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ZUARI AGRO CHEMICALS

LIMITED

Executive Summary for Fertilizer Blending unit for Customized NPK Production, Gas Turbine (GT), Heat Recovery Steam Generator (HRSG), Atmospheric Ammonia Storage Tank (AAST) & Urea Granulation Unit for Fertilizers Production at Zuarinagar, Sancoale Village, Mormugao Taluka, South Goa District, GOA.

APRIL 2016

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

M/S. ZUARI AGRO CHEMICALS LTD. EC FOR FERTILIZER BLENDING UNIT, GT, HRSG,

AAST & UREA GRANULATION UNIT AT ZACL EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | APRIL 2016 1

EXECUTIVE SUMMARY

The Executive Summary provides the justification for implementation of the proposed project, enumerates the

proposed means and measures to mitigate any adverse effects on the environment. It also summarizes the

findings of the EIA (Environmental Impact Assessment) study which is structured in accordance with the

Appendix III A of EIA Notification, 2006 as amended till date.

PROJECT DESCRIPTION

Company and Project Proponent

M/s. Zuari Agro Chemicals Limited (ZACL) promoted in 1967 in Goa, by pioneering industrialist (Late) Dr.

K.K. Birla, is one of the leading fertilizer conglomerates in India. The company is also a significant importer of

fertilizers and farm nutrients. The company produces high-quality complex fertilizers of various grades along

with seeds, pesticides, micro nutrients, and specialty fertilizers. The ZACL fertilizer plant, commissioned in

1973-75, is a landmark in large-scale industry development in Goa. At the time of installation, the plant was

the largest industrial undertaking in Goa, acting as a catalyst for economic growth in the neighbouring areas.

The plant was started as a financial and technical collaboration between the House of Birla’s, US Steel

Corporation (USX), International Finance Corporation, and the Bank of America.

The entire manufacturing facility comprises of four separate plants, namely Ammonia, Urea, NPK-A and NPK-B.

All products are marketed under the "Jai Kisaan" brand. ZACL continues to nourish its core fertilizer

manufacturing operations, with extensive modernization, revamping and expansion program at its plants.

ZACL has won various prestigious National and International Awards with its state-of-the-art technology, high

quality standards and productivity and environment-conscious work force.

ZACL has been following a three pronged strategy for environment preservation viz. 3-R’s (Reduce, Recycle,

Reuse):

Reduce pollutants at source by adopting low pollution or no pollution alternatives wherever feasible;

Develop fruitful utilization for pollutants, whether solids, liquids or gaseous;

Treat balance effluents/ wastes to achieve Zero Liquid Discharge (ZLD).

The Company Leadership/Management is dedicated towards allocation of adequate resources for Continuous

Environment Protection.

Proposed Project

The Proposed Project falls under S. No. 5(a), “Chemical Fertilizers” of ‘Project or Activity - Manufacturing/

Fabrication’, in Category ‘A’ as per Schedule in EIA Notification dated September’ 14, 2006, as on date.

Brief Description of the Proposed Project

S. No. Details Description

1 Nature Chemical Fertilizer

2 Size Customized NPK Fertilizers Unit : 30 TPH

Steam Power Generation Unit: GT : 25 MW




S. No. Details Description

HRSG : Generation of Medium Pressure (MP) Steam (37 Kg/cm2g, 390 °C) – Capacity (Unfired/With Supplementary Firing)= 50/70 MT/hr

Atmospheric Ammonia Storage Tank (AAST) : 1 X 5000 MT

Urea Granulation Unit : 600 MTPD

3 Plot Area

Customized NPK Grade : 1,125 M2 GT : 1,952 M2 HRSG : 1,860 M2 AAST : 7,999 M2 Urea Granulation Unit : 1,500 M2

4 Location Plot Survey no. 110 to 252, Zuarinagar, Sancoale Village, Mormugao Taluka, South Goa District, Goa State.

5 Cost of the Project ~ INR 788.60 Crore

6 Power About 2 MW- Sourced from Captive Generation

7 Fuel About 0.17 MMSCMD & 2,000 SCMD NG / RLNG will be used in steam power generation unit and Customized NPK Fertilizers Unit respectively. The NG will be sourced from the existing GAIL NG Pipeline..

8 Water

The estimated water consumption of the overall complex will be reduced due to adoption of modernization technologies such as Machinery Drive Replacement (from Condensing Steam Turbines to Electrical Motor) and Dedicated Process Condensate Stripper Packages in the Ammonia and Urea plants. Therefore, there is no additional water requirement for the proposed project.

Raw Water requirement will be met through existing source of Water Resource Department (WRD) Supply, Govt. of Goa & existing Captive Rainwater Harvesting Storage.

9 Manpower

Direct Jobs

During its operational lifecycle of the project around 80-100 jobs will be created.

Indirect Jobs

Approx. 100-150 jobs will be indirectly created by the setting up of the project during its construction & operational lifecycle.

Process

Customized NPK Fertilizers Unit

The Customized NPK Fertilizers will be produced by bulk blending of various Raw Materials. It is the simplest,

most economical as well as a very versatile method of producing Customized NPK Fertilizer grades along with

the fortification with Micronutrients.

Based on the product grade, Raw Materials (and Micronutrients) are fed into the system through hoppers. The

feed mixture of uniform particle through means of Particle Size Reduction and Classification is feed to the

Granulator wherein Steam and Water are deployed to aid in Granulation. From the Granulator, the Material is

fed to a Rotary Dryer which is equipped with Hot Gas Generator so as to remove the Moisture from the

Granules (Drying). From the Dryer, the Granules are fed to a Rotary Cooler wherein the Material is cooled. The

Granules from here is fed to the Process Screens to remove the Oversize and Undersize particles from the

“Product-size” Granules. The Product-size Granules is fed to the Coating Drum wherein the Product is coated

with Coating Oil which improves the handling and storage properties of the Final Product. The Oversize

material is crushed and along with the fines is recycled to the Granulator. The Air Stream from the Cooler is

passed to Cyclone sand Bag Filters to remove Dust while the Air/Gaseous Streams from the Dryer and

Granulator is treated in a two stage Wet Scrubbers.




The Final Product from the Coating Drum is conveyed to product storage hoppers which supply the material to

the bagging section.

Atmospheric Ammonia Storage Tank

Liquid Ammonia received from road tankers & from Ammonia Plant will be stored in an Atmospheric Ammonia

Storage Tank having a net effective capacity to store 5,000 MT of liquid Ammonia excluding vapor space. The

outer tank is designed for full containment of vapors and liquid in the event of failure of inner tank.

The tank is equipped with two pressure relief valves to safeguard against overpressure. (Isolation valves will

be provided with suitable mechanical interlock).

The tank shall rest on elevated foundation. Tank pressure is maintained between 450-900 mm WCg and

adequate alarms and interlocks are provided to safeguard the tank against pressure excursions on either side

of the operating range.

Refrigeration System

Liquid Ammonia, at a maximum rate of 90 MT/hr, is received from the tanker unloading line through a 8” line

and at a rate of 45 MT/hr through 6” line from existing Ammonia plant line with suitable tapping taken at

Battery limit (B/L) near the tank. Vapors from flashing and boil off are withdrawn by two Ammonia

Refrigeration Screw Compressors. The gas is compressed and condensed in water cooled condensers and sent

to the Ammonia Receiver.

Liquid is withdrawn from the Receiver under level control. A part of this liquid is flashed in the Economizer,

which operates at a pressure of approximately 1.5 Kg/cm2g. Flashed Ammonia vapors at about -15°C are

admitted into the Economizer port of the Screw Compressors. The balance liquid Ammonia from the Receiver

gets cooled to about – 10°C in the Economizer by the resultant chill from the above described flashing and is

returned back to the storage tank.

Transfer of Liquid Ammonia

Liquid Ammonia from tank will be transferred at the rate of 46 m3/h to NPK A/B plants by using the Ammonia

Transfer Pumps and existing Ammonia Preheater.

Flare System

A Hot Flare system shall be provided for the Ammonia tank (for emergency purposes). Thermal relief valves

are provided in sections of pipelines where liquid Ammonia can get blocked in.

GT & HRSG (Steam Power Generation Unit)

A Gas turbine, also called a Combustion Turbine, is a type of Internal Combustion Engine. It operates on the

Brayton Power Cycle. It has an upstream rotating Compressor coupled to a downstream Turbine, and

a Combustion Chamber in between.

The basic operation of the Gas Turbine is similar to that of the Steam Power plant except that Air is used

instead of Water. Fresh atmospheric Air flows through the Compressor that brings it to higher

pressure. Energy is then added by spraying Fuel (Natural Gas) into the Air and igniting it so the combustion

generates a high-temperature gas flow. This high-temperature, high-pressure gas enters a Turbine, where it

expands down to the exhaust pressure, producing a shaft work output in the process. The Turbine shaft work

is used to drive the Compressor and other devices such as an Electric Generator (generation of Power) that is




be coupled to the shaft. The energy that is not used for shaft work comes out in the exhaust gases, so these

have either a high temperature and/or a high velocity.

A Heat Recovery Steam Generator (HRSG) is an Energy Recovery Heat Exchanger that recovers heat from a

hot gas stream (GT Exhaust gas). It produces Steam that can be used in a process (Cogeneration) or used to

drive a Steam Turbine (Combined cycle). ZACL proposes to the Cogeneration mode of operation. HRSGs

consist of four major components: the Economizer, Evaporator, Superheater and Water Preheater. The

different components are put together to meet the operating requirements of the unit. The HRSG is equipped

with a Steam Drum connected to the Evaporator section where Water is converted to Steam. This Steam then

passes through Superheaters to raise the temperature beyond the one at the saturation point. Some HRSGs

include supplemental, or duct firing. These additional burners provide additional energy to the HRSG, which

produces more steam. HRSGs also have diverter valves to regulate the inlet flow into the HRSG. This allows

the Gas Turbine to continue to operate when there is no Steam demand or if the HRSG needs to be taken

offline. There is also an added flexibility to generate Steam from HRSG by firing Fuel whilst the Gas Turbine is

offline.

Urea Granulation Plant

New Casale Vortex Granulation

In this M/s CASALE’s proprietary technology for Urea Granulation, the prills from the prilling tower are screened

in a Prills Screener to separate the fine product (i.e. prills with a diameter about 1.2-1.3 mm). This will be used

as Seed Material for the Granulation Unit. Due to the unique design of Vortex Granulation ® technology on spec

product at the granulator outlet is obtained without of screening crushing and recycling.

The seeds are lifted to the granulator feeder by a small bucket elevator, or, depending on the plant layout, via

a belt conveyor. The seeds will be enlarged to an average diameter of about 2.8 mm, spraying the Urea

solution having a concentration of 96%.

The temperature of the fluidized/rotating bed granulator will be controlled by 5 heaters installed on the

fluidizing air duct. The granulated product will be preliminarily cooled in the Granulator itself to about 75°C and

then will be fed to the Solid Cooler (Bulk Flow Cooler) to reach 45°C at its outlet.

The exhaust air from the Granulator will be scrubbed to reduce the dust content to about 30 mg/Nm3. The

Urea solution from the scrubbing system will be sent to the underground drain tank and then recycled.

Waste Water Treatment and Disposal

There will be reduction in effluent quantity after proposed expansion due to modernization in technology.

So, there will be no additional load. Effluent will be treated on site in ETP followed by recycling RO

(Reverse Osmosis) system;

Both the Ammonia and Urea plants would be retrofitted with dedicated waste water (Process condensate)

treatment systems. The treated water would be boiler feed water quality and therefore the DM water

make up demand reduces substantially;

As the Drives of several Machinery will be converted from Condensing Steam Turbine to Electric Motor the

Cooling Water Circulation Rate is reduced significantly. This also means a reduction in Blow-down from the

systems;

The domestic sewage will be treated in sewage treatment plant (STP) provided at site;

There will be no disposal of liquid effluent outside of project premises as Zero Liquid Discharge system is

adopted by using ETP & recycling RO.




Air Emissions & Control

The point source emission of pollutants like PM, SO2, NOx, NH3 from the proposed project will be through

flue gas stacks and process vents;

Vehicular movement is envisaged which involves vehicular air emissions, majorly CO & HC’s;

Suitable control measures have factored into the design of the processes so as to control the fugitive

emission (primary and secondary) during loading/ unloading, storage and handling of chemicals;

Appropriate Stack height, Dry low NOx Combustors, appropriate Scrubbing systems will be provided for air

emission control.

Noise generation & Control

Noise will be generated from equipment like pumps, blowers, conveyor, rotary dryer and due to vehicular

movements;

Sufficient engineering control during installation of equipment and machineries is to be ensured to reduce

noise levels at source, acoustic enclosures & personal protective equipment will be provided.

Hazardous and other Solid Waste

The following solid / hazardous wastes will be generated from the site operations:

Hazardous Waste: Used/ Spent Oil, Used bags;

Domestic Solid Waste: Paper and Food waste;

Small amounts of e-waste and scrap

These will be managed as per the applicable Rules, as amended till date namely, Hazardous Waste

(Management, Handling, Storage and Transboundary) Rules 2008; and e- Waste (Management and Handling)

Rules 2011.

DESCRIPTION OF THE ENVIRONMENT

Study Period and Area

Baseline Environmental Study was carried out from March to May’13 (Summer season) within 10 km radius of

the proposed site.

During this study 9 nos. Ambient Air samples, 6 nos. Surface Water samples, 10 nos. Ground Water & 10 nos.

Soil samples were collected and analyzed. Noise measurement was carried out at 10 locations.

Land use and Land cover

Land use of study area is classified as Waste land (~2.0%), Agricultural land (~12.15%), Water bodies

(~50.82%), Vegetation cover (~27.63%), Habitation (~6.64%) & Others (~0.75%).

Meteorology

Based on the long-term Climatological Tables, published by Indian Meteorological Department (IMD) for

Marmugao (Station ID: 43196), Goa, during summer season the mean highest Temperature recorded is 34.1°C

and mean lowest Temperature recorded is 21.7°C. In morning & evening, the Relative Humidity is 74 – 75%

and 69 – 72% respectively. Average wind speed is 3.4 m/s. Predominant wind direction is from NW direction

and the average calm conditions are observed to be 4.3%.




Site-specific Meteorological data was collected at existing site. The same shows maximum and minimum

Temperature to be 34.3°C & 24.1°C respectively. Mean hourly Relative Humidity was 37.7%. Average Wind

Speed & Predominant Wind Direction was 3.4 m/sec & from NW. Calm wind contributed to about 2.13%.

Ambient Air Quality

The broad findings of the Ambient Air Quality Monitoring are as follows:

Average concentration of all the parameters are within prescribed limits.

Average concentration of PM10 recorded ranged from minimum 35 µg/m3 (Nagoa village) to maximum 95

µg/m3 (Zuarinagar);

Average concentration of PM2.5 recorded ranged from minimum 21 µg/m3 (Sancoale & Pale village) to

maximum 51 µg/m3 (Zuarinagar);

The concentration of SO2 (<8.0 – 15.9 µg/m3), NOx (<10 – 21.9 µg/m3), NH3 (<20 – 57.2 µg/m3), HF

(<0.1 – 0.23 µg/m3) are within permissible limits as prescribed by CPCB & Factories act;

The concentration of VOC were recorded to be <1 ppm at all locations;

No abnormal emissions were found in stack monitoring.

Noise

Noise monitoring were done at both Industrial and Residential site:

Within Industrial area, Noise level during day was observed in range of 52.7 dBA (At Project Site – near

main gate) to 69.2 (At project site near Lab) while during night, 49.6 dBA (At project site – Near main

gate) to 57.5 dBA (At project site near Lab) were observed. Noise level during day and night was observed

to be within the CPCB standards for industrial area (75 – 70 dBA);

Within Residential area, Noise level during day was observed in range of 49.1 dBA (At Pale Village) to 62.6

dBA (At Zuarinagar village) while during night, 41.3 dBA (At Pale village) to 51.9 dBA (At Zuarinagar

village). Noise level during day and night time was observed higher than the CPCB standards for

Residential area (55 – 45 dBA).

Surface Water Quality

The marine water can be compared with the class SW-II as per the classification for Coastal

Water standards;

TDS, Chloride and Electrical conductivity is high in River Water as there is tidal impact on river

and it meets estuary;

TDS, Chloride, Total Hardness, Fluoride, Calcium, Magnesium are high in stream at Pale;

Heavy metals like Cadmium, Iron and Lead are high at Verna pond water;

Cadmium, Iron and Nickel are found high in stream near the pale;

Iron and Lead are observed high at Zuari dam Water;

Total Coliform and Faecal Coliform which is found to be high at pond and Rainwater Catchment Water.

Quality of Ground Water

It was observed from the analysis report that, all the results are below permissible limit except heavy

metals at some places. Ground Water at Pale village is showing higher TDS owing to its close proximity to

sea.




Quality of Soil

From the surrounding area of the project ten soil samples were collected. The soil analysis data indicate that

the porosity and water holding capacity are minimum in Pale area but permeability is very high due to sandy

texture of soil. The soil is non-saline and non-sodic as ESP (Exchangeable sodium percentage is <.01) and EC

(Salinity is <0.8) except in Sancoale which is 0.33 and 0.987 μmohs/cm for ESP and EC, respectively and for

Cortalim EC is 0.996 μmohs/cm. The soil of Nagoa (pH 3.51) and Cortalim (pH 4.80) is highly acidic which

require lime as an amendment. The values of water soluble cations is low due to lateritic nature of soil.

Biological Environment

As a part of terrestrial biodiversity study, 69 species of trees belong to 29 families, 37 species of shrubs

belongs to 17 families, 65 herbaceous species belong to 21 families, 21 species of dominant Climbers and

Twiners were observed.

Major Cereal crop cultivated in the study area is Rice, Minor crops practiced in this region were Makai, Gahu

and Sugar cane. Pulses like Mug and Tur. The vegetables grown in the study area were, Choli, Ringan and

Tomato.

Large population Betel nut, Coconut, Jack fruit, Mango were observed in this locality mostly as homestead

plantation. Banana cultivation was also a major agricultural activity at some part of this region. In addition to

this Kokam were also observed growing in large number in the study area. Cashew, Betel nut, Coconut, Jack

fruit, Kokam and Mango are the major horticulture crops in the area.

Among the plants recorded from the study area none of them can be assigned in a threat category as per the

RED data book of Indian Plants (Nayar and Sastry, 1990).

In faunal species, 59 Birds, 20 butterflies, 6 herpetofauna & 10 mammals species were found.

Among the birds in the study area, Common peafowl is included in Schedule-I of the Wild life protection act,

1972 amended till date. Grey Jungle fowl is schedule -II bird and many other

birds are included in schedule IV of the Wild life protection act, 1972 amended till date.

Two of the butterfly species Danaid Egg fly and Crimson rose belongs to the Schedule-I of Wild life protection

Act, 1972 amended till date.

Among mammals, Indian fox and Common Mongoose are protected by including in schedule – II of WLS act

(1972). Indian Cobra and Common rat snake are provided protection as per Schedule-II of Wild life protection

act, 1972 amended till date.

None of the sighted animal species can be assigned endemic species category of the study area.

Marine biodiversity study shows that, buffer zone supports phytoplankton, zooplanktons, benthos, fishes and

other marine fauna.

Mangrove patches has been observed north-east side (~5.5 km) of the proposed location.

Socio-Economic Environment

Social studies were carried out covering the following topics within the study area. The summary of the results

are also provided (Reference: as per 2011 census data):

Population and its distribution: There are 36 villages, with a total population of 4,15,802 persons and

98,118 households;

Educational Facilities: Primary & Secondary schools are available in all the villages;




Literacy rate is about 80.66% in the study area;

Drinking water: Tap water connections & wells are available in study area;

Power supply is available in all villages.

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

Air Environment

Maximum 24 hourly average GLC’s for PM10 (2.57 µg/m3), SO2 (0.08 µg/m3), NOx (1.39 µg/m3) and

Ammonia (0.85 µg/m3) are within 500 m from the proposed site;

Incremental GLC’s at all villages will continue to be well within specified norms of CPCB for Ambient Air

Quality.

Mitigation Measures for Proposed Plants

Mitigation measures for air quality impacts are:

Stacks with adequate height will be provided as per the statutory requirements;

Proper periodic maintenance of scrubbing systems will be done to ensure its efficient operation;

Proper operating procedures will be followed during startup and shutdown;

Plant load will be maintained so as to have the Air emissions well within the prescribed norms;

Well-designed/ engineered Air pollution control equipment’s with “Sate-of-Art” technology will be installed,

Monitoring will be done on regular basis;

Proper PPE like masks will be provided to workers;

The engines and exhaust systems of all vehicles and equipment used will be maintained as

such, that exhaust emissions are low and do not breach statutory limits set for the concerned

vehicle/equipment type.

Traffic

From the proposed project, additional approximate 100 trucks per day will be required for

carrying raw materials and finished products;

Thus, maximum incremental traffic will be 297 PCU;

Carrying capacity of the approach road, connecting site from Zuarinagar to Vasco is 900

PCU5;

Thus, the road is capable of carrying the more traffic than the proposed traffic.

Increase in transportation will lead to road traffic, dispersion of dust, emission of pollutants and noise

generation.

Mitigation measures

The trucks transporting raw materials and finished goods will be covered;

It will be assured that vehicles are PUC certified;

Ensuring the availability of valid Pollution Under Control Certificates (PUCC) for all vehicles

used on site;

Adequate measures will be taken to avoid spillage or leak of raw material and drivers will be

instructed to control leakages and collection of spilled material;

Traffic management plan shall be made and implemented.




Noise Environment

The Sound Pressure Level after the proposed expansion predicted, at a distance of 100 meters from the

project boundary is in the range of 40~42 dB. Whereas, the background noise level measured at the project

site, was measured in the range of 52~57 dB. Addition of the component of 42 dB due to the added machinery

at the project site is not likely to make an impact beyond 0.5 dB of addition in the current measured Noise

levels, and hence they are within the acceptable limits as well.

Mitigation measures

Procurement of equipment meeting prescribed noise standards will be done;

Sufficient engineering control during installation of equipment and machineries will be

ensured to reduce noise levels at source;

Acoustical Enclosures with Very high transmission loss rating will be installed;

Room Acoustical Treatment shall be done;

Use of Removable acoustical blankets which are effective and economical in reducing the noise level would

be explored;

Personnel Protective Equipment (PPE) like ear plugs/muffs is to be given to all the workers at

site and it will be ensured that the same are wore by everybody during their working hours.

Water Environment

During rainy season, storm water shall not meet the nearest surface water body. Also, the unit shall comply

the ZLD system. Hence, surface and ground water will not be impacted.

Reuse & recycle of waste water practice will be adopted so consumption of water will be reduced.

Rainwater harvesting system is proposed to store the water for reuse.

Land Environment

Proposed expansion will be carried out within existing site premises for industrial purpose. So, there will not be

any impact on land environment.

Biological Environment

Removal of site specific floral species will not have significant or permanent impact on the habitat structure of

associated faunal diversity. All identified impacts shows that, release of gaseous emissions from proposed

projects in operational phase rated as a “Low/ Moderate”.

However, since the emissions from the plant are regulated and minimal with respect to the specified norms,

and since a very healthy greenbelt is evidenced at the site in the form of several species, it follows that the

biological environment will continue to be protected.

Socio-Economic Environment

While assessing the socio-economic and sociological impact including health impacts to surrounding people, it

has been noticed that the upcoming project will bring job opportunities for the local people, during the

construction & operation phase. There will be no impact on health.




ENVIRONMENTAL MONITORING PROGRAM

Environmental Monitoring and Management Cost

S No. Activity Schedule/Frequency

C1 C2 C3

Air Pollution Monitoring

1 Ambient air monitoring of parameters PM10, PM2.5, SO2, NOx

& NH3 from time to time within the site area Online AAQM within site.

2 Ambient air monitoring of parameters PM10, PM2.5, SO2, NOx

& NH3 from time to time at nearby project area Once every month (except monsoon) at 4

locations by authorized third party

3 Stack monitoring as given in air consent from time to time Once in 3 months by authorized third party.

4 Workplace monitoring Once in 3 months by authorized third party.

Noise Pollution Monitoring

5 Workplace monitoring Once in a month (Hourly reading for 24 hours

at each location)

Water Pollution Monitoring

6 Monitoring of water consumed in various activities from raw water intake and waste water generated from various areas

of plants

Parameters like pH and flow will be monitored continuous

7

Monitoring of wastewater inlet and outlet at ETP & STP plants for the principal parameters (such as pH, COD, BOD, SS, TDS, Color, Ammonical nitrogen) as specified by GSPCB

in their water consent from time to time.

Daily

8 Monitoring of other specific parameters as per GSPCB

consent conditions. Weekly

Soil Pollution Monitoring

9 Soil Monitoring within Site As required

Solid Waste Generation Monitoring / Record Keeping

10 Monitoring of solid / hazardous waste from process and

ETP/STP and preparation of compilation of records of daily generation.

Quarterly

11 Records of daily generation of Solid / Hazardous Waste. As required

12 Record of treatment, storage and dispatch, transportation of

solid / hazardous waste to recyclers, re-processors, etc. As required

Environmental Statement

13 Environmental statement under the EP (Act), 1986. Once a year

It is expected that ZACL shall incur approximate capital expenditure of about INR 10.35 Crore and an annual

recurring expenditure of about INR 0.91 Crore, at current price on environmental matters.

ADDITIONAL STUDIES

Comparison of the existing Horton Spheres and proposed double wall double integrity type atmospheric tank

for Ammonia Storage:

In the double wall double integrity tank, the inner tank and outer tank each can contain the liquid

ammonia inventory safely. Therefore in comparison to Horton sphere (Pressurized Storage), the likelihood of

failure of double wall double integrity tank is negligible.




According to the best industry practice, double wall double integrity tank has proven to be the safest mode of

storage of liquid ammonia.

The individual risk at plant boundary is very much reduced by replacing the Horton spheres by atmospheric

Ammonia storage tanks.

M/s. ZACL already have emergency management system (onsite emergency plan) to tackle any emergency

situation for proposed facilities.

PROJECT BENEFITS

This project would generate opportunities for Employment in Skilled, Semi-skilled and unskilled categories.

Skilled & semi-skilled manpower would consist of Plant management Staffs, Production Staffs and other office

staffs. Unskilled manpower would consist of Production workers, Drivers, Office assistants, Crane operators,

Pay loader operators, Bagging and loading workers, etc.;

Apart from that approx. 100-150 jobs will be indirectly created by the setting up of the project during its

construction & operational lifecycle, we envisage Local civil, Mechanical contractors, Local small business would

be benefitted from the proposed project.

ENVIRONMENT MANAGEMENT PLAN

Environmental Management Plan

S

No.

Expected Aspect due to

Proposed Activity Impact Zones Management Plan

Air Environment

1 PM, SO2 , NOx & NH3

emissions from Rotary dryer/ Co-current dryer

250 to 1,000 meters in predominant wind direction

Provision of adequate stack height ~ 30 m will

be ensured;

Ensure periodic monitoring of stacks for

parameters prescribed by GSPCB.

2 Dispersion of Ammonia in

atmosphere 1,500 meters in

predominant wind direction

Provision of dyke wall will be ensured;

Proper operation will be ensured;

Ensure Onsite plans are made and followed,

also stricktly adhered to offsite plans too.

3 NOx & SO2 emissions from

GT/HRSG operation 250 to 1,000 meters in


Provision of Dry Low NOx Combustors will be

ensured;


be ensured;

Ensure periodic monitoring of stacks for SO2 &

NOx concentrations.

4 PM & NH3 from Urea

Granulation 250 to 1,000 meters in


Provision of Wet scrubber will be ensured;


be ensured;

Ensure periodic monitoring of stacks for

parameters prescribed by GSPCB.

5 Dust generation due to Transportation activity

Nearby villages & roads Transportation of raw materials and finished

goods will be carried out in covered trucks.

Water Environment

1 Monitoring of Surface water Nearest water bodies Ensuring periodic monitoring;




S

No.

Expected Aspect due to

Proposed Activity Impact Zones Management Plan

Storm water management;

Rain water harvesting for storage.

2 Monitoring of ETP & STP Within site Ensuring periodic monitoring;

Reuse & recycle scheme.

Land Environment

1 Soil analysis/ monitoring Around the project site

Ensuring monitoring during Pre & post

monsoon and in the event of accidental

spillage.

Noise Environment

1 Noise generation due to construction activities

Workers at site

Properly certified, tested and calibrated

equipment will be used;

Ear muffs and ear plugs will be provided to

workers.

2

Noise generation due to operation of various

equipment like pumps, blowers, compressors, gas

turbine, DG Sets and due to popping up of safety valves

Workers at site

At design stage, procurement of low noise

equipment will be ensured;

Proper engineering control measures will be

taken;

Periodic maintenance of equipment shall be

ensured;

Adequate acoustic enclosures will be placed.

Social Environment

1

Job opportunities, ancillary developments in and around

project site and CSR activities

Nation wide Timely approval of funds for new and

proposed CSR activities.

Greenbelt

ZACL has achieved ‘Best Plantation Puraskar’ from Govt. of Goa during 1997-98. Existing developed & lush green belt

will be maintained.

Rainwater Harvesting System

Rainwater harvesting captive dam site with capacity of 1.1356 Million m3 is already developed by Zuari Agro

Chemicals Ltd.

Environment Management Cell

An Environmental Management Cell with adequate professional expertise and resources shall be been

established to discharge responsibilities related to environmental management including statutory compliance,

pollution prevention, environmental monitoring, etc. Objectives of the cell will be to:

Collect information from regular monitoring and create a database;

Analyze the data and decide thrust area;

Based on the data collected, decide target for each thrust area;

Carry out ‘Projects’ in each thrust area to arrive at practical solutions to environmental problems;

Discuss the reports of study on environment and disseminate the information;

Work out ‘Action plan’ for implementation of the recommendations made in the reports;

Prepare Management Information System (MIS) reports and budget for EMP;




Achieve objectives of the ‘Environment Protection Policy’ of the management.

CONCLUSION

For proposed project:

There will be no additional water requirement;

Expansion will be within site;

No discharge of effluent as Zero liquid discharge status will be maintained;

Very negligible amount of Hazardous waste will be generated;

Power will be met through internal source;

Safest and Environment friendly technology will be adopted;

Existing pollution load will be reduced and

Appropriate air pollution control equipment, treatment of waste water generation and solid / hazardous waste

management and Properly certified, tested and calibrated equipment will be used which leads to very negligible

environmental impact which will be mitigated by taking preventive measures.

Based on the baseline studies as per TOR, there are no Protected Areas, Critically polluted areas, Eco-sensitive

areas, Interstate boundaries and international boundaries located in 10 km of study area.

Well-defined and practiced Onsite management plan by experienced and trained staff is available.

There is employment potential for skilled, semi- skilled and unskilled labors both during construction and

operational phases of the project.

The EIA study has concluded that the project would be environmentally acceptable, in compliance with

environmental legislation and standards. Hence the proposed project may be considered for getting

Environmental Clearance

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

SPAZE IT Park, Unit No. 1124, Sector 49, Near Omax City Centre Mall, Sohna Road, Gurgaon

– 122 022 E: [email protected]; T: 0124-4242430

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