIT LODHA SP. BGS 213015

FIRE SERVICE CO-ORDINATOR

HALDHAR MANDAL

DFO,BGS 101/213133

MEDICAL SERVICE CO-ORDINATOR

RAJESHWAR THAKUR

CIVIL SURVEON, BGS

215512

TRANSPORT CO-ORDINATOR

KHURSHID ALAM DTO, BGS 9431425761

MEDIA & WELFARE CO-ORDINATOR

A.J. HASMI DDC. BGS 218934

COMMUNICATION CO-ORDINATOR

JYOTI BHUSHAN PRASAD

TDM, BGS 242600

INDUSTRY CO-ORDINATOR

I.B. CHOUDHARY GM, DIC, BGS 212055

ALTERNATIVE CO-ORDINATORS (STATE GOVERNMENT)

CO-ORDINATOR NAME (S/SHRI) DESIGN TEL. NO.CHIEF CO-ORDINATOR

RAM CHANDRA KUMAR

ADM. COLLECTRATE. BGS.

212940

SECURITY CO-ORDINATOR

PANKAJ KUMAR DSP, BGS 215003

FIRE SERVICE CO-ORDINATOR

DINESH PRASAD YADAV

AFO,BGS 101/213133

MEDICAL SERVICE CO-ORDINATOR

ASST. CHIEF SURGEON, BGS

215512

TRANSPORT CO-ORDINATOR

A.K. JHA NDC, BGS 212835

MEDIA & WELFARE CO-ORDINATOR

DINESH KUMAR DPRO, BGS 212809

COMMUNICATION CO-ORDINATOR

L.L. CHOUDHARY DET, BGS 242500

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7.0 Project Benefits Envirotech East Pvt. Ltd.

CHAPTER-7

PROJECT BENEFITS

The installation of the new projects will result in the large beneficial impacts on several fronts. The Installation of the MS Quality Upgradation Project will ensure compliance with the MS specifications (EURO-III Regular Grade) as per MoEF Gazette Notification in May 1996. With the installation of DHDT 3rd

Reactor, there will be reduction in input cost by processing cheaper crude whose Gas Oil cetane number is low and incremental gross refining margin is Rs. 42 Crores/ Annum. The installation of High Sulphur Crude Maximisation Project will result in the reduction of the input cost by the absorption of more HS crude. There will be improvement in the margin by Rs. 155 Crores/ Annum.

In addition, gross economic yield shall increase through increase in agricultural produce, animal husbandry produce, high income group and through marketing multiplier effect. The benefits accrued shall be obviously tremendous in local as well as regional context.

BR has been paying special attention to improve the socioeconomic environment in the neighbouring areas. It has contributed a lot in uplifting the standard of rural and urban areas as listed below:

- Provision of handpumps and erection of well in neighbouring rural areas.- Promotion of health care facilities in the surrounding villages. - Financial assistance to Begusarai Municipality in constructing and repairing the national

high way.- Construction & repairing of School Buildings in the surrounding villages- Organising sports and tournament in the surrounding areas- Providing training on Tailoring & Sewing with distribution of sewing machine among

woman trainees- Conducting Kala - Azar prevention programme.

Medical facilities of the rural areas were observed to be unsatisfactory. It was also learnt that BR has spent money under rural development programme including medical facilities to rural areas. Besides, several other activities like construction of platform in the tank at Bihat village, construction of public shed near CivilCourt, Begusarai, construction of foot steps & toilets at Simaria Ghat for villagers/ pilgrims, donation to Madarsa school, Deona, providing solar system & computer to Viplavi Pustakalaya at village Godargamaetc. were also undertaken.

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8.0 Environment Management Plan Envirotech East Pvt. Ltd.

CHAPTER-8

ENVIRONMENTAL MANAGEMENT PLAN

8.1 BASIC CONTENTSEnvironmental Management Plan is the key to ensure a safe and clean environment. A plant may have taken proper pollution control measures but without a management plan to assure its proper function, the desired results may not be obtained.

A comprehensive environmental management plan consisting of mitigatory measures for abatement of the undesirable impacts elucidated earlier has been drawn up, which is discussed in the next few sections.

Barauni Refinery is an existing refinery running for more than four decades. It has a detailed Environmental Management Programme and it meets all statutory requirements. The following management activities are discussed to highlight its importance in improving environmental quality.

Various pollutants’ generation, their control & disposal have been discussed in Chapter-2. In this chapter, various mitigatory measures taken by the refinery to improve the performance of various equipment along with the overall Environmental Management System of the refinery are discussed.

8.2 VARIOUS MITIGATORY MEASURES8.2.1 Energy Conservation Measures

There has been continuous thrust on the reduction of energy usage by means of adopting various energy conservation (ENCON) measures. ENCON is an ongoing process and plans have been formulated to achieve a further saving in the coming years. The fuel & loss (% wt) during last five years has been shown in Figure-8.1.

In addition to these measures, monitoring of furnace operations, insulation survey of furnaces and hotlines and audits by internal and external teams are carried out in periodic manner to improve the performance which helps in reducing emissions. The refinery has upgraded efficiency of its furnaces and boilers from (65-70)% in the early sixties to over (88 – 92)%, thereby bringing down energy consumption.

8.2.2 Loss Control/Resource Conservation MeasuresSimilar to ENCON, there is a constant thrust on loss control and resource conservation measures.

There has been considerable reduction in Fresh Water consumption by diverting once through cooling water to circulating water system in various units.

Treated effluent is reused for fire water, cooling tower make up, coke cutting purposes, horticulture, green belt development and also in Eco ponds where adequate life flourishes.

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There has been minimal discharge of effluent to the river Ganga since 1997 is a significant achievement towards conservation of natural resources.

Recycling of treated effluent in the fire water make up, coke cutting water and for coker blow down operation has helped in conserving fresh water resources and efforts are being made to increase this further.

Further steam leak, pump/valve gland leak and comprehensive loss control surveys by internal and external teams are done to reduce losses. These measures have also helped in reducing the refinery loss.

8.2.3 Process/Product Quality ImprovementCatalytic Reforming Unit (CRU) is installed at Barauni Refinery for the supply of low lead petrol. Besides, RFCCU & DHDT have been provided for premium and low sulphur gasoline and High Speed Diesel. Also, sulphur removal from product streams and recovery of elemental sulphur as by product is carried out in Sulphur Recovery Unit (SRU).

10.110.210.110.2

11.2

10.1

8

9

10

11

12

2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

FUEL

& L

OSS

, % W

t

ENERGY PERFORMANCE

(Outlook)

*

* BXP Unit stabilization / operation

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8.2.4 Crude/Product Movement by PipelineSince the crude oil supply to Barauni Refinery will continue through the pipeline and additional products after meeting the local demand will be also dispatched through product pipeline, the refinery operations after the new projects (at 6.0 MMTPA) will not have any impact on the surrounding environment. Transportation of crude and petroleum products by means of cross-country pipeline is the most environment friendly and economical option.

8.3 OTHER MITIGATORY MEASURES i) To protect ozone layer

Halon gas used in fire extinguishers is an ozone destroyer. Barauni Refinery has stopped procurementof Halon type extinguishers and old stocks have already been phased out.

ii) Management of Oily SludgeHot gas oil circulation is employed to minimise the sludge generation at source itself. The sludge is then treated in the melting pit for recovery of oil and residual sludge is biodegraded in the identified disposal site. Residual sludge ex melting pits is disposed off through microbial route and natural weathering.

iii) Installation of flue gas scrubber (first time in India) for reducing the particulate matter and SO2 emission from RFCC regenerator stack.

iv) Double seals in LPG and Naptha and phenol pumps to reduce fugitive emissions.

v) Provision of drum skimmers in guard basin to recover floating oil from liquid effluent.

vi) Closed storage of phenolic effluent from coker unit to reduce emission of toxic vapour.

vii) Stoppage of KTU and commissioning of CRU eliminating the use of hazardous chemicals viz, SO2, and TEL.

viii) Installation of Sulphur Recovery Unit to reduce Sulphur content in fuel gas thereby reducing SO2emission from refinery stacks.

(iii) Ecological commitmentsBarauni Refinery has a beautiful ecological park developed with its inhouse expertise and resources where flora and fauna and aquatic life are thriving on treated effluent. This park symbolizes the harmony between industry and environment and infact is manifestation of all the green activities in the refinery has undertaken in the field of environment protection.

Spread over an area of 75 acres, its lush green lawns, a large variety of trees and shrubs, pretty flowers and lot of fresh air- all these asserting fact that in Barauni Refinery, industrial environment is in perfect harmony with nature.

Efforts have been made to go far beyond the obvious in environment protection. Even scrap material of refinery is innovatively used to beautify the park.

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The eco- pond of park attracts hundreds and thousands of migratory birds in every winter. These ponds are full of aquatic vegetation.

A large variety of fruit bearing and herbal plants along with 31 varieties of roses are the proud possession of this park with rabbits, ducks, wild cats, mongoose, snakes and jackals roaming around with free abandon. The park is always studded with variety of seasonal flowers and the flora and fauna draw their sustenance from the treated effluent – which always meets and exceeds the quality standards sets as MINAS (Minimal National Standards). The outstanding features of this unique Ecological park have been applauded and appreciated by various dignitaries, distinguished visitors and media as well.

Ecological Park- A live testimony

8.4 MITIGATORY MEASURES DURING CONSTRUCTION The impacts of the construction phase on the environment would be basically of transient nature and are expected to wear out gradually on completion of the construction programme. However, once the construction of the units is completed and its operations started, these operation stage impacts would overlap the impacts due to the construction activities. In this present case, however, the construction phase impacts would be minimum at the plant site, as the site is already in acquisition.

The impacts in different aspects of environment due to the construction programmes have been elucidated in Chapter-4. In order to mitigate such impacts and restrict them within tolerable levels, the Authorities would adopt the following measures:

i) Designation and demarcation of sites for construction camps and ensuring due provision of necessary infrastructural services as water supply, sewerage and drainage facilities and electrification.

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ii) Implementation of necessary drainage facilities, inclusive of catchpits or sedimentation basins for the drainage of construction wastewater, prior to discharge.

iii) Regular sprinkling of water around vulnerable areas of the construction sites from trucks or through installation of water sprinklers or any other suitable methods, to control fugitive dust as and when required.

8.5 GREENBELT DEVELOPMENTA comprehensive green belt development plan was prepared for the refinery in consultation with eminent ecologist Dr D N Rao and consequently, a large number of trees were planted inside the refinery premises to enhance the aesthetic look of the refinery as well as to serve the purpose of a pollution sink. Utmost priority is given to the Tree plantation activity, which is undertaken on a regular basis both inside the refinery premises and in township.

Besides above, extensive tree plantation has been done in the premises of Bio - treatment Plant and an area of about 75 acres has been developed as an Eco-Park by developing landscapped gardens, flower beds and fragrant shrubs. Assistance of experts from Zoological and Botanical Survey of India, Calcutta and landscape architect has been taken in the development of this beautiful park. The migratory fauna populations invading the polishing pond indicate the quality of the water of the polishing pond.

Over 1,25,000 trees have been planted in the Refinery and Township. The list of the species planted are given below:

Arjun, Leechi, Ashok, Neem, Menishri, Gulmohar, Karang, Peepal, Bargad, Amaltash, Mahaneem, Sagwaan, Gular, Sharifa, Pakor, Papaya, Jungle Jilebi, Lemon, Jhau, Coconut, Bottle Brush, Arkesia, Maulshri, Seesham, Copper pod.

In addition to above, to improve aesthetic look, lawns and flower beds are developed in Refinery and Township in the proximately of Offices, Workshop, Laboratory, Hospital, Community Centre, School etc.

8.6 FIRE AND SAFETY MANAGEMENTFull-fledged fire fighting facilities are provided in the refinery to tackle any fire contingency. Regular safety audits by internal and external teams are carried out for improving safety performance. Onsite and offsite Disaster Management Plans have been developed and mock drills are conducted at regular intervals to keep the disaster management team in a state of full preparedness.

In addition to above, refresher training programmes are conducted at regular intervals for IOC's own employees/ contractors' labourers as well as tank lorry crews engaged in transportation of products to enhance their safety awareness and preparedness.

8.7 ENVIRONMENTAL AWARENESS CAMPAIGNIn addition to training of employees in various aspects of pollution control activities of the refinery, programmes like celebration of World Environment Day, screening of films on environment, tree

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plantation etc are regularly carried out in order to create greater awareness towards environment protection amongst employees and the people in the neighbouring areas.

8.8 LEGAL AND STATUTORY COMPLIANCEAll the environmental standards/stipulations are fully complied with by Barauni Refinery and the same will be continued after the future projects (at 6.0 MMTPA crude processing level).

The plant has to obtain yearly clearance from the State Pollution Control Board for liquid, gases & hazardous wastes disposal. Specific information in prescribed forms is to be submitted as per Water (Prevention & Control of Pollution) Act, Air (Prevention & Control of Pollution) Act, Hazardous Waste (Management & Handling) Manufacture, Storage & Import of Hazardous, Chemicals Rules etc. It is to be supervised that all requirements under these Acts and Rules are met and if not met, the explanation for it. Besides, under Environment (Protection) Act, Environmental Statement for each financial year is also to be submitted.

The engineer-in-charge for the Environmental Cell will prepare these reports with the help of the production engineers.

BR is at present meeting all statutory requirements.

8.9 DOCUMENTATIONAll the monitoring data, environmental and health related, should be stored in systematic manner so that the specific records are easily available as required.

8.10 INFORMATION DISSEMINATION AND PUBLIC RELATIONSEverybody now a days is concerned about environmental pollution. A chemical plant is therefore susceptible to people as a source of local pollution. It is therefore needed that people should be provided with environmental data related to the plant so that wrong apprehensions can be removed. This requires a well-planned public relation and information dissemination process so that unnecessary public intervention is avoided. In this connection, the refinery has been observing Environment week, organising different programmes with participation from local bodies, encouraging local community in environmental projects (like tree plantation) etc.

8.11 QUALITY ASSURANCEA quality assurance plan has already been developed which includes all reference methods for monitoring, relevant analytical technique, calibration of equipment, standard of reagents, collection and presentation of results, frequencies of monitoring etc. Data reporting and system audit plan is included therein. This Quality Assurance Plan will continue after the installation of the new projects.

8.12 POLLUTION CONTROL CELLA dedicated pollution control cell consisting of experienced and qualified engineers coordinates all the activities related to environmental management in the refinery. This cell apprises day to day performance of pollution control activities to the higher management as well as develops plans for further improvement in the existing facilities.

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Similarly, there is a full-fledged pollution control laboratory, having modern and sophisticated equipments and manned by qualified personnel to monitor performance on a day to day basis.

8.13 OCCUPATIONAL HEALTH ACTIVITIES8.13.1 Occupational Health Centre

Occupational health monitoring of the employees is being done since inception by the refinery hospital. However, the existing facilities have been further strengthened by setting up a full fledged Occupational Health Centre (OHC) equipped with latest clinical, pathological and work environment monitoring equipment and manned by professionally qualified and trained Doctors and paramedical staff. The OHC has started functioning from middle of 1994.

8.13.2 Medical Check upOccupational health is given utmost importance in Barauni Refinery. A full fledged occupational health centre manned by an occupational physician, occupational hygienist and other paramedical staff is fully operation. This centre is equipped with the following modern diagonostic equipments:

1. Self-Interpreting ECG machine 2. Audiometer 3. Titmus Vision Tester 4. Snails chart 5. Direct and Indirect Opthalmoscope 6. Respirometer 7. Complete Pathology Lab 8. Atomic Absorption Spectrophotometer.To ensure proper health of employees and detect any problems well in time, the following medical check ups are conducted:

Pre-employment check upBefore joining, an employee is thoroughly examined to ensure that he is medically fit to perform his duties.

Annual medical check upAll employees above the age of 40 have to undergo this medical check up annually once.

Canteen/contract worker's check upAll canteen and contract workers are medically examined to see that they are suitable for the jobs they perform.

Territorial Army & CISF personnel's check upVolunteers of Territorial Army and Central Industrial Security Force personnel are given medical check up on need basis.

Heavy Equipment OperatorsHeavy equipment operators like loco drivers and crane operators are also given regular medical check up once a year.

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Medical check up of personnel working in Hazardous areaAll workers employed in hazardous areas are given thorough medical check up.

8.13.3 Training of EmployeesDuring First-Aid training programme, classes on occupational health & hygiene are held for the officers & staff. All employees are exposed to this training.

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9.0 Executive Summary Enirotech East Pvt Ltd

CHAPTER-9

EXECUTIVE SUMMARY

9.1 INTRODUCTIONBarauni Refinery (BR) of Indian Oil Corporation Limited (IOCL), a public sector undertaking of the Govt. of India, is located at Barauni in Begusarai district of the state of Bihar. The refined products fulfil the requirement of the eastern region by road, rail and also a product pipeline going upto Kanpur, UP via Patna, Mughalsarai & Allahabad. A branch pipe line from Gowria (Near Kanpur) also supplies product to Lucknow. The imported crude oil from African countries (eg. Nigeria, Congo etc.), Middle East Countries and Malaysia is supplied to Barauni Refinery through a Haldia – Barauni crude oil pipeline.

In view of the future specification, the demand of quality petroleum products, particularly HSD and MS, will increase notably in the country. Having realised and identified the need, the management at Barauni Refinery has planned to install some additional facilities to improve the HSD & MS quality in Barauni Refinery. Besides, in order to optimize refinery product pattern and economic viability, facilities for increased processing of high sulphur crude are also envisaged.

As per EIA Notification 2006, published on 14th September 2006, all projects or activities, including expansion and modernization of existing projects or activities or change in Product Mix, falling under Category ‘A’ in the Schedule shall require prior Environmental Clearance from Ministry of Environment & Forests, Govt. of India.

All projects of Petroleum Refining Industry shall be treated as Category ‘A’ projects and ‘therefore, shall require prior Environmental Clearance from Ministry of Environment & Forests, Govt. of India. In this connection, Barauni Refinery submitted an application along with filled up ‘Form I’ in the prescribed format and Pre-feasibility Report to MoEF for seeking prior Environmental Clearance for its proposed project vide Letter No. EP/EC-APPL dated 08.12.2006. Subsequently, the proposal was considered by the Expert Appraisal Committee (Industry) in its 63rd meeting, held on 28th March 2007 to determine the Terms of Reference (TOR) for undertaking detailed EIA study for obtaining Environmental Clearance in accordance with the provisions of the EIA Notification 2006. Accordingly, MoEF issued a letter (Ref. F. No. J-11011/491/2006-IA II (I)) dated 7th May 2007, with mention of the finalized Terms of Reference. The Expert Appraisal Committee approved the TOR, as proposed by Barauni Refinery. The Committee also suggested some additional TORs for the preparation of the EIA/EMP Report.

As advised, the Draft EIA/EMP Report was prepared, accommodating all the components, based on finalized TOR for its submission to Bihar State Pollution Control Board.

Subsequently, the Public Hearing was conducted on 25.09.2007 at Officers’ Club, Barauni Refinery Township. Barauni Refinery has already planned to take/ has taken actions on the relevant issues raised during the meeting.

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This EIA Report is prepared on the basis of the available secondary data/ literature along with the on-site data during the period (20th March 2007 – 19th June 2007) representing the summer season, generated through on-site monitoring of relevant environmental components and parameters.

9.2 PROJECT DESCRIPTIONBarauni Refinery was commissioned in the year 1964 with a Crude Processing Capacity of 1.0 MMTPA with one Crude Distillation Unit. This capacity was increased to 3.3 MMTPA with the addition of two CDUs in the years 1966 and 1969 respectively.

Its present refining capacity is 6 MMTPA, through the revamp of the existing primary units along with the installation of the units like RFCCU, DHDT unit, LPG treating unit, Gasoline Treating Unit, Hydrogen Unit and Sulfur Recovery Unit.

In order to meet BS-III Specifications, Barauni Refinery has planned to incorporate some new facilities in their existing Refinery System in connection with the MS Quality and HSD Quality upgradation projects.

Also, in order to optimize refinery processing economics and at the same time to enlarge the refinery product slate with production of Bitumen and ATF as finished products, maximization of high sulphur crude processing is envisaged. This will involve changes in configuration of Process units like RFCCU & Cokers along with suitable metallurgy upgradation as part of major revamp ofthe facilities.

The following new units are proposed under MS Quality Upgradation Project:

1. Reformate Splitter Unit 2. Naphtha Hydro-treating & Splitter Unit (NHDT) 3. Isomerisation Unit (ISOM) 4. FCC Gasoline Selective Hydro-treating (SHU) – Prime G + Unit 5. FCC Gasoline Hydro-desulphurisation Unit (HDS) – Prime G + Unit 6. Hydrogen Generation Unit (HGU) 7. DHDT Naphtha Splitter Unit

Besides, existing Catalytic Reforming Unit will be revamped with the addition of one new reformer reactor by replacing one existing reformer reactor.

Under HSD Quality Upgradation Project, DHDT unit, installed under 6.0 MMTPA expansion project will be modified with the inclusion of one additional reactor.

The following new units are proposed under High Sulphur Crude Maximisation Project:1. Bitumen Unit (BBU)2. ATF Treating Unit3. Sulphur Recovery Unit (SRU)

Apart from this, the existing units i.e., Delayed Coker Unit (Coker-A) and Residue Fluidised Catalytic Cracking Unit will be revamped.

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Among the proposed offsite and associated facilities, Storage Tanks [5 X 5000 m3 (for Intermediate Products), 3 X 3000 m3 (for ATF), 2 X 3000 m3 (for Bitumen)], Hydrogen Bullet (1 X 225 m3), Cooling Tower Cells (1 X 2650 m3/hr, 1 X 3250 m3/hr capacities), Turbine Generators (1 X 20 MW) at existing TPS, Boiler (1 X 150 TPH) at existing TPS, DM Water Plant (130 m3/hr capacity), Air Compressor (1 X 6500 Nm3/hr capacity) + Dryer (1 X 1500 Nm3/hr capacity), Nitrogen Unit and Bitumen Dispatch Facilities are envisaged.

All these facilities will come under MS Quality Upgradation and High Sulphur Crude Maximisation Projects. No additional auxiliary facilities have been considered under HSD Quality Upgradation Project. All other offsite & utility requirements would be met through the existing facilities which include Fire Fighting Facilities, ETP, Raw water etc.

The refinery has a Captive Power Plant for meeting the requirement of steam and power. There are 5 boilers, each of 75 MT/hr capacity. There are three Turbo Generators (TG), two of 12 MW capacity each and the third of 12.5 MW capacity. The TPS has a DM plant to meet the boiler feed water requirement and an independent cooling tower. In addition to 3 nos. of TGs., there are 2 nos. Gas Turbines (GTs) of 20 MW each, integrated with HRSG, each of 40 MT/hr steam genration capacity. Peak demand of Power at the existing refinery operation is of the order of 42 MW. This is being met from the existing system by operating 5 nos. boilers (each 75 MT/hr steam generation capacity) and 3 nos. turbo generators (two of 12 MW and one of 12.5 MW capacity)and the GTs. This will go up to around 52.5 MW after the commissioning of the new facilities. One Steam Turbine Generator (STG) of 20 MW capacity with one boiler of 150 MT/hr capacity has been proposed, which will be integrated to the existing CPP (Captive Power Plant). After implementation of all the facilities, total 4 boilers (3 Existing + 1 New) and 2 GTs (existing) and 1 TG (new) will be in operation. With the installation of new boiler & TG, numbers of equipment in operation will be reduced.

The fresh water requirement of the refinery is met by ground water, supplied through 9 nos. of artesian tube wells installed in close proximity of the refinery boundary. In the refinery, water is required for operation of the process units, cooling towers and TPS, and also to meet the domestic demand within the refinery. The existing water requirement for the refinery stands at 1155 m3/hr. This will go up to 1397 m3/hr after the installation of the new projects.

The fuel supply for the heaters in the process plant consists of low "S" fuel oil and sweet fuel gas which is obtained from the refinery fuel gas network. In addition, naphtha / HSD is also supplied to GTs as fuel from separate tanks.

The imported crude oil from Nigeria, Malaysia and Middle East Countries is supplied to Barauni Refinery through a Haldia – Barauni crude oil pipeline.

The finished products from the refinery are despatched by three different modes viz. Rail, Road and Pipeline. Two broad gauge tank wagon loading gantries are provided for loading white oil and black oil products.

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White oil is transferred to the tanks of adjacent terminal of IOC (Marketing) to despatch to local areas. Tanks truck loading gantry (1 no.) is provided for the despatch of special products. While oil products are pumped through Barauni/ Kanpur product pipeline (1.8 MMTPA capacity) with the tap-off points at Patna, Mughalsarai, Allahabad, Kanpur and Lucknow. The products received from the Haldia-Barauni Pipeline are also despatched through the Barauni- Kanpur Pipeline.

In addition to the major facilities mentioned above, the refinery has elaborate fire protection facilities and fire water network covering all the areas, LPG bottling plant to fill LPG cylinders, bulk LPG despatch facilities, Quality Control Laboratory, various site offices and the Administrative Block.

Barauni Refinery has been provided with an Effluent Treatment Plant since its inception, so that the effluent quality meets the specifications. Subsequently, facilities like Chemical Treatment, Bio-Treatment plant (BTP) were added to ensure that the effluent meets the quality as per the latest and more stringent quality standards under Environment (Protection) Act, 1986. A separate pumping station has been provided for the recycling of the treated effluent back to the refinery for various end uses.

There are a number of sources where liquid effluents get generated at the refinery which ultimately are routed to the Effluent Treatment Plant to take care of the pollutants carried by these streams. The treated water ex ETP along with the township (domestic) effluent is subsequently treated in BTP to meet Minimal National Standards (MINAS), as notified by Central Pollution Control Board. The total effluent load from the refinery after the installation of the proposed projects will be about 520 m3/hr. The waste water streams due to the proposed projects will be similar to those,generated in the existing refinery. The existing ETP has a design capacity of 600 m3/hr and that of the BTP is 1162 m3/hr. Therefore, the effluent load of around 520 m3/hr in the ETP and around 694 m3/hr in the BTP will be easily treated there.

Performance evaluation of the Effluent Treatment Plant & the Biological Treatment Plant is conducted on the daily basis. The effluent quality is well within MINAS regulations both qualitatively and quantitatively. After the commissioning of the additional units, pollution load will increase but will meet MINAS both qualitatively and quantitatively.

The existing Effluent Treatment and Biological Treatment Plants are undergoing the process of modernisation. The capacity of the ETP will be increased from the existing level of 600 m3/hr to 1000 m3/hr and that of BTP from 1162 m3/hr to 1500 m3/hr, with the modification of the existing equipment in both the ETP and the BTP. This will create the spare capacity to meet contingencies.

Barauni Refinery is reusing most of the treated effluent for:

Fire Tank/ cooling water make up Coke Cutting Gardening and horticulture and, Eco Ponds

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Storm water gets generated during rains from various catchment areas in the refinery such as Tank farms, Loading Gantries, paved areas in various units, building roofs, roads and surrounding open areas. Presently a large fraction of storm water generated flows through the storm water open channel particularly in monsoon. The storm water from various areas gets routed through the network of open channels which are interconnected and finally the storm water flows out of the refinery to a burrow pit. The coke cutting water is also routed to the storm water channel.

At Barauni Refinery, the storm water was observed to be free from oil. Any accidental spillage of oil from tank farm dyked area (provided, the dyke valves are open for storm water channel) or pipe leaks etc might lead to oil passage to the storm water system. Every storm water stream, therefore, has passed through single and double oil catchers to arrest such accidental oil spillage. BR has provided good facilities for oil recovery from tank wagon loading leaks or floor washings by providing a number of oil / traps and separators which were found to be quite effective.

Mainly four types of solid wastes are generated in the Refinery and its townships; namely oily sludge, biological sludge (from the biological treatment of the wastewater), other industrial solid wastes (intermittent) and the domestic solid wastes.

The oily-sludge and spent catalyst of RFCCU are the hazardous wastes generated in refinery operations. The oily sludge is subjected to the melting pit treatment, through which the maximum amount of oil recoverable is extracted from the sludge and the residual oil sludge used to be disposed off through biodegradation at bio-remediation site through weathering by a special bacterial consortium. The residual oily sludge was accumulated in a synthetic lined pit of 2500 m3

before storage. From March, 2007, the recovery of oil in the oily sludge is being done by Mechanised skid process wherein the residual oily sludge oil content is in the range of 5-10% against previous 15-20%. The residual oily sludge water content is lesser by 10-20% leading to lower sludge quantity for bio-remediation. The residual oily sludge generated as in previous years will be harmlessly degraded into waste and carbon dioxide using a process called bio-remediation. In this process, the sludge is spread out on earmarked site and a bacterial consortium oilivorous –S is applied along with nutrients. The designated area is tilled every fortnight using a tractor trailer. The bacteria, jointly developed by M/s TERI and IOCL (R&D) eats away the oil and sulfur present in the sludge. The added nutrients speed up the process. In a period of 10-12 weeks, the oily sludge is bio-degraded and the site is used again for a fresh phase of bio-remediation of additional new sludge. About 18000 MT of residual oily sludge has been biodegraded during 1998-2007. The quality of soil at the Bio-remediation site is checked regularly w.r.t. accumulation of heavy metals. Also, underground water quality is checked in the periphery of the site. So far, no adverse impact has been found.

The spent catalyst from RFCCU is stored in concrete lined pits as well as packed in empty polybags. These polybags are containers in which fresh catalyst is received at Refinery. The polybags are then stored under roof to safegaurd from inclement weather.

With regards to its disposal, the same can be utilised either as filler in bituminous mixture used for road construction or as raw material for the cement industries. The use in road construction is corroborated by a research carried out by Central Road Research Institute and communicated to IOCL which says that 3% spent catalyst mixed with 2% lime in bitumen improves the road quality.

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In regards to use of spent catalyst in cement industry, the same is corroborated by the report of National Coucil for Cement and Building Material in December'03. The report suggests the use of spent catalyst as a replacement of fly ash used as raw material in Cement Production. Accordingly, a trial was carried out at M/s Kalyanpur Cement Limited, Banjari with 50 MT of spent catalyst in Jan-Feb'07. Based on the encouraging results, disposal of spent catalyst by means of regular supply to M/s KCL, Banjari through bulk trucks is being pursued. In addition, Ambuja Cement Ltd., Darlaghat, HP, which is currently taking similar catalyst from Panipat Rerfinery, has also agreed to take the spent catalyst ex BR. The modalities & transportation arrangements are being worked out. In the meantime, the catalyst will continue to be disposed off in the concrete lined pits.

The biological sludge from the sludge drying bed is being used as manure by the refinery in their township and the ECO Park etc.

The metallic wastes or the scraps are auctioned. There will not be any additional solid waste generation due to the new projects except tank bottom sludge in due course of tank M & I.

Presently, there are 15 stacks. There will be another 6 new stacks after the installation of the proposed projects. Major pollutant, emitted is sulphur dioxide (SO2) and oxides of nitrogen (NOx). Other emissions are negligible. The total SO2 load after the installation of the proposed projects will be 1035 kg/hr.

The expected date of the commissioning of the proposed project is December 2009. There is marginal permanent employment generated by the project but during construction and erection there will be a large number of skilled and unskilled manpower requirement for the project. An additional 5-10 persons will be permanently employed in the proposed project. The total cost of the project will be around Rs 1550.24 Crores.

9.3 BASELINE ENVIRONMENTAL SCENARIO9.3.1 Study Area and General Environment

Barauni Refinery (BR) is located in Development Block Barauni of District Begusarai of the State of Bihar, about 8 kms. away from the Northern or left bank of Ganges. From Patna, the state capital, BR is about 125 km due east. The latitude and longitude at the Refinery site is 25o26' N and 86o04' E respectively. The district head quarters town of Begusarai is about 6 km to the East and the Refinery Township is just adjacent to Begusarai, thus being about 5 km from the refinery. The block head quarter town of Barauni is about 10 km due WNW. The region surrounding BR is extremely plain and the variation in ground levels is mainly seen only on approaching the "diaras" between 40 and 44 m above MSL. With the mighty Ganga forming its southern boundary, the Ganga flood-plains (or "diaras") constituting at least 25% of the geographical area and a reasonable annual rainfall averaging over 1110 mm, the area is not subject to water scarcity. The sandy alluvial soils of the study area favour wheat, maize, millets, oilseeds and pulses besides a variety of vegetables and fruits. The area, particularly Northern upland tracts has had prosperous agriculture and fruit orchards for centuries. No forests or wild life sanctuaries are found within the study area.

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9.3.2 Environmental Impact Assessment Methodology This Environmental Impact Assessment (EIA) study has been carried out to determine the environmental impacts on different disciplines of environment that would be caused due to the installation of the proposed projects, and ultimately to formulate an Environmental Management Plan (EMP) consisting of recommendations of mitigatory measures to control the adverse impacts and formulation of an environmental monitoring programme.

This EIA study is based on field enquiries and investigations, collection of the existing information and generation of data, whichever is applicable and necessary for the relevant environmental parameters as soil, land use, meteorology, water quality, air quality, noise, terrestrial & aquatic ecology, and demography & socioeconomics.

This EIA report is prepared on the basis of the available secondary data/ literature along with three months’ (20th March, 2007 – 19th June, 2007) on-site data through on-site monitoring of the relevant environmental components and parameters. The impacts have been evaluated over the study area, which encompasses all areas within a 10 km radius around the project site.

9.3.3 Soil & Land UseSoil samples have been collected from 5 locations within the study area once during the month of May, 2007.

Soils in the area are mostly silty or clay loam in texture and contain large percentage of silt and clay and hence, possess high water holding capacity and good fertility status. The soils are observed to possess reasonable amount of Nitrate (67.54 – 78.65) ppm, Phosphate (1.15 – 2.45 ppm) and Potassium (0.87 – 3.12) ppm, which indicate moderate to good fertility or agricultural potential of the soils. The levels of other elements are appreciably good.

The land use pattern within the study area of around 10 kms. radius from the plant of BarauniRefinery has been assessed using Geographic Information System (GIS).

9.3.4 Air QualityTo establish the background data on air quality, ambient air quality monitoring was conducted at 8 appropriate locations within the study area at a frequency of twice a week for the entire three months’ monitoring period (20th March, 2007 – 19th June, 2007). The parameters monitored included SPM, RPM, SO2 & NOx.

The overall mean (mean of all the 8 locations) of 24-hourly average values of SPM, RPM, SO2 and NOx in the area were 217 µg/m3, 64 µg/m3, 10 µg/m3 and 32 µg/m3 respectively which were much within the permissible limits for industrial areas.

9.3.5 MeteorologyThe climate of the area is tropical humid and generally variable, characterised by four distinct seasons namely summer (March to May), monsoon (June to September), post-monsoon (October to November) and winter (December to February). May-June is the hottest and December-January is the coldest month.

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The nearest existing meteorological station maintained by India Meteorological Department (IMD) is situated at Patna, located about 125 km west of the project site and hence deemed representative for the study area. The station is observed to be well manned and equipped with thermometer, barometer, raingauge and wind monitor. Another IMD observatory is located at Bhagalpur, about 150 km east of the project site. Therefore, it may be presumed that the climate of the site will be in between of Patna and Bhagalpur.

Maximum temperatures at Patna are recorded during May (mean maximum 38.9oC) while minimum temperatures occurred during January (mean minimum 11.0oC). Similarly, maximum temperatures at Bhagalpur are recorded during May (mean maximum 38.3oC) while minimum temperatures occurred during January (mean minimum 11.8oC). Humidity is usually moderate to high. During the monsoon months, particularly July to September it was found ranging (80-83% in the morning and 75-78% in the evening). The corresponding values at Bhagalpur were found ranging between 82-84% in the morning and between 74-80% in the evening.

The average annual rainfall is about 1,110 mm (at Patna) and about 1,143 mm (at Bhagalpur).

Though wind speeds at Bhagalpur in summer are slightly higher than at Patna, Patna is more windy than Bhagalpur in other seasons, particularly monsoon and winter. From the distribution of wind direction at Patna, the monsoon months of June to September, SE-E-NE are the most frequent corridors both at morning and evening hours. However, during winter months, particularly November to March, the most frequent wind corridors are NW-W-SW. At Bhagalpur, during the monsoon months of June to September, the frequent corridors are SE-E-NE. During the postmonsoon and winter months, particularly November to February, wind reverses itself with the NW-W-SW sectors being the principal directions. During summer months of March and April, the principal directions are E, W and SE.

An on-site meteorological observatory was set up close to the project site, which was operated continuously for three months (20th March, 2007 – 19th June, 2007). The parameters monitored on a daily/hourly basis at this observatory included temperatures, relative humidity, atmospheric pressure, wind speed and wind direction.

9.3.6 Water QualityThe River Ganga flows from NW to SE at about 8 km south of Barauni Refinery. The Ganga, being the life-line of the region, its quality and ecology have been attracting the attention of masses and are becoming matter of concern. As the main drainage channel of the region, Ganga receives pollutional loads of domestic and industrial waste waters and also agricultural run off. The treated IOC effluent is discharged into it through an underground pipeline at Kasha Diara, 5 km. downstream from Rajendra Bridge. Presently, very low quantity of the treated effluent is being discharged into Ganga. Most of the treated effluent is being re-used as a make up in fire water, coke cutting water, cooling tower and for watering plants/shrubs in ecological park and as make up water to eco-ponds. To assess the quality of water in river Ganga intercepted in the study area and the impact of Refinery discharges on the water quality, if any, 2 stations were selected and monitored. 8 monitoring stations in the study area were identified for the assessment of the ground water quality. Water samples were drawn at a frequency of once in a month during the entire sampling period of March, 2007 to May, 2007 and analysed for physical, chemical and

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bacteriological parameters as well as trace inorganics, heavy metals and toxic constituents for drawing up the baseline data.

As regard to water quality of the river Ganga, the ranges of various parameters monitored were: conductivity (307 – 351) µmhos/cm, DO (7.7 – 8.2 mg/l, BOD (2.4 – 3.8) mg/l, COD (4.9 – 6.1 mg/l), chlorides (16.4 – 21.1) mg/l, sulphates (17.2 –27.4) mg/l. Hence, no significant impact on water quality of river Ganga due to BR effluent is perceived.

As far as ground water quality is concerned, the values of various parameters observed were: Conductivity (706 – 746) µmhos/cm, hardness (311 - 378) mg/l, chlorides (25 – 57) mg/l and iron (0.75 – 1.18) mg/l. It reveals that the ground water is free of any kind of industrial and urban pollution and is fit for human consumption, in general.

9.3.7 NoiseIt is observed from the ambient noise monitoring carried out once at 21 locations around the project site that the day and night time noise levels beyond the refinery boundary were within the permissible limit.

9.3.8 EcologyThere is no natural forest in the area, however there are plantations developed by the forest department along road sides. Also there are self growing plants, vegetation and grasses. The land in the study area is well suited for different types of crops. Generally, agriculture is practiced in two phases during monsoon (Kharif crops) and winter (Rabi crops). In Kharif, maize, Jawar, Paddy are main crops and pulses are grown at few pockets of the study area. In Rabi wheat, maize, oilseeds such as mustard, caster oil are cultivated. Besides these main crops, different types of vegetables are grown during both the seasons.

The ecology of Ganga River was found in the healthy state and there was no impact due to the discharge of the treated effluent of Barauni Refinery.

9.3.9 Demography and Socio-economicsBarauni Refinery falls in Begusarai district of Bihar. The study area includes either partly or entirely 129 villages and 3 urban areas namely Barauni, Begusarai and IOC Township. As per 2001 census, the population of the total villages, consisted of 6,04,478. The Study area had an average family size of 6.05 persons per household. The sex ratio (females per 1000 males) is about 889. 11.99 % population belonged to Scheduled Castes (SC) and about 0.3 % are Scheduled Tribes (ST). The overall literacy rate is about 45.12%. The working population or main workers comprise about 28.49 % of the total population.

In all, there are 212 primary schools, 62 middle schools, 21 Secondary schools, 13 Adult Literacy Class/Centre, 4 Graduate College, 1 Industrial School, 6 Senior Secondary School and 2 other educational institutions in the study area. 122 villages in the study area have electricity connections. The primary source of drinking water is hand pumps & wells.

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9.4 ANTICIPATED ENVIRONMENTAL IMPACTS9.4.1 Impacts on Soil and Land use

Sludge is processed through “Mechanised Skid Process”, wherein the residual oily sludge oil content is in the range of only 5-10%. The residual oily sludge generated will be harmlessly degraded into waste and carbon dioxide using a process called bio-remediation, wherein the sludge is spread out on earmarked site and a bacterial consortium oilivorous – S is applied along with nutrients. The added nutrients speed up the process. In a period of 10-12 weeks, the oily sludge is bio-degraded and the site is used again for a fresh phase of bio-remediation of additional new sludge. The quality of soil at the Bio-remediation site is checked regularly w.r.t. accumulation of heavy metals. Also, underground water quality is checked in the periphery of the site. So far, no adverse impact has been found.

As the proposed project will be accommodated within the existing plant boundary, there will be no impact on the Land use pattern of the area outside the plant.

9.4.2 Impacts on Hydrology and Water UseThe water requirement at BR is met by the ground water supplied through 9 nos. of the artesian tube wells installed in close proximity of the refinery boundary. The abstraction of about 1397m3/hr (1155 m3/hr for existing 6.0 MMTPA capacity and 242 m3/hr of the additional water for the proposed projects) for use by Barauni Refinery should not cause any concern about ground water depletion. The annual consumption by BR shall work out to be about 12 million m3. If one were to assume natural local recharge to be 13 cms. from about 12% of the annual average rainfall of 1110 mm percolating to the underground water-table, all it would need is around 85 sq km. area to recharge the abstracted amount which is only 27% of the study area.

The additional water requirement of the project will be met through the existing tubewells developed to cater to the present demand, thus having no impact on the surrounding users as far as water use is concerned.

9.4.3 Impacts on Water QualityThe chances of the groundwater contamination under the plant site is small because most chemicals are used in the areas that are paved and water falling on those locations are subjected to treatment.

The treated effluent of the refinery is discharged into it through an underground pipeline at Kasha Diara, 5 km. downstream of Rajendra Bridge. Presently, little quantity of the treated effluent is being discharged into Ganga. The major portion is being recycled back to the refinery for various end uses. Even after the installation of the proposed projects, this practice will continue and, hence, no impact on the Ganga water is envisaged.

9.4.4 Impacts on Air QualityThe major sources of emission in a refinery are a number of heaters in the different units. Fuel oil is burnt in the heaters. Besides the heaters, the Captive Thermal Power Station also burns fuel oil to raise steam for the power generation and supply of process steam. Naphtha/ diesel is also used as fuel in GTs for power generation. Naphtha/ diesel is also used as fuel in GTs for power generation. As a result, stack emissions would be constituted of mainly sulphur dioxide (SO2) and oxides of nitrogen (NOx). Other emissions like particulates (SPM) & carbon monoxide (CO) will be

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much lower or negligible compared to SO2. Considering stack characteristics pertaining to all the stacks (the existing and the future) it is evident that there are 21 stacks of various heights ranging from 40 to 80.47 m with stack exit diameter varying from 0.61 to 3.5 m. While stack gas temperature varies from 90 to 350C, the stack gas exit velocity varies between 5.27 and 21.4 m/s.

The hourly meteorological data like ambient temperature, wind speed and wind direction used for air quality modelling have been taken from such data, generated through continuous on-site monitoring during three months’ period (March 2007 – June 2007).

The absolute maximum of the predicted GLCs of SO2 & NOx would be about 67 & 9.4 g/m3

respectively, which will occur in future at a distance of about 1.1 – 1.4 kms, i.e., close to the plant boundary. This also includes the contributions from the existing units of the plant though its contribution is already reflected in the baseline ambient air quality, and thus provides a picture of the total contribution of the plant.

The predicted maximum GLCs of SO2 & NOx due to operation of the plant, in any case, are within the permissible limit of 80 g/m3 applicable for industrial areas as stipulated in the National Ambient Air Quality Standards.

9.4.5 Impacts on NoiseThough operational activities is not expected to cause any undue disturbances to the people living in the proximate areas outside the plant boundary, impacts on persons working very close to the said unit are likely.

Impacts of noise on workers could be minimised through adoption of adequate protective measures in the form of (a) use of personal protective equipment (ear plugs, ear muffs, noise helmets etc.), (b) education and public awareness, and (c) exposure control through the rotation of work assignments in the intense noise areas.

9.4.6 Impacts on EcologyThe harmful effects of such air pollutants as SPM, SO2, and NOx in affecting growth and other similar functions of trees, either singularly or synergistically is well known. However, such effects are experienced only at high levels. The levels of pollutants contributed by the project are much lower and are not envisaged to cause any such stress.

No thermal pollution is expected as closed cycle cooling system will be adopted. As the effluent of the proposed units will be completely treated and its quality is expected to be similar to the level achieved now, no impact on water bodies is envisaged.

9.4.7 Impacts on Demography and Socio-economicsSome workforce comprising of skilled, semi-skilled and unskilled labourers will be needed at the peak period of construction phase. Since most of labour force will be drawn from established neighbourhood, no new environmental problem is anticipated. Only for a few skilled personnel, brought to site from outside the locality, proper housing/accommodation would be provided in the established township.

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As the construction phase will be limited to a very short time span, it would not have any long term effect.

IOCL proposes to continue the current community development and awareness programmes for the people in the surrounding area.

9.5 ENVIRONMENTAL MONITORING PROGRAMMEAn Environmental Monitoring Programme is already in progress at the existing plant and all the facilities for monitoring exist at the site. The monitoring shall be strengthened further to include requirement of the proposed projects. Monitoring will be done as per stipulation of the State Pollution Control Board.

9.6 PROJECT BENEFITSThe installation of the new projects will result in the large beneficial impacts on several fronts. The Installation of the MS Quality Upgradation Project will ensure compliance with the MS specifications (EURO-III Regular Grade) as per MoEF Gazette Notification in May 1996. With the installation of DHDT 3rd Reactor, there will be reduction in input cost by processing cheaper crude whose Gas Oil cetane number is low and incremental gross refining margin is Rs. 42 Crores/ Annum. The installation of High Sulphur Crude Maximisation Project will result in the reduction of the input cost by the absorption of more HS crude. There will be improvement in the margin by Rs. 155 Crores/ Annum. In addition, gross economic yield shall increase through increase in agricultural produce, animal husbandry produce, high income group and through marketing multiplier effect. The benefits accrued shall be obviously tremendous in local as well as regional context.

9.7 ENVIRONMENTAL MANAGEMENT PLANBarauni Refinery is an existing refinery running for more than four decades. It has a detailed Environmental Management Programme and it meets all statutory requirements.

There has been continuous thrust on the reduction of energy usage by means of adopting various energy conservation (ENCON) measures. ENCON is an ongoing process and plans have been formulated to achieve a further saving in the coming years. The refinery has upgraded efficiency of its furnaces and boilers from (65-70)% in the early sixties to over (88 – 92) %, thereby bringing down energy consumption.

Similar to ENCON, there is a constant thrust on loss control and resource conservation measures. There has been considerable reduction in Fresh Water consumption by diverting once through cooling water to circulating water system in various units. Treated effluent is reused for fire water cooling tower make up, coke cutting purposes, horticulture, green belt development and also in Eco ponds where adequate life flourishes. There has been minimal discharge of effluent to the river Ganga since 1997, which is a significant achievement towards conservation of natural resources.Further, steam leak, pump/ valve gland leak and comprehensive loss control surveys by internal and external teams are done to reduce losses. These measures have also helped in reducing the refinery loss.

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Catalytic Reforming Unit (CRU) is installed at Barauni Refinery for the supply of low lead petrol. Besides, RFCCU & DHDT have been provided for premium and low sulphur gasoline and High Speed Diesel. Also, sulphur removal from product streams and recovery of elemental sulphur as by- product is carried out in Sulphur Recovery Unit (SRU).

Since the crude oil supply to Barauni Refinery will continue through the pipeline and additional products after meeting the local demand will be also dispatched through product pipeline, the refinery operations after the new projects (at 6.0 MMTPA) will not have any impact on the surrounding environment. Transportation of crude and petroleum products by means of cross-country pipeline is the most environment friendly and economical option.

A comprehensive green belt development plan was prepared for the refinery in consultation with eminent ecologist Dr D N Rao and consequently, a large number of trees were planted inside the refinery premises to enhance the aesthetic look of the refinery as well as to serve the purpose of a pollution sink. Utmost priority is given to the Tree plantation activity, which is undertaken on a regular basis both inside the refinery premises and in township. Over 1,25,000 trees have been planted in the Refinery and Township. All the environmental standards/stipulations are fully complied with by Barauni Refinery and the same will be continued after the future projects (at 6.0 MMTPA crude processing level).

A dedicated pollution control cell consisting of experienced and qualified engineers coordinates all the activities related to environmental management in the refinery. There is a full-fledged pollution control laboratory, having modern and sophisticated equipments and manned by qualified personnel to monitor performance on a day to day basis.

Occupational health monitoring of the employees is being done since inception by the refinery hospital. However, the existing facilities have been further strengthened by setting up a full fledged Occupational Health Centre (OHC) equipped with latest clinical, pathological and work environment monitoring equipment and manned by professionally qualified and trained Doctors and paramedical staff.

All the environmental standards/ stipulations are fully complied with by Barauni Refinery and the same will be continued after the future projects (at 6.0 MMTPA crude processing level).

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