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Environmental Impact Assessment &

Environmental Management Plan

for

Expansion Project of - Ammonia 2200 MTPD & Urea 3850 MTPD, at Village

Piprola, Distt Shahjahanpur, U.P

Submitted by:

KRIBHCO Shyam Fertilizers Limited

April 2015

Environmental Consultant:

EQMS INDIA PVT. LTD. INDIA

304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower,

Community Centre, Karkardooma, Delhi – 110092

Phone: 011-30003200, 30003219; Fax: 011-22374775

Website: www.eqmsindia.com ; E-mail – [email protected]

http://www.eqmsindia.com/

mailto:[email protected]


EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, atVillage Piprola, Distt

Shahjahanpur, U.P

EQMS INDIA PVT. LTD. i

Table of Contents

Executive Summary ........................................................................................................................... x Chapter 1. Introduction and Background ...................................................................................... 7

1.1. Preamble ............................................................................................................................ 7 1.2. Importance and Need of an EIA ......................................................................................... 7 1.3. Project & Project Proponent ............................................................................................... 8 1.4. Objectives of the EIA Study .............................................................................................. 10 1.5. Project Site and Regulatory Compliance Status ............................................................... 10 1.6. Scope of Study ................................................................................................................. 12 1.7. Public Hearing .................................................................................................................. 19

Chapter 2. Project Description .................................................................................................... 20 2.1. Introduction ...................................................................................................................... 20 2.2. Existing Status.................................................................................................................. 20 2.3. Proposed Project .............................................................................................................. 21 2.4. Existing Plant and Facilities .............................................................................................. 23

2.4.1. Ammonia Plant ............................................................................................................. 23 2.4.2. Urea Plant .................................................................................................................... 27 2.4.3. Power Plant and Utilities ............................................................................................... 30 2.4.4. Waste Water / Effluent Treatment System in KSFL ...................................................... 31 2.4.5. Solid Waste Disposal System ....................................................................................... 36 2.4.6. Sources of Gaseous Emissions .................................................................................... 36 2.4.7. Noise Environment ....................................................................................................... 38

2.5. Proposed Expansion Project ............................................................................................ 40 2.5.1. Ammonia plant ............................................................................................................. 40 2.5.2. Urea Plant .................................................................................................................... 42 2.5.3. Utilities and Offsite Facilities ......................................................................................... 44 2.5.4. Air Emission ................................................................................................................. 50 2.5.5. Noise Environment ....................................................................................................... 51 2.5.6. Effluent Generation and Control System ....................................................................... 51 2.5.7. Solid Waste Management ............................................................................................. 52

2.6. Green Belt Development .................................................................................................. 52 2.7. Occupational Health and Safety ....................................................................................... 56 2.8. KSFL CSR (Corporate Social Responsibilities) Activities .................................................. 56 2.9. CREP Compliance ........................................................................................................... 58

Chapter 3. Description of the Environment ................................................................................. 62 3.1. Prelude ............................................................................................................................. 62 3.2. Site Location and its surroundings .................................................................................... 63 3.3. Physical Environment ....................................................................................................... 63

3.3.1. Physiographic and Topography .................................................................................... 63 3.4. Geomorphology ................................................................................................................ 66 3.5. Climatology and Meteorology ........................................................................................... 66 3.6. Micro-Meteorology ............................................................................................................ 67 3.7. Baseline Environment....................................................................................................... 69 3.8. Air Environment ................................................................................................................ 72 3.9. Noise Environment ........................................................................................................... 78 3.10. Water Environment ........................................................................................................... 78 3.11. Soil ................................................................................................................................... 82 3.12. Land use .......................................................................................................................... 88 3.13. Biological Environment ..................................................................................................... 90 3.14. Demographic and Socio-Economic Features .................................................................. 100

Chapter 4. Anticipated Environmental Impacts and Mitigation Measures ................................. 114 4.1. Prelude ........................................................................................................................... 114



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EQMS INDIA PVT. LTD. ii

4.2. Air Environment .............................................................................................................. 114 4.3. Noise Environment ......................................................................................................... 131 4.4. Water Environment ......................................................................................................... 132 4.5. Effluent Generation and Discharge ................................................................................. 133 4.6. Land Environment .......................................................................................................... 134 4.7. Biological Environment ................................................................................................... 135 4.8. Socio – Economic Environment ...................................................................................... 136

Chapter 5. Environmental Management Plan ........................................................................... 137 5.1. Prelude ........................................................................................................................... 137 5.2. Objectives of EMP .......................................................................................................... 137 5.3. Components of EMP ...................................................................................................... 137 5.4. Central Pollution Control Board {CPCB} Guidelines for Fertiliser Industry ...................... 138

5.4.2. Air Environment .......................................................................................................... 141 5.4.3. Noise Environment ..................................................................................................... 142 5.4.4. Water Environment ..................................................................................................... 143 5.4.5. Biological Environment ............................................................................................... 143 5.4.6. Land Environment ...................................................................................................... 144 5.4.7. Socio-economic Environment ..................................................................................... 144 5.4.8. Environmental Management Cell ................................................................................ 144 5.4.9. Post – Operational Monitoring Program ...................................................................... 145

Chapter 6. Hazard Evaluation and Risk Analysis...................................................................... 147 6.1. Prelude ........................................................................................................................... 147 6.2. Hazards Survey .............................................................................................................. 147 6.3. Hazard Evaluation .......................................................................................................... 149 6.4. Potential Hazards ........................................................................................................... 150 6.5. Inventory Analysis .......................................................................................................... 151 6.6. Methodology, Approach and Damage Criteria for Risk Assessment ............................... 153 6.7. General Control Measures ............................................................................................. 160

Chapter 7. On Site Emergency Plan......................................................................................... 163 7.1. Introduction .................................................................................................................... 163 7.2. Probable Hazards & Risk ............................................................................................... 163 7.3. Emergency Management Plan ....................................................................................... 165

7.3.13. Role of Head Security / Security Officer / Asst. Security Officer .................................. 171 7.4. Post Emergency Recovery ............................................................................................. 172 7.5. Enclosures ..................................................................................................................... 173

Chapter 8. Disclosure of Consultants ....................................................................................... 177



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EQMS INDIA PVT. LTD. iii

List of Tables

Table 1.1 : Awards & Certifications Received .............................................................................. 10 Table 1.2 TOR Compliance Status............................................................................................... 12 Table 2.1 : Plant and Facilities Required for the Expansion Project ............................................. 22 Table 2.2 Bulk Hazardous Materials Storages (Existing) .............................................................. 31 Table 2.3 Existing Emission Load ................................................................................................ 37 Table 2.4 UPPCB prescribed norms for Prilling Tower at KSFL ................................................... 37 Table 2.5 Noise Survey of KSFL Complex ................................................................................... 38 Table 2.6 Ambient Air Quality Standards with respect to Noise .................................................... 40 Table 2.7 Raw Material ................................................................................................................ 44 Table 2.8 : Estimated Stack Emission Load (Kg / hr.) due to Expansion for KSFL ....................... 50 Table 3.1 Summary of Climatic Condition at the Site ................................................................... 67 Table 3.2 Details of Sampling Locations ...................................................................................... 69 Table 3.3 Ambient Air Quality Data around the various villages of KSFL in 10 km radius ............ 73 Table 3.4 National Ambient Air Quality Standards (CPCB), 2009 ................................................ 74 Table 3.5 Ambient Noise Quality Results ..................................................................................... 78 Table 3.6 Surface Water Analysis at various locations around KSFL ........................................... 79 Table 3.7 Ground Water Analysis around various Location of KSFL ............................................ 81 Table 3.8 Physicochemical Characteristics of Soil ....................................................................... 84 Table 3.9 Land use category in the Study Area ........................................................................... 88 Table 3.10 List of Tree and Shrub Flora Recorded in the Study Area .......................................... 92 Table 3.11 List of Herbs, Climbers and Grasses Recorded in the Study Area .............................. 94 Table 3.12 List of Mammalian Fauna Recorded in the study area ................................................ 96 Table 3.13 List of Avi- Fauna Recorded in the study area ............................................................ 97 Table 3.14 List of Herpetofauna Recorded in the study area ....................................................... 97 Table 3.15 List of Fish Fauna Recorded in the study area ........................................................... 98 Table 3.16 : Village-wise details of population ........................................................................... 100 Table 3.17 Production and Productivity of major crops cultivated .............................................. 107 Table 3.18 Comprehensive List of Infrastructures present in the Study Area ............................. 110 Table 4.1 Stack Parameters and Emission Load (Existing and Proposed Expansion Project).... 116 Table 4.2 Summary of Maximum 24-hour GLC due to the Existing Facility ................................ 117 Table 4.3 Summary of Maximum 24-hour GLC due to the Proposed Expansion ........................ 118 Table 4.4 Summary of Maximum 24-hour GLC due to the Existing Facility and Proposed

Expansion ........................................................................................................................... 118 Table 4.5 Summary of Maximum GLC at Monitoring Locations due to the Existing Facility and

Proposed Expansion ........................................................................................................... 119 Table 5.1 : Action Points ............................................................................................................ 139 Table 5.2 : Environmental Monitoring Program .......................................................................... 146 Table 6.1 : Hazardous Materials Storages ................................................................................. 148 Table 6.2 : Likely Accident Scenario .......................................................................................... 152 Table 6.3 : Effects due to Incident Radiation Intensity ................................................................ 153 Table 6.4 : Thermal Radiation Impact to Human ........................................................................ 154 Table 7.1 : Probable Hazards .................................................................................................... 163



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List of Figures Figure 1.1 10 Km radius Google Map of the Project ..................................................................... 12 Figure 2.1 Plant Layout Showing Expansion Location ................................................................. 21 Figure 2.2 : Ammonia Plant Process Flow Diagram ..................................................................... 25 Figure 2.3 Flow diagram of the Urea Plant ................................................................................... 28 Figure 2.4 : ETP System in KSFLShahajahanpur (Existing) ......................................................... 40 Figure 2.5 Ammonia Plant Block Flow Diagram ........................................................................... 42 Figure 2.6 Urea Plant Block Flow Diagram .................................................................................. 44 Figure 2.7 : Water Balance in KSFL Shahajahanpur (Existing) .................................................... 48 Figure 2.8 : Water Balance in KSFL Shahajahanpur (Expansion) ................................................ 49 Figure 3.1 Location Map of study Area ........................................................................................ 63 Figure 3.2 Digital Elevation Model (DEM) of the Study Area ........................................................ 65 Figure 3.3 Contour map of the Study Area ................................................................................... 65 Figure 3.4 Geomorphological Map ............................................................................................... 66 Figure 3.5 Wind Rose .................................................................................................................. 68 Figure 3.6 Wind Class Frequency Distribution (Post Monsoon Season) ...................................... 69 Figure 3.7 Sampling Locations in Study Area .............................................................................. 71 Figure 3.8 Statistical Comparison of PM2.5 Concentration (Post Monsoon Season) ................... 76 Figure 3.9 Statistical Comparison of PM10 Concentration (Post Monsoon Season) .................... 76 Figure 3.10 Statistical Comparison of SOx Concentration (Post Monsoon Season) ..................... 77 Figure 3.11 Statistical Comparison of NOx Concentration (Post Monsoon Season) ..................... 77 Figure 3.12 Soil map of Shahjahanpur District ............................................................................. 83 Figure 3.13 Landuse / Land Cover Statistics of the Study Area ................................................... 89 Figure 3.14 Land use map of the Study Area ............................................................................... 89 Figure 3.15 A View of Thick Green Belt around project boundary from Shajahanpur-Farrukhabad

Highway ................................................................................................................................ 99 Figure 3.16 National Parks and Sanctuaries in Uttar Pradesh .................................................... 100 Figure 3.17 Sex wise SC, ST Population in Study Area ............................................................. 103 Figure 3.18 Percentage wise break up of SC, ST and General Population in Study Area .......... 103 Figure 3.19 Gender-wise Distribution of Literate and Illiterate in Study Area .............................. 104 Figure 3.20 Workers Scenario of the Area ................................................................................. 105 Figure 3.21 Distribution of Main Workers ................................................................................... 106 Figure 3.22 Distribution of Marginal Workers ............................................................................. 107 Figure 4.1 Isopleth for NOx GLC due to operation of Existing Facility ........................................ 121 Figure 4.2 Isopleth for SPM GLC due to operation of Existing Facility ....................................... 122 Figure 4.3 : Isopleth for NH3 GLC due to operation of Existing Facility ...................................... 123 Figure 4.4 Isopleth for SOx GLC due to Proposed Expansion .................................................... 124 Figure 4.5 : Isopleth for NOx GLC due to Proposed Expansion ................................................. 125 Figure 4.6 : Isopleth for SPM GLC due to Proposed Expansion ................................................. 126 Figure 4.7 Isopleth for NH3 GLC due to Proposed Expansion ................................................... 127 Figure 4.8 : Isopleth for SOX GLC due to Existing Facility and Proposed Expansion ................. 128 Figure 4.9 Isopleth for NOX GLC due to Existing Facility and Proposed Expansion ................... 129 Figure 4.10 Isopleth for SPM GLC due to Existing Facility and Proposed Expansion ................. 130 Figure 4.11 : Isopleth for NH3 GLC due to Existing Facility and Proposed Expansion ............... 131 Figure 6.1 :Rupture in NG Line .................................................................................................. 155 Figure 6.2 Failure in Ammonia Line ........................................................................................... 157 Figure 6.3 Ammonia Tank Heavy Leakage Stability Class “F” .................................................... 158 Figure 6.4 Ammonia Tank Heavy Leakage Stability Class “D” ................................................... 159 Figure 6.5 Chlorine Cylinder Leakage ........................................................................................ 160 Figure 7.1 : KSFL’s Internal Emergency Communication Network ............................................. 166



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EQMS INDIA PVT. LTD. v

Abbreviation

AAQ Ambient Air Quality

AAQMS Ambient Air Quality Monitoring Station

ADM Additional District Magistrate

AFFF Aqueous Film Forming Foam

APC Ammonia Process Condensate

APTI Air Pollution Tolerance Index

Asstt. Assistant

BA Breathing Apparatus

BFW Boiler Feed Water

BOD Biological Oxygen Demand

CCR Central Control Room

CGWA Central Ground water Authority

CHC Community Health Center

CII Confederation of Indian Industries

CO Carbon Monoxide

CPCB Central Pollution Control Board

CPP Captive Power Plant

CSR Corporate Social Responsibility

CT Cooling Tower

dB Decibel

DCS Distributed Control System

Dept. Department

DM De Mineralization

DMP Disaster Management Plan

EC Environment Clearance

ECC Emergency Control Centre



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EQMS INDIA PVT. LTD. vi

EHS Environment, Health & Safety

EIA Environmental Impact Assessment

EMP Environmental Management Plan

ENE East- North- East

ETP Effluent Treatment Plant

FAI Fertilizers Association of India

FRP Fiberglass Reinforced Plastics

GAIL Gas Authority of India Limited

GLC Ground Level Concentration

GM (O) General Manager (Operation)

GOI Government of India

HC Hydro Carbon

HDPE High Density Polyethene

HR, Admn & CD Human Resources, Administration and Community Development

HRSG Heat Recovery Stream Generator

HTAS Haldor Topsoe

HTS High Temperature Shift converter

IS Indian Standards

ISCST Industrial Source Complex - Short Term

ISO International Standard Organization

IVRI Indian Veterinary Research Institute

KSFL Kribhco Shyam Fertilizers Limited

KBR Kellogg Brown & Root

KVA Kilovolt-Ampere

LDPE Low Density Polyethylene

LTS Low Temperature Shift Converter

MAGP Modern Agro Growth Programme



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EQMS INDIA PVT. LTD. vii

Mbgl Meters below Ground Level

MINAS Minimum National Standards

MoEF Ministry of Environment & Forests

MSDS Material Safety Data Sheet

MSRL Mild Steel Rubber Linned

MTPD Metric Tonsper Day

MW Mega Watt

NDT Non-Destructive Testing

NG Natural Gas

NGO Non - Government Organization

NH3 Ammonia

NNW North-North-West

NOC No Objection Certificate

NOx Nitrous Oxide

P&QA Process & Quality Assurance

PGRU Purge Gas Recovery Unit

PHC Primary Health Center

PT Prilling Tower

PVC Poly Vinyl Chloride

QC&E Quality Control & Environment

REIA Rapid Environmental Impact Assessment

RO Reverse Osmosis

RSPM Respiratory Suspended Particulate Matter

SBU Strategic Business Unit

SG Stream Generation

SGP Steam Generation Plant

SGWA State Ground Water Authority



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EQMS INDIA PVT. LTD. viii

SH State Highway

SHG Self Help Group

SO2 Sulphur Dioxide

SOx Sulphur Oxides

SPM Suspended Particulate Matter

Sr. Senior

ST Scheduled Tribe

STP Sewage Treatment Plant

TC Total Cloud

TDS Total Dissolved Solids

TERI The Environment Research Institute

TOR Terms of Reference

TS Technical Services

TSDF Treatment, Storage, and Disposal Facility

UP Uttar Pradesh

UPC Urea Process condensate

UPPCB Utter Pradesh Pollution Control Board

USEPA United State Environment Protection Agency

WNN West-North-North

ZnO Zinc Oxide



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EQMS INDIA PVT. LTD. ix

Annexure

Annexure I : KSFL Environment Policy

Annexure II : Environmental Clearances/ NOC of existing Plant

Annexure III : Ramky Certificate for Hazardous Wastes

Annexure IV : Ambient Noise Standards

Annexure V : Ground Water Approval

Annexure VI : UPSIDC Industrial Area Documents

Annexure VII : Land allotment documents

Annexure VIII : Environmental Cell set

Annexure IX : KSFL DMP

Annexure X : Ambient Air Quality Monitoring Results

Annexure XI : Compliance of Environmental Conditions



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. x

EXECUTIVE SUMMARY

Introduction and Background Project Highlight

KRIBHCO Shyam Fertilizers Limited (KSFL) was incorporated on December 8, 2005 pursuant to a

joint venture agreement between KRIBHCO and Shyam Group to acquire the urea manufacturing

facilities at Shahjahanpur in the state of Uttar Pradesh in India from Oswal Chemicals & Fertilizers

Ltd. in the shareholding ratio of 60:40. Effective March 30, 2009 the shareholding ratio of KRIBHCO

and Shyam group is 85:15.

KRIBHCO was incorporated on April 17, 1980 as National Level Multistate Cooperative Society and

is governed by Multistate Cooperative Society Act, 2002. KRIBHCO’s paid up capital as on March

31, 2013 is Rs. 390.18 crore.

KRIBHCO has state-of-the art Fertilizer Complex based on natural gas at Hazira, District Surat,

Gujarat consisting of two streams of Ammonia Plant and four streams of Urea Plant with annual

capacity of 1.00 Million MT and 1.73 Million MT respectively. KRIBHCO is in advanced stage of

implementing revamp of its Fertilizer Complex which will increase the annual capacity of ammonia&

Urea Plants to 1.25 Million MT and 2.19 Million MT respectively. KRIBHCO is also producing Argon

Gas from its Fertilizer Complex at Hazira.

The management control of the Company rests with KRIBHCO, a cooperative society engaged in

manufacturing nitrogenous and bio-fertilizers since 1980. KRIBHCO’s long and valuable experience

in fertilizer sector provides the Company the advantage of their management expertise and

business know-how. The Company leverages on the extensive marketing and distribution network

of KRIBHCO, under which our products are marketed. The Company also has access to ’, ‘

’ brand, which is a well-established and respected brand amongst farmers and co-operative

societies across India.

KSFL manufactures nitrogenous fertilizer viz. urea through our integrated urea and ammonia

manufacturing facility at Shahjahanpur. The Plant is the latest Greenfield Urea Plant in India-

commissioned in November 1995 and is strategically located in North India, right in the middle of a

high urea consumption belt and based on Natural Gas as feedstock supplied through the Hazira-

Vijaypur-Jagdishpur ("HVJ") gas pipeline.

The Plant has an installed capacity of 864,600 MTPA (2 x 1310 MTPD) of urea and 501,600 MTPA

(1 x 1520 MTPD) of ammonia. The Plant is operating at more than 100% capacity utilisation since

acquisition.

The plant is ISO 9001:2008, ISO-18001(OHSAS) and ISO 14001:2004 certified by BSI Group India

Pvt. Ltd. The marketing of Urea and surplus ammonia produced by the Company is undertaken by

KRIBHCO, one of the promoters Company

The total land acquired at Shahjahanpur is about 780.75 acres (including township). About 33% of

the land is under green cover.



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EQMS INDIA PVT. LTD. xi

KRIBHCO Shyam Fertilisers Limited (KSFL), Ammonia – Urea complex is located in the Village

Piprola Distt Shahjahanpur in Uttar Pradesh, 12 km from the district town of Shahjahanpur and 80

km from Bareilly town. The plant is well connected by rail and road. The nearest airport is at New

Amausi (~180 km from site). The total land available under KSFL / Township is around 780.75

acres. About 33% of the land is under green cover. Balance land is outside the industrial complex.

The site is well connected with road and rail network.

The power requirement for both existing plant is met by Gas Turbines of 2X25 MW capacities. In

addition there is provision of emergency power supply from 2000KVA DG sets.

Existing facilities also comply with the conditions made by the Ministry of Environment and Forest,

Government of India, Central Pollution Control Board and UP State Pollution Control Board.

As a forward looking company KRIBHCO Shyam (KSFL) considered the future demand of fertiliser

in the country and initiated for expansion of Shahjahanpur unit by proposing to set up a grass root

Natural Gas /RLNG based Ammonia plant of 2200 MTPD single stream and Prilled Urea plant of

3850 MTPD with provision for augmentation of utilities and other off-site facilities considering

available infrastructure. The new expansion project will be located within the existing complex

where adequate land is available.

The key facilities for the proposed expansion project shall be as below:

Sl. No. Plants & Facilities Provisions

1. Ammonia Plant 2200 MTPD 2. Urea Plant 3850 MTPD 3. Main Raw Material --NG/LNG

Transportation & Metering Station

By GAIL Pipeline and metering station provided

4. Product Storage & Handling Facilities

a] **Ammonia Storage Tank b] Silo c] Empty Bag Storage d] Bagging Plant

5000 MT at -330C and atmospheric pressure 30000 MT - (6+2) Slats each of 60 TPH (design capacity)

5. Cooling Tower a] Ammonia Plant

b] Urea Plant 24000 m3/hr. each 21000 m3/hr. each

6. Power Generation & Supply a] Power Generation (GTG)

b] Substation for receiving power from State Grid Emergency DG Set

1X25 MW 1X2000 kVA

7. Steam Generation Facilities

HRSG (GT set) 100 MT/hr

8. Water Supply Treatment & Distribution



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EQMS INDIA PVT. LTD. xii

Estimated Capital cost of the proposed expansion of Fertilizer plant is estimated as Rs. 4132 crores

including foreign component of Rs.1319 crores.

The proposed modernisation cum expansion project is a brownfield project and hence no alternate

site examination is needed. Expansion is proposed within the existing plant premises. The land is

already under industrial use. Hence, no alternative sites have been examined.

(**, installation of new 5000 MT Ammonia Storage tank shall be taken up in first stage of

implementation of project , which will also be used for inspection of existing Ammonia Storage tank

for ensuring safety of the tank.

In second stage of the project, proposed new ammonia & Urea Plant shall be commissioned and

after that existing as well as new proposed Ammonia Storage Tanks will be used for the storage

purpose of surplus ammonia generated from existing & proposed ammonia plants.)

The main suppliers of ammonia technology are:

HaldorTopsoe (HTAS), Denmark

a) Raw Water Supply System b) DM Water Plant c) Cond. Polishing Unit

Bore wells (2+1)×150 m3/hr. (2+1)×200 m3/hr.

9. Yard Piping Provided as per requirement

10. Instrument Air Facilities a] Compressor b] Drying Unit c] Receiver

(1+1)×3000 Nm3/hr. (1+1)×3000 Nm3/hr.

11. Inert Gas Generation 600 Nm3/hr. Of N2; Liquid N2 Storage: 30 m3 with vaporizer

12. Safety & Fire Fighting System including fire water ring with Hydrant System

For the proposed expansion project, existing firewater rings and other facilities shall be augmented as per requirement.

13. Auxiliary services, workshop equipment, laboratory equipment, weighbridge, fire engine, continuous monitoring system, NDT equipment, telephone& telecommunication, Public Address System, etc.

Extra telephone exchange facilities and additional lab and NDT equipment considered

14. General & Welfare Facilities Existing facilities will be augmented as per requirement.

15.

Transport Facilities a] Locomotive b] Railway Siding and lead line c] Road Transport

1X1200 HP To be developed

16. Construction equipment By construction contractor

17. Township &Public Building Existing facilities will be augmented as per requirement.

18. Non-plant Building Existing facilities will be augmented as per requirement.



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EQMS INDIA PVT. LTD. xiii

Kellogg Brown & Root (KBR), USA

Uhde, Germany

The main processes used today in the production of urea are the stripping processes offered by:

Stamicarbon, Netherlands

Snamprogetti (Now Saipem), Italy

Toyo Engineering Corporation (TEC), Japan

**Additional Ammonia Storage Tank: The capacity of ammonia storage tank shall be 5,000 MT. The

ammonia storage tanks will be of double wall double integrity type and provided with suspended

deck. The liquid ammonia produced in the ammonia plant shall be stored at atmospheric pressure

and at a temperature of –33oC. The facilities include one no. double walled insulated atmospheric

storage tank, ammonia boil off compressor, ammonia flare stack and ammonia transfer pumps etc.

for safe operation of the system.

The requirement of raw material and utilities for the proposed project has been worked out on the

basis of rated capacity operation of the plants. The main raw material for the proposed plants is

natural gas and utility is raw water. The requirements of these inputs for 2200 MTPD ammonia and

3850 MTPD urea plants are summarized in Table below:

Sl. No.

Raw Material/Utilities Unit Requirement

1.0 Natural Gas (through GAIL) Sm3/hr. 99035

2.0 Water (Bore well) m3/hr. 1122

Pollutants Generation, Treatment and Disposal

Gaseous Emissions

The KSFL plants will have seven continuous sources of emission after expansion

In Proposed Expansion:

The three continuous sources of emission shall be, namely

Reformer flue gas stacks in ammonia plant.

Urea Prilling tower

Power Plant (GTG / HRSG)

The emission from stacks will be well within the stipulated norms. Urea Prilling tower shall be a

natural draft circular tower with ~ 26 m diameter and 102 m height. The tower is so designed that

exhaust gases contain less than 50 mg/Nm3 of urea dust. Emissions from process section of the

plant are controlled through the use of eco-friendly fuel (NG and in case of its shortage, naphtha is

used to a limited extent during short supply of NG only) and high stacks (more height than required

as per norms).



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EQMS INDIA PVT. LTD. xiv

Fugitive emission occurs in the bagging plant where large quantity of urea is handled. In order to

control the dust, the plant has been provided with de-dusting system. Dust from various points is

collected & sent to Urea plant where it is dissolved in urea solutions and reprocessed in urea plant.

In Existing Plant:

The gaseous emission of the KSFL existing plant is through four number of main stack viz. Service

boiler stack, GTG I&II stack, Ammonia reformer stack, prilling tower There are number of other

stacks viz. Vent stack Ist and IInd, Blow down stack, CO2 compressor vent (2 no.), main flare stack,

ammonia flare stack, ETP Stripper, CO2 vent. These stacks are not continuous and operate only

during abnormality in plant. The emission from continuous stacks is well within the stipulated

norms. Urea Prilling tower is a natural draft circular tower with ~ 26 m diameter and 102 m height.

The tower is so designed that exhaust gases do not contain more than 50 mg/Nm3 of urea dust.

Liquid Effluents

KSFL has followed the policy of “at source treatment of effluents and recycling of treated effluents

back into the process”. The major potential liquid pollutants emanating from the KSFL complex are

from the Ammonia and Urea process plants, Demineralization plant regeneration waste water,

cooling tower blow down, boiler blow down etc. Various categories of effluents generated in the

complex and their treatment philosophy is as given below:

Effluents treated in the individual plant battery limits

Ammonia plant process Condensate is treated in the ammonia plant, recycled to DM plant

and after polishing used as boiler feed water.

Urea plant process condensate treated in urea plant, recycled to DM plant and after

polishing used as boiler feed water.

Turbine steam condensate treated in DM plant (polishing unit) and recycled back as BFW.

Demineralization water plant effluent, neutralized before sending to Guard pond via settling

chamber.

Effluents treated outside the main process plant

Domestic waste water from the plant and township area is treated in Sewage treatment

plant.

Ammonia and Urea process Condensate at ETP in case of upsets.

Floor washings / process drains from ammonia and urea plants at ETP in case of non-

confirming quality.

Oily waters if any generated from various sections of Urea and Ammonia plants is collected

in oily water pit provided in the respective plant. The water is pumped to oily water pit at

ETP.

Sanitary waste water from township & factory in Sewage treatment plants.



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Contaminated pond having capacity of 5000 m3 is provided for collecting floor washing of

urea and ammonia plants and also the condensates of ammonia and urea plants during

any emergencies for further treatment before discharge.

A balance pond having capacity of 30,000m3 is provided for balancing and equalizing the

effluent coming from DM plant, cooling tower and stripper outlet.

The balance pond water overflows to guard pond-having capacity of 5000m3. Treated

effluent from guard pond is pumped to stabilization pond for final discharge/ green belt

irrigation within project premises.

Proposed Expansion Project:

KSFL is in the field of fertilizer production having its production facilities at Shahjahanpur (U.P.) and

produces prilled urea. In the process of urea production from natural gas, ammonia is also

produced as intermediate product which is consumed for urea production. There is also some

surplus generation of ammonia because of the feed quality and quantity of surplus ammonia

depends on Carbon/Hydrogen ratio of Gas (feed). In its existing plant some treated effluent water,

confirming to PCB norms, is disposed off to water bodies. KSFL proposes to implement its

Brownfield Expansion Project for production of ammonia (2200 MTPD) & urea (3850 MTPD).

Solid Waste

KSFL being an environmentally conscious organization has always stresses on pollution prevention

rather than pollution Control. It has insisted on the protection and enrichment of the environment,

conservation of the natural resources. To strengthen the waste management system, different

types of wastes are identified along with proper disposal mechanisms. Basically the following types

of solid wastes are generated at KSFL:

Biodegradable wastes

Non-biodegradable waste

Township Waste and

Hazardous wastes

Following wastes are generated at KSFL as per Hazardous Waste (Management, Handling &Trans

boundary Movement) Rules, 2008

Spent catalyst (Nickel, Chromium & Copper based)

Spent / used oil

Wastes are disposed off as per rules.

Green Belt:

A thick green belt has been provided almost all around the plant. The tree plantation is an on-going

process & KSFL is planting number of trees every year to fill up extra land available with them.

KSFL has developed a thick green cover in and around the plant complex including township. The



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xvi

tree cover is sparse in the immediate vicinity of the Plant, which includes township area, market

places, office complexes, residential areas etc.

Environmental Status of Plant Site and Study Area

Site Characteristics

KSFL fertilizer complex is located at a distance of 12 km from Shahjahanpur town near village

Piprola on the State Highway No.29 to Farrukhabad and lies close to the broad gauge railway line

from Lucknow to Moradabad and the National Highway No. 24. The nearest airport is in Amausi

(Lucknow), at a distance of 150 km.

KSFL plant is located in the state of Uttar Pradesh. Uttar Pradesh stretches into two of India’s major

physiographic divisions, namely the Great Plains of North India and the Peninsular Plateau. Almost

90% of the total area in Uttar Pradesh is Under Great Plains of North India, while the Southern part

of the state belongs to the Peninsular Plateau. Both of these major divisions in U.P. are marked by

a variety of physiographic and relief features.

District Shahjahanpur is situated in South East of Rohilkhand Division. It was established in

1813.Before its creation it was a part of district Bareilly. It Consists of 4 Tehsils, 15 Blocks, 922

Gram Panchayats, 1 Constituency and 6 Assembly Areas.

Land of district Shahjahanpur is plains and fertile. Land of district Shahjahanpur on the side of the

river bank is low and other side it is comparatively high side of land is called Bangar and low side is

called 4 khadar. The north side land of tehsil Puvayan as is domat land. Land in the west side of the

district is comparatively very low due to land erosion of the rivers. Due to this reason at the time of

rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat and

matiyar. In the district water level is 20’ to 25’ below GL. The area is located in the Doab of upper

Ganga, the main drainage feature of the area. The next important drainage channel is Mahuwa,

flowing along the left terrace of the Ganga.

Soil

The soils of Shahajahanpur are complex, highly variable, reflecting a variety of parent materials,

physiographic land features, range of distribution of rainfall, and its effects etc. As such different

soils create different types of habitat for plant growth, therefore, the true choice and afforestation

patterns on such kind of soils vary greatly. Soils are thus, variable in their soil-water-plant

relationship, conservation needs and production potentials.

The mantle of alluvium in this area is confined to the North Eastern sector. It is then on Sandstone

plateaus, where over large spread of bare rock is there. Usually it is light loam, sandier over

sandstone tracts, and more clayey upon the shale.

The fertility of soils of the study area is medium and is known to be good for cultivation.



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xvii

Water Resources and Water Quality

The annual rainfall data from meteorological department in the district is 907 mm. The winter rains

are uncertain. Light showers may occur during December and January.

The primary drains comprise the river Ganges. It flows in a wide and sandy bed and changes its

channel year to year. The river is perennial and shows effluent behaviour throughout the stretch of

the study area. The banks of the river are alternatively sloping and steeper cliffs, a cliff on one side

being usually faces by a slope on the other.

Ground water is important source of drinking water. In larger part of the area the aquifer is

unconfined at shallow depths depending upon the thickness of overlying clay horizon. Estimation of

ground water resources of Shahjahanpur has been carried out based on the methodology

recommended by the Ground Water Estimation Committee (GEC’97). The net ground water

availability of the District is 140974.03 Ham and gross ground water draft is 83111.52 Ham. Thus

the level of development is 58.96. District Shahjahanpur come under Safe Category.

Surface and ground water samples were collected and analysed for suitability as drinking water (IS

10500).Surface water samples analysis indicates that water from all the location meet the ‘desirable

limits’ of drinking water. Total Dissolved Solids levels are high in almost all the samples. Ground

water analysis indicates that all the ground water samples have high magnesium content (even

crossing permissible limits in the absence of alternate source). Other parameters though do not

meet the ‘desirable limits’ of drinking water and in but are within the ‘permissible limit in the

absence of alternate source’

Meteorology

Uttar Pradesh climate greatly varies according to the variation in the topography of the region. The

climate of the state is tropical, but variations exist because of difference in altitudes. The Himalayan

region is cold. The average temperature varies in the plains from 3 to 4 °C in January to 43 to 45°C

in May and June. There are three distinct seasons - winter from October to February, summer from

March to mid-June, and the rainy season from June to September. The landlocked state is devoid

of moderating influence of the sea.

Summer: The month of April marks the start of summers in Shahjahanpur and it lasts till June.

Temperature ranges between 22°C to 48°C during these months.

Monsoon: Shahjahanpur experiences the monsoon season from July till October. The city remains

drenched during these months. Average annual rainfall is 907 mm.

Winter: Winters in Shahjahanpur start in the month of November and last till February. The weather

is pleasant during these months and the temperature ranges between a comfortable 2°C to 23°C.

This is the apt time for visiting the city.

A metrological station was set up inside the plant and temperature, wind velocity and direction,

humidity and rainfall were recorded for the winter season (three months). Maximum and minimum



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xviii

(mean) temperature recorded was 34 and 90C.Highest relative humidity during the study period is

observed as 94% and lowest as 8 %. The predominant wind directions are North West and West.

Air Quality

National AAQ norms for residential areas are always met for NH3, SOX and NOX. For SPM /RSPM

they could not be met due to local phenomenon.

Noise

Ambient standards both Ld and Ln with respect to noise applicable for residential area during day

time {55 dB (A)} and night time Ln {45 dB (A)} are mostly met except near commercial areas.

Environmental Impact Assessment

Topography and Soils

The proposed KSFL plant expansion will have some construction activities and as such both

construction phase will have very limited impact (within the plant boundary limit only).The operation

phases will have no impact on the topography and soils of the study area.

Air Quality

During the operation of the proposed expansion project/ plant, three new sources of gaseous

emission are added. The existing sources of emission i.e. Reformers in Ammonia Plant, auxiliary

Boiler, Gas Turbine and Prilling Tower in Urea Plant will be emitting NOx (from Reformer, boilers

and Gas Turbine), SPM and NH3 (from Prilling Tower). The summary of GLC at monitoring station

due to the existing facility and proposed expansion marked in below Table.

Incremental increase in ground level concentration due to expansion project has been predicted

using the 'Industrial Source Complex - Short Term Version 3 (ISCST-3)' comes out to be:

Summary of Maximum GLC at Monitoring Locations due to the Existing Facility and Proposed Expansion

Location Rise in GLC

Max. Background

Concentration

Impact from Project

NAAQS

(µg/m3) (µg/m3) (µg/m3) (µg/m3)

Project Site

SOX 0.0017 6.04 6.042 80

NOX 0.0861 11.78 11.87 80

SPM 0.0046 153.18 153.184 200

NH3 0.0058 22.54 22.55 400

Sahjana

SOX 0.13 5.55 5.68 80

NOX 6.51 9.8 16.31 80

SPM 1.30 139.97 141.27 200

NH3 1.31 20.83 22.14 400

Sikarpur SOX 0.07 5.99 6.06 80

NOX 3.08 11.6 14.68 80



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xix

Location Rise in GLC

Max. Background

Concentration

Impact from Project

NAAQS

(µg/m3) (µg/m3) (µg/m3) (µg/m3)

SPM 0.83 146.81 147.64 200

NH3 0.70 20.79 21.49 400

Akhtyarpur

SOX 0.10 5.86 5.96 80

NOX 4.40 10.92 15.32 80

SPM 1.00 149.24 150.24 200

NH3 0.98 21.33 22.31 400

Lalpur

SOX 0.002 5.87 5.87 80

NOX 0.05 10.86 10.91 80

SPM 0.02 147.2 147.22 200

NH3 0.02 20.79 20.81 400

Khalauli

SOX 0.01 5.37 5.38 80

NOX 0.30 10.72 11.02 80

SPM 0.07 138.47 138.54 200

NH3 0.06 19.63 19.69 400

SOX: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum SOx concentration of 6.06 µg/m3 at Sikarpur village with project

impacts of 0.07 µg/m3and baseline contribution of 5.99 µg/m3.The total impact from the project of

6.06 µg/m3 is well within the stipulated standard of 80 µg/m3for industrial as well as residential

areas.

NOx: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum NOx concentration of 16.31 µg/m3 at Sahjana village with project

impacts of 6.51 µg/m3 and baseline contribution of 9.80 µg/m3.The total impact from the project of

16.31 µg/m3 is well within the stipulated standard of 80 µg/m3for industrial as well as residential

areas.

SPM: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum SPM concentration of 153.18 µg/m3 at project site with project

impacts of 0.0046 µg/m3 and baseline contribution of 153.18 µg/m3.The total impact from the

project of 153.184 µg/m3 is well within the stipulated standard of 200 µg/m3for industrial as well as

residential areas.

NH3: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum NH3 concentration of 22.55 µg/m3 at project site with project

impacts of 0.0058 µg/m3 and baseline contribution of 22.54 µg/m3.The total impact from the project

of 22.55 µg/m3 is well within the stipulated standard of 400 µg/m3for industrial as well as residential

areas.



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xx

Noise

The operation of expanded capacity of KSFL plant will have no adverse impact on noise generation

because quality machines are being added. The new machines will have latest technology and

features for low energy consumption, less noisy and eco-friendly. The plantation done all around

the plant helps in attenuation of sound waves and as such has created a natural barrier for sound

spreading.

A critical review of noise monitoring shows that:

Within the plant area noise level was more near synthesis compressor in ammonia (~73 -

74 dB (A)) and near Prilling Tower (~72 dB (A) etc. However the noise level along the plant

boundary gets reduced to considerable extent as monitored at main security gate (~49 dB

(A)), and Technical Building (~49 dB (A)).

In township the noise level was measured in public places like Temple and guest house. It

was 42 to 60 dB (A).

Employees working near turbines, blowers, compressors or gas turbines are exposed to slightly

high decibels noise (+ 80 dBA). Very few employees work in such areas and have been provided

cabins with acoustic protection and have also been provided with ear plugs etc.

Water Resources and Water Quality

Water Resources

Water requirement for existing plant (after debottlenecking) is around ~878 m3 / hr. (~ 21072

m3/day) including 2184 m3/day for domestic purpose (both plant and township). The water

consumption in proposed expansion project will be ~1122 m3 / hr. (26928 m3/day). The water will

be drawn from existing as well as from additional tube wells. Necessary approval / clearance from

Central Ground Water Authority/ Board are being taken.

Industrial wastewater after it is discharged into surface water body should not produce significant

deterioration in its water quality. The effects on surface water depend on wastewater characteristics

and quantity. The impact on surface water depends on the characteristics and also on quantity of

water in the receiving water body.

KSFL is consuming water for their process below the specified value i.e. < 7.8 m3/t of urea against

the CPCB (Probe 97/2002-03) Norms 8.0 m3/t of urea

The operation of the expansion plants will have no adverse impact on ground water resources

although there will be some increase in treated effluents quantum. The effluents from the expansion

plant will be recycled or reused in green belt development.

The treated effluent use for irrigation / development of green belt will not have any adverse impact

on ground water quality as the treated effluents are well within the norms laid down by the UP

Pollution Control



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xxi

Water Quality

The process effluents from the proposed expansion unit shall be treated in the existing effluent

treatment system (after augmentation) i.e.

APC (Ammonia Process condensate) treated in in Ammonia plant, UPC (Urea Process

condensate) treated in in Urea plant and along with turbine condensate shall be recycled as

BFW after polishing in DM plant.

Acidic & alkaline effluents from DM plant &Waste water from laboratory are mutually

neutralized in Neutralisation pits in DM Plant and then sent to ETP for further treatment.

Oily water from plant goes to Oily water treatment plant and after treatment, treated water

go to ETP.

The treated effluents will go to balance pond and then to guard pond. The effluents meeting

the norms will be discharged to Garrai Nala.

Domestic wastewater will be treated in oxidation ponds and the treated effluents are utilized

for irrigation in KSFL green belt / horticulture.

As such the expansion project will not have any impact on water (ground or surface water

resources) sources.

Climatology and Meteorology

The little construction activities and operation of the proposed KSFL expansion plant will have no

impact on climatology and meteorology of the study area.

Land Use

The impacts on land environment are generally physical impacts due to change in topography, soil

erosion, etc. KSFL is not carrying any construction activities outside the premises. The construction

activities within the premises are not going to alter the topography of the area and as such adverse

impacts are not going to take place.

The construction and operation of the proposed expansion of KSFL plant will have no impact on the

land use in the study area as no fresh land is being acquired for the plant or township.

Biological Environment

The proposed Construction and Operation of the plant will have no impact on ecology of the study

area. However, growth of plantation and development of green belt at the site is likely to improve

flora at the site.

Demographic and Socio-economic

The proposed operation of the plant will have no adverse impact on the demography, agricultural

pattern and other socio-economic conditions. However, the operation of proposed expansion plant

will have slightly positive and beneficial impact on the status of job opportunities (due to some fresh



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xxii

intake of staff (limited numbers only), increased inflow of raw materials and out flow of products and

other commercial activities) and increase in industrial and commercial activities.

OHS System

Health hazards associated with the occupation are called occupational hazards. In chemical

industry due to handling of toxic and hazardous chemicals there are possibilities of developing

occupational diseases. KSFL currently employs various measures with respect to occupational

health and safety (more details in Chapter 2).

Risk Assessment

KSFL fertilizer plant uses a number of hazardous chemicals, namely NG, Naphtha, NH3, Acids,

fuels etc. The use of these chemicals is inevitable. KSFL has MSDS and understands the risks

associated with these chemicals. Adequate control measures have been taken by the KSFL to

prevent any dangerous incident.

KSFL plant has a qualified and trained safety manager along with supporting staff / equipment to

assist plant personnel working in the plant & to take all the safety precautions while carrying out

various tasks. KSFL has provided PPE to operating personnel (as per requirement) for carrying

hazardous activities.

All the employees are being retrained through refresher in Fire & Safety training once in a year.

Regular health check of staff is carried out as per norms. Health reports are available to the staff for

the information.

Disaster Management Plan

On-site DMP is prepared to minimize the damage to plant machinery and personnel for the

selected accident scenarios. A copy of the DMP has been submitted to Factory Inspector.

Mock drills for the selected emergencies have been carried out, weak links in the system

noted and need full actions have been taken.

On-site DMP also discusses suitable management procedures to handle emergencies

caused by accidental release or spill of toxic or inflammable material or fire.

Environmental Management Plan

Air Environment

In order to mitigate the adverse environmental impact due to the operation at expanded / increased

capacities following measures are recommended:

The control measures through proper upkeep; preventive maintenance and good

housekeeping will considerably reduce the fugitive emission.

Monitoring of fugitive emission should be continued at human receptive points as per

existing practice.



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xxiii

Existing schedule monitoring system under ISO-14001 for air pollutants like SOx, NOx,

ammonia and SPM should be continued.

Leakages {of gases / liquids/ dust} should be checked and promptly attended.

Water Environment

KSFL has gradually reduced its water consumption/ effluent generation and energy consumption.

The treatment philosophy adopted by KSFL has given very good results. The treated effluent

quality has also considerably improved. The existing system and efforts to conserve water and

treatment of effluents should continue and now efforts should be directed to:

“Control of pollutant at source” practices should continue.

Increase the use of treated effluents in horticulture and green belt developments.

The treated sewage should be utilized for irrigation in farm house whenever required.

Excess use of pesticide and herbicide (in green belt) should be avoided as they can cause

ground water contamination.

Water is a precious commodity and it should be conserved. Monitoring of underground

water level in pre and post monsoon should be started.

Awareness program should be continued to increase the interest among employees for

conservation of water.

Water harvesting schemes should be taken up (use of ground water) where ever possible.


The construction and operation of the proposed expansion of KSFL plant will not affect meteorology

and Climatology of the study area and as such no management plan will be required.

Green Belt

KSFL has developed green belt all around it and also along roads, as groves of fruit trees, as forest

blocks, lawns and ornamental / flowering bushes. Mostly the trees have been planted in blocks of

one particular plant-Acacia Arabica, Alibizzia lebbeck, Alibizzia procera, Alstonia scholaris,

Anthocephalus cadamba, Ficus religiosa etc.

Block plantation of same species of trees is not a healthy practice as it may cover the entire

area if single tree is affected with diseases. Such type of plantation should be avoided in

future.

The trees, which have attained their age, should be cut and new trees should be planted.

Some indicator species of SO2, NOx & NH3 should be planted near the pollution causing

units. These plants would act as an early warning system. The species are well known.

Proper maintenance is required for the avenue trees such as:

o Avenue trees should not block the view of road or building. This is necessary from

safety and security point of view.



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. xxiv

o The distance of avenue trees should not be less than 4 to 5 meters.

o The road curbs should not have trees rather shrubs.

Environment Monitoring Plan

Additional points in EMP have been proposed.

Public Hearing

The proposed project site is situated at notified UPSIDC Industrial Area, village & Post Piprola /

Kanth Tehsil Sadar, District Shahjahanpur, Uttar Pradesh.

As per Office Memorandum dated 10th December, 2014 viz. Exemption from public Consultation

for the projects/ activities located within the Industrial Estates/ Parks, the proposed project is

exempted from public hearing since the proposed project is located in notified industrial area.

Hence, no public hearing was conducted for the proposed project.



Shahjahanpur, U.P

EQMS INDIA PVT. LTD. 7

CHAPTER 1. INTRODUCTION AND BACKGROUND

1.1. Preamble

The Ammonia-Urea Complex of M/S KRIBHCO Shyam Fertilisers Limited located at Village

Piprola about 12 km in south west direction of Shahjahanpur city is one of the six Urea

producing fertilizer plant based on Natural Gas as feed stock available from Mumbai High Sea.

The other fertilizer plants based on same feed stocks are namely:

NFL Vijaipur (M.P)

IFFCO, Aonla (U.P)

Indogulf Fertilisers Ltd (U.P)

Chambal Fertilisers & Chemicals Ltd, Kota (Raj)

Tata Chemicals Ltd, Babrala (U.P)

The sixth and last fertilizer plant of this series M/S KRIBHCO Shyam Fertilisers Limited

(Formerly Oswal Chemicals and Fertilisers Ltd.) Shahjahanpur was commissioned in November

1995 having rated production capacity for 8,64,600 MT per annum Urea and 5,02,000 MT per

annum Ammonia along with necessary utilities and in house auxiliary facilities.

KSFL plant is based on the technology and processes know how as below:

For Ammonia - M/s Haldor Topsoe, Denmark

For Urea - M/s Snamprogetti, Italy

The detailed engineering of entire complex including preparation of plant lay out, offsite, effluent

treatment and environmental protection measures etc. was executed by M/s Projects and

Development India Ltd (PDIL) a renowned Govt. of India Undertaking.

1.2. Importance and Need of an EIA

Government of India, as per its policy has given emphasis on Sustainable Development. While it

is supporting the industrial growth, the environmental protection has been made the integrated

criteria for this support. In line with this policy, Ministry of Environment & Forests has defined

elaborated ‘Environment Clearance (EC)’ framework under The Environmental (Protection) Act,

1986 (Environmental Impact Assessment Notification, 2006) for establishing/expanding an

industry/development project. The EC process takes into consideration local conditions, public

concerns, effectiveness of impact assessment and proposed mitigation measures in sustaining

environmental equilibrium. The base documentation/ study report, called Environmental Impact

Assessment (EIA) detailing baseline conditions, environmental impacts, mitigation measures

and management plan is required to be prepared for start of EC process. Prior Environmental



Shahjahanpur, U.P


Clearance is required from concerned authorities for all projects detailed in the ‘Schedule’ as

given in the ‘Notification dated 14th September, 2006’. The projects listed as category ‘A’ under

EIA notification and require EIA report for appraisal by expert committee prior to EC. As per this

category all fertiliser projects require environmental clearance. Since EIA preparation and

compliance to EC requirement is time consuming, MoEF has started accepting one season

based EIA study to reduce the overall clearance cycle time.

The remarkable progress achieved in fertilizer consumption, during last 4-5 decades, has been

possible mainly because of fertilizer was available to the millions of farming community spread

over more than 6 lakhs villages. This task has been achieved by: Continuous building up of

fertilizer capacity in the Country;

Equitable distribution of the available fertilizers in all parts of the Country by evolving coordinated

supply plan under the Essential Commodity Act (ECA) and; however there is huge gap in the

demand and indigenous supply of urea fertiliser. Arranging imports as indigenous production

capacity has been inadequate to meet the ever-increasing demand for fertilizers.

In order to close this gap in demand and supply of urea fertiliser Kribhco Shyam Fertilisers

Limited (KSFL), has planned expansion of its fertilizer manufacturing facilities at Shahjahanpur,

UP by installing an Ammonia Plant Capacity –2200 MTPD, Urea Plant Capacity –3850 MTPD

other associated facilities including ammonia storage tank of capacity 5000 MT to be used for

existing (for inspection of installed ammonia storage tank) as well as expansion project and

upgrading some existing utilities and other off site facilities for the proposed expansion project.

The estimated cost of the proposed expansion project is Rs 4132 crores including foreign

component of Rs 1319 crores.

1.3. Project & Project Proponent

Kribhco Shyam Fertilizers Limited (KSFL) was incorporated on December 8, 2005 pursuant to a

joint venture agreement between KRIBHCO and Shyam Group to acquire the urea

manufacturing facilities at Shahjahanpur in the state of Uttar Pradesh in India from Oswal

Chemicals & Fertilizers Ltd. in the shareholding ratio of 60:40. Effective March 30, 2009 the

shareholding ratio of KRIBHCO and Shyam group is 85:15.

KRIBHCO was incorporated on April 17, 1980 as National Level Multistate Cooperative Society

and is governed by Multistate Cooperative Society Act, 2002. KRIBHCO’s paid up capital as on

March 31, 2013 is Rs. 390.18 crore.

KRIBHCO has state-of-the art Fertilizer Complex based on natural gas at Hazira, District Surat,

Gujarat consisting of two streams of Ammonia Plant and four streams of Urea Plant with annual

capacity of 1.00 Million MT and 1.73 Million MT respectively. KRIBHCO is in advanced stage of



Shahjahanpur, U.P


implementing revamp of its Fertilizer Complex which will increase the annual capacity of

ammonia & Urea Plants to 1.25 Million MT and 2.19 Million MT respectively. KRIBHCO is also

producing Argon Gas from its Fertilizer Complex at Hazira.

The Shyam Group is an integrated player in telecom industry with interests in basic and satellite

telephony, ISP and VSAT services, manufacture of a wide range of telecom equipment and agri-

business initiatives such as contract farming and fertilizers. The Group was promoted by Mr.

Rajiv Mehrotra, Mr. Ajay Khanna and Mr.Alok Tandon, who are also directors on the Board of

various group companies. Shyam Basic Infrastructure Projects Private Limited (“SBIPPL”) was

incorporated in 1996 and part of the Shyam Group.

The management control of the Company rests with KRIBHCO, a cooperative society engaged

in manufacturing nitrogenous and bio-fertilizers since 1980. KRIBHCO’s long and valuable

experience in fertilizer sector provides the Company the advantage of their management

expertise and business know-how. The Company leverages on the extensive marketing and

distribution network of KRIBHCO, under which our products are marketed. The Company also

has access to ’, ‘ ’ brand, which is a well-established and respected brand amongst

farmers and co-operative societies across India.

KSFL manufactures nitrogenous fertilizer viz. urea through our integrated urea and ammonia

manufacturing facility at Shahjahanpur. The Plant is the latest Greenfield Urea Plant in India-

commissioned in November 1995 and is strategically located in North India, right in the middle of

a high urea consumption belt and based on Natural Gas as feedstock supplied through the

Hazira-Vijaypur-Jagdishpur ("HVJ") gas pipeline.

The Plant has an installed capacity of 864,600 MTPA (2 x 1310 MTPD) of urea and 501,600

MTPA (1 x 1520 MTPD) of ammonia. The Plant is operating at more than 100% capacity

utilisation since acquisition.

The plant is ISO 9001:2008, ISO 18001 (OHSAS) and ISO 14001:2004 certified by BSI Group

India Pvt. Ltd. The marketing of Urea and surplus ammonia produced by the Company is

undertaken by KRIBHCO, one of the promoters Company. KSFL has well laid down environment

policy duly signed by Managing Director (Annexure I). The Environment Policy provides and

guides all concerned about the KSFL commitment for environment.

The total land acquired at Shahjahanpur is about 780.75 acres (including township). About 33%

of the land is under green cover.

The power requirement for both existing plant is met by Gas Turbines of 2X25 MW capacities

operating on Natural Gas/Naphtha. In addition there is provision of emergency power unit of

2000 KVA.



Shahjahanpur, U.P


Existing facilities also comply with the conditions made by the Ministry of Environment and

Forest, Government of India, Central Pollution Control Board and UP State Pollution Control

Board.

The proposed expansion project will augment the urea manufacturing facilities of KSFL and

meet the soaring demand of urea in the country.

KSFL plants are very well operated, maintained that have been acknowledged and praised time

to time by various national & international institutes as mentioned below:

Table 1.1 : Awards & Certifications Received

Sl. No.

Year Name of Award Presentation Institute

1 2010-2011 National Energy Conservation Award-2011

[“Certificate of Merit” in Fertilizer Sector]

Ministry of Power (Bureau of Energy Efficiency), New

Delhi.

2 2010-2011

Improvement in Company’s Overall

Performance

[First Prize in the Fertilizer (Ammonia & Urea) Plant]

The Fertilizer Association of India, New Delhi.

3 2011-2012

Improvement in Company’s Overall

Performance

[Joint Runner-up in the Fertilizer (Ammonia & Urea) Plant]

The Fertilizer Association of India, New Delhi.

1.4. Objectives of the EIA Study

The objectives of the present EIA are to:

Assess the impacts on various environmental components viz water, air, soil, flora

fauna, noise, land use, resource use due to proposed Expansion of urea production

Capacity of KSFL.

Suggest appropriate Impact Mitigation Measures and Environmental Management Plan

to ensure that the adverse impacts if any are eliminated or minimized.

1.5. Project Site and Regulatory Compliance Status

The proposed project is located at Village & Post Piprola, close to the town of Shahjahanpur of

District Shahjahanpur in Uttar Pradesh at approximately 790 50’ E longitudes and 270 50’ N

latitude. The location map for the plant is presented in Figure 1.1. The plant is located on a plot



Shahjahanpur, U.P


of about 780.75 acres. KSFL site is approximately 12 km in south west direction of

Shahjahanpur town near village Piprola. Bareily is about 80 km and state capital Lucknow is

~180 km from site. State highway 29 to Farrukabad and National Highway NH 24 are close by.

Shahjahanpur is the nearest railway station (~ 15 km) located on Lucknow - Moradabad BG

railway line. Shahjahanpur has got all weather approach road from Delhi, Aligarh, Badaun and

Moradabad.

KRIBHCO Shyam Fertilizers Limited (KSFL) unit was set up after obtaining Environmental

Clearance from Ministry of Environment & Forests (MoEF), Govt. of India vide their letter No.J-

11011/15/90-IA (II) dated 1st March 1993. The company has enhanced the production upto

Ammonia 1800 MTPD and Urea 3000 MTPD through revamp by utilizing the in built margins

provided in the design of various equipments / machineries of the plant.

As per the ‘Notification dated 14th September, 2006’ KSFL had also obtained the environmental

clearance vide letter no. F. No. J-11011/53/2008-IA-II(I) Dated : June 11, 2008 for the production

of Ammonia 1800 MTPD & Urea 3000 MTPD and also for the proposed enhancement in the

capacity upto Ammonia 1950 MTPD & Urea 3130 MTPD through debottlenecking. However

KSFL has not implemented the debottlenecking scheme due to techno-economic reasons.

The plant operation has been subjected to other procedural and compliance monitoring

programme viz. annual consents under Water (Prevention and Control of Pollution) Act, 1974;

Air (Prevention and Control of Pollution) Act, 1981; authorization under Hazardous Waste

(Management, Handling & Transboundary Movement) Rules, 2008; Environment (Protection)

Act, 1986; requirements and statutory norms as per UP Pollution Control Board etc. The

production level of this plant has been as per the clearances/consents.

In addition to environmental regulatory compliance, KSFL is also complying with following other

statutory rules and regulations:

Fuels and other hazardous (Inflammable & Explosives) materials storages (As per Chief

Controller of Explosives, Nagpur; rules and guide lines)

Labour laws and Safety guide lines as per Labour Commissioner, Government of Uttar

Pradesh,

Boiler Regulations as per Chief Inspector of Boilers, ESIC etc.



Shahjahanpur, U.P


Figure 1.1 10 Km radius Google Map of the Project

(Source: Google Earth)

1.6. Scope of Study

The scope of study is as based on as per the proposed TOR (Terms of Reference) for the REIA

study submitted to MoEF. The EIA report has been prepared based on the same:

1.6.1. Terms of Reference

The Ministry of Environment & Forests (MoEF), New Delhi vide dated 22nd November 2013 has

prescribed the following terms of reference (Point wise compliance of the TORs including index).

Table 1.2 TOR Compliance Status

Sr. No.

Terms of Reference Status

1. A separate chapter on status of compliance of Environmental Conditions granted by State/Centre to be provided. As per

Annexure XI



Shahjahanpur, U.P


Sr. No.


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. Executive summary of the project Attached

3. Justification of the project. Chapter 1, Section 1.2

4. Promoters and their back ground. Chapter 1, Section 1.3

5. Regulatory framework. Chapter 1, Section 1.5

6. Environment clearance for the existing unit issued by the Ministry (reasons, if not obtained), Consent to Operate and Authorization accorded by the UPPCB.

Environment clearance for the existing unit

issued by the Ministry, Consent to Operate and Authorization accorded by the UPPCB is given

vide

Annexure II

7. Compliance to the conditions stipulated in the Environmental Clearance / NOC granted by the SPCB.

Compliance to the conditions stipulated in

the Environmental Clearance/ NOC

granted by the UPPCB is given vide Annexure II

8. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, compliance to the notice(s).

No Notice Received

9. Data for the stack emissions, fugitive emissions; water requirement and water balance chart; wastewater generation, treated effluent quality, re-utilization and disposal of solid/hazardous waste for the existing unit.

Section 2.4.4; 2.4.5 and 2.4.6

10. Project location and plant layout. Plant location in Section 3.2, Figures 3.1 and Plant layout Figure 2.1

11. Details of the existing fertilizer plant. Existing status of fertilizer plant is given in

Section 2.4



Shahjahanpur, U.P


Sr. No.


12. Infrastructure facilities including power sources for the proposed expansion.

Plant facilities required for expansion of project

given in Table 2.1/ Section 2.5

13. Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures

Estimated Capital cost of the proposed modernization &

expansion of Fertilizer plant is estimated as Rs.

4182 crores.

Recurring Cost ~ Rs 21 crore per annum.

14. Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests etc.

Project Site location Figure 3.1

15. Present land use based on satellite imagery for the study area of 10 km radius.

Section 3.12 and figure 3.14

16. Location of National Park/Wild life sanctuary/Reserve Forest within 10 km radius of the project.

There is no National Park or Wildlife

Sanctuary within 10 km radius of the site

boundary. Details are provided in Section 3.13

17. Details of the total land and break-up of the land use for green belt and other uses.

Land use detail of the study area given in

Section2.1

18. List of products along with the production capacities. List of products is given vide Table 2.1

19. Manufacturing process details along with the chemical reactions and process flow chart.

Manufacturing process details along with the

chemical reactions and process flow chart is

given vide Section 2.4



Shahjahanpur, U.P


Sr. No.


20. Detailed list of raw material required and source, mode of storage and transportation.

Detailed list of raw materials are given vide Section 2.5.3 & Table

2.2 & 2.7 21. Ammonia storage tank shall not exceed 5000 T. Maximum Capacity of

new storage tank shall be 5000 T

22. A note on the long term strategy for the gas availability. Alternative, if the gas is not available

Chapter 2, Section 2.5.3.1

23. A note on the viability of the project in absence of non-availability of gas.

Chapter 2 Section 2.5.3.1

24. Action plan for the transportation of raw materials and products. Chapter 2 ; Raw Material- Section 2.5.3.1 Product- Section 2.5.3.7

25. Ambient air quality monitoring and stack emission data for the relevant parameters including PM10, PM2.5, SO2, NOx, CO, NH3, HC (Methane and Non-methane) and VOCs for all the stacks for the existing fertilizer plant.

Ambient Air Quality Monitoring: Chapter-3

Section 3.8.2 and Table 3.3; Stack Emission

Data: Chapter 2: Table 2.3

26. Data for surface and ground water, treated effluent quality data, noise pollution and solid waste management for the existing plant should also be included.

Chapter 3; Section 3.10 Surface water details

analysis given in Table 3.6 and ground water

detailed analysis given in Table 3.7; Table 2.2

(Solid & Hazardous Wastes)

27. Air pollution control measures proposed for the effective control of gaseous emissions within permissible limits.

Chapter 2; Section 2.5.4

28. Plant-wise air pollution control measures proposed for the control of emissions from all the sources particularly uncontrolled NOx emission and method to control NOx.


29. Name of all the solvents to be used in the process and details of solvent recovery system.

Not applicable

30. Details of water and air pollution and its mitigation plan. Section 2.5.4 and 2.5.6; Sections 4.2 & Section



Shahjahanpur, U.P


Sr. No.


4.4; Sections 5.4.2 and 5.4.4

31. Action plan to control ambient air quality as per NAAQMS Standards notified by the Ministry on 16th September, 2009


32. An action plan to control and monitor secondary fugitive emissions from all the sources.


33. Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modeling for proposed plant

Air quality modeling for proposed plant, the

isoplethe for existing, increase in GLC after

expansion shown in Fig. 4.1 to Fig. 4.11

34. Details of water requirement for existing and proposed expansion. Water balance chart for existing and proposed expansion including water intake, effluent generated, recycled and reused and discharged is to be provided.

Chapter 2; Figures 2.7 and 2.8; Section 2.5.6

35. Action plan to reduce fresh water requirement. Methods adopted/to be adopted for the water conservation should be included.


36. Layout plan indicating surface water collection. Internal water supply arrangement to be submitted.

Sections 2.5.3.2; Figures 2.7 and 2.8

37. ‘Permission’ for the drawl of existing and proposed water

requirement from the Competent Authority. Attached as Annexure V

38. Design details of the ETP and STP as well as air pollution control equipment (Bag filters/ wet scrubber etc.). Installation of Continuous TOC analyzer to holding tank before discharge of effluent


39. Action plan for ‘Zero’ discharge of effluent should be included. Section-2.5.6

40. Ground water monitoring minimum at 6 locations should be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic).

Ground water monitoring minimum at

6 locations given in section 3.10.3 and

Table 3.7



Shahjahanpur, U.P


Sr. No.


41. Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management

Ground water monitoring minimum at

6 locations given in section 3.10.3 and

Table 3.7

42. The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste

Chapter 2; Section 2.5.7/ Table 2.2

43. Precautions to be taken during storage and transportation of hazardous chemicals should be clearly mentioned and incorporated

Chapter 6; Section 6.7

44. Plan for the implementation of the recommendations made for the fertilizer plants in the CREP guidelines must be prepared and included.

Chapter 2; Section 2.9

45. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.

Attached as

Annexure III

46. An action plan to develop green belt in 33 % area. Layout map for existing and proposed Greenbelt

The total land acquired at Shahjahanpur is about 780.75 acre

(including township) about 33% (296 acres)

of the land is under green cover

47. Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.

Chapter 5; Section 5.4.4.

48. Details of occupational health program.

i) To which chemicals, workers are exposed directly or indirectly.

ii) Whether these chemicals are within Threshold Limit Values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation.

iii) What measures company have taken to keep these chemicals within PEL/TLV?

iv) How the workers are evaluated concerning their

Section – 2.7



Shahjahanpur, U.P


Sr. No.


exposure to chemicals during pre-placement and periodical medical monitoring.

v) What are onsite and offsite emergency plan during chemical disaster.

vi) Liver function tests (LFT) during pre-placement and periodical examination.

vii) Details of occupational health surveillance programme.

49. Socio-economic development activities should be in place. Chapter 2; Section 2.8

50. Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.

Chapter 5

51. EMP should include the concept of waste-minimization, recycle / reuse / recover techniques, Energy conservation, and natural resource conservation.

Energy trend in KSFL given in Section 4.5

52. Corporate Environmental Responsibility

(a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.

(b) Does the Environmental Policy prescribe for standard operating process /procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms/ conditions? If so, it may be detailed in the EIA report.

(c) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions? Details of this system may be given.

(d) Does the company have a system of reporting of non-compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report

Approved Policy is attached as Annexure I.

Please describe accordingly.

Environment management Cell

structure is attached as Annexure VIII.

53. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof

Nil



Shahjahanpur, U.P


Sr. No.


54. Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made

Chapter 1, Section 1.7

1.7. Public Hearing

The proposed project site is situated at notified UPSIDC Industrial Area, village & Post Piprola /

Kanth Tehsil Sadar, District Shahjahanpur, Uttar Pradesh.

As per Office Memorandum dated 10th December, 2014 viz. Exemption from public Consultation

for the projects/ activities located within the Industrial Estates/ Parks, the proposed project is

exempted from public hearing since the proposed project is located in notified industrial area.

Hence, no public hearing was conducted for the proposed project.



Shahjahanpur, U.P


CHAPTER 2. PROJECT DESCRIPTION

2.1. Introduction

KRIBHCO Shyam Fertilisers Limited (KSFL), Ammonia – Urea complex is located in the Village

Piprola Distt Shahjahanpur in Uttar Pradesh, 12 km from the district town of Shahjahanpur and 80

km from Bareilly town. The plant is well connected by rail and road. The nearest airport is at New

Amausi (~180 km from site). The total land available under KSFL/ Township is around

780.75acres .The present land use is Industrial complex including residential area:

Total Area: 780.75 acres

About 33% (296 acres) of the land is under green cover. Balance land is outside the industrial

complex. The site is well connected with road and rail network.

KSFL plant started the commercial production in 1995 and soon stabilized and achieved rated

capacity. The plant was based on NG as feed stock (main raw material) supplied through GAIL

HVJ pipe line network. But due to shortage of NG KSFL has developed facilities to handle,

storage, feeding and processing of Naphtha for use as fuel for steam generation, power

generation and also in Ammonia plant.

2.2. Existing Status

Each section of KSFL complex has been performing very well right from the inception.

Considering the consistent good performance of the plant & in order to improve further, KSFL

Ammonia and Urea complex plant capacity has been revised / enhanced (through revamping) as

given below:

Name Plate rated capacity was Ammonia-1350 MTPD and Urea-2250 MTPD. (Ministry of

Environment & Forests (MoEF), Govt. of India vide their letter No.J-11011/15/90-IA(II)

dated 1st March 1993

Capacity reassessed by Dept. of Fertiliser – ammonia- 1520 MTPD and Urea- 2620

MTPD Capacity enhancement through optimization (obtained NOC from UPPCB – letter

no. 09865/191.5/NOC-104/2006/6 dated 14 – 12 2006) Ammonia – 1800 MTPD and

Urea 3000 MTPD, through revamp by utilizing the in built margins provided in the design

of various equipment / machineries of the plant.

As per the ‘Notification dated 14th September, 2006’ KSFL had also obtained the

environmental clearance vide letter no. F. No. J-11011/53/2008-IA-II(I) Dated : June 11,

2008 for the production of Ammonia 1800 MTPD & Urea 3000 MTPD and also for the

proposed enhancement in the capacity up to Ammonia 1950 MTPD & Urea 3130 MTPD

through debottlenecking. However KSFL has not implemented the debottlenecking

scheme due to techno-economic reasons.



Shahjahanpur, U.P


Figure 2.1 Plant Layout Showing Expansion Location

(Source: KSFL)

2.3. Proposed Project

As a forward looking company KRIBHCO Shyam (KSFL) considered the future demand of

fertiliser in the country and initiated for expansion of Shahjahanpur unit by proposing to set up an

grass root Natural Gas /RLNG based Ammonia plant of 2200 MTPD single stream and Prilled

Urea plant of 3850 MTPD with provision for augmentation of utilities and other off-site facilities

considering available infrastructure. The new expansion project will be somewhere within the

existing complex where adequate land exists. The rationale behind the proposed expansion

project is:

Availability of existing infrastructure facilities.

Lower capital cost compared to a grass root project resulting in lower cost of production

and retention price and consequently lower incidence of subsidy.

To meet the gap in demand and supply of urea in the country.

The project would essentially consist of new ammonia and urea plants and related offsite and

utility facilities considering utilisation of the existing facilities to the maximum extent possible. The



Shahjahanpur, U.P


broad provision of plants and facilities to be made for proposed project has been presented in

following:

Table 2.1 1: Plant and Facilities Required for the Expansion Project

1** installation of new 5000 MT Ammonia Storage tank shall be taken up in first stage of implementation of project, which will also be used for inspection of existing Ammonia Storage tank for ensuring safety of the tank In second stage of the project, proposed new ammonia & Urea Plant shall be commissioned and after that existing as well as new proposed Ammonia Storage Tanks will be used for the storage purpose of surplus ammonia generated from existing & proposed ammonia plants.

Sl. No. Plants & Facilities Provisions

1. Ammonia Plant 2200 MTPD 2. Urea Plant 3850 MTPD 3. Main Raw Material --NG/LNG

Transportation & Metering Station

By GAIL Pipeline and metering station provided

4. Product Storage & Handling Facilities

a] **Ammonia Storage Tank b] Silo c] Empty Bag Storage d] Bagging Plant

5000 MT at -330C and atmospheric pressure 30000 MT - (6+2) Slats each of 60 TPH (design capacity)

5. Cooling Tower a] Ammonia Plant

b] Urea Plant 24000 m3/hr. each 21000 m3/hr. each

6. Power Generation & Supply a] Power Generation (GTG)

b] Substation for receiving power from State Grid Emergency DG Set

1X25 MW 1X2000 kVA

7. Steam Generation Facilities

HRSG (GT set) 100 MT/hr

8. Water Supply Treatment & Distribution

d) Raw Water Supply System e) DM Water Plant f) Cond. Polishing Unit

Bore wells (2+1)×150 m3/hr. (2+1)×200 m3/hr.

9. Yard Piping Provided as per requirement

10. Instrument Air Facilities a] Compressor b] Drying Unit c] Receiver

(1+1)×3000 Nm3/hr. (1+1)×3000 Nm3/hr.



Shahjahanpur, U.P


2.4. Existing Plant and Facilities

2.4.1. Ammonia Plant Ammonia Plants is based on HaldorTopsoe technology and is using Natural Gas as feedstock.

Following process steps are involved in the manufacturing of liquid ammonia:

De-sulphurization of Feedstock

Steam Reforming

Gas Purification (Shift Conversion and CO2 Removal)

Ammonia Synthesis & Refrigeration

Ammonia Absorption and Condensate Recovery

Flow diagram of the Ammonia Plant is given in Figure 2.2.

2.4.1.1 Desulphurisation of Feed Stock

Natural Gas is fed to De-sulphurisation unit where the sulfur present in Natural Gas is converted

into Hydrogen Sulfide in presence of hydrogen rich gas & hydrogen sulfide formed is absorbed by

zinc oxide in ZnO Absorber as per the following reaction. The final De-sulphurised feedstock

contains less than 0.1-ppm sulphur:

11. Inert Gas Generation 600 N m3/hr of N2; Liquid N2 Storage: 30 m3 with vaporizer

12. Safety & Fire Fighting System including fire water ring with Hydrant System

For the proposed expansion project, existing firewater rings and other facilities shall be augmented as per requirement.

13. Auxiliary services, workshop equipment, laboratory equipment, weighbridge, fire engine, continuous monitoring system, NDT equipment, telephone& telecommunication, Public Address System, etc.

Extra telephone exchange facilities and additional lab and NDT equipment considered

14. General & Welfare Facilities Existing facilities will be augmented as per requirement.

15.

Transport Facilities a] Locomotive b] Railway Siding and lead line c] Road Transport

1X1200 HP To be developed

16. Construction equipment By construction contractor

17. Township &Public Building Existing facilities will be augmented as per requirement.

18. Non-plant Building Existing facilities will be augmented as per requirement.



Shahjahanpur, U.P


RSH + H2 RH + H2S

C4H4S + 4H2 C4H10 + H2S

ZnO + H2S ZnS + H2O

2.4.1.2 Steam Reforming

The Desulphurised feed gas is mixed with Process Steam to achieve steam to carbon ratio (3.2 in

Phase-I) and heated in the convection section of Primary Reformer. The mixture then passes

through vertical Primary Reformer tubes containing nickel-based catalyst. Since the reforming

reaction is endothermic, the furnace provides necessary heat is provided in the furnace by

burning fuel. The Primary Reformer furnace is designed to achieve maximum thermal efficiency

and uniform heat distribution. Maximum heat is recovered from the flue gases in the convection

section of Primary Reformer to pre-heat mixed feed (gas/steam mixture), Process air for

Secondary Reformer, Combustion air and to superheat the High Pressure steam. Primary

Reformer reforming reaction is given below:

C2H2n+2 + 2H2O Cn-1H2n + CO2 + 3H2 – HEAT

CH4 + H2O CO + 3 H2 - HEAT

CO + H2O CO2 + H2 - HEAT

CH4 + 2H2O CO2 + 4H2 - HEAT



Shahjahanpur, U.P


Figure 2.2 : Ammonia Plant Process Flow Diagram

(Source: KSFL)



Shahjahanpur, U.P


The partially reformed gas from Primary Reformer is mixed with Process air and the mixture flows

through a bed of nickel based catalyst in the Secondary Reformer. Process Air Compressor

supplies process Air to Secondary Reformer. The quantity of air is controlled to provide nitrogen

in the required proportion for the formation of ammonia. The process gas from the Secondary

Reformer is routed to a Waste Heat Boiler to generate high-pressure steam.

2.4.1.3 CO Shift Conversion

Gas leaving the Waste Heat Boiler system enters the High Temperature CO Shift converter

(HTS) charged with Iron-oxide catalyst. Here the CO content is converted to CO2. Since the

reaction is exothermic, the outlet temperature rises. This gas is then cooled down in another

Waste Heat Boiler by producing HP Steam. Finally the gas is cooled in BFW Pre-heater before

entering Low Temperature CO Shift Converter (LTS). In LTS Converter, CO is further converted

to CO2 by reaction over a Copper based Catalyst. This reaction is also exothermic, which is

given below:

CO + H2O CO2 + H2 + HEAT

Gas is then further cooled in two BFW Pre-heaters. Then it enters the Re-boiler of CO2 removal

system after the removal of process condensate in a separator. This process condensate is sent

to Process Condensate treatment section.

2.4.1.4 CO2 Removal

GV is the Process Licensor of CO2 Removal Process in Ammonia. Carbon Dioxide is removed by

absorption in Hot Potassium Carbonate solution.

The process gas from the Re-boiler is cooled after exchanging heat in a BFW Pre-heater enters

the CO2 Absorber where its CO2 content is brought down. The absorber is a packed column. The

Hot Potash solution is introduced into the Absorber at two places, the lean solution is at the top

bed and the semi-lean at the middle-bed. The CO2 rich solution from the Absorber bottom is

depressurized through a Hydraulic Turbine with a steam recovery system, before it is discharged

to the top of the Regenerator, where the CO2 flashes off. The heat for regeneration is supplied to

the regenerator partly from the Re-boiler and partly from flashed steam/live steam. The

regenerated solution is then pumped to the Absorber by Lean & Semi-lean solution circulation

pump. CO2 is sent to Urea Plant.

2.4.1.5 Methanation

The gas from Absorber is pre-heated by heat exchange with the outlet gas from the Methanator in

a Gas/Gas exchanger. The small quantities of CO and CO2 in the gas are converted to methane

by reaction with hydrogen over a nickel-based catalyst. This reaction, which is given below is



Shahjahanpur, U.P


exothermic and the heat is used for heating the feed gas. The gas from Gas/ Gas Exchanger

outlet is cooled in a final gas cooler and sent to the suction of Synthesis Gas Compressor:

CO2 + 4H2 CH4 + 2H2O + HEAT

CO + 3H2 CH4 + H2O + HEAT

2.4.1.6 Ammonia Synthesis & Refrigeration

The synthesis gas, which has hydrogen & nitrogen in a volumetric ratio of 3:1 and some inert, is

compressed to synthesis loop pressure by Synthesis Gas Compressor and is introduced into the

synthesis loop from where it goes to the series of Ammonia Converters (two radial converters) to

get maximum ammonia conversion along with the re-circulating gas. Ammonia Converter

synthesis reaction is given below:

N2 + 3H2 2 NH3 + HEAT

The converter effluent gas is cooled in a Waste Heat Boilers after both the converters for

generating HP Steam. This is further cooled in a BFW pre-heater and then in a hot heat

exchanger. It is then cooled in water cooler & chillers. The condensed ammonia is separated

from the circulating gas in Ammonia Separator. From this Ammonia Separator, separated hot

ammonia is sent directly to Urea Plant and cold ammonia can be sent to Atmospheric Ammonia

Storage tank.

Ammonia Refrigeration system consists of centrifugal Refrigeration compressor along with

condenser.

2.4.1.7 Ammonia Absorption and Condensate Recovery

In Ammonia, purge gases from the synthesis loop are fed to PGRU for hydrogen recovery. Let-

down & inert gases from the Synthesis loop are fed to an Absorber where ammonia is absorbed

in the circulating water. The ammonia free gas is then sent to fuel system. The Ammonical water

is treated in a distillation Column to strip out free ammonia, which is condensed and sent to

ammonia accumulator in the refrigeration system. The process condensate and CO2 absorption

section condensate are treated in a high-pressure process condensate stripper to remove

ammonia, CO2 and methanol etc. The treated condensate is sent to off sites and Utility facility for

reuse as Boiler Feed water after polishing

2.4.2. Urea Plant Urea plant is based on Snamprogetti, Italy process and having two streams with common Prilling

Tower and Process Condensate Treatment Sections.

The Urea production process involves the following steps:

Urea Synthesis



Shahjahanpur, U.P


Urea Purification

Urea concentration

Urea Prilling

Process Condensate Treatment

Flow diagram of the Urea Plant is given in Figure 2.3.

Figure 2.3 Flow diagram of the Urea Plant

(Source: KSFL)

2.4.2.2 Urea Synthesis

Synthesis of Urea is carried out at high pressure of 156 Kg/Cm²g and temperature of about

190°C in a carbon steel Rector with SS 316 L modified liner. The liquid ammonia coming directly

from the Ammonia Plant is collected in the Ammonia Receiver. From the receiver, it is pumped

by means of a pump and fed to the Urea Reactor. The carbon dioxide is also compressed to

Synthesis pressure by a centrifugal compressor and fed to the Reactor. The small quantity of air

is added into carbon dioxide for Passivation of the stainless steel surfaces and thus protects the

equipment form corrosion.



Shahjahanpur, U.P


Exothermic reaction between Liquid ammonia & gaseous carbon dioxide in Urea Reactor is given

below:

Carbonate Formation

2 NH3 + CO2 NH2 COO NH4 + HEAT

Dehydration

NH2 COO NH4 NH2 CO NH2 + H2O - HEAT

The reaction products from the Reactor flow to the steam heated falling film type Stripper

operating at Synthesis pressure. The mixture is heated as it flows down and the carbonate is

decomposed by the stripping action. The carbonate decomposition heat is supplied by steam on

the shell side. The overhead gases from the stripper flow to the carbamate condenser along with

recycle carbamate solution from downstream, where these are condensed and recycled back to

Reactor. Condensing the gases at high-pressure results in low-pressure steam generation in

carbamate condenser, which is utilized in the process.

2.4.2.3 Urea Purification

Urea purification takes place in two pressure stages i.e. MP pre-decomposition (proposed to be

installed in revamp case) and MP Decomposition at operating pressure of 17 Kg/Cm²g and LP

Decomposition at operating pressure of 3 Kg/Cm²g. When solution is let down from high pressure

to lower pressure, gaseous ammonia & carbon dioxide are generated. These gaseous mixtures

are condensed/absorbed at respective pressures and recovered Carbamate solution is recycled

back to the Reactor.

2.4.2.4 Urea Concentration Section

Urea solution leaving the LP decomposer shall be sent to first vacuum concentrator operating at

0.3 Kg/Cm²A pressure.

The gases leaving from pre-concentrator & Ist vacuum separator are removed first vacuum

system. Final concentration of 99.7 % is achieved in the second vacuum concentrator operating

at 0.03 Kg/Cm²A pressure. The gases leaving the top separator are removed by the second

vacuum system. Water vapours from the concentration section are condensed in cooling water

Surface Condensers and recovered condensate, which contains urea mist, CO2 and Ammonia is

sent to Process Condensate treatment section.

Urea Pre-Concentrator shall also to be installed under energy saving scheme before Ist vacuum

separator.



Shahjahanpur, U.P


2.4.2.5 Urea Prilling

The molten Urea solution after final concentration in vacuum section is fed to the Prilling bucket

by means of a Urea Melt pump. The urea coming out from the rotating prill bucket encounters

cold airflow in a natural draft Prilling tower, which causes its solidification. The product urea prills

falling to the bottom of the Prilling tower are collected through a rotary scrapper and are sent to

Bagging Plant.

2.4.2.6 Process Condensate Treatment

The process condensate containing small amount of CO2, Ammonia and Urea coming out of

vacuum condensers is collected in a buffer tank. The solution from this tank is fed to Process

Condensate Stripper to strip ammonia and CO2. The solution drawn from an intermediate tray of

this column is sent to a Hydrolyser. In the Hydrolyser Urea is hydrolysed to ammonia and carbon

dioxide. Hydrolyser vapours are recycled to the stripper for further stripping of ammonia & CO2.

The treated condensate is sent to off sites and Utility facility for reuse as Boiler Feed water after

polishing.

2.4.3. Power Plant and Utilities 2.4.3.1 Raw Materials

Natural gas is the main raw material and fuelling KSFL. It is supplied by GAIL through HBJ pipe

line. However KSFL has taken approval for using Naphtha as feed stock and fuel in the plant.

Naphtha is used only when there is acute shortage of NG.

2.4.3.2 Water Treatment System

Fresh water for the existing plant is drawn from the bore wells. The total requirement is (878)

m3/hr. KSFL has permission from U. P. ground water Board to draw 2000 m3 /hr. Water is treated

in DM plant for supplying as Boiler feed water to SG plant. In DM plant mixed bed units are there

to polish treated condensate from ammonia and urea plant.

2.4.3.3 Steam Generation System

KSFL has two numbers of gas fired boilers each of 100 tph capacity and two numbers of HRSG

each capacity 100 tph. The total requirement of steam for the existing operation is ~ 4080 MTPD

is met from the existing facilities.

2.4.3.4 Power Generation Plant

Presently, Power requirement is met through the existing two gas turbines have 25 MW

capacities each.

In addition there is provision of emergency power supply from 2000 KVA DG Set.



Shahjahanpur, U.P


2.4.3.5 Other Facilities

The other facilities like liquid ammonia storage facilities, bagging plant {seven lines}, fire fighting

system, storages etc. are adequate for the existing capacity of the plant. There are existing bulk

storages for Liquid Ammonia and other materials as given in Table-2.2.

Table 2.2 Bulk Hazardous Materials Storages (Existing)

S.

No.

Hazardous chemicals

handled

Quantity Handled

/ In process Type of Storage

1

Naphtha 4600 KL

1350 KL

600 KL

3 nos. MS Tanks

2 Main Raw Material-

Natural Gas

--- Supply from GAIL through HVJ gas

line

3 Ammonia 1 X 5000 MT Double walled, double integrity,

Atmospheric Tank

4 Chlorine Gas 0.9X12.0 MT Tonnage Cylinders

5 Sulphuric Acid 35 MT, 30.5 MT 2 XMS storage tanks

6 Hydrochloric acid 3X 60 MT (each) MSRL (Mild Steel Rubber Lined)

storage tank.

7 Caustic Lye (Sodium

Hydroxide)

2 X 44 MT (each) MSRL (Mild Steel Rubber Lined)

storage tank

8 Liquid Nitrogen 2 X 25 KL (each) Double Wall Storage Tank

9 Diesel 3 X 12 KL (each) 3 tanks

2.4.4. Waste Water / Effluent Treatment System in KSFL 2.4.4.1 Sources of liquid Effluent and Treatment system

Process Condensate from Ammonia Plant In the primary reformer excess steam is feed along with natural gas due to process requirements.

After reforming and shift reactions are completed, the excess steam in process gas along with the

methanol, ammonia and water formed during the methanation is separated by the cooling the



Shahjahanpur, U.P


process gas. The condensate coming out after cooling the process gas contains impurities

namely Ammonia 500ppm and methanol 200 ppm.

Treatment at source The condensate is feed to CO2 stripper and then to steam stripper (F-1321) for the treatment of

ammonia and methanol. The treated effluent contains 5 ppm of NH3, 10ppm of CO2 and 5ppm of

methanol.

Treatment at ETP In case the quantity of condensate is not good enough to be sent to DM plant for polishing due to

temporary process disturbance, it is sent to ETP, where it is stripped in steam stripper at ETP.

The stripped condensate is then pumped to balance pond. The balance pond water overflows to

guard pond. From guard pond it is pumped to stabilization pond for final discharge.

Floor washings/ process drains: All the process drains and floor washings from ammonia plant have an average flow of 1.0m3/hr.

(range, 0.5-3m3/hr.) and the following characteristics-

NH3 500ppm Methanol 20ppm

This effluent is pumped to ETP. After steam stripping at ETP, stripped effluent is sent to the

balance pond. Balance pond water overflows to guard pond. From guard pond it is pumped to

stabilization pond for final discharge.

Oil Leakage/ Spillage from Ammonia plant The runoff water from the compressor house, pump house, inters stage separators of

compressors are normally polluted with oily water along with the oil spillage from the refrigeration

system. Waste water containing oil with an average flow of 1 m3/hr. (range 0-2 m3/hr.) having

TSS as 200 ppm and oil as 1000 ppm is collected separately in a pit in ammonia plant. Then it is

pumped to oil separator at ETP. The clear water containing less than 10 ppm of oil is further

treated in the stream stripper at ETP for removal of contaminants like ammonia, if any, and is

pumped to balance pond.

Process condensate from Urea plant Total process condensate coming from the urea plant ranges between 45-60 m3/hr. with an

average of 55 m3/hr. it contains various impurities like,

NH3-5.0% CO2-1.50% Urea-0.9%

2.4.4.2 Treatment at source

Waste water containing ammonia, CO2 and urea coming out from 1st and 2nd vacuum system is

collected in tanks, from where it is feed in the distillation tower through centrifugal pumps. Before

feeding it to the distillation tower, solution is preheated by means of bottom outlet product heat

exchange. From middle of the distillation column, solution is feed to urea hydrolyses, where urea



Shahjahanpur, U.P


is decomposed it CO2 and ammonia. Solution free from urea is again feed to distillation tower to

remove ammonia and CO2 present in the solution. In the distillation column, ammonia and CO2 by

means of 3.5 atmospheres saturated stream. The vapours coming from the top of the tower is

condensed in overhead condenser and collected in a Carbonate solution accumulator. A part of

the solution is recycle back to the top of distillation tower as reflux and thus remaining is sent to

the urea plant. The bottom product coming out of the distillation tower contains a max. Of 5 ppm

of ammonia and urea each. This condensate is sent to the DM plant for polishing to make it

suitable for boiler feed.

2.4.4.3 Treatment at ETP

In case of quality of condensate is not good enough for sending it to demineralisation plant for

polishing due to temporary process disturbance, it is sent to ETP, where it is stripped in steam

stripper. The stripped condensate is then pumped to balance pond.

Floor washings/ process drain All the floor washing/ process drains form the urea plant having an average flow of 1.5m3/hr. with

ammonia concentration as 200 ppm and traces of urea is collected in a pit and then pumped to

contaminated pond at ETP. After being stripped in stream stripper at ETP, the stripped effluent is

sent to the balance pond.

Oil leakage/ spillage form the Urea plant Waste water containing TSS as 200 ppm and oil and grease as 1000 ppm is collected separately

in a pit in the urea plant and pumped to oil separator at ETP. The clear water containing less than

10 ppm of oil is further treated in stream stripper in ETP for removal of contaminants like

ammonia, if any and is finally pumped to the balance pond. Oil and grease are always not

traceable in the stabilization pond’s sample.

Turbine Steam Condensate Condensate produced by condensing of the steam in condensing turbine is normally 30m3/hr.

having TDS as 1-5 ppm and traces of ammonia. It is sent to demineralisation plant for polishing

and then recycled back as boiler feed water.

Urea Stream Condensate Condensate produced by condensing heating steam in various heat exchangers in urea plant

varies from 45-60 m3/hr. This condensate also has traces of ammonia with TDS as 1-5 ppm and

traces of TSS. It is sent to mixed bed units in DM plant for polishing and then used as boiler feed

water.

Boiler Blow down Water Its average flow ranges from 0-2 m3/hr. with TDS as 50 ppm and phosphate as 6-10 ppm. This

blow down water is sent to ammonia cooling tower and used as a makeup.



Shahjahanpur, U.P


Demineralisation Plant Waste water In the demineralisation plant, mixed bed units consist of 3 numbers each of strong anion-cation

exchanger I & II in series, weak base anion exchanger and strong base anion exchanger in series

and mixed bed units. The anions and cation are regenerated in through fare manner, i.e.

regenerate consumption and produces weak acidic and weak alkaline effluents. These effluents

are segregated and collected into separate pits. These acidic and alkaline effluents are

proportionately mixed and neutralized in a neutral effluent pit. These acidic and alkaline effluents

are proportionately mixed and neutralized in a neutral effluent pit. After proper neutralization i.e.

pH between 6.5 to 8.0,average flows is measured as ranging between 9-15 m3/hr. Its TDS is as

high as 1500-2100 ppm this neutralized effluent is sent to balance pond.

Cooling Tower Waste Water The treatment made for circulating closed loop cooling water system is non-chromate based.

Cooling tower wastewater comprises of blow down flow ranges and filters back wash. Cooling

tower blow down average flow ranges between 10-20 m3/hr. and that of filter back wash water is

25-30 m3/hr., both having the TDS as 1500-2100 ppm, Zn 2ppm and a max. Of 2-8 ppm of

phosphate as per the requirements of cooling water treatment. Biocides and dispersants are

added in cooling tower, and these are non-toxic and biodegradable. Treated effluent from this

section is partly sent to the fire water pond as a makeup and rest is sent to balance pond. The

balance pond water overflows to guard pond. From guard pond it is pumped to stabilization pond

for final discharge.

2.4.4.4 Effluent Treatment Facilities

The details of equipment/ vessels at ETP and their functions as follows:

Ammonia Steam Stripper Ammonia steam stripper in ETP is designed to strip the incoming floor washing effluents from

Ammonia and Urea plants and also the upsets condensates discharged during any emergencies

in Ammonia and Urea plants. The stripped effluent is discharged to balance pond. The balance

pond water overflows to guard pond. From guard pond it is pumped to stabilization pond for final

discharge. The steam stripper is in two sections. The bottom horizontal cylindrical vessel receives

the effluent where it is heated with steam. Above this, in the vertical section there are two packed

beds of pall rings. This heat exchanger is used for exchange of heat between bottom product

from stripper and feed to stripper. In this way, the feed entering the stripper is getting heated and

bottom product from the stripper is getting cooled. This saves energy in terms of steam used for

stripping.



Shahjahanpur, U.P


Contaminated Pond Contaminated pond having capacity of 5000 m3 is provided for collecting floor washing of urea

and ammonia plants and also the condensates of ammonia and urea plants during any

emergencies for further treatment before discharge.

Balance pond A balance pond having capacity of 30,000m3 is provided for balancing and equalizing the effluent

coming from DM plant, cooling tower and stripper outlet.

Guard pond The balance pond water overflows to guard pond-having capacity of 5000m3. Treated effluent

from guard pond is pumped to stabilization pond for final discharge.

Disc Oil Separator Oily waters if any generated from various sections of Urea and Ammonia plants is collected in oily

water pit provided in the respective plant. The water is pumped to oily water pit at ETP.

2.4.4.5 The Effluent Treatment Plant (ETP)

Effluent treatment system in KSFL is described as follows. The following effluents from fertilizer

complex have been considered.

Cooling tower blow down Cooling water system based on non-chromate treatment system has been adopted. The cooling

tower blow down and the filter backwash water containing non-toxic chemicals and suspended

solids within the limit laid down for discharge are sent to the balance pond for further dilution and

stabilization before being discharged outside.

Effluent from ammonia plant Process condensate from ammonia plant and GV section are treated in condensate stripping unit

and sent to the DM plant for further treatment for making boiler feed water. In the case of

emergency and during start-up, the condensate containing little ammonia is sent to the

contaminated effluent pond and then treated through stripper to strip off whatever little ammonia

present and taken to the balance pond from where discharged outside complex through

stabilization pond.

Process condensate from urea plant Process condensates from urea plant are treated in hydrolyser and stripper system where

ammonia is recovered. The treated condensate is sent to the DM plant for making boiler feed

water. In case of emergency and during start up, the urea plant waste water containing ammonia,

urea and CO2 is sent to the contaminated effluent pond where it is stripped off. This treated

effluent is sent to the balance pond where it gets further diluted and stabilized then discharged

through stabilization pond.



Shahjahanpur, U.P


Treated Oily Waste Water Oily waste water from urea and ammonia plant is pumped to the oily waste water pit in ETP and

the oil is separated by discoil unit. The disc oil collects the floating oil in water and the

accumulated oil is stored in drums. The clear water after oil separation with oil content 10 mg/l is

pumped to the contaminated pond and after stripping it goes to balance pond and discharged

finally through stabilization pond.

Floor washing Floor washing drains from urea plant is received in RCC pit in urea plant and pumped to the

Effluent treatment section of effluent collection tank before treatment. The above effluent is

treated through sand filter, steam stripper etc. and then treated effluent is collected in balance

pond.

Guard pond and stabilization pond The overflow of balance pond comes to the guard pond to give more retention time. The water

from guard pond is pumped to a very large stabilization pond having capacity of 1, 20,000m3.

Finally the treated effluent from this pond is discharged to Garrai nallah after meeting all the

required environmental standards through a closed conduit.

2.4.4.6 Sewage Treatment Plant

Domestic waste water from the plant and township area is treated in Sewage treatment plant.

When it passes through screen chambers the grits are screened and separated from the sewage

water and then allowed to flow under gravity to the Aeration tank. In the aeration tank, the waste

water is subjected to vigorous aeration and the sludge is allowed to settle in sludge settling tanks.

The supernatant water is collected in effluent pit and discharged. The remaining sludge is

collected in sludge drying beds for use as manure. The discharged water flows out with the BOD

of less than 30 mg/l and used for green belt development / discharged in Garrai Nallah.

2.4.5. Solid Waste Disposal System Catalysts after their expected life in the form of spent catalyst are sold to authorized vendors for

its metal value. The other solid wastes are segregated and stored in the separate storage space

and finally sold to the authorized vendors time to time.

2.4.6. Sources of Gaseous Emissions The gaseous emission of the KSFL is through five number of main stack viz. Service boiler stack,

GTG-1 stack, GTG-II stack, Ammonia reformer stack, prilling tower There are number of other

stacks viz. Vent stack Ist and IInd, Blow down stack, CO2 compressor vent (2 no.), main flare

stack, ammonia flare stack, ETP Stripper, CO2 vent. These stacks are not continuous and

operate only during abnormality in plant. The continuous stacks attached to different facilities are

as given below:



Shahjahanpur, U.P


Table 2.3 Existing Emission Load

Stack Stack(m) SOx

ppm

NOx

ppm

SPM

mg/Nm3

NH3

ppm

Remark

Height Dia. Temp0C

Primary

Reformer

32 3.0 160 NT 100 NT NT Fuel:

NG/Naphtha;

Avg gas Velocity:

14 m/sec

Service Boilers

I &II

30 3.2 150 NT 65 NT NT Fuel:

NG/Naphtha;

Avg gas Velocity:

7.7 m/sec

GTG I &II(20

MW)

30 3.2 170 NT 60 NT NT Fuel:

NG/Naphtha;

Avg gas Velocity:

15.5 m/sec

Prilling Tower 102 26 57 NT NT 36 46 Avg gas Velocity:

0.7 m/sec

Source: KSFL

Table 2.4 UPPCB prescribed norms for Prilling Tower at KSFL

Pollutants Ammonia

ppm

Urea Dust

mg / Nm3

Emission norms 100 50

Fugitive Emission Fugitive emission occurs in the bagging plant where large quantity of urea is handled. In order to

control the dust the plant has been provided with wet dedusting system. Centrifugal fans sucks

the urea dust laden air from various dust emission points and delivers to the venturi scrubbers.

The scrubber liquor which is under circulation dissolves most of the dust and clean air leaves the

stack. The solution at intervals is sent for urea recovery in urea plant. Cyclone separators have

been provided at transfer points during conveying for controlling urea dust. Dust thus collected at

these points is further dissolved in urea solution for reprocessing in Urea plant. The system is



Shahjahanpur, U.P


effective in controlling air pollution at work place and creates a dust free atmosphere for better

working conditions and to increase ultimate plant efficiency.

2.4.7. Noise Environment The fertilizer complex has large machines as well as other sources of noise like boiler and other

high pressure vent valves. In addition there is movement of vehicles and railway wagons. There

are provisions and attempt to reduce the noise levels at the source itself and in specific areas

where it cannot be further reduced, plant personnel have been provided with ear protective

appliances. The noise survey of the KSFL plant and township was carried out and the results are

given in Table - 2.5. The Ambient air Quality standards with respect to noise are given in Table -

2.6.

Table 2.5 Noise Survey of KSFL Complex

A: - Ambient Noise

S No. Location Noise dB (A)

Day Night

1 Main Gate Factory 48 39

2 Town Ship Gate 49 40

3 Guest House 49 39

4 B-Type Quarter 49 40

5 A1-A2 Type Quarter 48 39

6 A- Type Quarter 48 39

7 Near Temple 49 40

8 Piprola Village Kesorai Side 49 39

9 Labor Colony -LDPE Gate Side 49 40

10 Kesorai Village 49 39

11 Boundary Wall N.E. Side 48 40

12 Near Gail Metering 49 39

B: - Work Place Noise



Shahjahanpur, U.P


S No Plant Location Noise dB (A)

1 Ammonia Process Air Compressor 74

Refrigeration Compressor 73

Syn. Gas Compressor 73

I. D. Fan 74

Control Room 51

Operator Cabin 61

2 Urea CO2 Compressor 11- Unit 74

CO2 Compressor 21- Unit 74

Near Prilling Tower 72

Control Room 52

Operator Cabin 11-Unit 60

Operator Cabin 21- Unit 61

3 Off-Site HRSG 74

Service Boiler 73

DM Plant Control Room 54

Cooling Tower-Ammonia 73

Cooling Tower-Urea 73

Control Room 52

Operator Cabin 61

4 E & QC Central lab 57

5 Bagging Near Machine 71



Shahjahanpur, U.P


Table 2.6 Ambient Air Quality Standards with respect to Noise

Category of Area Limits Leq, dB(A)

Day Time Night Time

Industrial 75 70

Commercial 65 55

Residential 55 45

Silence 50 40

Figure 2.4 : ETP System in KSFLShahajahanpur (Existing)

(Source: KSFL) To Fire Water Pond

2.5. Proposed Expansion Project

2.5.1. Ammonia plant Ammonia is produced commercially from non-renewable hydrocarbon sources like coal, fuel oil,

naphtha, coke oven gas, refinery gas, natural/associated gas etc. Among the various feedstocks,



Shahjahanpur, U.P


natural gas is the most preferred feedstock for ammonia production because of simpler process

sequence and low capital requirement as compared to other feedstock. The basic steps of

producing ammonia from natural gas are same:

Hydrogen production (usually by reforming of natural gas or partial oxidation of heavier

hydrocarbon feedstock including coal)

Synthesis gas purification (including CO2 removal)

Ammonia synthesis and purging of inert

Air is the ultimate source of nitrogen, and methane or heavier hydrocarbons are usually the main

source of hydrogen. Of the hydrogen feedstock sources - natural gas, coal, and petroleum

fractions – natural gas is the most often employed in commercial ammonia plants, with coal

derived synthesis gas making up the majority of the remainder.

A typical ammonia system will consist of the following steps:

Desulphurization – Natural gas contains large percentage of methane along with ethane,

propane, butane, pentane, carbon-di-oxide, and nitrogen sulphur compounds. Small quantities of

sulphur compounds in the gas are removed by passing the gas through desulphurization unit.

Reforming – Sulphur free gas is then mixed with steam and sent to Primary Reformer where

reforming reaction takes place in the presence of catalyst & produces a gaseous mixture of

hydrogen, carbon monoxide & carbon-di-oxide. Further reforming takes place in the Secondary

Reformer where air is added to furnish the nitrogen required for Ammonia synthesis.

Shift Conversion – Hot reformed gases from Secondary Reformer are cooled by heat recovery in

waste heat boiler and introduced in the shift converters where most of carbon monoxide gets

converted to carbon-di-oxide.

CO2 Removal - Carbon-di-oxide from the gaseous mixture is separated in the CO2 Absorber

using 2- stage efficient absorbing chemicals media and sent to Urea Plant.

Methanation - Residual oxides of carbon in the synthesis gas leaving Absorber are converted to

methane in the Methanator.

Ammonia Synthesis –. Pure synthesis gas from Methanator is compressed and sent to Ammonia

convertors where Ammonia is formed. Ammonia product obtained is sent to urea plant for the

production of Urea.

The main suppliers of ammonia technology are:

HaldorTopsoe (HTAS), Denmark

Kellogg Brown & Root (KBR), USA



Shahjahanpur, U.P


Uhde, Germany

To achieve zero effluent from the plant, the following inbuilt facilities have been considered:

Process condensate stripper to strip off dissolved gases from process condensate with

steam. After stripping the condensate is sent to DM plant for further treatment to convert

it to the Demineralized Water

Turbine condensate is sent to DM plant for polishing and used as boiler feed water

Boiler blow down is used as cooling tower make up.

Ammonia Process Flow Block Diagram (HaldorTopsoe Process) is given Figure 2.5

KSFL is considering various options for finally selecting the technology, the prime

consideration being the energy consumption and eco-friendly nature (least pollution).

Figure 2.5 Ammonia Plant Block Flow Diagram

(Source: KSFL)

2.5.2. Urea Plant



Shahjahanpur, U.P


Urea manufacturing technology has more or less been perfected. All technology suppliers have

been concentrating on:

Specific consumption of Ammonia and Steam

Specific consumption of other utilities power and CW

Least pollution potential i.e. release of ammonia and urea (dust) to environment.

The Ammonia and carbon dioxide produced in Ammonia Plant are again made to react to form

first Ammonium carbonate and then to Urea. The concentration of urea is progressively increased

by the decomposition and separation of Ammonium carbonate the melt urea of 99.8%

concentration is sprayed in a prilling tower through revolving bucket. The solid particles of prilled

urea are packed in 50 kg polythene lined urea bags.

The process steps are:

CO2 Compression

Urea Synthesis

High Pressure Recovery

Medium Pressure Recovery

Low Pressure Recovery

Urea Purification

Urea Prilling

Waste Water Treatment

The main processes used today in the production of urea are the stripping processes offered by:

Stamicarbon, Netherlands

Snamprogetti (Now Saipem), Italy

Toyo Engineering Corporation (TEC), Japan

Stamicarbon and Saipem have been market leaders in terms of installed capacity with

approximately 90 per cent of the total.

Urea Process Flow Block Diagram (Saipem Process) is given in Figure 2.6.



Shahjahanpur, U.P


Figure 2.6 Urea Plant Block Flow Diagram

KSFL is studying the salient features of technologies and weighing various options before arriving

at the final decisions. Energy and environmental are the main considerations.

2.5.3. Utilities and Offsite Facilities The layout of the plant has been shown in Figure 2.1 detailing the different plant facilities.

2.5.3.1 Raw material

The requirement of raw material and utilities for the proposed project has been worked out on the

basis of rated capacity operation of the plants. The main raw material for the proposed plants is

natural gas and utility is raw water. The requirements of these inputs for 2200 MTPD ammonia

and 3850 MTPD urea plants are summarized in Table below:

Table 2.7 Raw Material

Sl. No. Raw Material/Utilities Unit Requirement

1.0 Natural Gas Sm3/hr. 99035



Shahjahanpur, U.P


Sl. No. Raw Material/Utilities Unit Requirement

2.0 Water m3/hr. 1122

Natural Gas

Natural Gas / RLNG are considered to be available through HVJ pipeline in the plant battery limit.

The material and energy balance for the project has been developed based on the representative

analysis of the gas. The total requirement of natural gas at rated capacity operation of the plants

is estimated at about 99035 Sm3/hr. (LHV 8200 Kcal/Sm3).

2.5.3.2 Raw water Treatment Plant

Water is considered to be available through bore wells. Water requirement for the proposed

project is approximately 1122 m3/hr. Water is used after treatment. The requirement of treated

water is mainly for cooling water make up. Other requirement of process water is as make up

water to DM water plant

Domestic water supply is presently catered by the bore wells in the factory & township.

2.5.3.3 Steam and Power Generation

The normal power requirement for the proposed project is envisaged to be met by new captive

power plant. Natural gas based turbo generator of 25 MW along with HRSG of 100 MTPH will be

installed. The exhaust gas from the gas turbine (GT) shall be utilised for generating HP steam

required in urea plant. No additional service/auxiliary boiler has been provided for the complex.

The requirement of steam for Urea Plant and other facilities would be met by surplus steam

available from ammonia plant and HRSG boiler of Gas Turbines of CPP. In Gas Turbines of

Captive power plant, provision has been made for supplementary and additional firing and also

HRSG can be operated independently even if Gas Turbines are not in operation. Hence, no

additional boiler has been considered for the project to raise the steam for start-up purpose.

2.5.3.4 Cooling Tower

Latest design induced draft type cooling towers separately for ammonia and urea plants along

with pumps, side stream filters etc. would be provided for expansion plants. The capacity of each

cell shall be 3000 m3/hr. for both ammonia and urea to minimise the spare needed for cooling

Towers. The number of cell in ammonia CT and urea CT shall be (7+1) and (7+1) respectively

and both the cooling Tower units will be interconnected. The sump and deck of both the cooling

towers shall be covered to prevent the external material from falling into the system. Return



Shahjahanpur, U.P


headers of CW shall be located at ground floor instead of located at deck in existing system. All

the cooling water pumps shall be motor driven.

2.5.3.5 Proposed Ammonia Storage and Handling

In first step of project, there is a provision for the installation of new 5000 MT Ammonia Storage

tank, which will be used for inspection of existing Ammonia Storage tank to ensure safety of the

tank. In second stage of the project, proposed new ammonia & Urea Plant. Shall be

commissioned and after that existing as well as new proposed Ammonia StorageTanks will be

used for the storage purpose of surplus ammonia generated from existing& proposed ammonia

plants.

The liquid ammonia produced in the ammonia plant shall be stored at atmospheric pressure and

at a temperature of –33oC. The capacity of this proposed ammonia storage tank shall be 5,000

MT. The ammonia storage tank will be of double wall double integrity type and provided with

suspended deck. The facilities include one no. double walled insulated atmospheric storage tank,

ammonia boil off compressor, ammonia flare stack and ammonia transfer pumps etc. for safe

operation of the system.

2.5.3.6 Instrument Air Facilities

The normal instrument air requirement for the plant will be met from the Process Air Compressor.

However, as instrument air is very vital for process control instruments, (1+1) Centrifugal Air

Compressors each having a capacity of 3000 Nm3/hr. along with air dryer and receiver units have

been provided for the Project. This arrangement will add to the fail-safe system of instrument

control.

2.5.3.7 Urea Storage and Bagging Plant

For the proposed project, one silo of 30,000 MT capacities has been envisaged. Provision of

automatic bagging (6+2) bagging streams, each of 60 TPH, have also been considered. Modern

and automatic system has been considered for bagging and loading of product into railway

wagons/trucks. The system broadly consists of lifting of empty bags from the sack magazine,

placement of empty bags on the bag holder, stitching of filled bags and flattening of filled bags on

subsequent flat belt conveyor; loading of filled bags into rail wagons/trucks shall be completely

automatic involving very little manual labour. Product shall be transported through strengthen the

existing road transportation system, moreover, railway siding is considered to be developed by

KRIBHCO Infrastructure Limited (KRIL) and integrated with Indian Railway system

2.5.3.8 Inert Gas Generation

Provision has been made for one unit of Inert Gas Generation of 600 Nm3/hr. of Gaseous N2 or

100 Nm3/hr. equivalent liquid N2. Requirement of inert gas nitrogen is mainly arises during start-



Shahjahanpur, U.P


up and shutdown and that shall be met from the centralized inert gas supply system. Provision of

one storage tank of 30 m3 capacity with vaporizer has also been made.



Shahjahanpur, U.P


Figure 2.7 : Water Balance in KSFL Shahajahanpur (Existing)



Shahjahanpur, U.P


Figure 2.8 : Water Balance in KSFL Shahajahanpur (Expansion)


EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, at Village


50

2.5.3.9 Pollution Sources and Control Measures- After Expansion

KSFL is well conversant with the stringent regulations of State as well as Central Pollution

Control Boards. The company will take necessary steps towards getting all statutory clearances

and approvals from the concerned agencies. The sources of pollution in the KSFL plant after

expansion will increase but the types of pollution will not change (since the coming units are

similar to existing one).

2.5.4. Air Emission Main sources for the air emissions will be the stacks in Ammonia, Power plant (GT/HRSG) and

Prilling tower System in Urea plant. The suitable stack height will be considered to take care of

proper dispersion of pollutants and based on suitable dispersion modelling. Quality of

emissions will be monitored and ensured to confirm the stipulated standards.

The three continuous sources of emission shall be, namely

Reformer flue gas stacks in ammonia plant.

Urea Prilling tower

Power Plant (GTG /HRSG)

The emission from stacks will be well within the stipulated norms. Urea Prilling tower shall be a

natural draft circular tower with ~ 26 m diameter and 102 m height. The tower is so designed

that exhaust gases contain less than 50 mg/Nm3 of urea dust.

2.5.4.1 Emission Load

Expected emission load in terms of relevant pollutants from new stacks in the KSFL fertilizer

complex is given in the Table – 2.8. The expected emission load for SPM, ammonia and NOx

works out to be as below:

Table 2.8 : Estimated Stack Emission Load (Kg / hr.) due to Expansion for KSFL

Stack Stack(m) SPM NOx SOX NH3 Remark

Hei

ght

Dia

me

ter

Tem

p0 C

mg/

Nm

3

Kgm

/ h

r.

pp

m

Kgm

/ h

r.

pp

m

Kgm

/ h

r.

mg/

Nm

3

Kgm

/ h

r.

Primary

Reformer

30 3.0 160 <5.0 1.5 ≤400

Mg/NM3

as

76.19 <5.0 2.7 CO-

<100ppm




51

NO2at

3%O2

HC<50

ppm

3,02,117

m3/h

GT/HRSG 30 3.2 200 <5.0 1.9 <100 47.5 <5.0 3.3 CO-

<100ppm

HC<50

ppm

3,80,000

m3/h

Prilling

Tower

102 26 75 <50 53.3 <100

ppm

80.9 13,60,000

m3/h

2.5.5. Noise Environment KSFL fertilizer complex expansion to increase the plant capacity to by 3850 MTPD of urea will

require installations of number of new equipment and machines which will generate noise.

However the quality and technology of these equipment and machines will ensure that noise

generation will be minimum. The additional noise will not disturb the neighbourhood due to

extensive thick green belt all around which will attenuate the same. There can be some

additional vehicles and railway wagons load due to increased plant capacity.

2.5.6. Effluent Generation and Control System 2.5.6.1 Proposed Zero Liquid Discharge (ZLD)

The final treated effluent from effluent treatment plant will have a very good quality for the use

of green belt irrigation. KSFL has developed a thick green cover in and around the plant

complex, including township. The tree plantation is an on-going process & KSFL is planting

number of trees every year to fill up extra land available within its premises. For maintaining &

development of green belt areas at KSFL, an appreciable quantity of water is required for

irrigation purpose on regular basis.

By extending the irrigation pipe line network in leftover greenbelt areas, within total land

acquired area, KSFL will make efforts to utilise the final treated effluent, to maximum possible

extent, for the purpose of irrigation or developing green belts, to achieve Zero discharge,

except rainy season.




52

Sewage

Presently domestic wastewater from the plant and township area is treated in Sewage

Treatment Plant (STP). In STP, after passing through screen chambers the grits are

screened and separated from the sewage water and then the sewage water is allowed

to flow under gravity to the Aeration Tank. In the Aeration Tank, the wastewater is

subjected to vigorous aeration and the sludge is allowed to settle down in sludge

settling tanks. The overflowing water, meeting with all required environmental

standards, is collected in effluent pit from where it is discharged to Garrai Nallah or

used for the irrigation of greenbelt. The remaining sludge is collected in sludge drying

beds and used as manure.

Additional sewage water generated from the proposed fertilizer complex has been

considered to be treated by using existing sewage treatment facilities after necessary

augmentation or a new unit shall be set up.

2.5.7. Solid Waste Management The solid waste generation from the ammonia plant, urea and bagging plants will remain similar

in nature. There will be some increase in solid waste generation from the expansion units. Solid

and other hazardous wastes generated in the process plants will be properly stored and

disposed of as per the prevailing environmental regulations. All hazardous wastes will be

handled, stored, and disposed off as per the prevailing Hazardous waste (management,

handling and Trans boundary movement), Rules 2008.

2.6. Green Belt Development

A green belt of thickness 50 -to-100 meters is provided almost all around the plant. The tree

plantation is an on-going process &KSFL is planting number of trees every year to fill up extra

land available with them. KSFL has developed a thick green cover in and around the plant

complex including township. The tree cover is sparse in the immediate vicinity of the Plant,

which includes township area, market places, office complexes, residential areas etc. Beyond

this zone, the tree cover is considerably high, which can be further improved by extensive

plantation in residential areas, school complexes, parks etc. Other areas where there is still

scope for increasing the plant cover are:

In the residential and private settlement areas

In the unused areas,

Along the roadsides, outer zone of the plant area.




53

Factory and Township: A green belt of 100 m width in the half the periphery of the actual

factory area and of 50 m width in the remaining periphery area has been developed. The total

green belt area is about 296 acres of the total land in possession of KSFL.

Plan for further Greenbelt development: Considering the present status of the greenery in and

around the Plant complex and keeping in view the proposed expansion program, the following

plan is recommended for greenbelt development.

A. SELECTION OF PLANT TYPES

The following evergreen trees and shrubs are recommended for greenbelt development and for

improvement of the existing green cover in and around the Plant. These plants are selected on

the basis of their growth find morphological characteristics (height, crown cover, and

ornamental values) and on their performance in adverse environmental conditions in urban

areas.


EIA&EMP Report for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, at Village Piprola, Distt

Shahjahanpur, U.P

| EQMS INDIA PVT. LTD. 54

Eucalyptus

Sheeshum

Arjun

Neem

Jamun

Sirsa

Babool

Kangi

Teak

Jungle

Jalebi

Gold mohr

pakar

ashok

Peepal

phycus

molshree

bottle brush, silver oak

ornamental trees

B. LOCATIONS FOR GREEN BELT DEVELOPMENT

Inside the Plant Area, there is dense green belt is surrounding the periphery of the plant.

However; the degree of tree cover may be increased by carefully selecting locations in between

units, on both sides of internal roads and near the boundary wall. Taking into account the security

and other aspects, only small-sized evergreen trees may be selected for this area and the

following species may be chosen for plantation:

Careya arboreal,

Holarrhena antidysenterica,



Shahjahanpur, U.P


Mallotus philippinensis,

Murraya exotica,

Randia dumetorum,

Wrightia tomentosa,

Zizyphus mauritiana

The outer zone of the Plant: Though there is not much open space available for development of

a proper greenbelt zone, there is scope for intensifying the existing tree plantation; in the

residential areas, the public places and on the roadside. The plants recommended for this zone

are:

Adhatoda sp.,

Callicarpa macrophylla,

Carissa opaca,

Clerodendron viscosum,

Colebrookia oppositifolia,

Euphorbia royleana,

Ixora sp.,

Murraya sp.,

Woodfordia sr.

Zizyphus sr.

The above trees should be planted with a regular distribution depending on the availability of

space. Where there is limitation of space, trees with smaller crown cover may be preferred (e.g.

Wrightia tomentosa Zizyphus mauritiana]

Wild Animals: Although there is no ecological sensitive area (like biosphere reserve, national

park, sanctuary, or water body/lake etc.) within 25 km of KSFL complex, Open scrub Jhau and

Sarkanda bushes of this area inhabits Nilgai, deer, rabbits etc. Nilgai are observed throughout the

year but deers are seen during the rainy season.

Natural / Birds: There is no Zoo or animal or bird sanctuary in the study area. common birds or

animals, based on the observations by the field team or information collected locally exist in the



Shahjahanpur, U.P


study area Migratory Birds area within the plant (near natural ponds). After October when Indian

climate starts getting cooler some migratory birds are observed:

TadomaFerruginea Surkhab/Brahmany duck

Sarkidiomismelanotos Comb ducks/Nakhta ‘Pinant’

Grus Antigone Saras Crane

Greyleg Goose Kalhansa

Greater Flamingo Hansavar

Painted Stork Bugla

2.7. Occupational Health and Safety

Health hazards associated with the occupation are called occupational hazards. In chemical

industry due to handling of toxic and hazardous chemicals there are possibilities of developing

occupational diseases. KSFL currently employees the following measures with respect to

occupational health and safety:

1. A fully fledged occupational health centre exists at site having adequate infrastructure and

under the supervision of the qualified medical practitioner.

2. On-site 24 x 7 ambulance support.

3. Pre - employment medical check-up at the time of employment.

4. Annual medical check-up for all employees.

5. Yearly and monthly check up for employees working in hazardous process.

6. monitoring of occupational hazards like noise and chemical exposure (of working areas) at

regular intervals and record the data,

7. Engineering controls, wherever possible, to reduce workplace hazards.

8. Training to employees on personal hygiene, health, personnel protective equipment & first aid.

2.8. KSFL CSR (Corporate Social Responsibilities) Activities

WELFARE MEASURES HAVE BEEN TAKEN BY THE COMPANY IN THE SURROUNDING

VILLAGES

1. KSFL have adopted a residential girls college named as Kasturba Gandhi Aavasiya

Balika Vidhyalaya of Jalalbad, Distt. Shahjahanpur, for improvement in facilities for

education of poor girls.



Shahjahanpur, U.P


2. KSFL is providing assistance to Samvardhan Society for upliftment of children suffering

from malnutrition and for their health & cleanliness. The society has been formed by

District Administration.

3. Hand pumps installed in Piprola village to provide the neat & clean drinking water for

villagers.

4. Primary School building constructed in Kesorai village for welfare of children.

5. A road has been constructed to connect the Kesorai village from State Highway,

supported for fund mobilization from Govt agency.

6. Public toilets have constructed in Kesorai and in Piprola village for the use of villagers.

7. To help the poor workers at Bareilly, KSFL distributed hand Rickshaws by the Chief

Minister of Utter Pradesh,

8. To prevent the villagers of Piprola from water born disease due to stagnation of rainy

water, a cemented channel with culvert has been constructed from Piprola village to

Garrai Nallah.

9. An earthen road in Piprola village has been constructed to make better connectivity

among villagers.

10. To make connectivity between Piprola & Kishurhai village one pucca road has been

made.

11. A Temple has been constructed by the KSFL for worship by the people of surrounding

areas.

12. A branch of Oriental Bank of Commerce has been opened in our township land with the

ATM facility, which is being utilized by our employees as well as nearby villagers.

13. A good shopping complex has been established where all items of day to day use and

medicines are available and is being used by our employee as well as nearby villagers.

14. A very good English Medium school up to 10+2 level affiliated with C.B.S.E. Board has

been opened in township for the welfare of the wards of employees and also for the

children of surrounding areas.

Continuous activities-

1. To empower the widow women in nearby villages, KSFL is providing pensions to widows

under its widow pension scheme for the residents of villages like Piprola, Kant, Kesorai,



Shahjahanpur, U.P


Kamalanpur, Jamaur, and Mutihasa & Chakmamrejpur. Pensions to each widow are

being credited in their saving bank account directly.

2. Weekly medical check-up is being carried out by company’s Doctor in the surrounding

villages and the lifesaving drugs is also being distributed to them free of cost. Beyond this

the facility of free consultation to the villagers by our Company’s Doctors in all week days

is also being provided at KSFL Health Centre.

3. “Krashak Gosthi” is being organized from time to time for the villagers of the surrounding

areas for upgrading their knowledge about optimum use of fertilizers, use of bio-fertilisers

& other good farming practices.

4. Constructed boundary wall of nearby temple to increase the safety of pilgrims.

5. Repairing of earthen road in Piprola village being done time to time.

6. Cleaning of pucca channel in Piprola village has been done to avoid water born disease

due to stagnation of water.

7. As per request of District Administration Shahjahanpur, KSFL is providing Rs 15000/- per

month for the development of Shaheed Udyan Park, at Shahjahanpur.

8. With the help of Gramin Vikas Trust the KSFL has started to train the farmers of nearby

area for up-gradation the farming practices to get good quality and high yield of crops.

2.9. CREP Compliance

KSFL is complying all the applicable norms on CREP as given below:

Status of Implementation of the action points in charter on corporate responsibility for

Environment Protection

No. Waste Water Management

Efforts will be made for conservation of water ,particularly

with a target to have consumption less than 8, 12 & 15

m3/tone of urea produced for plant based on gas, naphtha and

fuel oil, respectively In case of plants using naphtha and gas

both as feed stocks, water consumption target of less than 10

m3/tone will be achieved. An action plan for this will be

submitted by June 03 and targets will be achieved by March

Through various efforts for water

conservation, we have achieved

water consumption less than 8

m3/tone of urea. (Annually)

1.



Shahjahanpur, U.P


04.

2 Use of Arsenic for CO2 absorption in Ammonia Plant and

Chromate based Chemicals for cooling systems, which is still

continuing in some industries, will be phased out and replaced

with non – arsenic and non- chromate systems by Dec-2003. In

this regard, action plan will be submitted by Jun-2003.

a) We do not have Arsenic based CO2 absorber in Ammonia Plant.

b) We have selected Non Chromate Treatment for our Cooling water system.

3 Adequate treatment for removal of oil, chromium (till non

chromate based cooling system is in place) and fluoride will be

provided to meet the prescribed standards at the source (end

of respective process unit) itself. Action plan will be firmed up

by Jun-2003for compliance by Mar-2004.

We have provided oil skimmer for

the removal of oil in waste water.

Since we do not have chromate

based treatment for our cooling

water, there is no need for

chromate removal system.

4 Proper and complete nitrification and de-nitrification will be

ensured, whenever such process is used for effluent treatment

by Sep-2003.

Not Applicable

5 Ground Water monitoring around the storage facilities and

beyond the factory premises will be carried out at regular

intervals particularly for pH, fluoride.

Ground water monitoring is being

done for pH& Fluoride on regular

basis.

6 No effluent arising from process plants and associated facilities

will be discharged to the storm water drain. The quality of

storm water will be regularly monitored by all the industries.

No effluent is allowed to go to

storm water drain. However,

monitoring of storm water is

being done regularly.

7 The industries where waste water/ effluent flows through the

storm water drains even during dry season will install

continuous systems for monitoring the storm water quality

for pH, NH3& fluoride. If required, storm water will be routed

through effluent treatment before discharging. An action plan

will be submitted by June 2003 and necessary action will be

taken by June 2004.

No waste water/effluent flow

through the storm water drain. A

provision has been made to divert

storm water to Effluent Treatment

Plant.

1

Air Pollution Management

All the upcoming urea plants will have urea prilling towers

based on natural draft so as to minimize urea dust emissions

We have natural draft based urea

prillling tower



Shahjahanpur, U.P


2 The existing urea plants particularly the plants having forced

draft prilling towers will install appropriate systems (for

example scrubber etc.) for achieving existing norms of urea

dust emissions. In this regard, industries will submit action

plan by Jun-2003 and completion of necessary action by June-

2004.

Not Applicable.

3. The Sulphuric Acid plants having SCSA system will switch over

DCDA system by Mar-2004. To meet the emission standard for

SO2 as 2.0 kg/tone of H2SO4 produced. An action plan for this

will be submitted by June-2003.

Not Applicable.

4. Sulphuric Acid plants having DCDA system will improve the

conversion and absorption efficiencies of the system as well as

the scrubbers to achieve SO2 emission of 2.0 kg/tone of Acid

produced, in case of plants having capacity above 300tpd &

2.5 kg/tone, in case of plants having capacity up to 300tpd. An

action plan will be submitted by Jun-2003and emission levels

will be complied by Sep-2004.

Not Applicable

5 Stack height for Sulphuric plants will be provided as per the

guidelines and on the basis of normal plant operations (and

not when the scrubbers are in use) by June-2003. The

scrubbed gases are to be let out at the same height of the

stack.

Not Applicable

6 An action plan for providing proper dust control systems at

rock phosphate grinding unit in phosphoric acid plants/single

super phosphate plants, so as to achieve particulate emission

levels of 150mg/nm3 will be submitted by Sep-2003 and

complied with by Mar-2004.

Not Applicable

7 Particulate as well as gaseous fluoride will be monitored and

adequate controls systems will be installed by Jun-2004to

achieve the norms on total fluoride emissions (25mg/nm3).

Not Applicable

8 Continuous SO2 emission monitoring systems will be installed

in sulphuric acid plants (having capacity 200tpd and above) by

Mar-2004. Action plan for this will be submitted by Jun-2003.

Not Applicable



Shahjahanpur, U.P


9 Regular monitoring of ambient air quality with regard to SO2,

NOx, and PM, SO3, fluoride and acid mist will be carried out.

Ambient air quality is monitored

regularly for applicable parameter

like PM, SO2, NOx, &NH3.There is

no source of SO3, fluoride and acid

mist in this type of plant.

1

Solid Waste Management

Gypsum will be effectively managed by providing proper lining,

dykes with approach roads and monitoring of ground water

quality around storage facilities. Accumulated gypsum will be

properly capped. In this regard, action plan will be submitted

by June-2003& for compliance by Dec-2003.

Not Applicable.

2

An action plan for proper handling, storage and disposal of

spent catalyst having toxic metals will be submitted by Jun-

2003 and implemented by Sep-2003. The industry will also

explore recovery /by- back of spent catalyst by Sep-2003.

Spent catalyst will be sold to

venders approved by CPCB /

MoEF/SPCB as per Hazardous

Waste Rule and If there is no such

approved parties are available,

same shall be given to approve

TSDF.

3 Carbon slurry, sulphur muck and chalk will be properly

managed and disposed of in properly designed landfill either

with in premises or in common facility. Action plan on this will

be submitted by June-2003 & implemented by Mar-2004.

Not Applicable

4 Existing stock of chromium and arsenic bearing sludge will be

properly disposed by Dec-2003. Industries will also explore

recovery of chromium from the sludge. CPCB will provide

guidelines for the proper disposal of the sludge.

Not Applicable


EIA&EMP for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD, at Village Piprola, Distt

Shahjahanpur, U.P


CHAPTER 3. DESCRIPTION OF THE ENVIRONMENT

3.1. Prelude

The anthropogenic activities specifically related to industrial sector are expected to cause impacts

on environmental quality in and around the project location. However, the intensity of

environmental impacts from a specific project depends on several factors such as type of process

(Physical, Chemical, fuel combustion etc.) involved in the project, processing capacity (scale/

Size of the project), type and extent of pollution control measures, project location, surrounding

geomorphology etc. To assess environmental impacts from proposed project at a specific

location, it is essential to monitor the environmental quality prevailing in the surrounding area

prior to implementation of the proposed project. The environmental status within the study zone is

used for identification of significant environmental issues to be addressed in the impact

assessment study.

The impact from an existing industrial project on its surrounding environment are mainly regulated

by the nature of pollutants, their quantities discharged to the environment, existing environment

quality, assimilative capacity of the surrounding environment and topography and terrain of the

project site (its location) as well as the surrounding area.

In other to identified and establish the extent of likely impact, it is essential to assess existing

environmental parameters with regards to various components of the environment namely:

3.1.1. Physical Environment

Topography and physiographic


Air Environment

Noise Environment

Water Environment

Soils

Land use Pattern

3.1.2. Biological Environment

Terrestrial Ecology

Terrestrial Wild Life

Aquatic Ecology



Shahjahanpur, U.P


3.1.3. Socio-Economic Environment

Demography & Socio-Economic Features

3.2. Site Location and its surroundings

KSFL fertilizer complex is located at a distance of 12 km from Shahjahanpur town near village

Piprola on the State Highway No.29 to Farrukhabad and lies close to the broad gauge railway line

from Lucknow to Moradabad and the National Highway No. 24. The nearest airport is in Amausi

(Lucknow), at a distance of 150 km.

Figure 3.1 Location Map of study Area


3.3. Physical Environment

3.3.1. Physiographic and Topography

KSFL fertilizer complex is located at a distance of 12 km from the district headquarter

Shahjahanpur town near village Piprola on the State Highway No.29 to Farrukhabad and lies

close to the broad gauge railway line from Lucknow to Moradabad and the National Highway No.

24. India, the major portion of the Indian subcontinent, lying atop the Indian tectonic plate, a minor

plate within the Indo-Australian Plate. Uttar Pradesh is India's fifth largest and most populous

state, located in the north-central part of the country. It spreads over a large area, and the plains

of the state are quite distinctly different from the high mountains in the north. Uttar Pradesh



Shahjahanpur, U.P


stretches into two of India’s major physiographic divisions, namely the Great Plains of North India

and the peninsular Plateau. Almost 90% of the total area in Uttar Pradesh is under Great Plains

of North India, while the Southern part of the state belongs to the Peninsular Plateau. Both of

these major divisions in U.P. are marked by a variety of physiographic and relief features.

District Shahjahanpur is situated in South East of Rohilkhand Division. It was established in

1813.Before its creation it was a part of district Bareilly. It Consists of 4 Tehsils, 15 Blocks, 922

Gram Panchayats, 1 Constituency and 6 Assembly Areas.

Land of district Shahjahanpur is plains and fertile. Land of district Shahjahanpur on the side of the

river bank is low and other side it is comparatively high side of land is called Bangar and low side

is called 4 khadar. The north side land of tehsil Puvayan as is domat land. Land in the west side

of the district is comparatively very low due to land erosion of the rivers. Due to this reason at the

time of rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat

and matiyar. In the district water level is 20’ to 25’ below.

A digital elevation model (DEM) is a digital representation of ground surface topography or

terrain. It is also widely known as a digital terrain model (DTM). A DEM can be represented as a

raster (a grid of squares, also known as a height map when representing elevation) or as a

triangular irregular network. The proposed plant location is shown in that Relief map.

For the relief study of the area very higher quality ASTER (Advanced Space borne Thermal

Emission and Reflection Radiometer) DEM is downloaded. These DEMs of the Terra satellite is

freely available for 99% of the globe, and represents elevation at a 30 meter resolution. After

downloading the DEMs the farther processing is done using the ARC GIS 9.2 version.30 m

interval contours are generated using the 3 D Analyst -Surface analysis – Contour option. Then

the TIN model is generated using the height source of these contours in the 3 D Analyst

environment.

The digital elevation model of the project site is shown in the Figure 3.2 with the height range.

http://en.wikipedia.org/wiki/Digital

http://en.wikipedia.org/wiki/Surface

http://en.wikipedia.org/wiki/Topography

http://en.wikipedia.org/wiki/Terrain

http://en.wikipedia.org/wiki/Raster_graphics

http://en.wikipedia.org/wiki/Square_%28geometry%29

http://en.wikipedia.org/wiki/Heightmap

http://en.wikipedia.org/wiki/Triangular_irregular_network

http://en.wikipedia.org/wiki/Advanced_Spaceborne_Thermal_Emission_and_Reflection_Radiometer

http://en.wikipedia.org/wiki/Advanced_Spaceborne_Thermal_Emission_and_Reflection_Radiometer

http://en.wikipedia.org/wiki/Terra_satellite

http://en.wikipedia.org/wiki/Meter



Shahjahanpur, U.P


Figure 3.2 Digital Elevation Model (DEM) of the Study Area

(Source: SRTM DEM)

Figure 3.3 Contour map of the Study Area

(Source: SRTM DEM)



Shahjahanpur, U.P


3.4. Geomorphology

Located in the south-east of Bareilly Division, Shahjahanpur is an agriculture-based district of

Uttar Pradesh. As per government notification it was established in the year 1813. Before its

creation it was a part of Bareilly district. Geographically, it is situated at 27.35 N Latitude and

79.37 E longitude. It has an average elevation of 194 metres (600 feet) from sea level. It is

bounded on North Wet by Bareilly district, on north by Pilibhit district, in the east district Kheri, in

the south district Hardoi, in the south west district Farrukhabad and in the west district Badaun.

The total geographical area of the district is 4575Km2.This is Agriculture based District of Uttar

Pradesh.Ramganga, Garrah & Gomti are the main rivers of district.Kathana, Jhukma & Mensiare

are the attached rivers of Gomti. Garrah is the main river. Khannaut, Suketa and Kai are the

attached rivers of Garrah.Flood - mostly effects Jalalabad Tehsil.Major crops of the district are

Wheat, Gram, Millet & Potato.

There exists an army cantonment, and a major clothing factory for defence forces called

Ordnance Clothing Factory. Shahjahanpur Club is a famous club of the district, whose

membership was once regarded as very exclusive.

Figure 3.4 Geomorphological Map

3.5. Climatology and Meteorology

Metrological plays vital role in affecting the dispersion of pollutants into the environment after their

discharge into the atmosphere. Uttar Pradesh climate greatly varies according to the vacation in



Shahjahanpur, U.P


the topography of the region. The climate of the state is tropical, but variations exist because of

difference in altitudes. The Himalayan region is cold. The (extreme) temperature varies in the

plains from 3 to 40C in January to 43 to 450C in May and June. There are three district seasons-

winter from November to February, summer from April to June and the monsoon season from

July to October.

Summer Season

The month of April marks the start of summers in Shahjahanpur and it lasts till June. Temperature

ranges between 22°C to 48°C during these months.

Monsoon Season

Shahjahanpur experiences the monsoon season from July till October. The city remains drenched

during these months. Average annual rainfall is 907 mm.

Winter Season

Winters in Shahjahanpur start in the month of November and last till February. The weather is

pleasant during these months and the temperature ranges between a comfortable 2 °C to 23°C.

This is the apt time for visiting the city.

3.6. Micro-Meteorology

Meteorological study exerts a critical influence on air quality as it is an important factor in

governing the ambient air quality. The meteorological data recorded during the study period is

used for interpretation of the baseline information as well as input for air quality simulation

models. Meteorological data was collected for the post-monsoon months of October through

December; 2013.Utmost care was taken to ensure that the stations were free from obstructions to

free flow of winds. Wind speed, wind direction, temperature and relative humidity data was

collected daily on an hourly basis during the study period. The summary of the climatic conditions

collected during the study period are tabulated in Table 3.1.

Table 3.1 Summary of Climatic Condition at the Site

Month Parameters Temp (Deg C) RH (%)

October Max 34.0 94.0

Min 20.0 0.0

Mean 26.3 44.2

November Max 29.0 88.0



Shahjahanpur, U.P


Month Parameters Temp (Deg C) RH (%)

Min 14.0 8.0

Mean 20.8 59.3

December Max 25.0 95.0

Min 9.0 23.0

Mean 16.4 69.1

(Source: Field Survey)

The wind rose diagram for the study area is shown in Figure 3.5 and the wind class frequency

distribution is shown in Figure 3.6. The analysis of the average wind pattern shows predominant

winds from NE and W with wind frequencies of 3.85% and 3.13%, respectively. Calm conditions

were prevailed for 82.92% of the total time. Average wind speed was observed as 0.19m/s during

the study period.

Figure 3.5 Wind Rose

(Source: Interpretation of Meteorological Data)



Shahjahanpur, U.P


Figure 3.6 Wind Class Frequency Distribution (Post Monsoon Season)

(Source: Interpretation of Meteorological Data)

3.7. Baseline Environment

Sampling Location:

Monitoring of Baseline Environmental Quality of the Study Area has been done during Post

Monsoon Season (October’13 to December’13). Table 3.2 Shows the Sampling location which

are also depicted in Figure 3.7

Table 3.2 Details of Sampling Locations

Code Location Distance from the Site Direction Ambient Air Sampling Locations

AQ1 Project site - - AQ2 Sahjana 2.66 Km E AQ3 Sikarpur 5.33 Km SE



Shahjahanpur, U.P


Code Location Distance from the Site Direction AQ4 Akhtyarpur 2.70 Km N AQ5 Lalpur 4.70 Km ENE AQ 6 Khalauli 4.73 Km S

Noise Sampling Locations NQ1 Nearest Road NQ2 Project site - - NQ3 Sahjana 2.66 Km E NQ4 Sikarpur 5.33 Km SE NQ5 Akhtyarpur 2.70 Km N NQ6 Lalpur 4.70 Km ENE NQ7 Khalauli 4.73 Km S

Ground Water Sampling Locations GW1 Project site - - GW2 Sahjana 2.66 Km E GW3 Sikarpur 5.33 Km SE GW4 Akhtyarpur 2.70 Km N GW5 Lalpur 4.70 Km ENE GW6 Khalauli 4.73 Km S

Surface Water Sampling Location SW1 Near Pirola Village 1.16 Km S SW2 Garrah Nallah 6.10 Km E

Soil Sampling Locations SQ1 Project site - - SQ2 Sahjana 2.66 Km E SQ3 Sikarpur 5.33 Km SE SQ4 Akhtyarpur 2.70 Km N SQ5 Lalpur 4.70 Km ENE SQ6 Khalauli 4.73 Km S



Shahjahanpur, U.P


Figure 3.7 Sampling Locations in Study Area




Shahjahanpur, U.P


3.8. Air Environment

Prevailing air environment i.e. baseline conditions in an area is primarily governed by the different

activities going on in that area including industrial, agricultural, domestic and commercial

activities. The pollutant concentrations in the atmosphere is also governed by the meteorology,

topography, natural settings in terms of plantation, forest cover, vegetation etc. as these factors in

combination with each other are responsible for dispersion, diffusion, transportation and

assimilation of pollutants in the local air shed.

3.8.1. Reconnaissance Survey

The prime objective of the AAQ survey within the study area around the fertilizer plant was to

establish the existing background levels for various air pollutants e.g. PM10, PM2.5, SO2, NOx,

CO, NH3, HC (Methane and Non-methane), and VOCs.

3.8.2. Ambient Air Quality (AAQ) Monitoring

In order to establish existing status of atmospheric conditions of study area in terms relevant

pollutants namely particulate matter (PM10, PM2.5), sulphur dioxide, nitrogen oxides and

ammonia, AAQ monitoring was carried out for the Post Monsoon season a network of six

numbers of AAQ stations were set up to establish the base line conditions of air environment in

the study area. The AQ stations locations were selected keeping in mind the findings of the

reconnaissance survey, major settlements, micrometeorology and topography of the study area.

The locations and bearing of the AAQ stations have been projected in Table 3.2 and Figure

3.7.The respirable dust sampler and PM2.5 sampler along with the analytical methods prescribed

by CPCB were used for carrying out air quality monitoring. The data on pollutants concentrations

were processed for different statistical parameters like arithmetic mean, minimum and maximum

concentration and 90 percentile value.

3.8.3. Baseline Status

The ambient air quality levels at all the sampling locations were within the limits as specified by

CPCB for industrial/ mixed use and residential/ rural use. The existing PM10, PM2.5, SO2, NOx,

CO, NH3, HC and VOCs concentrations (average of the three months) in the above sites

described are given in Table 3.3 and National Ambient Air Quality Standards (NAAQS) are given

in Table 3.4. Detailed ambient air quality monitoring results have been presented in Annexure-X



Shahjahanpur, U.P


Table 3.3 Ambient Air Quality Data around the various villages of KSFL in 10 km radius

Location Parameter

PM2.5 (µg/m³)

PM10 (µg/m³)

SO2

(µg/m³) NOx

(µg/m³) NH3

(µg/m³) HC

(µg/m³) VOCs

(µg/m³) CO(µg/

m³)

Project site Max 55 76 6.8 13 27 <0.1 <0.1 <1.0 Min 40 60 5.1 10.1 18 <0.1 <0.1 <1.0

Avg 47.5 68.1 6.0 11.8 22.5 <0.1 <0.1 <1.0

98 percentile

55 75.5 6.8 13.0 27 <0.1 <0.1 <1.0

Sahjana Max 53 73 6.5 10.9 25 <0.1 <0.1 <1.0

Min 32 51 4.4 8.2 17 <0.1 <0.1 <1.0

Avg 42.6 62.2 5.6 9.8 20.8 <0.1 <0.1 <1.0

98 percentile

53 72.5 6.4 10.9 24.5 <0.1 <0.1 <1.0

Sikarpur Max 55 75 6.8 13.1 25 <0.1 <0.1 <1.0

Min 33 52 5.2 9.3 16 <0.1 <0.1 <1.0

Avg 45.4 65.3 6.0 11.6 20.8 <0.1 <0.1 <1.0

98 percentile

55 75 6.8 13.0 25 <0.1 <0.1 <1.0

Akhtyarpur Max 52 75 7.1 12.7 25 <0.1 <0.1 <1.0

Min 34 56 5.2 8.3 17 <0.1 <0.1 <1.0

Avg 43.96 66.33 5.86 10.92 21.33 <0.1 <0.1 <1.0

98 percentile

52 74.1 6.9 12.7 24.5 <0.1 <0.1 <1.0

Lalpur Max 56 74 6.5 12.7 25 <0.1 <0.1 <1.0

Min 35 51 4.5 9.3 16 <0.1 <0.1 <1.0

Avg 46.08 65.42 5.87 10.86 20.79 <0.1 <0.1 <1.0

98 percentile

55.5 74 6.5 12.6 25 <0.1 <0.1 <1.0

Khalauli Max 54 74 6.9 13.5 24 <0.1 <0.1 <1.0

Min 30 51 4.1 9.2 15 <0.1 <0.1 <1.0

Avg 41.13 61.54 5.37 10.72 19.63 <0.1 <0.1 <1.0

98 percentile

53.5 73.5 6.6 13.2 24 <0.1 <0.1 <1.0

(Source: ITL, Patila)



Shahjahanpur, U.P


Table 3.4 National Ambient Air Quality Standards (CPCB), 2009

S. No.

Pollutant Time Weighted average

Concentration in Ambient Air

Industrial, Residential, Rural and Other Area

Ecologically sensitive area (notified by Central Govt.)

Methods of Measurement

1 Sulphur Dioxide

(SO2), μg/m3

Annual* 50 20 •Improved West and

Geake

•Ultraviolet

fluorescence

24 hours** 80 80

2 Nitrogen Dioxide

(NO2),μg/m3

Annual* 40 30 •Modified Jacob &

Hochheiser (Na-Arsenite)

•Chemiluminescence

24 hours** 80 80

3 Particulate Matter (size less than 10

μm) or

PM10μg/m3

Annual* 60 60 •Gravimetric

•TOEM

•Beta attenuation

24 hours** 100 100

4 Particulate Matter (size less than 2.5 microns) or

PM2.5μg/m3

Annual* 40 40 •Gravimetric

•TOEM

•Beta attenuation

24 hours** 60 60

5 Ozone (O3) μg/m3

8 hours ** 100 100 •UV photometric

•Chemiluminescence

•Chemical method

1 hour ** 180 180

6 Lead (Pb) μg/m3

Annual* 0.5 0.5 •ASS / ICP method

after sampling on EPM 2000 or equivalent filter paper

•ED – XRF using Teflon filter

24 hours** 1.0 1.0

7 Carbon 8 hours** 2 2 Non Dispersive Infra-



Shahjahanpur, U.P


S. No.

Pollutant Time Weighted average

Concentration in Ambient Air

Industrial, Residential, Rural and Other Area

Ecologically sensitive area (notified by Central Govt.)

Methods of Measurement

Monoxide (CO) mg/m3

1 hour** 4 4 RED (NDIR) Spectroscopy

8 Ammonia (NH3) μg/m3

Annual* 100 100 •Chemiluminescence

•Indophenol blue

method

24 hours** 400 400

9 Benzene (C6H6) μg/m3

Annual* 5 5 •Gas

chromatography based continuous analyser

•Adsorption and

desorption followed by GC analysis

10 Benzo (a) Pyrene (BaP) – particulate phase only ng/m3

Annual* 1 1 Solvent extraction followed by HPLC / GC analysis

11 Arsenic (As) ng/m3

Annual* 6 6 AAS / ICP method after sampling on EPM 2000 or equivalent filter paper

12 Nickel (Ni) ng/m3

Annual* 20 20 AAS / ICP method after sampling on EPM 2000 or equivalent filter paper

* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at uniform interval.

** 24 hourly/ 8 hourly values should be met 98% of the time in a year. However, 2% of the time, it may exceed but not on two conservative days.



Shahjahanpur, U.P


3.8.4. Interpretation of result

PM2.5 (Post Monsoon): The highest PM2.5 level was observed Lalpur (56 µg/m3), while the

lowest level was observed at Village Akhtyarpur (52 µg/m3). The Average PM2.5 levels are within

the NAAQS levels for Industrial, Residential, Rural and Other Areas (60 µg/m3).

Figure 3.8 Statistical Comparison of PM2.5 Concentration (Post Monsoon Season)

(Source: EQMS)

PM10 (Post Monsoon):PM10 levels were found ranging from 73 to 76 µg/m3. The highest PM10

levels were found at Project Site (76 µg/m3) while the lowest levels was found at Village Sahjana

(73 µg/m3). The PM10 in the study area is contributed mainly by industrial emissions, vehicular

emissions, re-suspended dust from paved / unpaved roads and open areas as well as from

industrial activities. The Average PM10 levels are within the NAAQS levels for Industrial,

Residential, Rural and Other Areas

Figure 3.9 Statistical Comparison of PM10 Concentration (Post Monsoon Season)

(Source: EQMS)

0

10

20

30

40

50

60

Max

Min

Average

98 Percentile

01020304050607080

Max

Min

Average

98 percentile



Shahjahanpur, U.P


Sulphur Dioxide (Post Monsoon): The highest level of SO2 was found at the Village Akhtyarpur

(7.1 µg/m3) whereas lowest level was found at Village Sahjana and Lalpur (6.5µg/m3). The SO2

level of the Study area is well under the NAAQS Standard of 80 µg/m3. The main source of SO2

emission is vehicular.

Figure 3.10 Statistical Comparison of SOx Concentration (Post Monsoon Season)

(Source: EQMS)

Oxides of Nitrogen (Post Monsoon): The highest level of NOx was found at the Village Khalauli

itself (13.5 µg/m3) whereas lowest level was found at Village Sahjana (10.9 µg/m3). The NOx

level of the Study area is well under the NAAQS Standard of 80 µg/m3. The main source of NOx

emission is industrial & vehicular.

Figure 3.11 Statistical Comparison of NOx Concentration (Post Monsoon Season)

(Source: EQMS)

0

1

2

3

4

5

6

7

8

Max

Min

Average

98 Percentile

0

2

4

6

8

10

12

14

16

Max

Min

Average

98 percentile



Shahjahanpur, U.P


3.9. Noise Environment

Noise can be defined as an unwanted sound. Noise beyond a certain level has an adverse impact

on human beings and their environment. If intense enough it can damage hearing or is otherwise

annoying.

Noise monitoring was carried out at 7 locations that are described in Table 3.2. Noise

measurements were done using Cygnet Sound Level Meter Model 2031A. Monitoring was carried

out both in the day and night time and accordingly Leq day and night were derived from the

monitored data including the peak values.

The results of the monitoring are provided in Table 3.5. Monitored levels were compared against

Ambient Noise Standards prescribed under Gazette Notification 643 of Ministry of Environment

and Forests (Ref. Annexure IV), Government of India. The noise levels at all the residential

locations were found lower than the ambient noise standards. At the project site it was found to

be lower than the ambient noise standards.

Table 3.5 Ambient Noise Quality Results

S NO. Location Noise level in dB (A) Day Time

Noise level in dB (A) Night Time

1 Nearest Road 57.6 41.9

2 Project Site 52.3 42.1

3 Sahjana 48.5 39.5

4 Sikarpur 50.6 39.5

5 Akhtyarpur 48.5 39.6

6 Lalpur 47.9 39.5

7 Khalauli 47.6 39.8

(Source: ITL, Patiala)

3.10. Water Environment

Water environment of an area is broadly classified into the following categories

Surface water: Rivers, drains, canal, ponds etc.

Ground water: Water seepage and accumulations in deeper strata of ground.



Shahjahanpur, U.P


The only source of recharging for both surface and ground water source is from precipitation

(rainfall). The annual rainfall in 907 mm. The winter rains are uncertain. Light showers may occur

during December and January. Shahjahanpur is situated on a strip of alluvial plain extending

north of the Ganga River.

3.10.1. Surface Water Quality

Surface water samples were collected from 2 locations during the study period and analysed for a

number of physico-chemical parameters. The results of the physico-chemical analysis of Surface

water are given in Table 3.6.

Table 3.6 Surface Water Analysis at various locations around KSFL

S.No. Parameters Unit SITE SPECIFIC (Near Piprola

Village)

GARRAH Nallah

1 pH - 8.44 8.00

2 Turbidity NTU <5 <5

3 EC µMho/cm 512 422

4 TSS mg/L 26 18

5 TDS mg/L 314 274

6 Total Alkalinity as CaCO3

mg/L 198 164

7 Chloride as Cl- mg/L 21 12

8 Sulphate as SO42- mg/L 39 31

9 Nitrate as NO3 mg/L 5 2

10 Phosphate as PO4 mg/L 5 6

11 Total Hardness as CaCO3

mg/L 171 122

12 Calcium as Ca mg/L 89 70

13 Magnesium as Mg mg/L 82 52

14 Sodium as Na mg/L 34 36

15 Potassium as K mg/L <10 <10

16 Flouride as F- mg/L 1.6 1

17 Iron as Fe mg/L 0.6 0.2

18 Phenolic Compounds

mg/L 0.001 0.001

19 Cyanide as CN- mg/L 0.01 0.01

20 Residual Chlorine as Cl-

mg/L 0.01 0.01

21 Cadmium as Cd mg/L 0.001 0.001

22 Total Chromium as Cr

mg/L 0.01 0.01



Shahjahanpur, U.P


S.No. Parameters Unit SITE SPECIFIC (Near Piprola

Village)

GARRAH Nallah

23 Lead as Pb mg/L 0.01 0.01

24 Zinc as Zn mg/L 0.01 0.01

25 Manganese as Mn mg/L 0.01 0.01

26 Copper as Cu mg/L 0.01 0.01

27 Nickel as Ni mg/L 0.01 0.01

28 Total Coliforms MPN/ 100 ml 900 90

29 E-coli Absent/ml present present

30 Insecticides mg/L <0.002 <0.002

31 Dissolved oxygen mg/L 4.5 7.1 32 BOD (3 days at

27˚C) mg/L 34 14

33 Arsenic as As mg/L 0.01 0.01

34 Selenium as Se mg/L 0.01 0.01

35 Oil and grease mg/L 0.01 0.01

36 Mercury as Hg mg/L 0.01 0.01

37 Aluminum as Al mg/L 0.01 0.01

38 Anionic detergents as MBAS

mg/L 0.1 0.1


3.10.2. Ground water availability

Ground water is a dependable resource that is contained and transmitted through the interstices

in rock materials below the earth surface. It is considered and rather used to be a cheap and

easily extractable commodity. However, with a rapid growth of population and all around

development, there is incessant pressure on the ground water withdrawal resulting compulsive

awakening in terms of both the quality and quantity. Estimation of ground water resources of

Shahjahanpur has been carried out based on the methodology recommended by the Ground

Water Estimation Committee (GEC’97). The net ground water availability of the District is

140974.03 Ham and gross ground water draft is 83111.52 Ham. Thus the level of development is

58.96. District Shahjahanpur come under Safe Category.

3.10.3. Ground Water Quality

Ground water samples were collected from 6 locations during the study period and analysed for a

number of physico-chemical parameters. Sampling Locations are detailed in Table 3.2 and Figure

3.7. The results of the physico-chemical analysis of ground water are given in Table 3.7.



Shahjahanpur, U.P


Table 3.7 Ground Water Analysis around various Location of KSFL

SN PARAMETERS

UNIT PROJECT SITE

SAHJANA

VILLAGE

SIKARPUR

VILLAGE

AKHTYARPUR VILLAGE

LALPUR VILLAGE

KHALAULI VILLAGE

1 pH - 7.54 7.76 8.06 7.64 7.82 8.02 2 Turbidity NTU <5 <5 <5 <5 <5 <5

3 EC µMho/cm 554 447 492 689 567 420 4 TDS mg/L 341 291 320 448 369 270 5 Total Alkalinity

as CaCO3 mg/L 177 106 164 128 141 165

6 Chloride as Cl- mg/L 16 8 13 50 16 12 7 Sulphate as

SO42-

mg/L 31 18 26 38 14 26

8 Nitrate as NO3 mg/L 8 6 5 3 5 6 9 Phosphate as

PO4 mg/L 2.1 2.2 2.4 6.5 1.5 2.1

10 Total Hardness as CaCO3

mg/L 151 101 134 114 125 146

11 Calcium as Ca mg/L 78 64 84 69 76 84 12 Magnesium as

Mg mg/L 73 37 50 45 49 62

13 Sodium as Na mg/L 41 35 24 31 18 34 14 Potassium as

K mg/L < 10 < 10 < 10 < 10 < 10 < 10

15 Fluoride as F- mg/L 1.1 0.5 1.4 0.5 0.4 0.5 16 Iron as Fe mg/L 0.5 0.8 1.2 0.1 0.2 0.4 17 Phenolic

Compounds mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

18 Cyanide as CN-

mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

19 Cadmium as Cd

mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

20 Total Chromium as Cr

mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

21 Lead as Pb mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 22 Zinc as Zn mg/L 2.1 1.6 0.6 2.1 1.2 0.8

23 Manganese as Mn

mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

24 Copper as Cu mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 25 Nickel as Ni mg/L <0.02 <0.02 <0.02 <0.02 <0.02 <0.02

26 Total coliforms MPN/ 100 ml

Absent Absent Absent Absent Absent Absent

27 E-coli Absent/ml Absent Absent Absent Absent Absent Absent 28 Arsenic as As mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

29 Mercury as Hg mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001



Shahjahanpur, U.P



Discussion

The ground water quality in the region has been compared with respect to the Drinking Water

Quality Standards as per IS 10500:1991. It was observed that ground water samples on all six

locations were in the norms “Desirable Limits” of TDS, Turbidity, EC, Total Alkalinity, Chlorides,

Sulphate, Nitrate, Phosphate & Total Hardness while Calcium, Magnesium, Sodium & Potassium

comes under the norms “Permissible Limits.” It is observed that ground water sample of Village

Sikarpur contain iron (1.2 mg/l) which is more than permissible limit.

Surface water in the region has been compared with respect to the Water Quality Standards as

per IS 2296:1992.

Study shows the water quality comes under designed Class-C (Drinking Water Sources with

Conventional Treatment followed by Disinfection) of IS 2296:1982 and can be used for

domestic/Drinking use after conventional treatment and disinfection.

3.11. Soil

Soil is our most important natural resource and a natural resource is anything that comes from

the earth and is used by us. We depend on the soil for food, clothing, shelter, minerals, clay &

water. Soil is the seat of many macro and micro flora like algae, fungi, earthworms, bacteria etc.

These are very beneficial in promoting soil reactions and decomposing the organic matter by

which essential nutrients for plants are liberated. Most of the soil is made-up of two main parts:

Tiny bits of mineral particles which come from larger rocks, and humus, which is dark brown in

colour and consists of decaying remains of plants and animals.

Soil also contains water, air and living organisms, such as fungi, bacteria, earthworms,

roundworms, insects, etc. Actually more living organisms live in the soil than above it.

For general characterization of soil a few random samples from the study area to the depth of

about 15-cm may sufficient. Deeper soil samples may be needed only for the study of soil profile.

3.11.1. Study Area Soil Characteristics

Land of district Shahjahanpur is plains and fertile. Land of district on the side of the river bank is

low and other side it is comparatively high side of land is called Bangar and low side is called

Khadar. The north side land of tehsil Puvayan as is domat (Loam) land. Land in the west side of

the district is comparatively very low due to land erosion of the rivers. Due to this reason at the

time of rainfall the area become flooded. In the Block Kaur, Khutar, Nigohi & Jaitpur land is domat

(loam) and matiyar (clay).



Shahjahanpur, U.P


Most of the soil are sandy, clay loam and loam in the district. Sandy soils are found with 50%

sand in rain fed farming areas of the district. Loam& Clay Loam textured soil are found in Irrigated

areas & most of the crops are grown in these soils. Paddy, wheat and other oil seed & pulse

crops are grown in loam soils of the district. Soil map of Shahjahanpur district is shown as Figure

3.12.

Figure 3.12 Soil map of Shahjahanpur District

3.11.2. Methodology of Sampling

The soil samples were collected from Six (06) selected locations during Post-monsoon season.

The samples collected were homogeneous representative of each sampling location. At random

five sub-locations were identified at each location and soil samples were collected from 5 to 15-

cm below the surface. It was uniformly mixed before homogenizing the soil samples. The

samples about 500-gms were packed in polythene bags labelled in the field with location, number

and sent to the laboratory for the analysis of physicochemical parameters.

3.11.3. Selection of Sampling Locations

Six (06) soil sampling locations were selected based on the local land use conditions and the

agricultural practices.

3.11.4. Soil sampling locations

Soil sampling was conducted once during the study period of Post-monsoon season. Six (06) soil

samples were collected from selected locations in the vicinity of the proposed project. For

studying soil quality environment in the study area, sampling locations were selected to assess

the existing soil conditions in and around the existing plant area representing various land use

conditions. The homogenized samples were analysed for physicochemical characteristics. Soil



Shahjahanpur, U.P


sampling locations with their distance & directions with respect to the project site, are presented

in Table 3.2 & shown in Figure 3.7.

3.11.5. Analysis of Soil Samples

The soil samples were examined for various physicochemical parameters, to determine the

existing soil characteristics of the study area. Soil samples were collected from the vicinity of

proposed mine site. Physicochemical characteristics of soil are presented in Table: 3.8 given as

follows;

Table 3.8 Physicochemical Characteristics of Soil

S. No.

Parameters UNIT (S-1) (S-2) (S-3) (S-4) (S-5) (S-6)

Physical Characteristics 1 Texture - Sand

y Loam

Sandy Loam

Sandy Loam

Clay Loam

Sandy Loam

Sandy Loam

2 Porosity % 42 36 46 43 49 40 3 Bulk Density (BD) gm/cc 1.41 1.38 1.48 1.29 1.37 1.41 4 Water Holding

Capacity(WHC) % 36 32 42 38 46 35

5 Particle Size Distribution (I) Sand,%(>0.2 mm

Dia) % 42 46 40 41 42 40

(II) Silt,%(0.02 to 0.2 mm Dia)

% 36 32 37 32 32 28

(III) Clay,%(< 0.002 mm Dia)

% 22 22 23 27 26 32

Chemical Characteristics 6 pH (20%Slurry) 8.42 8.31 8.14 8.22 8.35 7.98 7 Conductivity µmhos/cm 544 428 487 524 434 511 8 Sodium Absorption

Ratio(SAR) %

0.458 0.612 0.584 0.574 0.647 0.612

9 Zinc as Zn meq/100gm <0.1 <0.1 0.2 <0.1 <0.1 0.2 10 Manganese as Mn meq/100gm <0.1 0.2 <0.1 <0.1 0.2 <0.1 11 Organic Carbon % 0.5 0.4 0.4 0.8 0.6 0.4 12 Boron as B meq/100gm <0.1 0.2 0.3 <0.1 0.2 0.4 13 Nitrogen as N mg/Kg 14 23 22 18 25 28 14 Phosphorus as P mg/Kg 12 16 14 11 18 16 15 Potassium as K mg/Kg 48 52 46 42 46 44 16 NPK index - 21 21 18 26 24 23 17 Exchangeable Ca meq/100gm 2.2 0.4 1.6 1.4 0.8 1.2 18 Exchangeable Mg meq/100gm 0.6 0.2 0.6 0.2 0.3 0.6 19 Exchangeable Na meq/100gm <0.1 0.2 <0.1 <0.1 0.2 <0.1 20 Fluoride meq/mg <0.1 <0.1 <0.1 <0.1 <0.1 <0.1




Shahjahanpur, U.P


3.11.6. Physico-Chemical Characteristics of Soil

Interpretation of Soil Characteristic has been dwelled in following sub-sections;

Physical characteristics of soil

Physical characteristics of soil greatly influence its use and behaviour towards plant growth.

3.11.6.1 Soil Texture

Texturally the soils of study area are observed as Sandy Loam, & Clay Loam Soils.

3.11.6.2 Bulk density

Bulk density of soil relates to the combined volumes of the solids and pore spaces. Soil with a

high pore space with loose solid particles will have lower bulk density than those that are more

compact and have less pore space. This is directly related to the movement of air and water

through soil thus affecting the productivity. The bulk density of the soils was found in the range of

1.29 to 1.48-gm/cm3.

3.11.6.3 Water Holding Capacity

Water-holding capacity is usually defined as the amount of water that soil can hold. Soil that have

fine particles are able to hold more water than coarse soils while rock fragments cannot hold any

water and contribute negatively to soil water-holding capacity. The type and composition of soil

are the controlling factors in this case. Water Holding Capacity of study area soils was observed

as 32 to 46%.

3.11.6.4 Chemical Characteristics of Soil

Soil Reaction Classes and Critical Limits for Macro and Micro Nutrients in Soil

According to Soil Survey Manual (IARI, 1970), the soils are grouped under different soil reaction

classes viz; extremely acidic (pH<4.5), very strongly acidic (pH 4.5-5.0 ), strongly acidic (pH 5.1-

5.5), moderately acidic (pH 5.6-6.0), slightly acidic (pH 6.1-6.5), neutral (pH 6.6-7.3), slightly

alkaline (pH 7.4-7.8), moderately alkaline (pH 7.9-8.4), strongly alkaline (pH 8.5-9.0).The soils are

rated as low (below 0.50 %), medium (0.50-0.75 %) and high (above 0.75 %) in case of organic

carbon, low (<280-kg/ha-1), medium (280 to 560-kg/ha-1) and high (>560-kg/ha-1) in case of

available Nitrogen, low (<10-kg/ha-1), medium (10 to 25-kg/ha-1) and high (>25-kg/ha-1) for

available Phosphorus, low (<108-kg/ha-1), medium (108 to 280-kg/ha-1) and high (>280-kg/ha-1)

for available Potassium and low (<10-mg/kg-1), medium (10-20-mg/kg-1) and high (>20-mg/kg-1)

for available Sulphur (Singh et. al. 2004, Mehta et. al.1988). Critical limits of Fe, Mn, Zn, Cu and

B, which separate deficient from non-deficient soils followed in India, are 4.5, 2.0, 0.5, 0.2 and

0.5-mg/kg-1 respectively. (Follet & Lindsay-1970 and Berger & Truog-1940).



Shahjahanpur, U.P


3.11.6.5 Soil Reaction

Soil pH is an important soil property, which affects the availability of several plant nutrients. It is a

measure of acidity and alkalinity and reflects the status of base saturation. The soil pH ranges

from 7.98 to 8.42, thereby indicating the soils are moderately alkaline.

3.11.6.6 Organic Carbon

The effect of soil organic matter on soil properties is well recognized. Soil organic matter plays a

vital role in supplying plant nutrients, cation exchange capacity, improving soil aggregation and

hence water retention and soil biological activity. The Organic Carbon content of soil varied from

0.4 to 0.8%, thereby implying that soils are low to medium in organic content.

3.11.6.7 Macronutrients

Nutrients like nitrogen (N), phosphorus (P) and potassium (K) are considered as primary nutrients

and sulphur (S) as secondary nutrient. These nutrients help in proper growth, development and

yield differentiation of plants and are generally required by plants in large quantity.

3.11.6.8 Available Nitrogen

Nitrogen is an integral component of many compounds including chlorophyll and enzyme

essential for plant growth. It is an essential constituent for amino acids which is building blocks for

plant tissue, cell nuclei and protoplasm. It encourages aboveground vegetative growth and deep

green color to leaves. Deficiency of nitrogen decreases rate and extent of protein synthesis and

results into stunted growth and develop chlorosis. Available nitrogen content in the surface soils

ranges between 14.0 and 28.0-mg/kg (30.0 & 60.0-kg/ha) thereby indicating that soils are low in

available nitrogen content.

3.11.6.9 Available Phosphorus

Phosphorus is an important component of adenosine di-phosphate (ADP) and adenosine tri-

phosphate (ATP), which involves in energy transformation in plant. It is essential component of

deoxyribonucleic acid (DNA), the seat of genetic inheritance in plant and animal. Phosphorous

take part in important functions like photosynthesis, nitrogen fixation, crop maturation, root

development, strengthening straw in cereal crops etc. The availability of phosphorous is restricted

under acidic and alkaline soil reaction mainly due to P-fixation. In acidic condition it gets fixed with

aluminium and iron and in alkaline condition with calcium. Available phosphorus content ranges

between 11.0 & 18.0-mg/kg (21.0 & 37.0-kg/ha) thereby indicating that soils are having medium

to high available phosphorus.



Shahjahanpur, U.P


3.11.6.10 Available Potassium

Potassium is an activator of various enzymes responsible for plant processes like energy

metabolism, starch synthesis, nitrate reduction and sugar degradation. It is extremely mobile in

plant and help to regulate opening and closing of stomata in the leaves and uptake of water by

root cells. It is important in grain formation and tuber development and encourages crop

resistance for certain fungal and bacterial diseases. Available potassium content in these soils

ranges between 42.0 and 52.0-mg/kg (81.0 & 108.0-kg/ha) thereby is indicating that the soils are

low to medium in potassium content.

3.11.6.11 Micronutrients

Proper understanding of micronutrients availability in soils and extent of their deficiencies is the

pre-requisite for efficient management of micronutrient fertilizer to sustain crop productivity.

Therefore, it is essential to know the micronutrients status of soil before introducing any type of

land use.

3.11.6.12 Available Manganese

Manganese is essential in photosynthesis and nitrogen transformations in plants. It activates

decarboxylase, dehydrogenize, and oxides enzymes. The available manganese content in

surface soils ranges between <0.1and 0.2-mg/kg-1. As per the critical limit of available

manganese (>2.0-mg/kg-1), most of the study area soils are sufficient in available manganese in

the vicinity of existing / proposed project.

3.11.6.13 Available Zinc

Zinc plays role in protein synthesis, reproductive process of certain plants and in the formation of

starch and some growth hormones. It promotes seed maturation and production. The available

zinc in surface soils of the study area ranges between <0.1 and 0.2-mg kg-1. As per the critical

limit of available zinc (>0.5-mg/kg-1), most of the study area soils are sufficient in available zinc in

the vicinity of existing / proposed project.

3.11.6.14 Available Boron

Boron increases solubility and mobility of calcium in the plant and it act as regulator of K/Ca ratio

in the plant. It is required for development of new meristematic tissue and also necessary for

proper pollination, fruit and seed setting and translocation of sugar, starch and phosphorous etc.

It has role in synthesis of amino acid and protein and regulates carbohydrate metabolism. The

available boron content in the soils ranges from <0.1and 0.4-mg/kg-1. The critical limit for

deficiency of the available boron is <0.5-mg/ kg-1.



Shahjahanpur, U.P


3.12. Land use

The basic purpose of land use pattern and classification in an EIA study is to identify the manner

in which different parts of land in an area are being utilized or not utilized. Remote sensing data

provides reliable accurate baseline information for land use mapping as it is a rapid method of

acquiring up-to-date information of over a large geological area.

Data Used in the land use map preparation is the satellite Imagery of Indian Remote Sensing

Satellite (IRS- ID, sensor P6, LISS III) of 23.5 m resolution. The Swath of the imagery is 141 Km

x 141 Km. LANDSAT imagery of 30 meter resolution and 185 x 185 km swath is also used for the

comparative and overall analysis of the area. LISS III imagery and LANDSAT imagery of 30

meter resolution were used for the complete coverage of the study area. (Software used- Arc GIS

9.3 & Erdas Imagine 9.1)

The area contains different types of land cover and land use:-

Agriculture land

Human settlements

Open lands-like Agricultural Fallow and other fallow areas

Water Bodies

Some shrub vegetation areas are also there in the study area

Barren land

Land use / land cover map of 10 km study area has been show in Figure 3.14 The agricultural

area and Agri fallow land represents around 59 % and 27 % of the whole land cover. Vegetation

covers about 6 % of the area. Table 3.9 & Figure 3.13 shows the land use categories with the

respective percentages in the study area.

Table 3.9 Land use category in the Study Area

Class Area(Sq km) Agricultural land 186.03 Agri. fallow land 84.74

Water body 5.59 Settlement 14.42

Vegetation/shrubs 18.64 Barren land 5.07

Total 314.49



Shahjahanpur, U.P


Figure 3.13 Landuse / Land Cover Statistics of the Study Area

(Source: EQMS)

Figure 3.14 Land use map of the Study Area

(Source: glovis.usgs.gov)

59% 27%

2% 4%

6%

2%

Land Cover Statistics

Agricultural land

Agri. fallow land

Water body

Settlement

Vegetation/shrubs

Barren land



Shahjahanpur, U.P


3.13. Biological Environment

Nature supports a great variety of living beings under a structural and functional unit called

ecosystem. In any natural ecosystem, there are several components which exist in harmony and

survive only by interdependence. These components may be either biotic or abiotic.

Developmental activities often have great impacts on the biodiversity both ecosystems as well as

species level. Present study has been carried out to inventories the biodiversity exist in the study

area of present project, to evaluate the possible impacts on biodiversity due to project activities

and suggest effective mitigation measures against the negative impacts.

Forest and Forest Types

The extent of Natural forests in Uttar Pradesh is very low and a total of 16583 km2 forest area

recorded in the State which is about 6.88 % of the total state’s geographical area. According to

Champion and Seth (1968), state has 6 major forest groups viz. Tropical Dry Deciduous Forests

(50.66%), Tropical Thorn Forests (4.61%), Tropical Semi-evergreen Forests (0.21%), Tropical

moist Deciduous Forests (19.68%), and Littoral & Swamp Forests (2.35%). Beside these forest

groups, a total of 22.49 % of planted forest is also present in the state. The present project falls in

the Shahajahanpur district which accounts for a geographical area of 4575 km2 having 122 km2

forest cover which is about 2.67% of the district’s geographical area. The forests of the district

support a variety of flora and fauna.

The baseline ecological surveys were carried out, based on various secondary sources (Forest

Department Data, Scientific Studies etc.) which further validated from various primary surveys,

and also through interviewing local people. Present biological studies were carried out in two

zones: core zone [Expansion Area of project- 60 Acre] and buffer zone (10 km surrounding the

core area). The area to be used for expansion project is open and very few shrubs and grasses

have been recorded in that area. Good greenery in the form of greenbelt and roadside plantation

already exist within the project area. There is no reserve forest area falls in the study area and

the natural vegetation of the area is assumed under anthropogenic pressure. The present primary

survey was carried out in following sampling locations:

Expansion Area (Core Area) S-I

Near Kanth (Surrounding Area) S-II

Near Shahajahanpur City (Surrounding Area) S-III

Flora

The present baseline floristic study has been carried out to inventories floral composition in the

study area. Three sampling locations; one in expansion area (core zone) and two in outer area



Shahjahanpur, U.P


within the 10 km of core zone (Buffer zone) were selected for carrying out vegetation survey and

in addition an inventory of various floral species was also prepared for each sampling locations.

In order to understand the composition of the vegetation, most of the plant species were identified

in the field itself whereas the species that could not be identified a specimen was collected along

with their photographs for identification later with the help of available published literature and

floras of the region.

The vegetation of the district belongs to moist deciduous forest and presents very open form so

that the trees and shrubs are widely spaced. The vegetation of study area generally divided into:

Vegetation of ruderal and waste lands, aquatic vegetation near water sources and weeds of

cultivation. Sharma and Dhakre (1993)2 reported a total number of 654 species of angiosperms

which belong to 116 families from Shahajahanpur district. They reported Cyprus, Euphorbia,

Ipomoea, Ficus, and Cassia as leading genera. In the present primary study, a total of 28 trees,

16 shrubs, 19 herbs, 4 climbers and 5 grasses were recorded in both core and buffer areas of

study. (Table 3.13 & 3.14)

Core Area (project expansion area)

In the project expansion area, few shrubs’ individuals like Calotropis procera, Cassia tora and

Cassia occidentalis are recorded. Ground vegetation of the area comprised with some herb

species (Parthenium hysterophorus, Argemone Mexicana, Oxalis corniculata, Cannabis sativa,

Ageratum conyzoides) along with seasonal grasses dominated with Cynodon dactylon. The list of

trees, shrubs, herbs, climbers and grasses found in the core zone area listed in Table 3.13 &

3.14.

Buffer Area (10 Km surrounding of core area)

In the buffer area of the project, main tree species recorded during field study were Kanju

(Holoptelea integrifolia), Pankar (Ficus sp), Neem (Azadirachta indica), Aam (Mangifera indica),

Shahtoot (Morus alba), Shisham (Dalbergia sissoo), Imli (Tamarindus indica), Jamun (Syzium

cumini), Pipal (Ficus religiosa), Mahuwa (Madhuca indica), Eucalyptus (Eucalyptus sp), Khajura

(Phoenix sylvestris) etc. Shrubby vegetation of this zone includes Aak (Calotropis procera),

Cassia tora, Cassia auriculata, Cassia occidentalis and Lantana camara. In the herbaceous flora,

Parthenium hysterophorus, Cynodon dactylon, Argemone Mexicana, Cannabis sativa,

Polygonum sp and Euphorbia hirta were found dominated along some grass species. The list of

floral species recorded in buffer zone is presented in Table 3.10 & 3.11

2Sharma and Dhakre (1993).Flora of Shahajahanpur District, Uttar Pradesh: An Enumeration of Flowering Plants, Vegetos 6 (182):

15-30



Shahjahanpur, U.P


Table 3.10 List of Tree and Shrub Flora Recorded in the Study Area

Sl. No.

Name Scientific Name Family Core Zone

(Expansion Site)

Surrounding Area

Trees S-I S-II S-III

1 Aam Mangifera indica Anacardiaceae *

2 Amaltas Cassia fistula Fabaceae *

3 Kanju Holoptelea integrifolia

Ulmaceae *

4 Asina Terminalia tomentosa

Combretaceae *

5 Ashoka Polyalthia longifolia Annonaceae *

6 Gulmohar Delonix regia Caesalpiniaceae *

7 Bargad Ficus bengalensis Moraceae * *

8 Bel Aegle marmelos Rutaceae *

9 Ber Zyzyphus jujube Rhamnaceae * *

10 Ehretia laeves Boraginaceae *

11 Eucalyptus Eucalyptus sp Myrtaceae *

12 Goolar Ficus glomerata Moraceae * *

13 Imli Tamarindus indica Fabaceae *

14 Jamun Syzygium cumini Myrtaceae *

15 Kachnar Bauhinia variegata Fabaceae * *

16 Semal Bombax ceiba Malvaceae *

17 Khajura Phoenix sylvestris Arecaceae * *



Shahjahanpur, U.P


Sl. No.


(Expansion Site)

Surrounding Area

18 Mahua Madhuca indica Sapotaceae *

19 Neem Azadirachta indica Meliaceae * *

20 Ailanthus excelsa Simaroubaceae *

21 Peepal Ficus religiosa Moraceae * *

22 Ratanjot Jatropha curcas Euphorbiaceae *

23 Reetha Sapindus mukorossi

Sapindaceae *

24 Sahtoot Morus alba Moraceae *

25 Shisham Dalbergia sissoo Fabaceae * *

26 Siris Albizia lebbeck Fabaceae * *

27 Subabool Leucaena leucocephala

Fabaceae *

28 Pankar Ficus spp Moraceae *

Shrubs

1 Karipatta Murraya sp Rutaceae *

2 Aak Calotropis procera Apocynaceae * * *

3 Karvanda Carissa congesta Apocynaceae * *

4 Cassia tora Caesalpinioideae * * *

5 Tarvad Cassia auriculata Caesalpinioideae

*

6 Lantana Lantana camara Verbenaceae * * *

7 Capparis sepiaria Capparaceae * *

8 Facourtia indica Salicaceae *

http://en.wikipedia.org/wiki/Caesalpinioideae

http://en.wikipedia.org/wiki/Caesalpinioideae



Shahjahanpur, U.P


Sl. No.


(Expansion Site)

Surrounding Area

9 Clerodendrum aculeatum

Verbenaceae *

10 Croton bonplandianum

Euphorbiaceae * *

11 Cassia occidentalis Caesalpiniaceae * *

12 Pisola Artemisia nilagirica Asteraceae *

13 Adhatoda zeylanica Acanthaceae *

14 Clerodendrum viscosum

Lamiaceae * *

15 Ipomoea sp Convolvulaceae *

16 Datura sp Solanaceae *

*Present

(Source: EQMS Field Study)

Table 3.11 List of Herbs, Climbers and Grasses Recorded in the Study Area

Sl. No. Name Scientific Name Family Core Zone (Expension

Site)

Surrounding Area

Herbs

1 Gazar ghass Parthenium hysterophorus Asteraceae * * *

2 Doob Cynodon dactylon Poaceae * * *

3 Argemone Mexicana Papaveraceae * * *

4 Dudhee Euphorbia hirta Euphorbiaceae * * *

5 Baraira Sida acuta Malvaceae *

6 Melochia corchorifolia Malvaceae * *



Shahjahanpur, U.P



Site)

Surrounding Area

7 Ambushi Oxalis corniculata Oxalidaceae * *

8 Desmodium triflorum Fabaceae * *

9 Ageratum conyzoides Asteraceae * *

10 Barleria cristata Acanthaceae *

11 Tridax procumbens Asteraceae *

12 Oldenlandia corymbosa Rubiaceae *

13 Polygonum sp Polygonaceae *

14 Cannabis sativa Cannabaceae * * *

15 Solanum nigrum Solanaceae * *

16 Leucas sp Lamiaceae *

17 Pogostemon bengalensis Lamiaceae * *

18 Colocasia sp Araceae *

19 Corchorus aestuans Tiliaceae * *

Climbers

1 Cocculus villosus Menispermaceae * *

2 Abrus precatorius Fabaceae *

3 Ichnocarpus frutescens Apocyanaceae * *

4 Smilax ocreata Liliaceae *

Grasses

1 Bothriochloa pertusa Poaceae * *

2 Dichanthium annulatum Poaceae * *

3 Dactyloctenium aegyptium Poaceae * *



Shahjahanpur, U.P



Site)

Surrounding Area

4 Setaria glauca Poaceae * *

5 Tetrapogon tenellus Poaceae * *

*Present


Fauna

In order to study the wild mammals, avifauna, heretofauna of the project area, a normal

systematic transect sampling was done in different strata. Under this sampling, a 2-3 km long

transect walks were carried out in the different locations. In addition to the field sampling

secondary data and information was also collected through indirect evidences such as calls,

signs and trophies of mammals, interviews of local villagers for the presence of various animal

species and the Forest Working Plan of the Forest Division.

Forest Department reported 19 big animals from the study area. (Forest Working plan)In the

present study, a total of 5 mammalian species were sighted from the study area which is listed in

Table 3.12

Table 3.12 List of Mammalian Fauna Recorded in the study area

S. No.

Scientific Name Order Family Schedule CS

1 Boselaphus tragocamelus

Artiodactyla Bovidae IV LC

2 Canis lupus Carnivora Canidae II LC

3 Vulpes bengalensis Carnivora Canidae II LC

4 Sus scrofa Artiodactyla Suidae IV LC

5 Funambulus palmarum Rodentia Sciuridae IV LC


Forest Department also reported 47 bird species in the study area. During the primary study a

total of 12 bird species has been recorded. The common birds recorded from the study area are:

http://en.wikipedia.org/wiki/Even-toed_ungulate

http://en.wikipedia.org/wiki/Bovidae

http://en.wikipedia.org/wiki/Carnivora

http://en.wikipedia.org/wiki/Canidae

http://en.wikipedia.org/wiki/Carnivora

http://en.wikipedia.org/wiki/Canidae

http://en.wikipedia.org/wiki/Even-toed_ungulate

http://en.wikipedia.org/wiki/Suidae

http://en.wikipedia.org/wiki/Rodent

http://en.wikipedia.org/wiki/Sciuridae



Shahjahanpur, U.P


Common Pigeon (Columba livia), Common Peafowl (Pavo cristatus), Common Myna

(Acridotheres tristis) and Common Myna (Acridotheres tristis). The list of avifauna and birds

recorded in the study area is listed in Table 3.13.

Table 3.13 List of Avi- Fauna Recorded in the study area

S. No.

Name Scientific Name Order Habit

1 Bank Myna Acridotheres ginginianus Passeriformes R

2 Black Drongo Dicrurus macrocercus Passeriformes R

3 Common Myna Acridotheres tristis Passeriformes R

4 Common Peafowl Pavo cristatus Galliformes R

5 Common Pigeon Columba livia Columbiformes R

6 House Crow Corvus splendens Passeriformes R

7 House Sparrow Passer domesticus Passeriformes R

8 Indian Pond Heron Ardeola grayii Pelecaniformes R

9 Jungle Bablar Turdoides striata Passeriformes R

10 Pied Kingfisher Halcyon rudis Coraciiformes R

11 Spotted Dove Stigmatopelia chinensis Columbiformes R

12 White-throated Kingfisher

Halcyon smyrnensis Coraciiformes R


Four species of lizards were sighted during the primary survey along with rat snake. (Table 3.14)

Table 3.14 List of Herpetofauna Recorded in the study area

S. No.

Name Scientific Name Order Family

http://en.wikipedia.org/wiki/Galliformes

http://en.wikipedia.org/wiki/Columbiformes

http://en.wikipedia.org/wiki/Passerine

http://en.wikipedia.org/wiki/Passeriformes

http://en.wikipedia.org/wiki/Coraciiformes

http://en.wikipedia.org/wiki/Coraciiformes



Shahjahanpur, U.P


1 Common House Gecko Hemidactylus frenatus Squamata Gekkonidae

2 Leopard gecko Eublepharis macularius Squamata Gekkonidae

3 Common garden lizard Calotes versicolor Squamata Agamidae

4 Indian chameleon Chamaeleo zeylanicus Squamata Chamaeleonidae

5 Oriental rat snake Ptyas mucosus Squamata Colubridae


Aquatic Ecology

Garrha River is the potential aquatic body present in the study zone along with Garai Nala. Some

birds like Pied Kingfisher and Cattle Egret has been sighted near river course. Fishing has not

been carried out under this survey and fish fauna was recorded from secondary information’s.

Forest working Plan reported 10 fish species from the study area in which following species were

confirmed under present survey:

Table 3.15 List of Fish Fauna Recorded in the study area

S. No.

Name Scientific Name Order Family CS

1 Rohu Labeo rohita Cypriniformes Cyprinidae LC

2 Lanchi Wallago attu Siluriformes Siluridae NT

3 Singhi Heteropneustes fossilis

Siluriformes Heteropneustidae LC

4 Catla Catla catla Cypriniformes Cyprinidae LC


http://en.wikipedia.org/wiki/Squamata

http://en.wikipedia.org/wiki/Gekkonidae


http://en.wikipedia.org/wiki/Gekkonidae


http://en.wikipedia.org/wiki/Agamidae

http://en.wikipedia.org/wiki/Chamaeleonidae


http://en.wikipedia.org/wiki/Colubridae

http://en.wikipedia.org/wiki/Cypriniformes

http://en.wikipedia.org/wiki/Cyprinidae

http://en.wikipedia.org/wiki/Siluriformes

http://en.wikipedia.org/wiki/Siluridae

http://en.wikipedia.org/wiki/Siluriformes

http://en.wikipedia.org/wiki/Heteropneustidae

http://en.wikipedia.org/wiki/Cypriniformes

http://en.wikipedia.org/wiki/Cyprinidae



Shahjahanpur, U.P


Bank Myna Pied Kingfisher

Black Drongo Cattle Egret

Ageratum conyzoides Cannabis sativa

Figure 3.15 A View of Thick Green Belt around project boundary from Shajahanpur-Farrukhabad Highway

National Parks/wildlife Sanctuary / Reserve Forest

There are no National Parks/wildlife sanctuaries in the 10 km radius of the study area.



Shahjahanpur, U.P


(Source: http://www.mapsofindia.com/maps/wildlife/wildlife-uttarpradesh.htm)

Figure 3.16 National Parks and Sanctuaries in Uttar Pradesh

3.14. Demographic and Socio-Economic Features

Demographic Profile of Study Area

The Study Area of 10 km radial Zone mainly falls in the Shahjahanpur district in Uttar Pradesh.

There are total 77 Rural Villages and 1 urban town in Study Area.

Population

Total Population of the Study area as per Census of India, 2011, is 158454 .The total number of

Households are 27660. The total Male and Female population of the Study area is 84152 and

74302 respectively. The Village-wise demographic details are given in Table 3.16

Table 3.16 : Village-wise details of population

District Village No. of

Household

Total Populatio

n

Male Populatio

n

Female Populatio

n

Shahjahanpur

Kishurhai 221 1025 542 483

Jamaur 569 3342 1750 1592

Piprola Ahmedpur 1009 5000 2660 2340

Abhain 404 2312 1253 1059

Barua Bujurg 108 680 352 328

Rawatpur 591 3592 1940 1652

Mohammedpur Azmabad 189 908 501 407

Mutiyasa 125 742 407 335

http://www.mapsofindia.com/maps/wildlife/wildlife-uttarpradesh.htm



Shahjahanpur, U.P


Chandgoi 377 2114 1132 982

Mathurapur 119 736 410 326

Aliyapur 191 994 544 450

Jajalpur 251 1344 727 617

Pandaincha 217 1151 616 535

Kurseli 67 401 212 189

Kailha Elaqa Sisnai 248 1211 646 565

Khijerpur 66 375 207 168

Baberpur 118 616 323 293

Bhudia 179 1135 588 547

Bhanpur 193 1196 650 546

Umraha 378 2229 1193 1036

Misripur 1619 9328 4912 4416

Rausar 279 1551 817 734

Bijlapur 121 727 379 348

Shahwazpur Daniapur 163 987 513 474

Sujatpur 303 1953 1035 918

Utaha 168 964 516 448

Chauthera 1703 10007 5419 4588

Bawakkarpur 196 996 542 454

Nagerpal 491 2595 1421 1174

Akrra Rasoolpur 471 2622 1395 1227

Dadroul 236 1310 687 623

Paintapur 60 394 225 169

Midi Gawan 338 1791 951 840

Bakian 275 1511 770 741

Panchouli 89 524 270 254

Chandapur Barkatpur 399 2181 1174 1007

Sisnai 356 1940 1018 922

Kari Makuapur 228 1242 655 587

Kalyanpur Nawadia 65 389 189 200

Nagaria Talluqa Gopalpur 246 1349 717 632

Rai Khurd 170 919 471 448

Shahbaz Nagar 2485 14044 7375 6669

Bamiahar 86 552 288 264

Bhedpur 186 998 527 471 Rahman Nagar Uaf Raikhera 326 1859 982 877

Lalpur 313 1806 938 868

Mauzampur 597 3500 1846 1654



Shahjahanpur, U.P


Mudiya Narain 117 662 346 316

Harnokha 191 1242 664 578

Dhakaurdharanpur 158 874 458 416

Bhursandi 271 1719 915 804

Mirpur Mafi 95 578 319 259

Khamriya 76 453 248 205

Hasanpur Raskoopa 213 1273 691 582

Parwatpur 201 1140 611 529

Gandhar 359 2004 1038 966

Bahadurpur Bishunipatti 108 548 283 265

Koelha Patti 123 588 314 274

Gulam Khera 370 1973 999 974 Akhtiyar Nagar Urf Eknaura 626 3394 1772 1622

Bawakkerpur Sarawar 191 1137 604 533

Ladpur Sarai 42 212 121 91

Jahangeerpur 60 370 178 192

Hari Pura 115 596 326 270

Endeypur 208 1319 720 599

Mitya Poufi 148 1057 582 475

Ptiyari 159 861 467 394

Mohanpur Mamraijpur 216 1219 632 587

Rajpur Gumtani 63 342 181 161

Mohddinpur 168 737 367 370

Kattupur 10 46 22 24

Dilawarpur 310 1703 877 826

Digurpur 232 1554 834 720

Hatipur Kurria 299 1594 864 730

Walipur 155 982 535 447

Mahanpur 158 942 529 413

Jarawan 169 1056 575 481

Kanth (NP) 4460 27137 14395 12742

Total 27660 158454 84152 74302

Sex Ratio

The Sex ratio of the Study area is 883 Females / 1000 Males and the child sex ratio (0-6 years) is

896 Females /1000 Males.

SC / ST Population



Shahjahanpur, U.P


A considerable population (13%) in the Study Area is constituted by SC/ST of which the former

population constitutes 13 % and the latter 0% of the total population of the study area. A graphical

presentation of SC/ST Population in Study Area with sex wise breakup is given in Figure 3.17 and

3.18 respectively.

Figure 3.17 Sex wise SC, ST Population in Study Area

(Source: EQMS)

Figure 3.18 Percentage wise break up of SC, ST and General Population in Study Area

Male, Total 158454, 84152

Male, SC 20961, 11188

Male, ST 7, 3

Female, Total 158454, 74302

Female, SC 20961, 9773

Female, ST 7, 4

Male Female

General Population,

137486, 87%

SC Population, 20961, 13%

ST Population, 7, 0%

SC/ST/General Population



Shahjahanpur, U.P


(Source: EQMS)

Literacy Rate

The Literacy Rate of the study area is 47.2% of which male and female literate are 54.6% and

38.7% respectively. The illiterates 52.8% of the total population of which female illiterates are

61.3%. The graphical presentation of both sexes of literates and illiterates in study area is given

in Figure 3.19

Figure 3.19 Gender-wise Distribution of Literate and Illiterate in Study Area

(Source: EQMS)

Employment Scenario

Workers Participation Ratio of the Area is 29%.Among this 23% is the Main workers and 6% are

the marginal Workers.

Total Population, Population,

158454

Total Population, Male, 84152

Total Population, Female, 74302

Literates Population,

Population, 74712

Literates Population, Male,

45976

Literates Population,

Female, 28736

Illiterates Population,

Population, 83742

Illiterates Population, Male,

38176

Illiterates Population,

Female, 45566

Total Population Literates Population Illiterates Population



Shahjahanpur, U.P


Figure 3.20 Workers Scenario of the Area

(Source: EQMS)

Main Workers

A considerable percentage (23%) of Main workers in the Study area belongs to Casual Labours

38%, Agricultural 32%, Household workers constitutes 3% and other workers 27% respectively.

Main Workers,

36675, 23%

Marginal Workers, 9879,

6%

Non Workers, 111900, 71%

Workers Scenario



Shahjahanpur, U.P


Figure 3.21 Distribution of Main Workers

(Source: EQMS)

Marginal Workers

A considerable percentage (6%) of Main workers in the Study area belongs to Casual Labours

12%, Agricultural 50%, Household workers constitutes 4% and other workers 34% respectively

Casual Workers

14134 38%

Agricltural Workers

11579 32%

Household Workers

947 3%

Others Workers

10015 27%

Main Workers



Shahjahanpur, U.P


Figure 3.22 Distribution of Marginal Workers

(Source: EQMS)

Cropping Pattern

Major Farming Systems/ Enterprises of district are as follows;

Crop production system

Crop production and livestock production system

Fruits/ vegetable/ floriculture/ farming

Fisheries, Poultry, Mushroom production and Goatary

Area, Production and Productivity of major crops cultivated in the district are listed below;

Table 3.17 Production and Productivity of major crops cultivated

S.N. Crop Area (ha) Production (Qtl) Productivity (Qtl/ha)

1 Rice 204615 459829000 22.44

2 Maize 297 5610000 18.87

3 Jowar 1553 1592000 10.25

4 Bajra 4666 5291000 10.25

Casual Workers, 1208, 12%

Agricltural Workers, 4888,

50%

Household Workers, 391,

4%

Others Workers, 3392,

34%

Marginal Workers



Shahjahanpur, U.P


5 Pulses (Kharif) 8483 5455000 -

6 Ground Nut 6101 6278000 10.29

7 Seasmum 4765 548000 1.15

8 Soybean 56 55000 9.76

9 Wheat 247112 864892000 35.00

10 Barley 574 1169000 20.36

11 Gram 543 483000 8.89

12 Pea 1600 1872000 11.70

13 Lentil 5412 3969000 7.33

14 Linseed 289 119000 4.13

15 Mustard 7677 7351000 9.58

16 Toria 12000 9608000 8.00

Infrastructure

Education facilities

There are 75 Primary School, 14 Middle School, 2 Secondary Schools and 1 Senior Secondary

Schools in 77 villages in study area. Higher education facilities are available in district

headquarters Shahjahanpur District.

Health facilities

There are 2 allopathic and 4 ayurvedic hospital in the study area villages and addition there are 2

ayurvedic, 9 homeopathic dispensary, 3 Primary Health Centre and 1 Primary Health Sub-

centres in the study Area. However, several private medical practitioner and community health

workers are also available.

Drinking Water facilities

Villagers mostly depend on groundwater resource for drinking/domestic water by various means

such as hand pumps (75 villages), well (61 villages) and Tap water facilities by the state

department has been provided in 47 villages.

Communication Facilities



Shahjahanpur, U.P


In the study area there are 11 post offices. There are 45 villages approach by paved road and

bus services are available for 2 (Dadraul and Gulam Khera) villages only. No of telephonic

connections are 88.

Banking Facilities

5 Banks and 7 Credit Societies operates in the study area.

Electricity

37 villages are electrified out of 77 villages in the study area. Comprehensive List of

Infrastructures presents in the Study Area as per Census records 2001 is given in Table



Shahjahanpur, U.P


Table 3.18 Comprehensive List of Infrastructures present in the Study Area

Village: Number of

primary

schools

Number of middl

e schoo

ls

Number of

secondary

schools

Number of

senior second

ary schools

Number of

colleges

Hospital

Dispensary

PHC

PHSC

Number of post

office

No. of telepho

nic connecti

on

Bank

Credit societi

es

Drinking water

facilities

Communication

facilities (Bus

services)

Approach

paved roads

Power

supply

facilities

Kishurhai 3 0 0 0 0 0 0 0 0 0 0

0 0 HP N I A A

Jamaur 1 0 0 0 0 0 0 0 0 1 5

0 0 WW, HP N I NA A

Piprola Ahmedpur 1 0 0 0 0 0 0 0 0 1 1

1 0 TW, WW,

HP N I A A

Abhain 1 0 0 0 0 0 0 0 0 0 1

0 0 TW, WW,

HP N I A A

Barua Bujurg 1 0 0 0 0 0 0 0 0 0 0

0 0 TW,HP N I NA NA

Rawatpur 1 1 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A

Mohammedpur Azmabad 1 0 0 0 0 0 0 0 0 1

11 0 0 HP N I A NA

Mutiyasa 1 0 0 0 0 0 0 0 0 0 1

0 0 TW, WW,

HP N I A NA

Chandgoi 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA A

Mathurapur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Aliyapur 1 0 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I NA NA

Jajalpur 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Pandaincha 1 0 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I A NA

Kurseli 1 0 0 0 0 0 0 0 0 0 0


Kailha Elaqa Sisnai 0 0 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I A A

Khijerpur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Baberpur 1 0 0 0 0 0 0 0 0 0 0

0 0 TW,HP N I NA NA

Bhudia 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A



Shahjahanpur, U.P


Bhanpur 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A

Umraha 1 0 0 0 0 1 AY 0 0 0 1 0

0 0 HP N I A A

Misripur 3 1 0 0 0 0 0 0 0 0 1

1 0 TW, WW,

HP N I A A

Rausar 0 0 0 0 0 0 1 HM 1 0 0 1

0 0 WW, HP N I A A

Bijlapur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Shahwazpur Daniapur 1 0 0 0 0 0 0 0 0 0

0 0 0 WW, HP N I NA NA

Sujatpur 1 1 0 0 0 0 0 0 0 0 0

0 0 HP N I A NA

Utaha 1 1 0 0 0 0 0 0 0 0 0

0 0 TW,HP N I A A

Chauthera 6 3 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I A A

Bawakkarpur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Nagerpal 1 0 0 0 0 0 1 AY, 1

HM 0 0 0 0

0 0 TW, WW,

HP N I A A

Akrra Rasoolpur 1 0 0 0 0 0 1 AY, 1

HM 0 0 0 0

0 0 TW, WW,

HP N I A A

Dadroul 1 1 0 0 0 1 AL, 1

AY 1 HM 0 1 1 0

1 2 WW, HP A A A

Paintapur 0 0 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I A A

Midi Gawan 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA A

Bakian 1 0 0 0 0 0 0 0 0 0 0


Panchouli 1 0 0 0 0 0 0 0 0 0 0

0 0 WW, HP N I A NA

Chandapur Barkatpur 1 1 1 1 0 1 AY 1 HM 0 0 1

0 0 2

TW, WW, HP N I A A

Sisnai 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Kari Makuapur 2 0 0 0 0 0 0 0 0 0 1

0 0 WW, HP N I A NA

Kalyanpur Nawadia 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Nagaria Talluqa Gopalpur 0 0 0 0 0 0 0 0 0 0

0 0 0 HP N I NA NA

Rai Khurd 1 0 0 0 0 0 0 0 0 0 0

0 0 TW N I A NA



Shahjahanpur, U.P


Shahbaz Nagar 3 2 0 0 0 1 AY 1 HM 0 0 1 50

1 0 WW, HP N I A A

Bamiahar 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Bhedpur 0 0 0 0 0 0 0 0 0 0 0

0 0 HP N I A NA

Rahman Nagar Uaf Raikhera 1 0 0 0 0 0 1 HM 0 0 1

0 0 1 TW,HP N I NA A

Lalpur 1 0 0 0 0 0 0 0 0 0 1

0 0 WW, HP N I A A

Mauzampur 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A

Mudiya Narain 0 0 0 0 0 0 0 0 0 0 0


Harnokha 1 0 0 0 0 0 0 0 0 0 0


Dhakaurdharanpur 1 1 0 0 0 0 0 1 0 0 5

0 1 WW, HP N I A NA

Bhursandi 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Mirpur Mafi 1 0 0 0 0 0 0 0 0 0 0


Khamriya 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Hasanpur Raskoopa 1 0 0 0 0 0 0 0 0 0 0


Parwatpur 1 0 0 0 0 0 0 0 0 0 0


Gandhar 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA A

Bahadurpur Bishunipatti 1 1 0 0 0 0 0 0 0 0

2 0 0 WW, HP N I NA A

Koelha Patti 1 0 0 0 0 0 0 0 0 0 4

0 0 TW, WW,

HP N I A NA

Gulam Khera 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP A A A

Akhtiyar Nagar Urf Eknaura 1 0 0 0 0 0 0 0 0 0

0 0 0

TW, WW, HP N I NA A

Bawakkerpur Sarawar 1 0 0 0 0 0 0 0 0 0

0 0 0

TW, WW, HP N I NA NA

Ladpur Sarai 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Jahangeerpur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW,HP N I NA NA

Hari Pura 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA



Shahjahanpur, U.P


Endeypur 1 0 0 0 0 0 0 0 0 1 0

0 0 TW,HP N I NA NA

Mitya Poufi 1 0 0 0 0 0 0 0 0 0 1

0 0 TW, WW,

HP N I A A

Ptiyari 1 0 0 0 0 0 0 0 0 0 0

0 0 TW,HP N I NA A

Mohanpur Mamraijpur 1 0 0 0 0 0 1 HM 0 0 1

1 1 1

TW, WW, HP N I A A

Rajpur Gumtani 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I NA NA

Mohddinpur 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A NA

Kattupur 0 0 0 0 0 0 0 0 0 0 0

0 0 - N I NA NA

Dilawarpur 1 0 0 0 0 0 0 0 0 1 1

0 0 TW, WW,

HP N I A A

Digurpur 2 1 1 0 0 0 0 1 0 0 1

0 0 TW, WW,

HP N I A NA

Hatipur Kurria 1 0 0 0 0 1 AL 1 HM 0 0 0 0

0 0 TW, WW,

HP N I A A

Walipur 0 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A

Mahanpur 1 0 0 0 0 0 0 0 0 0 0

0 0 HP N I NA A

Jarawan 1 0 0 0 0 0 0 0 0 0 0

0 0 TW, WW,

HP N I A A

Total 75 14 2 1 0 2 AL, 4

AY 2 AY, 9

HM 3 1 11 88

5 7 - - - -



Shahjahanpur, U.P


CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1. Prelude

The possible impact on various components of environment due to the proposed expansion of

KSFL plant can be assessed in terms of:

Physical and Biological Environment and

Demographic and Socio-economic Environment.

For proper assessment of significance and magnitude of environmental changes due to

construction and operational phases of the plant, the impacts are analysed on the 10 km radius

study area around the proposed plant site for each environmental parameter. Impact assessment

study for the existing KSFL unit is carried out by predicting net contribution of pollutants

(qualitative as well as quantitative) on overall qualitative assessment of various environmental

indicators. Prediction of impacts is an important component in environmental impact assessment

process. Several techniques and methodologies are in vogue for predicting the impacts due to

existing and proposed industrial development on physico-ecological and socio-economic

components of environment. Such predictions delineate contribution in existing baseline data for

the operational project and superimpose over the baseline (pre-project) status of environmental

quality to derive the ultimate (post-project) scenario of the environmental conditions due to the

proposed project. The quantitative prediction of impacts lead to delineation of suitable

environmental management plan needed for implementation during the construction,

commissioning and operational phases of the proposed project in order to mitigate the adverse

impacts on environmental quality.

Mathematical models are the best tools to quantitatively describe the cause- effect relationship

between source of pollution and different components of environment

4.2. Air Environment

The pre-project (baseline) ambient air quality status in the study area indicates that all the criteria

pollutants are well within the prescribed National Ambient Air Quality Standards (NAAQS) for

industrial, residential, rural and other areas.

The ambient air quality with respect to air pollutants will change during the operation phase of the

proposed project. However, adequate stack height will be provided for better dispersion of flue

gas as per the guidelines of UPPCB. In addition to that adequate greenbelt will be developed for

further control of air pollution.



Shahjahanpur, U.P


Compliance with the existing ambient air quality standards will be achieved by implementation of

the measures as outlined in EMP. This needs to be coupled with the continuous monitoring of air

pollutants within and around the project site as well as in adjoining areas.

To assess the impact of air emissions from various continuous point sources, air dispersion

modelling study has been conducted with the help of ISCST3 View 6.2 model of Lakes

Environmental. Detailed description has been given in the following sub-sections:

4.2.1. Model Brief

Air dispersion modelling can be used to predict atmospheric concentrations of pollutants at

specific locations (receptors) over specific averaging times (i.e. annual, daily, and hourly). An

atmospheric dispersion model accounts for the emissions from a source; estimates how high into

the atmosphere they will go, how widely they will spread and how far they will travel based on

temporal meteorological data; and outputs the pattern of concentrations that will occur for various

exposure periods, thereby providing the exposure risks for different receptors.

In the proposed project, prediction of impacts on air environment has been carried out employing

mathematical model based on a Steady State Gaussian Plume Dispersion Model designed for

multiple point sources for short term. In the present case, Industrial Source Complex Short-

term[ISCST3] dispersion model based on steady state Gaussian Plume Dispersion, designed for

multiple point sources for short term and developed by United States Environmental Protection

Agency (USEPA) has been used for simulations from point sources.

The predictions for air quality during operation phase were carried out for suspended particulate

matter (SPM), oxides of sulphur (SOx) and oxides of Nitrogen (NOx), ammonia (NH3)

concentration using ISCST3.

The options used for short-term computations are:

The plume rise is estimated by Briggs formulae, but the final rise is always limited to that

of the mixing layer

Stack tip down-wash is not considered

Buoyancy induced dispersion is used to describe the increase in plume dispersion during

the ascension phase

Calms processing routine is used by default

Wind profile exponents is used by default

Flat terrain is used for computation



Shahjahanpur, U.P


Pollutants do not undergo any physico-chemical transformation

No pollutant removal by dry deposition

Universal Transverse Meter (UTM) coordinates have been used for computation

A uniform polar grid was used for the computation and extended to 10 km from the centre

of the proposed project. In addition to that, receptors were also placed at the sampling

locations.

Emissions

The main sources of air pollution due to the operation of the plant are the existing boiler, service

boiler I and II, GTG I and II (20 MW), Primary reformer and prilling tower. With the proposed

expansion, the main sources of air pollution will be primary reformer, GT/HRSG and another

prilling tower. SPM, SOX, NOx and NH3 are the main air pollutants generated from the proposed

project. The emission rates and stack parameters of the sources are listed in Table 4.1.

Table 4.1 Stack Parameters and Emission Load (Existing and Proposed Expansion Project)

S.

No. Stack

Stack

Height

(m)

Stack

Diameter

(m)

Stack Exit

Velocity

(m/s)

Stack

Temperature

(K)

Emission Rates (g/sec)

SOX NOx SPM NH3

Existing Facility

1 Primary

Reformer 32 3.0 14.00

443.15 - 18.60 - -

2 Service Boilers I

& II 30 3.2 7.70

423.15 - 7.56 - -

3 GTG I & II (20

MW) 30 3.2 15.50

443.15 - 4.48 - -

4 Prilling Tower 102 26.0 0.70 330.15 - - 13.37 11.88

Proposed Expansion

5 Primary

Reformer 30 3.0 11.87 443.15 0.75 21.16 0.42 -

6 GT/HRSG 30 3.2 13.13 448.15 0.92 13.19 0.53 -

7 Prilling Tower 102 26.0 0.71 348.15 - - 14.81 22.47



Shahjahanpur, U.P


4.2.2. Meteorological Data

The meteorological data consists of wind speed, direction, temperature, humidity, solar radiation,

cloud cover and rainfall recorded during the months of October through December, 2013, on an

hourly basis. Wind speed, wind direction and temperature have been processed to extract the

24–hourly mean meteorological data for application in ISCST3.

4.2.3. Receptor Locations

A total of about 366 receptors – 360 receptors of which were generated with a polar grid from the

centre of the proposed project and extended to 10 km. Apart from these receptors, the sampling

locations were also taken into account to assess the incremental load on the baseline

environmental scenario.

4.2.4. Summary of Predicted GLC’s

The summary of maximum ground level concentrations (GLC) for the existing facility, proposed

expansion and the combined impact of the existing facility, proposed expansion and the

combined impact of the existing facility and proposed expansion are listed in Table 4.2, 4.3 & 4.4

respectively.

Table 4.2 Summary of Maximum 24-hour GLC due to the Existing Facility

Description Concentration (g/m3)

SOx NOx SPM NH3

Maximum Rise in GLC - 7.62 3.23 2.87

Distance of occurrence (km) - 5.13 4.07 4.06

Direction of Occurrence - SW SW SW

Maximum Baseline Concentration

reported

6.04 11.78 153.18 22.54

Total Concentration 6.04 19.40 156.41 25.41

Prescribed Standards 80 80 200 400



Shahjahanpur, U.P


Table 4.3 Summary of Maximum 24-hour GLC due to the Proposed Expansion


SOx NOx SPM NH3

Maximum Rise in GLC 0.42 8.78 2.43 3.34

Distance of occurrence (km) 5.02 5.13 6.06 6.10

Direction of Occurrence SW SW SW SW


reported

6.04 11.78 153.18 22.54



Table 4.4 Summary of Maximum 24-hour GLC due to the Existing Facility and Proposed Expansion


SOx NOx SPM NH3

Maximum Rise in GLC 0.42 16.39 5.59 6.13

Distance of occurrence (km) 5.02 5.13 5.10 5.09

Direction of Occurrence SW SW SW SW


reported

6.04 11.78 153.18 22.54



The above tables show that in the worst case scenario, the maximum ground level concentration

due to the existing facility and proposed project will be in the predominant SW direction. In the

post-project scenario, the 24-hour average concentration for all the criteria pollutants are well

within the ambient air quality standards for industrial, residential, rural and other areas in the

worst case. The isopleths of the pollutant concentration due to the impacts associated with the



Shahjahanpur, U.P


operation of the existing facility are shown in Figures 4.1 through 4.3 for NOx, SPM andNH3

respectively. The isopleths of the pollutant concentration due to the impacts associated with the

operation of the proposed expansion are shown in Figures 4.4 through 4.7 for SOX, NOx, SPM

and NH3respectively.The isopleths of the pollutant concentration due to the impacts associated

with the combined operation of the existing facility and proposed expansion are shown in Figures

4.8 through 4.11 for SO2, NOx, SPM and NH3 respectively.

Additionally, the cumulative impact of the proposed project at the monitoring locations within 10

km radius is provided in Table 4.5.

Table 4.5 Summary of Maximum GLC at Monitoring Locations due to the Existing Facility and Proposed Expansion

Location

Rise in GLC Max. Background

Concentration

Impact from

Project NAAQS

(g/m3) (g/m

3) (g/m

3) (g/m

3)

Project Site

SOX 0.0017 6.04 6.042 80

NOX 0.0861 11.78 11.87 80

SPM 0.0046 153.18 153.184 200

NH3 0.0058 22.54 22.55 400

Sahjana

SOX 0.13 5.55 5.68 80

NOX 6.51 9.8 16.31 80

SPM 1.30 139.97 141.27 200

NH3 1.31 20.83 22.14 400

Sikarpur

SOX 0.07 5.99 6.06 80

NOX 3.08 11.6 14.68 80

SPM 0.83 146.81 147.64 200

NH3 0.70 20.79 21.49 400

Akhtyarpur SOX 0.10 5.86 5.96 80



Shahjahanpur, U.P


Location

Rise in GLC Max. Background

Concentration

Impact from

Project NAAQS

(g/m3) (g/m

3) (g/m

3) (g/m

3)

NOX 4.40 10.92 15.32 80

SPM 1.00 149.24 150.24 200

NH3 0.98 21.33 22.31 400

Lalpur

SOX 0.002 5.87 5.87 80

NOX 0.05 10.86 10.91 80

SPM 0.02 147.2 147.22 200

NH3 0.02 20.79 20.81 400

Khalauli

SOX 0.01 5.37 5.38 80

NOX 0.30 10.72 11.02 80

SPM 0.07 138.47 138.54 200

NH3 0.06 19.63 19.69 400

As is evident from the Tables above, there will be no adverse impacts on the surrounding area.

Highly efficient air pollution control systems will be adopted to mitigate particulate matter as well

as gaseous emissions in the ambient environment.

Discussion of the Cumulative Impacts at monitoring locations:

SOX: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum Sox concentration of 6.06 µg/m3 at Sikarpur village with project

impacts of 0.07µg/m3and baseline contribution of 5.99µg/m3.The total impact from the project of

6.06µg/m3 is well within the stipulated standard of 80µg/m3for industrial as well as residential

areas.

NOx: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum NOx concentration of 16.31 µg/m3 at Sahjana village with project

impacts of 6.51µg/m3 and baseline contribution of 9.80µg/m3.The total impact from the project of



Shahjahanpur, U.P


16.31µg/m3 is well within the stipulated standard of 80µg/m3for industrial as well as residential

areas.

SPM: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum SPM concentration of 153.18 µg/m3 at project site with project

impacts of 0.0046µg/m3 and baseline contribution of 153.18µg/m3.The total impact from the

project of 153.184µg/m3 is well within the stipulated standard of 200 µg/m3for industrial as well

as residential areas.

NH3: The total impacts from the project (existing facility, proposed expansion and baseline

contribution) indicate maximum NH3concentration of 22.55 µg/m3 at project site with project

impacts of 0.0058µg/m3 and baseline contribution of 22.54µg/m3.The total impact from the

project of 22.55µg/m3 is well within the stipulated standard of 400 µg/m3for industrial as well as

residential areas.

As is evident from the tables and discussion above, there will be no adverse impacts on the

surrounding area. Highly efficient air pollution control systems will be adopted to mitigate

particulate matter as well as gaseous emissions in the ambient environment.

Figure 4.1 Isopleth for NOx GLC due to operation of Existing Facility



Shahjahanpur, U.P


Figure 4.2 Isopleth for SPM GLC due to operation of Existing Facility



Shahjahanpur, U.P


Figure 4.3 : Isopleth for NH3 GLC due to operation of Existing Facility



Shahjahanpur, U.P


Figure 4.4 Isopleth for SOx GLC due to Proposed Expansion



Shahjahanpur, U.P


Figure 4.5 : Isopleth for NOx GLC due to Proposed Expansion



Shahjahanpur, U.P


Figure 4.6 : Isopleth for SPM GLC due to Proposed Expansion



Shahjahanpur, U.P


Figure 4.7 Isopleth for NH3 GLC due to Proposed Expansion



Shahjahanpur, U.P


Figure 4.8 : Isopleth for SOX GLC due to Existing Facility and Proposed Expansion



Shahjahanpur, U.P


Figure 4.9 Isopleth for NOX GLC due to Existing Facility and Proposed Expansion



Shahjahanpur, U.P


Figure 4.10 Isopleth for SPM GLC due to Existing Facility and Proposed Expansion



Shahjahanpur, U.P


Figure 4.11 : Isopleth for NH3 GLC due to Existing Facility and Proposed Expansion

4.3. Noise Environment

The sources of noise during the operational phase of the plant are mainly turbines compressors,

blowers, pumps and furnaces. The other sources of noise are the movement of vehicles along the

road. The noise survey of the plant was carried out and the noise level at various locations is

given in Table - 2.6(in Chapter-II). The proposed expansion project will be similar but will have

advanced technology and improved equipment both in terms of energy efficiency and less noisy.

A critical review of Table – 2.6(in Chapter-II) shows that:

Within the plant area noise level was more near process air /synthesis compressors in ammonia

(~73 - 74 dB (A)) and near Prilling Tower (~72dB (A) etc. However the noise level along the plant

boundary gets reduced to considerable extent as monitored at main security gate (~49 dB (A)),

and Gas metering station (~49 dB (A)).

In township the noise level was measured in public places like Temple and guest house. It was

49 dB (A).

4.3.1. Impacts due to Transportation



Shahjahanpur, U.P


Noise level contributed from light medium and heavy vehicles on the roads can be considerable

depending upon the traffic density. The area around the employees and material gates is the

traffic- affected areas due to transportation activities. The light vehicles and two wheelers pass at

the shift hours only except vehicles of the visitors which are limited only. The heavy commercial

vehicles traffic is limited depending upon the material receipt and dispatch of fertilisers through

road transport. The large quantity of fertilisers shall be dispatched through railway rakes also.

4.3.2. Impact on Community

Equivalent sound levels are often used to describe community exposures to noise. Noise survey

was also carried out at 7 locations outside the plant but within the study area. Equivalent noise

levels were measured for residential area both in KSFL Township as well as in other places in

study areas (Chapter - 3). The Leq (day time) for these areas is found to be well within the

prescribed limit of 55 dB (A) except at near road where it was observed to be 57.6 dB (A) and

similarly Leq (night time) for all locations was within the prescribed limit of 45 dB (A).

The noise level norms in villages of study area are being met with respect to the norms of

‘Ambient Air quality Standards in Respect of Noise’.

The operation of KSFL proposed expansion project will have the noise level not exceeding the

present noise level and as such will not have any adverse impact on the human settlement

around it. The noise will not be audible beyond its boundary limit, particularly due to natural green

belt and other attenuators.

4.4. Water Environment

Impact on water environment due to KSFL proposed expansion project scheme will be in terms of

additional water consumption {water demand} and waste water / effluent generation and

discharge to environment.

4.4.1. Water Demand

4.4.1.1 Construction Phase

Since the KSFL expansion project will have water requirement both during construction period as

well as during operation. The requirement during construction period will be much less as

compared to that during operation and will be met with the withdrawal from existing tube wells. As

such then there will not be any additional water requirements for construction.

4.4.1.2 Operational Phase

Water during operational phase is normally required for:

Cooling Water



Shahjahanpur, U.P


Boiler Feed Water

Process Water

Domestic and Green Belt

Water requirement for existing plant (after debottlenecking) is around ~878 m3 / hr. (~ 21072

m3/day ) including 2184 m3/day for domestic purpose (both plant and township) as given in

“Water Balance {Existing Status}” in Figure 2.7.The water consumption in proposed expansion

project will be ~1122 m3 / hr. (26928 m3/day). The water will be drawn from existing as well as

from additional tube wells. Necessary approval / clearance from Central Ground Water Authority/

Board are being taken.

4.5. Effluent Generation and Discharge

Industrial wastewater after it is discharged into surface water body should not produce significant

deterioration in its water quality. The effects on surface water depend on wastewater

characteristics and quantity. The impact on surface water depends on the characteristics and also

on quantity of water in the receiving water body. KSFL has gradually reduced its water

consumption/ effluent generation and energy consumption as given below:

KSFL is consuming water for their process below the specified value i.e. < 7.8 m3/t of urea

against the CPCB (Probe 97/2002-03) Norms 8.0 m3/t of urea.

Energy Trend in KSFL Complex (in Gcal /MT of Urea)

2011 -12 5.5886

2012 – 13 5.5758

2013 – 14 5.5762

The treatment philosophy (treatment at source details in chapter – 2 adopted by KSFL) has given

very good results. The treated effluent quality has also considerably improved. Various measures

adopted are:

Awareness programs on EMS.

Arresting leaky points of TAN at source itself. And

Mapping of TAN generation points & countermeasures.

The sump pit and the guard ponds have got sufficient capacity to hold the effluents even during

emergency. The sump pits are lined with impervious lining to prevent seepage to ground water.



Shahjahanpur, U.P


The plant is operating since more than 18 years and no complaint of ground water contamination

has been received from neighbouring villages.

As a result the quality of treated effluents has considerably improved and most of the effluent is

being utilised for horticulture purposes except in rainy season when water requirement for

irrigation is nil or very less.

The existing philosophy of treating the effluents in the plant and recycling the same in the process

{process condensates} or send these to sump pits - guard ponds and after equalisation /

treatment use for irrigation of green belt or discharge to Garrah Nallah shall be followed. For

expansion project it is proposed to augment the existing Effluent Treatment Plant as per

requirement to accommodate the additional effluent.

The expected characteristics of treated effluents shall be maintained as today or shall be

improved further.

4.6. Land Environment

Essentially, the two major problems normally faced in impact on land environment due to any

development project are:

Diversion of land from designated use to the ‘project use’.

Deterioration of land / soil in terms of soil fertility and toxicity.

4.6.1. Land Diversion

KSFL expansion project is being located within the existing premises and as such no additional

land is required. Since there is no additional land required for KSFL expansion project, no soil

erosion or diversion of land is involved.

4.6.2. Land Deterioration

Low soil fertility is attributable to either to low levels of nutrients {e.g. nitrogen, phosphorus,

potassium etc.} in the soil or their being made unavailable for plant intake in some way. High

levels of elements or compounds being present in the soil cause soil toxicity. Some elements,

which are essential and beneficial for crops at low concentrations, become toxic to crops at

higher concentrations. The soil analysis shows that existing operations and urea emissions have

not caused any deterioration to nearby land in the study area. There can be slight increase in

nitrogen content of the soil and this elevated nitrogen content will have positive impact on the

plant growing in the area. Plant Proposed expansion project will improve the urea availability in

the area and consequently better crop yield.



Shahjahanpur, U.P


The healthy growth of trees and other plants both in factory as well as in township shows that

there is no deterioration of soil and land due to KSFL plant. This was also noted during the site

survey of limited villages in the study area.

The solid wastes generated in the plant are having intrinsic values and are sold to interested

parties. The plant operations after KSFL expansion project will be similar emission and solid

waste and as such not have any impact which is likely to affect soil, or effluents release likely to

affect soil. As such soil chemistry is not going to be affected with KSFL expansion project.

4.7. Biological Environment

4.7.1. Flora

The quality of soils in the premises of the KSFL {factory and township} shows that there is no

adverse effect of air, water and solid effluents on the soil system. A special thrust has been given

right from the beginning to develop the premises into a live green belt. Green belt has been

developed in an area of >33% within the premises with more than 100 species of trees thus the

plant has a significant positive impact on flora and fauna. The treated effluent is used for the

irrigation purposes to the maximum extent within the KSFL premises. This is confirmed by the

healthy growth and development of green belt consisting of variety of trees, plants and lawns

within and near the factory area.

The development of green belt provides habitat, food and breeding areas to birds, small animals

and insects. No rare or endangered species of fauna are reported to exist in the area. Thus, no

impacts on rare / endangered species are envisaged due to normal operations. The groves of

Neem, Kadamb, Kanchan, bottle bush, Bougainvillea sp., Nerium, Tabernaemontana Siris, Rain

tree, Queen’s flower, Queen of the Night, Scarlet Cordia, Tulip tree, Gul Mohar, growing within

the plant showed no adverse effect. The lawns and other plants after watering with treated

effluents continued their healthy growth. The leaf and flowers are all healthy and flowering pattern

has not changed. The KSFL expansion project would not affect the soil and so the plant growth in

the study area.

4.7.2. Fauna

The cattle and birds living in and around in KSFL factory area did not show any harmful

symptoms due to grazing or other soil contamination. The survey team carried out investigation

by checking with villagers in the study area and also discussed with doctors in state veterinary

centre. Thelarge numbers of birds were seen during the site visit. There is no Zoo or animal or

bird sanctuary in the study area. common birds or animals, based on the observations by the field

team or information collected locally exist in the study area Migratory Birds area within the plant

(near natural ponds). After October when Indian climate starts getting cooler some migratory



Shahjahanpur, U.P


birds are observed. Although there is no ecological sensitive area (like biosphere reserve,

national park, sanctuary, or water body/lake etc.) within 25 km of KSFL complex, open scrub

Jhau and Sarkanda bushes of this area inhabits Nilgai, deer, rabbits etc. Nilgai are observed

throughout the year but deers are seen during the rainy season.

4.8. Socio – Economic Environment

KSFL fertiliser plant was commissioned in November 1995 and during it’s more than 18 years of

operation it has spurred a lot of growth in the area. KSFL has carried out lots of social work (as a

part of its ‘CSR’ objectives).KSFL has undertaken a number of projects (CSR activities in brief are

given in Chapter 2).

In addition KSFL as good corporate citizen is carrying out a lot of social work (continuous

activities) as detailed in Chapter 2 section “WELFARE MEASURES HAVE BEEN TAKEN BY

THE COMPANY IN THE SURROUNDING VILLAGES”.

KSFL expansion project will have some impacts also on socio – economic environment of the

study area- some are as given below:

4.8.1. Positive Impacts

Proposed expansion project of the plant would result in handling of more product and raw

material, which will increase manpower requirement at some stages directly, or indirectly

resulting in more income of people.

KSFL expansion project would increase requirement from ancillary and auxiliary

industries in the vicinity e.g. bagging units.

With more load on infrastructure facilities – roads and rails; these facilities would be

improved.

More income to Government through more taxes on higher amount of production.

4.8.2. Negative Impact

Increased traffic on road due to more raw material requirement and more production results in

deterioration of road and increase likelihood of accidents.

However these can be handled and safety on roads can be ensured through increased

awareness and better management.



Shahjahanpur, U.P


CHAPTER 5. ENVIRONMENTAL MANAGEMENT PLAN

5.1. Prelude

Prediction of the potential adverse environmental and social impacts arising from development

interventions is at the technical heart of EIA process. An equally essential element of this process

is to develop measures to eliminate, offset, or reduce impacts to acceptable levels during

implementation and operation of projects. The integration of such measures into project

implementation and operation is supported by clearly defining the environmental requirements

within an Environmental Management Plan (EMP).

Normally, potential impacts are identified early during the initiation of project, and measures to

avoid or minimize impacts are incorporated into the alternatives being considered. In this

respect, some of the most important measures to protect the environment and local communities

become integral to the project design, and may not be reflected in a formal EMP.

KSFL by way of EIA study proposes to identify all the likely potential impacts, collect data

information and incorporate all the measures necessary to avoid or minimize impacts on

surrounding environment. Many of the mitigation measures are already in place as this is the

case of expansion of the plant where a similar unit is already operating efficiently with little

pollution. It is desirable to collect even such information in the EMP to facilitate better assessment

and communication as well as improve the systems and technologies to improve mitigation for

environmental components having moderate residual impacts.

5.2. Objectives of EMP

Overall objective of EMP:

Prevention: Measures aimed at impeding the occurrence of negative environmental

impacts and/or preventing such an occurrence having harmful environmental impacts.

Preservation: Preventing any future actions that might adversely affect an environmental

resource or attribute.

Minimization: Limiting or reducing the degree, extent, magnitude, or duration of adverse

impacts.

5.3. Components of EMP

EMP for KSFL to enhance the production capacity through expansion project (new Ammonia /

Urea / power complex) considers the following aspects:

Description of mitigation measures

Description of monitoring program



Shahjahanpur, U.P


Institutional arrangements

Implementation schedule and reporting procedures

Institutional framework includes the responsibilities for environmental management as

well as responsibilities for implementing environmental measures.

5.4. Central Pollution Control Board {CPCB} Guidelines for Fertiliser Industry

CPCB in its publication “Probe/97/2002 - 03”- ‘Environmental Management in Selected Industrial

Sectors Status / Needs’, which also includes fertilizer sector, has brought out suggestions /

recommendations and norms for fertilizer units. The suggestions / recommendations and norms

as applicable to KSFL and their compliance status are detailed below:

5.4.1. Emission and Effluent Standards

5.4.1.1 Emission

Emission from Prilling Tower:

o For units commissioned after January 01, 1986: 50 mg/Nm3 or 0.5 kg/t of

product;

KSFL Emission from Prilling Tower of Existing Unit:

o <40 mg/Nm3.

5.4.1.2 Water Consumption

For Straight Nitrogenous Fertilizer units 8 m3 / t of urea or equivalent

Existing Unit Water consumption rate < 8 m3 / t of urea

Waste Water Generation Rate 5 m3 / t of urea

Existing Unit wastewater generation <5 m3 / t of urea.

5.4.1.3 Energy Consumption

Energy consumption is also an indicator plant efficient running. KSFL energy consumption trend

is as follows.

2011 - 12 5.5886 Gcal/MT urea

2012 - 13 5.5758 Gcal/MT urea

2013 - 14 5.5762 Gcal/MT urea

2014-15 5.5341 Gcal/MT urea



Shahjahanpur, U.P


Table 5.1 : Action Points

Sr. No.

Action Points Status at KSFL

1. Purge gas recovery unit (PGRU) should be

installed by all ammonia plants for

recovery of gases.

KSFL has installed PGRU to recover

hydrogen.

2. All the plants should recover ammonia as

well as bottom water from condensate

arising from ammonia plant by installing

steam-stripping system.

KSFL has installed ‘Steam Stripping

System ’ in Ammonia plant to recover

condensate, Expansion project will also

have similar system

3. All the operating urea plants should install

deep hydrolyser – stripper as a facility for

treatment of condensate arising from urea

plant and to recycle ammonia and use

bottom water.

KSFL has installed deep hydrolyser –

stripping system for recovery of ammonia

and use of bottom condensate. Expansion

project will also have similar system

4. As far as possible, the treatment units

should be provided at the end of the

processing plant for specific pollutants

such as oil removal system at the place of

oil handling, phosphate and fluoride

removal system after phosphate and

fluoride bearing effluents, ammonia

removal system for ammonia bearing

effluents, chromium removal system for

CW blow down where chromate based

chemicals are used.

KSFL has followed this practice of treating

pollutants at the place of generation {

ammonia, acidic etc.} and will continue the

practice for Expansion project

5. Residual pollutants can be removed in a

centralized biological treatment plant,

where necessary by providing nitrification

and de -nitrification system. It must be

ensured that performance of de -

nitrification process is complete.

KSFL plant effluents are already meeting

the desired norms. Biological treatment of

effluents is not required.

6. The industries should install holding ponds KSFL have centralized treatment system



Shahjahanpur, U.P


Sr. No.


for storing occasional, accidental and

unforeseen effluents, which can disturb the

performance of effluent treatment system.

Such holding ponds should have an

arrangement to pump the effluents to ETP

at regulated rate.

and holding ponds {Sump pits with

treatment facilities and one Guard and one

Stabilization Pond.}.

7. Water Conservation: Industry should

consider and attempt dry floor cleaning so

as to minimize use of water for floor

washing. No process water is to be used

for floor washing.

KSFL follows this and will continue to do

so.

8. The leakages, overflows and spillages

taking place in distribution system should

be checked and controlled to avoid

wastage of water.


so.

9. For development of green belt treated

wastewater may be used instead of fresh

water.

KSFL follows this to full extent {as seen in

water balance diagram} and will continue

to do so.

10. Spillage urea around prilling tower should

be recovered by dissolving in urea

dissolving tank followed by recycle in the

process. At the bagging plant also spilled

urea and the de-dusting scrubber liquor

are to be collected and recycled in the

process plant through urea dissolving unit.


so.

11. Hazardous chemicals are to be adequately

stored and marked.

KSFL follows all norms as applicable

(hazardous chemicals-inflammable,

explosives and toxic) and will continue to

do so.

12. Solid Waste Management: Catalysts are KSFL follows – selling the solid waste



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Sr. No.


charged or made up based on loss of

activity after use for some time. The waste

catalysts are to be disposed. Disposal

should be done with appropriate and

organised manner – secured land fill,

returning to the supplier with special

contract at the time of purchasing, selling

for metal recovery.

(Catalysts) to authorized re-processors or

recyclers and will continue to do so.

13. Monitoring: AAQ monitoring at appropriate

locations.

Ambient Air Quality Monitoring at all the

four monitoring stations and at one place

outside the factory are being carried out as

per the standard procedures on bi-weekly

basis and data regularly submitted to

UPPCB.

14. Ground water monitoring around the

storage facilities and also beyond the

factory premises are to be carried out .at

the regular interval – particularly for the

parameters nitrate, fluoride, pH etc. The

records of sampling, Depth and locations

are to be maintained. The locations of

sampling stations should be indicted in a

map showing the contours of the area.

Monitoring of ground quality is being

carried out for pH, Nitrate, Fluoride, Ca &

Mg Hardness, Iron, Na, K etc. on monthly

basis and reports are being sent regularly

to UPPCB.

15. Environment Management Cell headed by

an experienced technologist and provided

with facilities like laboratory, library and

sufficient manpower.

KSFL has an Environment Management

cell headed by a senior executive and the

same system will continue.

5.4.2. Air Environment The emission from KSFL expansion project shall be mainly from the three stacks (Reformer,

HRSG/GT, PT), very limited fugitive emissions while handling product (as KSFL has urea dust

collection and recovery system in bagging plant). In order to mitigate the adverse environmental



Shahjahanpur, U.P


impact due to the operation at expanded / increased capacities following measures are

recommended:

The control measures (through proper upkeep / maintenance) and good housekeeping

will considerably reduce the fugitive emission.

Existing monitoring system of air pollutants SOx, NOx, ammonia and SPM should be

continued.

Regular monitoring of shop floor environment is to be carried out to control the fugitive

emission as well as shop floor safety.

Leakages {of gases / liquids/ dust} should be checked and promptly attended.

5.4.3. Noise Environment The statutory national standards for noise levels at the plant boundary and at residential areas

near the plant are being and are to be met. The following mitigation measures are proposed to

meet the objectives:

The selection of any new plant equipment is to be made with specification of low noise

levels. Noise suppression measures such as acoustic enclosures / cabins, buffers and /

or protective measures are be provided (wherever noise level is around +80 dB (A) and

exposure limits to workers is more than 8 hours a day) to limit noise levels within

occupational exposure limits. Areas with high noise levels are to be identified and

segregated where possible and will include prominently displayed caution boards.

However, in areas where noise levels are high and exposure time is less, employees will

be provided with ear protection measures like earplugs or earmuffs. Earplug should be

provided to all workers where exposure level is > 85 dB (A). The exposure of employees

working in the noisy area should be monitored regularly to ensure compliance with the

regulatory requirements.

The existing practice of regularly monitoring of noise levels is essential to assess the

efficacy of maintenance schedules undertaken to reduce noise levels and noise

protection measures.

The green belt around the plant and township attenuate the noise level but instead of

block plantation there should be variability in tree height and shape, as this would

disperse the sound waves more efficiently. Plant that attenuate should be planted at the

noise zone.



Shahjahanpur, U.P


5.4.4. Water Environment KSFL plant has taken ample precautions to reduce water consumptions and tackle effluents

problem. The philosophy of segregation of effluent streams and treatment near the source and

recycle back to the system has helped in reducing the water consumptions and effluent

generation considerably. These efforts should continue and now efforts should be directed to:

Increased use of treated effluents in horticulture and green belt developments.

Recycle of treated effluents in the system as far as possible.

The treated sewage should be effectively utilized in the plant after treating it (or for

irrigation in green belt).

The use of any chemical to check microbial activity should be avoided, as it would harm

the human health and fauna.

Use of pesticide and herbicide should be avoided as they can cause ground water

contamination.

Water is a precious commodity and it should be conserved.

KSFL is having 03 No of Rainwater harvesting ponds and they are considered in Ground

Water Survey Report.

5.4.5. Biological Environment KSFL has developed green belt all around it and also along roads, as groves of fruit trees, as

forest blocks, lawns and ornamental / flowering bushes. Mostly the trees have been planted in

blocks of one particular plant – Albezzia Lebbecks, Dalbergia Sissoo, Pinnata, Termenalia Arjuna

etc.

Block plantation of same species of trees is not a healthy practice KSFL should plant different

species of trees

The trees, which have attained their age, should be cut and new trees should be planted.

Proper maintenance is required for the avenue trees. Avenue trees should not block the

view of road or building. This is necessary from safety and security point of view.

The proper distance of avenue trees should be maintained.

The road curbs should not have trees rather shrubs.

The prevailing wind direction at KSFL rotates from NW to WNW (Post Monsoon Season).

Although wind rotates at all angles, the green belt is developed all around the industrial unit but



Shahjahanpur, U.P


the same is more critical towards the windward side and residential areas (villages / township).

The pollutants emitting from KSFL plant falls beyond 300 – 400 m from the source. Considering

this the green belt of width 200 – 300 m in the windward direction is enough to attenuate

pollutants. The scattered and fugitive emissions can be taken care by the plantation inside the

plant complex.

Some of the cautions and guidelines for green belt at KSFL complex area:

The high trees should have ground vegetation in between shrubs to give good coverage

and more attenuation area.

The trees around the boundary walls of township and plant should be fast growing and

perennial trees.

Block plantation should be restricted. Mixed plantations are good for the plant growth. In

the plant area more shrubs are needed close to the fugitive pollution sites.

To maintain healthy life of the plant, diseased plants (herbs, shrubs, trees) should be

removed.

5.4.6. Land Environment The expansion project will generate the solid wastes similar (in quality as well as increase in

quantity) to the existing system and the existing handling system for the same is to continue. No

additional measures are required.

5.4.7. Socio-economic Environment KSFL is carrying out various welfare programs in adjoining areas. The other agriculture

related programs like horticulture, bio fertilizers, compost from agriculture and domestic

wastes through worm , bio-pesticides etc. should be actively initiated with related

agencies.

As a good corporate citizen and major industry KSFL may consider adopting few more

selected villages in developing them as model villages (with educational facilities for

children, medical facilities, infrastructure as roads, sanitation facilities (more specifically

for ladies), improved agriculture techniques etc.).

More awareness program are to be initiated in immediate neighbouring villages about

KSFL plant activities and the various EHS measures undertaken to make the plant safe

and environment friendly.

5.4.8. Environmental Management Cell



Shahjahanpur, U.P


KSFL has an environment management cell headed by a senior executive and supported by

other supporting staff. It reports to Sr Vice President. The environment set up and guide lines are

given in Annexure VIII.

The Environment Management Cell is formed keeping the following objectives in view:

To update the Environmental Protection Measures.

Efficient control of Environmental degradation.

Conservation of Natural resources. To achieves the better productivity through the

Environmental Management.

Continuous monitoring of the Quality of liquid effluent, stack emissions and ambient air

quality.

Minimization of leakage of any toxic gases. Recycling and reuse of effluent.

EMC consists of various qualified experts of different discipline. Our targets are to keep clean

environment free from all pollutants and comply all the conditions laid down by UPPCB and MoEF

The plant also has well equipped quality and environmental control laboratory having

sophisticated instruments including:

Gas Chromatograph

Microscope,PM2.5 & PM 10 samplers , Gaseous Pollutants sampler, Handy samplers

Colony Counter

Spectrophotometer

Naphalometer

Stack Monitoring Kits.

Drager Pumps and tube kits

pH Meter

Gas Chromatograph for NG etc

A team of well trained and experienced staff carries out tests in the laboratory.

5.4.9. Post – Operational Monitoring Program KSFL is carrying out environment monitoring and has necessary equipment and associated

facilities. However monitoring plan proposed is as follows:



Shahjahanpur, U.P


Table 5.2 : Environmental Monitoring Program

Discipline Location Parameter Frequency Remarks Meteorology one Temp. {max.; min.};

Relative humidity; Rain fall; Wind speed and direction.

Daily Shall be complied

Ambient Air Quality

Five PM10,PM2.5, SO2, NO2and NH3

Twice a week Shall be complied

Stack Emission

All continuous

stacks

NOx & SO2 in Primary Reformer, GT/HRSG stacks and NH3 & PM in Prilling Tower

Fortnightly

Shall be complied

Effluents

Final effluents discharge point

pH, Free NH3, TAN; TKN;NO3;TSS; PO4as P, Oil-grease; COD; BOD

pH,& TAN -As & when discharge or utilized for irrigation& rest on weekly basis

Shall be complied

Sanitary TSS; BOD Weekly Shall be complied

Ground Water Quality

{Wells / Hand pumps}

pH, NO3, Floride & NH3

Monthly Shall be complied

Surface Water Quality (Upstream & Downstream) of Garrai Nallah

Two (100 mt up & 100 mt down from discharge point)

pH, Free NH3, TAN; TKN;NO3;TSS; PO4 as P, Oil-grease; COD; BOD

pH,& TAN -As & when final effluent discharged & rest on weekly basis

Shall be complied

Noise Plant area &neighboring villages

Day & Night time noise level

Monthly

Shall be complied

Health Check Up

All Plant Personnel

Occupational Health diseases

Annually Shall be complied



Shahjahanpur, U.P


CHAPTER 6. HAZARD EVALUATION AND RISK ANALYSIS

6.1. Prelude

Industrial plants deal with materials, which are generally hazardous in nature by virtue of their

intrinsic chemical properties or their operating temperatures or pressures or a combination of

these. Fire, explosion, toxic release or combinations of these are the hazards associated with

industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated

methods of Safety Engineering, such as, Hazard Analysis and Risk Assessment have now been

developed to improve upon the integrity, reliability and safety of industrial plants.

The primary emphasis in safety engineering is to reduce risk to human life, property and

environment. Some of the more important methods used to achieve this are:

Risk Analysis: Provides a relative measure of the likelihood and severity of various

possible hazardous events by critically examining the plant process and design.

Work Safety Analysis: The technique discerns whether the plant layout and operating

procedures in practice have any inherent infirmities.

Safety Audit: Takes a careful look at plant operating conditions, work practices and work

environments to detect unsafe conditions.

Together, these three broad tools attempt to minimize the chances of accidents occurring. Yet,

there always exists, no matter how remote, probability of occurrence of a major accident. If the

accident involves highly hazardous chemicals in sufficiently large quantities, the consequences

may be serious to the plant, to surrounding areas and the populations residing therein.

To meet emergencies caused by such major accidents, planning response strategies are termed

as On-site Emergency Plan /Disaster Management Plan (DMP).

DMP cannot be considered in isolation or act as a substitute for maintaining good safety

standards in a plant. The best way to protect against a major accident occurrence is by

maintaining very high levels of safety standards.

6.2. Hazards Survey



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Hazard identification and risk assessment studies can be performed at any stage, that is, at initial

design stage or as on-going operation in the system. Hazard survey is a formal systematized

approach employed for hazard identification.

Appraisal of material characteristics from Material Safety Data Sheet for various materials and

chemicals used or produced in the fertilizer plant of Kribhco Shyam Fertilizer Limited (KSFL)

indicates that some of the materials are highly inflammable/explosive (Natural Gas/Naphtha) and

some are toxic (Ammonia / Chlorine etc.). In addition some of the intermediate materials

produced in the process (hydrogen and carbon monoxide) are extremely dangerous considering

the process conditions.

All process materials which are capable of producing accidents/hazards owing to their physical

and chemical properties are identified and on the basis of material movement, hold ups are

calculated. Quantities in the pipelines are also taken in to account. Large and sub-sequential

inventories in storage or process are indicative of the potential hazards to the plant and its

surroundings. Flammability and toxicity factors of these inventories can lead to the unpredictable

incidents.

KSFL is producing urea for agriculture use. The major raw materials and other consumable used

are given in Table 6.1. Most of the materials consumed (except Naphtha, Ammonia, and

Chlorine) are non-hazardous in nature. However, the materials in the process i.e. NG, hydrogen,

carbon monoxide and ammonia are highly hazardous. The consequence of hazards is enhanced

considering the process conditions (high temperature and pressure). These materials need to be

handled very carefully to ensure safety.

Table 6.1 : Hazardous Materials Storages

S. No.

Hazardous Chemicals Handled

Quantity Handled /In

Process

Type of Storage

1 Naphtha 3 [4600;1350;

600] KL

MS Tanks (Main tanks 4600 KL & 1350 KL are having floating roof while day tank -600KL has fixed roof tank with N2 blanketing)

2 Main Raw Material-Natural Gas

--- Supply from GAIL through HBJ gas line

3 Ammonia 2X 5000 MT Double walled, double integrity Atmospheric Tanks



Shahjahanpur, U.P


S. No.

Hazardous Chemicals Handled

Quantity Handled /In

Process

Type of Storage

(0ne existing and in proposed expansion project).

4 Chlorine Gas 0.9X12 MT Tonnage Cylinders

5 Sulphuric Acid

2

[35;30.5] MT

MS Storage Tank

6 Hydrochloric acid

3

[60;60;60] MT

MSRL Storage Tank

7 Caustic Lye(Sodium Hydroxide)

2

[44;44] MT

MSRL Storage Tank

8 Diesel 3

[12;12;12] KL

MS Storage Tank

9 Liquid Nitrogen

2

[25;25] KL

Double Wall Storage Tank

6.3. Hazard Evaluation

The evaluation phase determines the extent and degree of employee’s exposure to toxicants and

other physical hazards in the work place environment. In the case of major accident/breakdown

occurrences, hazards exposure may cross plant boundary limit and persons/properties in the

neighbouring areas may be exposed. During the evaluation study, the likelihood of large and

small leaks is also considered. Hazardous substances may be released as a result of leaks or

catastrophic failures causing possible damage to the surrounding areas. The extent of damage

will depend upon the nature of release. The release of flammable and toxic materials and

subsequent ignition results in heat radiation, pressure wave or vapour cloud depending upon the

flammability, toxicity and its physical state.



Shahjahanpur, U.P


Sudden exposure to high concentrations of toxic chemicals via leaks or operational upsets (relief

valve pop up) may lead to acute effects, such as, unconsciousness, burning eyes, fits of

coughing, etc.

Chronic effect, however, arises by repeated exposure to toxic chemical concentrations mostly by

small leak. Many fine toxic dusts or vapours are invisible, colourless and odourless (CO). Small

leaks of these substances might not become obvious for months or even years.

6.4. Potential Hazards

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

lower threshold values in relation to those in case of explosive clouds (the lower explosive

limits).In contrast fires have localized consequences. Fires can be put out or contained in most

cases; there are few mitigating actions one can take once vapour clouds get released. Therefore,

major accident hazards occur upon release of flammable or toxic vapours or BLEVE in case of

pressurized flammable liquefied gases.

6.4.1. Toxic Release

In KSFL complex toxic hazards are mainly due to Ammonia (produced and stored in large

quantity) and chlorine.

Ammonia is a colourless with extremely pungent odour toxic and explosive gas (BP – 33.4C).

Ammonia is highly soluble in water (which can to an extent save an individual from its hazards).

Ammonia exposure limits are –TWA – IND 25 ppm; TWA – ACGIH 25 ppm; STEL- ACGIH 35

ppm. Ammonia is severe irritant respiratory tract. Some hazards arise due to production, transfer,

storage, handling and processing of liquefied ammonia. In case of fully refrigerated liquid

ammonia release, instantaneous flash due to adiabatic expansion is negligibly small. Evaporation

due to aerosol formation also does not occur. Release of liquid ammonia at pressure (in ammonia

plant synthesis section), gives rise to flash evaporation equivalent of the initial flash due to

adiabatic expansion. In case of HP ammonia stored at near ambient temperature liquid released

would completely vaporize with no pool formation. Ejection of high pressure ammonia appears to

entrain 10 to 15 times of its own weight of air enough to evaporate nearly all the liquid. Thus if an

HP release occurs unimpeded the ammonia entrains sufficient air to evaporate all the droplets

carried out with flash.

Chlorine is a toxic gas (B. P. is -34oC). In liquefied form chlorine is a clear amber dense liquid.

The gas is greenish-yellow, about 2.5 times as dense as air, and non-flammable. Liquid chlorine

causes severe irritation and blistering of skin. The gas has a pungent suffocating odour and is



Shahjahanpur, U.P


irritant to the nose and throat. It is an extremely powerful vesicant and respiratory irritant.

Typically, exposure to chlorine concentrations of 3 - 6 ppm results in a stinging and burning

sensation in the eyes. Exposures for 0.5 -1 hour to concentrations of 14 - 21 ppm cause

pulmonary oedema, pneumonitis emphysema and bronchitis. This is usually associated with

marked bronchospasm, muscular soreness and headache. Whilst there is inevitably a variation in

individual susceptibility, typically 4 ppm is the maximum concentration that can be breathed for

one hour without any damage, 40-60 ppm is dangerous for a 30-minute exposure and a

concentration of 1000 ppm is likely to be fatal after a few breaths. IDLH (immediately Dangerous

to Life and Health) value for chlorine is 30 ppm. Permissible limit in exposure of chlorine in work

environment under Factories Act, 1948 is 1 ppm Time Weighted Average (TWA) Concentration (8

hours).

6.4.2. Flammable Release

The flammable materials used at KSFL, involve natural gas used as feedstock, fuel gas and

synthesis gas produced in ammonia plant upstream of Synthesis converter, and naphtha. In

certain section of the plant the operating temperature itself exceeds the auto-ignition temperature

of hydrogen and carbon monoxide. In all such cases due to immediate ignition, a jet flame will

result.

6.4.3. Jet Release

Generally when a gas flows out of an opening at high velocity a turbulent free jet invariably

results. The out-flowing gas entrains a large quantity of the ambient air. The net results being the

jet getting diluted to LEL within the short distance from the release point. If ignited the jet flame

results, but if the released material does not get ignited immediately then the possibility of vapour

cloud explosion or delayed ignition is very remote because by this time free jet has lost its

momentum and the mass can begin to disperse due to environmental forces {the concentration of

flammable material has already fallen below the LEL}.

No vapour cloud explosion has therefore been considered. Jet flames due to impingement on the

adjoining important installations can lead to secondary effects (domino effect). In certain cases

the domino effects could lead/ result in loss of containment of ammonia with serious

consequences. The toxic effect of carbon -monoxide has also not been considered since any

such release due to high system operating pressure (and consequent high momentum) will either

get diluted to low concentrations within short distance from the source due to air entrainment or

will get ignited and hence the consequence distance will be rather small.

6.5. Inventory Analysis



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Inventory plays an important part in regard to the potential hazard. Larger the inventory of the

vessel or a system, larger would be the quantity of potential release. A practice commonly used

to generate an incident list is to consider the potential leaks and major releases from fractures of

pipelines and vessels containing sizable inventories. The potential vapour release (source

strength) depends upon the quantity of liquid release, the property of the materials and the

operating conditions (pressure). These when combined into matrix and vapour source strength

computed for each release case, a ranking should become a credible exercise. Plant inventory

can get discharged to environment due to loss of containment.

From the preliminary risk assessment study carried out for each participating unit, some of the

possible hazards have been identified. The likely accident scenarios considered are given in

Table 6.2:

Table 6.2 : Likely Accident Scenario

S. No. Scenario Vulnerability Zone

Remarks

1. Rupture in NG

line

Area close to

leak / release

Isolate the line / area; Cool / drench / dilute

the source point to prevent ignition.

2. Hole in Naphtha

line / tank

Area adjoining

leak / tank farm

Isolate the line / area; Cover the spillage with

foam / reclaim if possible to prevent ignition.

3. Ammonia line

leakage and

spillage

Surrounding

Area

Isolate the line / area. Approach with gas

mask / lifeline. Dissolve in water and store

and treat the water gradually.

4 Ammonia Tank

Heavy Leakage

Surrounding

Area

Try to reclaim Ammonia in other Tank/

Approach with gas mask / lifeline. Dissolve in

water and store and treat the water gradually.

5. Chlorine Tonner

Leakage

Surrounding

Area

Isolate the line / area. Approach with gas

mask / lifeline. Cover the cylinder with hood;

take a vent line from hood to caustic

scrubber.

The above mentioned hazards scenarios can further aggravate into much more serious incidents

if not intercepted in time. The fire in one tank of tank farm can spread to adjoining tanks and may

result in explosions. The vulnerability zone will be considerably enlarged. The vapours of toxic

fluids/dust if carried away by wind above TLV concentrations may further enlarge the vulnerability



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zone. Similarly, toxic fluid spillage and all wastes leaving the live processing zone if not

decontaminated properly can cause serious health hazard to plant personnel and persons in

nearby area.

6.6. Methodology, Approach and Damage Criteria for Risk Assessment

Consequence analysis is that part of risk analysis, which considers individual failure cases, and

the damage caused by the failure cases. It is done to predict the outcome of potentially serious

hazardous accidents to man and material in and around the plant boundary limits. The

advantages of carrying out consequence analysis are given below:

To improve plant layout

To meet statutory requirements

Protection of public in the nearby areas

Disaster management planning

Training tool

The findings of a consequence analysis provide information about hazardous effects resulting

from an accidental scenario. In addition, methods for dealing with possible catastrophic events

are also provided.

6.6.1. Damage Criteria

In order to understand the damages produced by various scenarios, it is appropriate to discuss

the physiological/physical effects of thermal radiation intensities. The thermal radiation due to

tank fire usually results in burn on the human body. Furthermore, inanimate objects like

equipment, piping, cables, etc. may also be affected and also need to be evaluated for damages.

Table 6.3 and Table 6.4, respectively give tolerable intensities of various objects and desirable

escape time for thermal radiation.

Table 6.3 : Effects due to Incident Radiation Intensity

Incident Radiation kW/m2

Damage Type

0.7 Equivalent to Solar Radiation 1.6 No discomfort on long duration

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn are likely).

9.5 Pain threshold reached after 8 sec. Second degree burn after 20 sec.



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Incident Radiation kW/m2

Damage Type

12.5 Minimum energy required for piloted ignition of wood, melting of plastic tubing etc.

Table 6.4 : Thermal Radiation Impact to Human

Exposure Duration

Radiation Energy {1% lethality;

kW/m2}

Radiation Energy for 2nd degree burns; kW/m2

Radiation Energy for 1st degree burns; kW/m2

10 sec 21.2 16 12.5 30 9.3 7.0 4.0

6.6.2. Selected Failure Cases

Few accidental scenarios have been considered and subjected to consequence analysis /

damage zone.

6.6.2.1 Rupture in NG Line

NG consisting of 98 % methane is the main raw material (Balance higher hydro carbons and

other gases) and is used to generate hydrogen to fix atmospheric nitrogen as ammonia. Any

leakage in the pipe line {through flange joint / valve/ instrumentation fittings/ welding failure}

would result in hazardous situation. NG will be released at pressure (+ 30 kg/cm2) and also at

high temperature (depending upon the leakage point in the process).

Ambient Temperature : 350 C

Leak source size : ~ 50 mm

Burning Rate : 577 kg / min.

Incident : Flash fire



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Figure 6.1 :Rupture in NG Line

Threat Zone: Threat is modelled for the thermal radiation from jet fire. The threat zones identified

are as follows:

Red : 14 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange : 19 meters --- (5.0 kW/ (sq m) = 2nd degree burns within 60 sec)

Yellow : 30 meters --- (2.0 kW/ (sq. m) = pain within 60 sec)

6.6.2.2 Hole in Naphtha Line/ Tank

Naphtha is used only in case NG shortage from GAIL. The two large and one small day naphtha

storage tanks and transfer lines are the likely sources of leakages. The leaked naphtha will form a

pool and in case of the naphtha catching fire, the radiation intensity / thermal load on the

adjoining area / material has been assessed as below.

Ambient Temperature : 30C Leaked Naphtha Pool Diameter : 20 m Intensity of Radiation : 71.6 kW / m2



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Thermal Load kW/m2

Distance from edge of the pool (m)

Remarks

25.8 1

17.0 4

9.0 10

4.0 21 1st degree burn

2.0 31

1.1 40

6.6.2.3 Failure of Ammonia Line

Liquid ammonia is the main raw material for urea plant. In addition to process hold up in ammonia

and urea plant, there is one large ammonia atmospheric storage tank of capacity- 5,000 mt.

Ammonia has got odour and any leakage can be immediately noticed and calls for an action

taken.

Ambient Temperature : 35C Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3 Source Strength:

o Puddle Diameter : 20 m o Puddle Volume : 100 m3 o Total Amount Released : 10,531 kg o Release Duration : 60 min

Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:

Red: 1.1 km --- (300 ppm = IDLH) Orange: 1.6 km --- (150 ppm = ERPG – 2) Yellow: 4.4 km --- (25 ppm = ERPG – 1)



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Figure 6.2 Failure in Ammonia Line

6.6.2.4 Ammonia Tank Failure

Heavy Ammonia Leakage – Puddle Volume 4000 m3. Ammonia evaporates and spreads all

around. Try to reclaim Ammonia to other tank. Ammonia has got odour and any leakage can be

immediately noticed and calls for an action taken.

Ambient Temperature :15C Stability Class- “F” Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3 Source Strength:

o Puddle Volume : 4000 m3 Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:

Red : 1.3 kilometers --- (1100 ppm = AEGL-3 (60 min))

Orange: 3.1 kilometers --- (300 ppm = IDLH)

Yellow: 4.9 kilometers --- (160 ppm = AEGL-2 (60 min))



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Figure 6.3 Ammonia Tank Heavy Leakage Stability Class “F”

Ambient Temperature :35C Stability Class- “D” Ammonia IDLH : 300 ppm STEL Value : 30 ppm or 24.3 mg/m3 Source Strength:

o Puddle Volume : 4000 m3 Threat Zone: Threat is modelled as Gaussian Model. The threat zones identified are as follows:

Red : 440 meters --- (1100 ppm = AEGL-3 (60 min))

Orange: 939 meters --- (300 ppm = IDLH)

Yellow: 1.4 kilometers --- (160 ppm = AEGL-2 (60 min))



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Figure 6.4 Ammonia Tank Heavy Leakage Stability Class “D”

6.6.2.5 Chlorine Cylinder Leakage

Chlorine is used as biocides in cooling water system and water purification Chlorine is highly toxic (IDLH – 10 ppm). Any leakages in the system will cause toxic release which will spread in down wind direction. The dispersion due to I cm (dia) leakages are considered for modelling as below:

Ambient Temperature : 35C Chlorine IDLH Value : 10 ppm Source Strength : ~ 2 kg/ min Release Duration : 60 min

Threat Zone: Threat is modelled with heavy gas model. The threat zones identified are as follows:

Red : 157 m --- (20 ppm = AEGL*-3 (60 min)3 Orange : 226 m --- (10 ppm = IDLH) Yellow : 526 m --- (2 ppm = AEGL-2 (60 min))

3AEGL – Acute Exposure Guideline Level



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Figure 6.5 Chlorine Cylinder Leakage

6.7. General Control Measures

Since some of the substances in use at KSFL are hazardous with severe fire and explosion potential and also toxic in nature, it is necessary to use appropriate control measures recommended for such substances:

6.7.1. Flammable Gas Fires

Fire control generally consists of directing, diluting and dispersing the inflammable gas/vapour to prevent contact with persons, to prevent it from infiltrating structures if the leak is out door, and to avoid its contact with ignition sources while, if possible, simultaneously stopping the flow of gas. NG is lighter than air it will go up in the atmosphere once its momentum due to pressure gets dissipated. Gas direction, dilution and dispersion require the use of a carrier fluid, and air, water and steam have proven to be practical carriers. Water in the form of spray, applied from hoses or



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monitor nozzles or by fixed water spray system may act as a good carrier fluid for inflammable vapours/gases.

6.7.2. Protection against BLEVE

A basic BLEVE safeguard is to reduce the chance of the thermal (fire) exposure to the container. During a fire exposure the application of water is a basic safeguard to prevent a BLEVE or a compressed gas container failure. Automatic sprinkler protection can greatly limit pressure rise from heat and high metal temperatures from fire exposures.

All pressure vessels and tanks should be periodically inspected for leakage from vessels and its appurtenances. Gas detection instruments/ acoustic gas leak detectors are invaluable help in detecting the leakages.

Over pressure protection devices, namely, relief valves, rupture discs, alarms, etc. are to be regularly checked and calibrated if required.

6.7.3. Commonly Recommended Control Measures

A number of preventive control measures for hazardous occurrences have been analysed and discussed above. Some more salient points are enumerated below:

All storage tanks in the tank farm should be dyked and those storing volatile material may be provided with non-combustible insulation within aluminium’s protection jacket. The tanks should have water deluge system.

Ammonia has got odour. Always look for wind direction while moving in ammonia prone area. Move / approach across or up wind direction. Ammonia is highly soluble in water. A wet handkerchief / cloth are helpful in such a case. While planning a job in such area keep breathing apparatus / gas mask/ water hose ready for emergency.

Concentration detectors for hazardous chemical vapours fire Smoke / heat detectors and fire alarm should be installed at all strategic locations in the plant.

A schedule for preventive maintenance including health survey of all plant equipment should be adhered to as far as possible.

Ensure the absence of ignition sources in Naphtha / HSD / Ammonia storage area. Ensure placement of fire fighting facilities, such as, carbon dioxide, dry chemical powder

and foam type fire extinguishers in addition to fire hydrant system, at strategic locations. Spill control measures, such as, removal of all ignition sources from the spill area and ventilating the area as well as soaking the spilled material with paper, towel or mud and letting the volatile substance evaporate slowly in a safe area.

Compulsory use of protective clothing, non-sparking tools and warning signs during critical operations and maintenance.

Training / refresher courses on safety information’s / norms. Eyewash and showers should be put up at strategic places for use during emergencies.

A group of plant personnel should be trained in first aid, rescue, fire fighting and emergency control measures. These personnel will form core group/emergency squad who will fight the emergency and also act as rescue and first aid team.

In order to ensure communication from isolated places/locations Walkie-Talkie be made available to persons working in these areas. This will considerably improve the effectiveness of emergency management.



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There is no substitute for training-mock drills and these must be held at regular interval keeping the following objectives in mind:

Real time mock-drill should be carried out for probable/likely hazardous situation. Target to be set up for various tasks and events during an emergency. Weak links should be marked and corrective action taken to improve effectiveness during

emergency. KSFL has already implemented many of the measures.



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CHAPTER 7. ON SITE EMERGENCY PLAN

7.1. Introduction

Kribhco Shyam Fertiliser Limited (KSFL) fertilizer plant at Shahajahanpur was commissioned in November, 1995. Subsequently a number of safety studies including Risk Analysis, Safety audits etc. have been carried out by various consultants. In addition KSFL also has an ‘On Site

Emergency Management Plan’ and have submitted the same to Director of Factories. KSFL

carries “mock drills” on a regular basis and observations are recorded & corrective actions are

taken immediately.

Admittedly, the best way of managing an emergency situation lies in its prevention. This is sought to be achieved by good engineering design and construction, use of latest technology and sophisticated equipment, reliable safety systems, careful personnel selection and training. Adequate knowledge of dangers and appropriate safety training ensures that all hazardous situations will be handled without any panic and controlled by rational actions. This is supplemented with repeated practices through real time exercises (mock drills) and noting the weak spots and taking needful corrective actions. Nevertheless, it is recognized that despite our best efforts, things can go wrong. Therefore, it is essential to plan and develop the support system, required in case an emergency arises.

7.2. Probable Hazards & Risk

Fertiliser plants have a number of unit processes and unit operations involving hazardous chemicals, consequently there are possibilities various incidents or accidents both minor and major. From the preliminary risk assessment study presented in Chapter 6 of this report, some of the possible major hazards have been identified. The most likely accident scenario identified is given below:

Table 7.1 : Probable Hazards

Sl. No. Scenario Vulnerability Zone Remarks 1. Rupture in NG

line Area close to leak / release

Isolate the line / area; Cool / drench / dilute the source point to prevent ignition.

2. Hole in Naphtha line / tank

Area adjoining leak / tank farm

Isolate the line / area; Cover the spillage with foam / reclaim if possible to prevent ignition.

3. Ammonia line leakage and spillage

Surrounding Area Isolate the line / area. Approach with gas mask / lifeline. Reclaim if possible or dissolve in water and store and treat the water gradually.

4. Chlorine Tonner Leakage

Surrounding Area Isolate the line / area. Approach with gas mask / lifeline. Cover the cylinder with hood; take a vent line from hood to caustic scrubber.

Above mentioned hazard scenario can further aggravate into a much more serious incident if not attended in time. The fire in one of the tank of tank farm can spread to adjoining tanks and may result in explosion. The vulnerability zone will be considerably enlarged. The vapours of



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inflammable fluids if carried away by wind above LEL concentrations may further enlarge the vulnerability zone.

7.2.2. Objectives

The Emergency Management Plan is developed to make the best possible use of the resources available at KSFL and the nearby agencies to provide help/assistance in case of an emergency in the plant. The activities will include:

Identify and assess the emergency and its potential. Categorize the emergency as per laid down procedure.

Try to control and confine the emergency (prevent it from spreading). Rescue the victims and give them the necessary medical attention in the shortest

possible time. Safeguard other person (evacuate them to a safer place). Contain the incident and control it with minimum damage to human and life and property. Provide necessary information to families/relatives of affected persons, outside agencies

including media and statutory bodies.

7.2.3. Assessing the Emergency / Emergency Control Centre

Levels of Emergency can be classified in three categories:

Level – 1 (L1): The leakage of hazardous gas or spillage, or fire or explosion of a minor nature that can be contained within the plant premises. L1-Emergency may be due to:

o Small spot fire in the plant. o Low level Toxic gas release for short duration. o Collapse of small equipment.

Level – 2 (L2): The moderate leakage of hazardous gas / flammable liquid / fire / explosion which is confinable within the factory premises. L2 - Emergency may be due to:

o Fire in the flammable liquid. o Medium scale explosion. o Heavy leakage of toxic gas for short duration.

Level – 3 (L3): Likely hood of cloud formation of a Toxic and / or Flammable gases and drifting of such cloud affecting the general public. L3-Emergency may be due to:

o Explosion in the vessel / pipe line containing Toxic / Flammable material. o Heavy leakage of Toxic / flammable / material for a long duration from pipe line

or storage tanks. The emergencies are handled / resources are deployed, external assistance is called as per the ‘level’ of emergency defined.

L1 - EMERGENCY: May be handled with the resources available within the section of the plant.

L2 –EMERGENCY: On-Site Emergency plan shall be activated. L3 –EMERGENCY: Inform immediately to the local and District Administration. Action to

be taken to activate the Off-Site Emergency Plan with the help of District authorities and local administration.

7.2.4. Emergency Siren

KSFL have two type of Siren one is emergency type wailing sound (15 – 5) for three minutes and other is All Clear continuous Siren for 1 minute.



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Every individual in the plant shall always be on lookout for any abnormal situation or observation. As soon as any such happening is noticed he should immediately notify Shift-In-Charge / Fire (in case of fire or likely fire). Specific type of emergency siren will be activated as per the situation / emergency.

7.2.4.1 On Hearing Emergency Siren

Non-essential personnel (other than production & maintenance employees of KSFL) shall follow safe route for evacuation.

Key personnel shall report to respective control room or emergency control room.

7.2.5. Escape Route and Assembly Points

Every individual inside the plant on hearing the emergency siren will contact the shift in charge and inform him and wait for his instruction. Non plant personnel on getting instruction will proceed towards assembly points. Plant areas have been divided in four zones as the nature of hazards. There are ten locations marked as assembly points (Annexure IX of KSFL’s DMP) and two

escape routes (as per wind direction).

7.3. Emergency Management Plan

Sr. Vice President (Works) may appoint any executive as the Main Emergency Controller (MEC) and he shall be the main guiding person directing the emergency operations. He shall be assisted by a number of executives.

The organizational set-up necessary for chain of commands during emergency situation is shown / briefly described below

7.3.1. KSFL’s Internal Emergency Communication Network

Accidents /emergencies do not give second chance. Even a small incident if ignored or taken lightly can develop in major one. Emergencies are to be dealt as team efforts with all resources. Communication is an important component / strength of team. KSFL has got a very well developed communication network.

7.3.2. Main Emergency Controller (MEC)

The MEC shall have overall responsibility for directing operations and calling outside help. The emergency control centre will be the main operation area.

A group of Sr. personnel shall assist MEC. They will report to MEC as soon as emergency (L2 or L3) is declared.

Look for wind direction & appropriate assembly point in case of gas leakage



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Figure 7.1 : KSFL’s Internal Emergency Communication Network

7.3.3. Some of the key functions of MEC are:

Ensure that Key-Personnel are called-in - All HOD's and medical officer. Direct all Emergency Operations within the approved area with the following priorities:

o Personnel Safety. o Plant, Property and Environment Safety. o Minimum loss of production.

Continuously review & assess possible developments to determine most probable cause of events.

Direct the safe shut down of plants in consultation with the Incident Controller and Key-Personnel if necessary.

MEC- Sr. V.P

(W). (WORKS)

ALTERNATE

CONTROLLER J.

G.M.

SERVICE S

COORDINATOR HEAD

(P&IR)

INCIDENT

CONTROLLER HEAD

(PROD.)

MAINTENANCE

COORDINATOR

HEAD (MAINT.)

MATERIAL

COORDINATOR

ENV. & QUALITY

COORDINATOR

HEADS (E & QC.)

HEAD

(SECURITY)

HEAD

(AMMONIA)

HEAD (ELECT) HEAD

(STORES)

HEAD

(PERSNL)

HEAD

(MEDICAL

HEAD

(ADMIN)

HEAD

(I.R.)

HEAD

(OFFSITES)

HEAD

(UREA)

HEAD

(BAGGING)

HEAD (INSTR)

HEAD

(CIVIIL)

HEAD

(MECH)

HEAD

(F&S)



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Check that all non-essential workers, visitors and contractors are evacuated to assembly points and shifted to safe place / shelter if required.

Give instructions to the Fire Fighting and rescue team and call second line of defence personnel.

If necessary arrange for evacuation and rescue of the neighbouring population. Ensure that search for casualties within the affected area has been carried out & arrange

for hospitalization of victims and additional help if required like shelter, catering etc. Ensure that Manager (Admn.) liaise with out-side agencies such as Police, District

Emergency Authorities, DM, ADM and Director of Factories / Dy. Director of Factories / Asstt. Director of Factories. Provide advice on possible effects to the areas out-side the factory.

Arrange for up-to-date recording of Emergencies. Do not restart the plant unless it is declared safe to start by competent authority. Give clear instructions to assisting staff to do the particular job. Ensure compliance of Checklist of MEC. (given in the end)

7.3.4. Role of Head – Production

In case of emergency in plant, the primary duty of Head – Production is to reach at the site as early as possible. His other responsibilities are as under:

He will direct and assist the Incident controller to take decision of stopping the Plant production / activities.

He will direct the manager of unaffected plant to take action to control the process parameter as per requirement of affected plant.

Remain in direct contact with MEC. Co-ordinate with Head Maintenance in decision making and ask for specific equipment

for maintenance / salvage. Arrange to ensure the evacuation process. Arrange to ensure the preservation of facts and clues for incident. Arrange for start-up of plant after consultation of MEC. Ensure the compliance of Departmental On – Site Emergency Plan

The departments shall need to follow the respective Department Emergency Plan in case of emergency

7.3.5. Role of Incident Controller [Manager / Plant In charge / Asst. Manager of Affected Plant]

Incident Controller’s (Head of affected plant) “Primary Duty” is to take charge of the scene of Incident. His other responsibilities / duties are as under:

By taking into the wide network of process units in SPN site the incident controllers of various units are identified to control the situation.

Incident Controllers of various areas are:-

Ammonia Storage, Chlorine and Naphtha Storage - HOD off-site Ammonia Plant - HOD Ammonia Urea Plant - HOD Urea Bagging Plant - HOD Bagging



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In any emergency Head (Prod) (main controller), Head (M)(Alternate controller), Head (P&A),Head (E), Head (E & QC), Head (Inst), Head (TS), Head(Civil) shall immediately move towards emergency control centre on hearing the emergency siren and report to Main Emergency controller. Head of plant O/S, Ammonia Urea, and Bagging shall move towards their respective plant.

HOD of Fire & Safety shall move towards incident site immediately.

Responsibilities of Incident controller

Following priorities are to be remembered while directing all operations.

Safety of the personnel. Minimum damage to plant, property and environment. Minimum loss of material. Advice fire fighting, rescue and other emergency services. Direct the search of casualties. Evacuate non-essential workers to assembly points. Brief, Main emergency controller about the developments. Preserve evidence for subsequent inquiry into the cause of emergency. Direct evacuation of the plant and areas likely to be affected by the emergency. Takes technical decision to control the incident and decides to continue or stop the

process plant. Ensures that the Main Emergency controller is informed.

Role of Incident Controller.

On reaching the site, he will take charge from the first responder and assess the gravity of the situation and do the following:

Declaration of major Emergency & inform F&S control room to activate the emergency Siren.

Direct the emergency control activities in consultation with the Main Emergency controller and safe shutdown of plant as the situation demands under intimation to Main emergency controller.

7.3.6. Direct emergency activities as mentioned in responsibilities mentioned in above. Role of Deputy Incident Controller (Asst. Manager / Shift Engineer)

7.3.6.1 Shift Engineer

Dy. Incident Controller (Shift Engr. In charge) is available in each of the respective plant. Dy. Incident Controller will assist the Incident Controller in handling the emergency.

In absence or till arrival of incident controller he will take the charge of incident controller and work as incident controller.

Help in plant shut down (if required) and evacuation of non-essential workers. Direct non-essential workers to take a safe route to the assembly points. Arrange to call for essential staff. Call the fire brigade. Call the security to control the traffic. Arrange to send the affected persons to the hospital.



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Up to date information to MEC.

7.3.6.2 Plant Operator (Affected Plant)

Try to control the emergency in safe manner using appropriate PPE. Inform shift Engineer about the emergency situation and follow the instruction given by

shift engineer. Assist in evacuation of non-essential workers. First - Aid and medical help to the affected person

7.3.7. Role of Manager / Plant In Charge / Asst. Manager (Other than Affected Plant)

All other plants personnel (other than the affected plant) are to safeguard their plant, assist the affected plant (through release of second line of defence personnel who are on duty) as per MEC instructions. Specific roles of personnel are briefly given below:

7.3.7.1 Manager

Take action to control the process parameters as per the requirement of affected plant. Remain in direct contact with Main Emergency Controller. Arrange to release second line of defence team members who are on duty.

7.3.7.2 Asstt. Manager

Inform the plant Manager about the incident and work as per instruction till his arrival. Put all field operators on alert. Take action to control the plant parameters.

7.3.7.3 Operator of Respective Plant

Inform shift Engineer about the incident. Stop all maintenance jobs. Work under the direction of the Shift Engineer. Direct all non-essential workers to take a safe route to assembly points.

7.3.8. Role of Manager / Asst. Manager (Fire & safety)

Some important roles / duties of fire and safety manager / Asst. Manager are as follows:

On receipt of information from the Shift In charge of the affected plant

Deputes one person to main Control room. Immediately reach the scene of incident with fire tender and crew. Position the fire tender depending on the wind direction. Reports to the shift in charge (first responder/ Incident controller) decide & start the

course of action to extinguish the fire or assist in controlling the gas leak. 7.3.8.1 Control Room (Fire Station)

Inform Head (F&S) and other officers (F&S). Ensures that the pressure in the fire hydrant system is maintained. Attend the telephone. Keep the fire station store open and ensure supplies to the incident site. On receipt of the information from incident controller, activate the “EMERGENCY SIREN”.



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7.3.8.2 Head (F&S)/ Officers (F&S)

On arrival head (F&S)/ Officers (F&S) at site, assume the charge of firefighting activities. On assessing the severity of the incident , report to the Main Controller. Inform to Main controller about the additional requirement of the fire tenders,

Extinguishing media, firefighting equipment’s and reinforcement. Organize the rescue activities. Coordinate with city fire service at incident site. If situation warrants advise the main controller to Evacuation of plant personnel.

7.3.8.3 Fire Crew Members

On hearing Fire alarm/Emergency siren they shall immediately proceed to the scene of emergency and work as per the direction of Shift-in-charge.

7.3.9. Role of Head (E& QC)

The duties and responsibilities of Head E & QC are briefly described below:

7.3.9.1 Head E & QC / Asstt. Manager-E & QC

Rush to the Emergency Control Centre and report to the Main Controller. Arrange complete laboratory staff and ensure availability of equipment’s

for sampling/analysis. Keep in touch with incident controller for taking samples. Keep in touch with services coordinator for taking samples and analysis

outside the factory area. Take samples at least in the range of 1-2 km in the wind direction to

evaluate concentration of toxic gases. If required, contact officials of U.P.P.C.B

7.3.9.2 Lab Analyst

Work under the guidance of Head (E& QC) / Asstt. Manager –E & QC

7.3.10. Role of Medical Department (Sr. MO / MO / Other medical Staff)

After receiving the information about the emergency he will immediately contact main controller and compounders in first aid center.

He will render necessary treatment at First Aid center and township hospital. He will arrange hospitalization and treatment at outside hospitals if required. He will mobilize extra medical assistances from outside, if necessary

7.3.11. RESPONSIBILITIES OF MAINTENANCE COORDINATORS – HEADS OF MAINTENANCE

The maintenance head shall reach Emergency Control Centre. They will take instructions from Main Controller and shall arrange the following as per requirement in their respective field:

Mobilize maintenance staff for arranging necessary equipment’s like crane, hydra, forklift, welding and cutting sets etc.



Shahjahanpur, U.P


Ensure arrangement of extra lighting, electrical isolation of the affected areas, if required. Make sufficient nos. of contractors, workers available to do civil jobs like filling sand bags,

making bunds, closing drains, excavation work as required for emergency. Keep workshop facilities open with necessary personnel.

7.3.12. Keep in constant touch with Main Controller for any assistance to him. Role of Head (Administration)

Head (Administration) and his team will provide all support related to transportation and other logistics. Some of the duties are as given below: Proceed immediately to the Emergency Control Centre and act as per the directions of the Main Controller.

Also work as a liaison officer during the emergency. Ensure that casualties receive adequate and immediate attention. Inform the relatives of

casualties, if necessary. Control traffic into the premises; ensure availability of alternate transport and free access

for temporary casualties. Arrange for canteen services for personnel on duty as well as in affected areas. Arrange security personnel to cordon off the affected area and helping fire & safety

personnel in fire and rescue operations. Arrange to close the school and shift the children and staff to the safest place, if required. Arrange the cash required for handling critical situations during the emergency. Co-ordinate to avail services from external agencies like police, fire brigade, hospitals

etc., if called for, following the declaration of emergency. Liaison with fire and police officials, safety officials, pollution control boards and other

statutory bodies. If required, issue authorized statement of press release to the media. If required, arrange for evacuation of adjoining areas and villages.

7.3.13. Role of Head Security / Security Officer / Asst. Security Officer

Security is one of the key parts of the organization at all times i.e. before, during and after the emergency. However it is all the more important and sensitive part during emergencies.

7.3.13.1 Head Security

Informs the location of fire/gas leak to the essential staff coming to the Plant. Deputes Security guards for manning the scene of fire/gas leak. Cordon off the area and control the public rushing to the incident site. Control unauthorized entry at the factory main gate. Mobilizes Additional security force for help. Directs the Ambulance and emergency service vehicles to the scene of incident by taking

wind direction into consideration. Operate P.A, system for alerting the employees/casual workers in the factory for safe

evacuation. Assists in shifting of the casualties’ to First aid post/Hospital.

7.3.13.2 Security Guards

Coordinates with Incident Controller and assists in searching for missing persons. Security Guards

On hearing the Emergency Siren, contact Security Officer and work under his directions.



Shahjahanpur, U.P


7.3.14. Role of Manager / Asst. Manager (HR)

Manager (HR) and his team will provide all support related to liason and other logistics. Some of the duties are as given below:

7.3.14.1 Role of Manager - HR / Asstt. Manager (HR)

He will report immediately to Main Emergency Controller. Coordinate to inform relatives of affected persons. Arrange for round the clock persons at the Hospitals to look after the need of the affected

personnel. Prepare record of affected personnel with local and permanent address. Arrange for tea, coffee, milk / snacks / food as required. Inform Director of Factories / Dy. Director of Factories / Asstt Director of Factories about

the incident. Remain in contact with MEC

7.3.14.2 Manning Assembly Points

He will be the overall in charge of Assembly Point No. 1, 2, 3 & 4. Depute one person at each of assembly points to record all personnel arriving there &

pass information to the Main Emergency Controller. Arrange to record the names and Departments of persons assembled there and transfer

them to other places / shelters as instructed by the Main Emergency Controller. Ensure the availability of oxygen and emergency medicine in sufficient quantity in the

hospital.

7.3.15. Role of Bagging

Product Packaging Plant's Control Room is an alternate Emergency Control Centre. It may require establishing if wind direction affects the emergency control centre at the safety office. Manager and Asstt. Manager shall keep their all resources ready to provide assistance to affected plant and other departments as directed by MEC. Some of their functions are:

Leave all labour to assemble at assembly point no. - 4, if wind direction is appropriate. Stop loading / bagging operation. Report immediately to MEC. Request MEC if any help required.

7.3.16. Role of Head (Materials)

Head (materials) and his team will provide all support related to material replenishment or arranging new materials and other logistics. Some of the duties are as given below:

7.3.16.1 Role of Head/ Dy. Manager/ Asstt. Manager (Materials)

Arrange additional man-power for handling store items etc., if required. Arrange to issue items / equipment required during emergency. Take immediate action of emergency procurements & arrange additional manpower for

local purchases etc., if required. Co-ordinate with Manager (Accounts) for financial requirements. Instruct all non-essential personnel to assemble at assembly points. Contract MEC for any help required.

7.4. Post Emergency Recovery



Shahjahanpur, U.P


The post-emergency procedures discussed briefly below are designed to successfully manage the damage / losses of an emergency event. The focus of these procedures is to move the plant back into normal operating mode as quickly and efficiently as possible.

Immediately after the “ALL CLEAR” an emergency meeting will be held in emergency control

centre to assess the loss both for men& materials, where in MEC, all managers and other executives will be present with attendance records, details of injured, outside situation and preparation of press release (if felt necessary)

7.4.1. Accident Investigation

a. As soon as possible after the emergency is over and plant operation has become normal, the investigation and analysis is to be carried out to determine the cause of the event.

b. Representatives from various disciplines will be members of the investigation and analysis team.

c. The areas of the events are to be sealed off so that tempering or alterations of the physical evidence are not likely to occur.

d. Key components are to be photographed and logged with time, place, direction etc.

e. Statements are to be taken from those who were involved with the operation or who witnessed the event.

7.4.2. Damage Assessment

This phase of recovery establishes the quantum of replacement machinery considered necessary for bringing back plant to normal operation; property and personnel losses accounted and culminates in a list of necessary repair, replacement and construction work.

Insurance companies will be informed of the damage and requested to pay the compensation as per claim.

7.4.3. Clean-up and Restoration

This phase will only begin once the investigation is complete. Reporting documentations are to be prepared and forwarded to appropriate authorities. Repair, clean up and restoration work to begin.

7.5. Enclosures

7.5.1. ‘MEC’s Check List

Is means of communication provided to you - walkie - talkie / phone and working satisfactorily?

Have the group paging done to inform the key personnel? Are assistants to MEC arrived? Do you want to call more no. of assistant?



Shahjahanpur, U.P


Are you getting message from incident site as well as from fire station? Have you got the message of Level of Emergency? Have you given clear instruction (fire / gas release) to fire station to blow the siren? Have off - duty fire crew been called? Have they blown the siren? Have you received environmental details - wind direction, speed? Do you have informed the affected assembly points - not to assemble as per prevailing

wind direction? Have key personnel arrived? Has second line of defence team reported? Have medical staffs reached at site? Have first aider reported to MEC? Has incident controller reported you about the root cause of incident? Have you assessed the situation and risk due to this incident? Have you given clear instruction for taking emergency steps to control the emergency? Is plant shut down necessary? Have you informed to railway authority of Shahajahanpur. Do want external help from nearby industries (if any). Have you ensured that HR Dept. communicated with local Govt. Official - SDM / CO -

Police / SHO? Have you received message from assembly points? Have you evaluated the requirement of transport? Is evacuation in township / villages’ necessary? In case of L3. Have non- - essential personnel / vendor / supplier been shifted to safe place? Have you instructed fire station to blow the all clear siren? Have you visited the site? Have you arranged emergency meeting to find out the root cause? Have you reviewed the methods / measures taken to handle the emergency?

7.5.2. PPE Availability& Location

Location

PPE

CCR Ammonia

Plant Urea 11

Urea 21

P.T. Lift

Amm. Storage/

ETP

CT/ DMP

Bagging Plant

Control Room

ECC Fire

Tender Fire

Station

B. A. Set (45 min)

2 2 1 1 2 1 1 - 2 4 12

B. A. Set (30 min)

- - - - - - - - - 2

B. A. Set (15 min)

Airline Respirator

- - - - - - - - - - 10

Airline Trolley

1 - 1 - - - - - -

Amm. Canister

- - 2 - 7



Shahjahanpur, U.P


Location

PPE

CCR Ammonia

Plant Urea 11

Urea 21

P.T. Lift

Amm. Storage/

ETP

CT/ DMP

Bagging Plant

Control Room

ECC Fire

Tender Fire

Station

Mask CO Canister

- - - - - - - - - -

Chlorine Canister

- - - - - - - - 5

Fire Entry Suit

- - - - - - - - - - 2

Gas Tight Suit

- - - - - - - - - - 6

Fire Proximity Suit

- - - - - - - - - - 4

AFFF - - - - - - - - -

3000 Ltrs.

180 Ltrs.

Rescue Tools

- - - - - - - - - - 1 Set

Chlorine Handling Kit

- - - - - - - - - - 2 Sets

HAZMAT Compound

-

- - - - - - - - -

7.5.3. Important Telephone Numbers (External)

IMPORTANT EXTERNAL AGENCIES/ OFFICERS

S.N. OFFICERS/AGENCY PHONE NO OFFICE

PHONENO RESIDENCE

MOBILE NUMBER

1 DISTRICT MAGISTRATE 222540 222221 9454417527

2 SUPRINTENDENT OF POLICE SHAHJAHANPUR

222553 222415 9454400306

3

ADDITIONAL SUPRINTENDENT OF POLICE (RURAL AREA) ADDL.S.P. (R.A.)

222553 223159 9454401114

4 SUB DIVISIONAL MAGISTRATE [SADAR]

222582 223094 9454415878



Shahjahanpur, U.P


IMPORTANT EXTERNAL AGENCIES/ OFFICERS

S.N. OFFICERS/AGENCY PHONE NO OFFICE

PHONENO RESIDENCE

MOBILE NUMBER

5 CHIEF MEDICAL OFFICER 222273 222587 9648935888

6 CIRCLE OFFICER (CITY) POLICE

223109 225862 9454401336

7 DISTT. CONTROL ROOM [POLICE LINES]

223133 -----

8 CITY CONTROL ROOM [SADAR] POLICE

223164/100 -----

9 DISTRICT FIRE OFFICER / STATION

223690/101 ----- 9412657983

10 U.P.POLLUTION CONTROL BOARD BAREILLY [Regional Office]

2585299 ----- 9415805240

11 U.P.POLLUTION CONTROL BOARD LUCKNOW [Head Office]

2720681 -----

12 MINISTRY OF ENVIRONMENT & FORESTS, Regional Office -Lucknow

2763147/ 2763248

-----

13 CITY MAGISTRATE 222582 222178 9454415888

14 CIRCLE OFFICER (SADAR) POLICE

223109 223277 9454401337



Shahjahanpur, U.P


CHAPTER 8. DISCLOSURE OF CONSULTANTS Declaration by Experts Contributing to this Report

Declaration by Experts Contributing to the Environmental impact assessment and Risk assessment for Expansion of Ammonia 2200 MTPD & Urea 3850 MTPD at village & Post Piprola, Shahjahanpur Industrial Area, District Shahjahanpur, Uttar Pradesh

I, hereby, certify that I was a part of the EIA team in the following capacity that developed the above EIA.

EIA Coordinator

Name: Prabhat Kumar Srivastava

Signature & Date:

Period of involvement ….. 2014 to finalization of report

Contact Information: 011-30003200

Functional Area Experts

Functional Areas Name of the Expert Involvement

(Period and Task**) Signature

Air Pollution

Monitoring & Control

(AP)

S K Jain

Astha Bishnoi (Team

Member)

Site visit, assistance in

selection of monitoring

locations, checking air

quality data, evaluation of

results of Ambient Air

Quality Monitoring

(AAQM)

Air Quality Modeling

and Prediction (AQ)

Sanjeev Sharma

Rajni Oshan (Team

Member)

Assistance in air quality

modeling and prediction:

met file generation and

model run

Landuse (LU) Anil kumar

Development of land use

maps of study area using

GIS / related tools, site

visit for ground truth

survey, finalization of

land use maps

Noise (NV) Sanjeev Sharma Assistance in selection of

monitoring locations,



Shahjahanpur, U.P


Functional Areas Name of the Expert Involvement

(Period and Task**) Signature

checking noise data,

evaluation of results

Water Pollution (WP)

S K Jain

Astha Bishnoi (Team

Member)


selection of sampling

locations for surface

water sampling, water

balance for the project

and contribution to EIA

documentation

Ecology and Bio-

diversity

Conservation (EB)

Dr. Sunil Bhatt



locations and contribution

to EIA documentation

Solid and Hazardous

Waste Management

(SHW)

S K Jain

Identification of waste

generated from the

industry, studying

adequacy of mitigation

measures for

management of

hazardous waste

Socio-Economics (SE) Anil Kumar

Site visit, contribution to

Baseline environment and

contribution to EIA

documentation

Risk and Hazards (RH) Prabhat Kumar

Srivastava

Site visit, Identification of

modeling scenarios,

consequence modeling

using PHAST, finalization

of DMP, contribution to

RA / DMP Documentation

and contribution to EIA

documentation

Soil Conservation (SC) Manoj Sharma



locations and contribution

to EIA documentation