EIA & EMP Report for Expansion of Brownfield...

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED

EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar, Bharuch, Gujarat.

NOVEMBER 2014

Kadam Environmental Consultants www. k a da m e nv i r o . co m

Environment for Deve lopment

M/S GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LTD.

EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH QUALITY CONTROL

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 I


EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar, Bharuch, Gujarat © Kadam Environmental Consultants (‘Kadam’), November, 2014

This report is released for the use of the Gujarat Narmada Valley Fertilizers & Chemicals Ltd, Regulators and relevant stakeholders solely as part of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Kadam.

QUALITY CONTROL

Name of Publication

EIA & EMP Report for Expansion of Brownfield Ammonia, Urea Plant, New Aniline, TDI-MDI Blend, Water Soluble Fertilizers (NPK) and CPSU Plants at GNFC, Narmadanagar,

Bharuch, Gujarat

Project Number 1211731618 Report No. 1 Version 1 Released November

2014

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also believes that the facts presented in the report are accurate as on the date it was written. However,

it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The

information is not intended to serve as legal advice related to the individual situation.



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EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH TABLE OF CONTENT

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CONTENTS

0 EXECUTIVE SUMMARY ................................................................................. 1

0.1 PROJECT DESCRIPTION .............................................................................. 1 0.1.1 About the Company and Project Proponent ................................................. 1 0.1.2 About Project ..................................................................................... 1 0.1.3 Regulatory Framework .......................................................................... 1 0.1.4 Location of the Project .......................................................................... 2 0.1.5 Project Cost ....................................................................................... 2 0.1.6 Raw Materials and Source ...................................................................... 2 0.1.7 Utilities ............................................................................................. 2 0.1.8 Description of the Process ...................................................................... 3 0.1.9 Waste Water ...................................................................................... 4 0.1.10 Air Emissions...................................................................................... 4 0.1.11 Hazardous and Other Solid Wastes ........................................................... 4

0.2 DESCRIPTION OF THE ENVIRONMENT ............................................................ 4 0.2.1 Study Period and Area .......................................................................... 4 0.2.2 Land Use of the Study Area .................................................................... 5 0.2.3 Climatology ....................................................................................... 5 0.2.4 Ambient Air Quality .............................................................................. 5 0.2.5 Noise ............................................................................................... 6 0.2.6 Surface Water and Ground Water Quality ................................................... 6 0.2.7 Soil ................................................................................................. 7 0.2.8 Biological Environment .......................................................................... 7 0.2.9 Air Emissions...................................................................................... 8 0.2.10 Waste Water Quality ............................................................................ 8 0.2.11 Solid / Hazardous Waste Management ....................................................... 8

0.3 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES................... 8 0.3.1 Air Environment .................................................................................. 8 0.3.2 Noise Environment ............................................................................... 9 0.3.3 Water and Waste Water ...................................................................... 10 0.3.4 Land Environment ............................................................................. 11 0.3.5 Biological Environment ........................................................................ 12 0.3.6 Socio-Economic Environment ................................................................ 12

0.4 ENVIRONMENTAL MONITORING PROGRAMME ................................................ 12 0.5 ADDITIONAL STUDIES ............................................................................. 13

0.5.1 Public Hearing .................................................................................. 13 0.5.2 Hazard Identification and Consequence Assessment .................................... 13 0.5.3 Onsite and Offsite Emergency Plan ......................................................... 14

0.6 PROJECT BENEFITS ................................................................................. 14 0.7 ENVIRONMENTAL MANAGEMENT PLAN ......................................................... 15 0.8 CONCLUSION ........................................................................................ 17



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1 INTRODUCTION ........................................................................................ 19

1.1 PURPOSE OF THE REPORT ......................................................................... 19 1.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................. 19 1.3 BRIEF DESCRIPTION OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION ....................................................................................................... 21

1.3.1 Brief Description of Project ................................................................... 21 1.3.2 Importance of the Project to Country & Region .......................................... 22

1.4 REGULATORY FRAMEWORK ....................................................................... 22 1.4.1 Environmental Clearance for Proposed Project ........................................... 22 1.4.2 Status of Environmental Clearances & CC&A/CTO for Existing Units .................. 23 1.4.3 Statutory Clearances and Other Permissions .............................................. 23

1.5 SCOPE OF THE STUDY .............................................................................. 25

2 PROJECT DESCRIPTION ............................................................................. 33

2.1 TYPE OF THE PROJECT ............................................................................. 33 2.1.1 Condensed Description of Aspects .......................................................... 33

2.2 NEED FOR THE PROJECT ........................................................................... 33 2.2.1 Ammonia ........................................................................................ 33 2.2.2 Urea .............................................................................................. 33 2.2.3 Aniline............................................................................................ 34 2.2.4 TDI-MDI Blend (TM Blend) ................................................................... 35 2.2.5 Water Soluble Fertilizer (NPK) ............................................................... 35 2.2.6 CPSU ............................................................................................. 35 2.2.7 Condensed Description of Aspects .......................................................... 35

2.3 LOCATION ............................................................................................ 35 2.3.1 General Location of the Site .................................................................. 35 2.3.2 Specific Location of the Site with Project Boundary ...................................... 35 2.3.3 Location of Severely Polluted Area from Site .............................................. 39 2.3.4 Approach to the site ........................................................................... 39 2.3.5 Condensed Description of Aspects .......................................................... 40

2.4 SIZE AND MAGNITUDE OF OPERATION ......................................................... 40 2.4.1 Condensed Description of Aspects .......................................................... 42

2.5 RAW MATERIAL, STORAGE AND MODE OF TRANSPORT ...................................... 42 2.6 LIST OF SOLVENTS AND SOLVENT RECOVERY SYSTEM ...................................... 46

2.6.1 Naphtha ......................................................................................... 46 2.6.2 Methanol ........................................................................................ 46 2.6.3 aMDEA (Activated Methyl Di-Ethanol Amine) .............................................. 46 2.6.4 ODCB (Ortho-Di-Chloro Benzene) ........................................................... 46

2.7 UTILITY REQUIREMENT ............................................................................ 46 2.7.1 Fuel ............................................................................................... 46 2.7.2 Power Consumption ........................................................................... 47 2.7.3 Manpower Requirement ...................................................................... 48 2.7.4 Water ............................................................................................ 48

2.8 PROJECT IMPLEMENTATION SCHEDULE ........................................................ 48



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2.9 TECHNOLOGY AND PROCESS DESCRIPTION ................................................... 49 2.9.1 Ammonia (Proposed) .......................................................................... 49 2.9.2 Urea (Proposed) ................................................................................ 55 2.9.3 Water Soluble Fertilizers (Proposed) ........................................................ 58 2.9.4 Aniline (Proposed) ............................................................................. 60 2.9.5 TDI – MDI (80:20) Blend (Proposed) ....................................................... 64 2.9.6 Cogeneration Power & Steam Unit (CPSU) - 45 MW ..................................... 66

2.10 WATER CONSUMPTION, WASTE WATER GENERATION & DISPOSAL DETAILS ......... 67 2.10.1 Unit-I ............................................................................................. 67 2.10.2 Unit-II ............................................................................................ 87

2.11 AIR EMISSIONS .................................................................................. 108 2.11.1 Point Source Emissions ...................................................................... 108 2.11.2 Area Source Emissions ....................................................................... 118 2.11.3 Line Source Emissions ........................................................................ 119 2.11.4 Fugitive Emissions ............................................................................ 119

2.12 SOLID AND HAZARDOUS WASTE IDENTIFICATION, QUANTIFICATION, STORAGE AND DISPOSAL ................................................................................................... 121

2.12.1 Quantification and Classification of Solid and Hazardous Wastes generated (Unit I) 121 2.12.2 Quantification and Classification of Existing and Proposed Solid and Hazardous Wastes (Unit-II) ......................................................................................... 129 2.12.3 Details of Hazardous Waste Handling, Storage, Utilization and Disposal ............ 139 2.12.4 Other Solids Wastes .......................................................................... 140

2.13 PROJECT DESCRIPTION ........................................................................ 141 2.13.1 Land Distribution at Site ..................................................................... 141 2.13.2 Layout Plans of Proposed Plants............................................................ 146 2.13.3 Mitigation Measures at Design Stage ...................................................... 149

2.14 ASSESSMENT OF NEW AND UNTESTED TECHNOLOGY .................................... 152

3 DESCRIPTION OF THE ENVIRONMENT ........................................................153

3.1 STUDY AREA ........................................................................................... 153 3.2 PERIOD ................................................................................................ 153 3.3 COMPONENTS.......................................................................................... 153 3.4 METHODOLOGY ........................................................................................ 153

3.4.1 Primary data Collection ...................................................................... 153 3.4.2 Secondary Data collection ................................................................... 155

3.5 ESTABLISHMENT OF BASELINE FOR VALUED ENVIRONMENTAL COMPONENTS AND BASE MAPS ....... 155 3.5.1 Long Term Meteorology ..................................................................... 155 3.5.2 Land Use ....................................................................................... 162 3.5.3 Ambient Air Quality ........................................................................... 170 3.5.4 Noise ............................................................................................ 184 3.5.5 Vibration ........................................................................................ 188 3.5.6 Hydrology and Groundwater ................................................................ 189 3.5.7 Geology ......................................................................................... 210



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3.5.8 Soil .............................................................................................. 212 3.5.9 Ecology and Biodiversity ..................................................................... 219 3.5.10 Socio-Economics .............................................................................. 236

4 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES ........244

4.1 INVESTIGATED ENVIRONMENTAL IMPACTS DUE TO THE PROPOSED PROJECT ........ 244 4.1.1 Assessment of Significance of Impacts .................................................... 244

4.2 AIR ENVIRONMENT ................................................................................ 250 4.2.1 Sources of Emissions and Emission rates ................................................. 254 4.2.2 Fugitive Emissions & Control ................................................................ 262 4.2.3 Area Source Emissions ....................................................................... 262 4.2.4 Line Source Emissions ........................................................................ 263

4.3 NOISE ENVIRONMENT............................................................................. 269 4.3.1 Noise Modeling Study ........................................................................ 269 4.3.2 Mitigation Measures to control Noise Emission ........................................... 270

4.4 WATER ENVIRONMENT ........................................................................... 272 4.4.1 Ground Water ................................................................................. 272 4.4.2 Impact on Ground Water .................................................................... 272 4.4.3 Mitigation measure ........................................................................... 272 4.4.4 Surface / River Water ........................................................................ 272 4.4.5 Impact on Surface Water .................................................................... 272 4.4.6 Mitigation measure ........................................................................... 273

4.5 LAND USE AND LAND COVER ..................................................................... 277 4.5.1 Site Preparation ............................................................................... 277 4.5.2 Green Belt Development ..................................................................... 277 4.5.3 Mitigation Measures for Impact on Land Use / Land Cover ............................ 277

4.6 SOIL CONSERVATION ............................................................................. 279 4.6.1 Mitigation Measures for Soil Conservation ................................................ 279

4.7 ECOLOGY AND BIODIVERSITY ................................................................... 283 4.8 SOCIO ECONOMIC ................................................................................. 285 4.9 OCCUPATIONAL HEALTH AND RISK ............................................................. 288

4.9.1 General Safety Measures .................................................................... 288 4.9.2 Mitigation Measures .......................................................................... 288

5 ANALYSIS OF ALTERNATIVES ....................................................................292

5.1 SITE ALTERNATIVE .................................................................................... 292 5.1.1 At Existing Site ................................................................................ 292 5.1.2 At New Site, Dahej............................................................................ 293

5.2 ANALYSIS OF ALTERNATIVE RESOURCES & TECHNOLOGIES ........................................... 293 5.2.1 Ammonia Technologies ...................................................................... 293 5.2.2 Urea Technology .............................................................................. 294 5.2.3 Innovation in Unconventional Technologies in Ammonia production ................. 295

5.3 NOTE ON VIABILITY OF THE PROJECT IN ABSENCE OF AVAILABILITY OF NATURAL GAS .............. 295

6 ENVIRONMENT MONITORING PROGRAM ....................................................297



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6.1 INTRODUCTION .................................................................................... 297 6.2 THE OBJECTIVES OF MONITORING ............................................................. 297 6.3 ENVIRONMENTAL MONITORING PROGRAMS.................................................. 297

6.3.1 Air Environment ............................................................................... 297 6.3.2 Noise Environment ............................................................................ 299 6.3.3 Water Environment ........................................................................... 301 6.3.4 Land Environment ............................................................................ 304 6.3.5 Ecology and Biodiversity ..................................................................... 308

6.4 PROJECTED EXPENDITURE ON ENVIRONMENTAL MATTERS ............................... 310

7 ADDITIONAL STUDIES ..............................................................................313

7.1 PUBLIC CONSULTATION ............................................................................... 313 7.1.1 Notice of Public Hearing ..................................................................... 313 7.1.2 Publicity of Public Hearing ................................................................... 313 7.1.3 Panel ............................................................................................ 314 7.1.4 Proceedings .................................................................................... 314

7.2 QUANTITATIVE RISK ASSESSMENT .................................................................... 319 7.3 OBJECTIVE............................................................................................. 319 7.4 STUDY METHODOLOGY ................................................................................ 319

7.4.1 Plant Data ...................................................................................... 320 7.4.2 Generic Failure Rate Data ................................................................... 320 7.4.3 Population Data ............................................................................... 320 7.4.4 Meteorological Data .......................................................................... 320 7.4.5 Ignition Source Data ......................................................................... 321

7.5 HAZARD (OR FAILURE CASE) IDENTIFICATION ........................................................ 321 7.5.1 Hazard and Damage Assessment .......................................................... 322

7.6 RISK ASSESSMENT / CONSEQUENCE ANALYSIS ........................................................ 324 7.6.1 Selection of Material .......................................................................... 325 7.6.2 Scenarios Considered for Risk Analysis .................................................... 327 7.6.3 Consequence Analysis ........................................................................ 328 7.6.4 Conclusion...................................................................................... 340

7.7 CONSEQUENCE CALCULATIONS ........................................................................ 341 7.8 RISK CALCULATIONS .................................................................................. 341

7.8.1 Risk Presentation .............................................................................. 342 7.8.2 Risk Assessment .............................................................................. 342 7.8.3 Risk Tolerability Criteria ...................................................................... 342 7.8.4 Individual Risk Criteria ....................................................................... 342 7.8.5 Group Risk Criteria – FN Curves ............................................................ 343

7.9 THE APPROACH TO CALCULATE FAILURE FREQUENCY ................................................. 344 7.10 RESULTS ANALYSIS RESULTS ....................................................................... 346

7.10.1 Individual Risk ................................................................................. 346 7.10.1.1 Group Risk-FN Curve....................................................................... 350 7.10.2 Risk Contribution .............................................................................. 353

7.11 CONCLUSIONS ...................................................................................... 353



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7.12 MITIGATIONS ....................................................................................... 354 7.13 ONSITE EMERGENCY PLAN .......................................................................... 355

7.13.1 Emergency Categorized ...................................................................... 355 7.13.1.1 Emergency controllable within the plant / area ....................................... 355 7.13.1.2 Emergency confinable within the Factory premises .................................. 355 7.13.1.3 Likelihood of vapor cloud with formation of toxic / flammable gases drifting and affecting the general public (i.e. outside of plant premises) ..................................... 355 7.13.2 On Site Emergency Plan for GNFC, Bharuch.............................................. 355 GNFC have a detailed On Site Emergency Plan in place covering all the plants for more than 15 years. The Plan is supported by the following: ................................................. 355 7.13.2.1 Mutual Aid Scheme ......................................................................... 356 7.13.2.2 Information on the Preliminary Hazard Analysis ...................................... 356 7.13.2.3 Details about the Site ...................................................................... 357 7.13.2.4 Hazards in Various Plants ................................................................. 358 7.13.2.5 Details Regarding Warning, Alarm, and Safety and Security Systems ............. 359 7.13.2.6 Rescue Tools ................................................................................ 364 7.13.2.7 Detectors .................................................................................... 365 7.13.2.8 Inventory for Fire Protection ............................................................. 366 7.13.2.9 Occupational Health of the Contract and Sub contract Workers .................... 367 7.13.2.10 Antidote and First Aid Box .............................................................. 371

7.14 PRECAUTIONS TAKEN DURING STORAGE AND TRANSPORTATION OF HAZARDOUS CHEMICALS ..... 372

8 PROJECT BENEFITS ..................................................................................378

8.1 TECHNOLOGICAL BENEFITS ............................................................................ 378 8.2 SUBSTANTIAL SOCIO-ECONOMIC BENEFITS ............................................................ 378 8.3 OTHER TANGIBLE BENEFITS ........................................................................... 378

9 ENVIRONMENTAL COST BENEFIT ANALYSIS ................................................379

10 ENVIRONMENTAL MANAGEMENT PLAN ....................................................380

10.1 INTRODUCTION ................................................................................. 380 10.2 PURPOSE OF EMP ................................................................................ 380 10.3 ENVIRONMENTAL MANAGEMENT PLANS .................................................... 380

10.3.1 Air Environment ............................................................................... 380 10.3.2 Water Environment ........................................................................... 380 10.3.3 Land Environment ............................................................................ 382 10.3.4 Socio-Economic Environment ............................................................... 385

10.4 ENVIRONMENT MANAGEMENT CELL ......................................................... 389 10.5 SUMMARY OF EMP ............................................................................... 390

11 SUMMARY AND CONCLUSION .................................................................392

11.1 SUMMARY ......................................................................................... 392 11.2 CONCLUSION ..................................................................................... 392

12 DISCLOSURE OF CONSULTANTS ENGAGED ................................................393



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12.1 BRIEF RESUME AND NATURE OF CONSULTANCY .......................................... 393 12.2 EIA TEAM MEMBERS ............................................................................ 394

13 CERTIFIED COMPLIANCE REPORT OF EC CONDITIONS ...............................399

13.1 COMPLIANCE REPORT FOR EC FROM MOEF (FOR EXPANSION UNITS OF WNA, CAN, METHANOL, ACETIC ACID, FORMIC ACID ETC.) ............................................................................ 399 13.2 COMPLIANCE REPORT FOR EC FROM SEIAA (ETHYL ACETATE) .................................... 410 13.3 NON-COMPLIANCES / PARTLY COMPLIANCES FOR EC FROM MOEF FOR EXPANSION UNITS OF WNA, CAN, METHANOL, ACETIC ACID, FORMIC ACID ETC. ......................................................... 433 13.4 NON-COMPLIANCES / PARTLY COMPLIANCES FOR EC FROM SEIAA FOR ETHYL ACETATE ......... 438

LIST OF ANNEXURES

Annexure 1: The Letter/application for EC ................................................................................... 443

Annexure 2: Document of Notified Industrial Area ....................................................................... 444

Annexure 3: ToR Letter from MoEF, New Delhi ............................................................................ 454

Annexure 4: Corporate Environmental, OH&S and Quality Policy of GNFC ...................................... 458

Annexure 5: ISO 14001:2004 and OSHAS 18001:2007 Certificates ............................................... 459

Annexure 6: Environment Clearance for the Existing Unit Issued by the Ministry ............................ 461

Annexure 7: Copies of Consent to Operate and Authorization Accorded by the GPCB ..................... 481

Annexure 8: ‘Permissions’ for the Drawl of Water ........................................................................ 519

Annexure 9: Inprinciple Approval for additional 24 MLD Water Requirement for Proposed Projects .. 534

Annexure 10: Comfort Letter for Gas Supply from GSPC & MoU with Hazira LNG Pvt. Ltd. .............. 538

Annexure 11: Commitment Regarding No Additional Storage for Ammonia .................................... 547

Annexure 12: CREP Compliance of GNFC .................................................................................... 548

Annexure 13: MSDS of all Chemicals Involved in the Project ......................................................... 551

Annexure 14: Process Description for Existing Products................................................................ 552

Annexure 15: Block Diagram of Existing Central ETP (Unit-I) ........................................................ 566

Annexure 16: Block Diagram Proposed Sewage Treatment Plant (Unit-I) ....................................... 567

Annexure 17: Block Diagram for Effluent Treatment System after Proposed Expansion (Unit-I) ....... 568

Annexure 18: Block Diagram Existing Aniline ETP (Unit-II) ........................................................... 569

Annexure 19: Block Diagram Proposed Aniline ETP (Unit-II) ......................................................... 570

Annexure 20: Details of Online TOC Meter and Ammonical Nitrogen Analyzer ................................ 571

Annexure 21: Membership Certificates for Solid Waste and Hazardous Waste (Existing & Proposed) 574

Annexure 22: Definitions of First and Second Level of Classification .............................................. 584



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Annexure 23: Climatological Data for Broach (Bharuch) District .................................................... 588

Annexure 24: National Ambient Air Quality Standards .................................................................. 590

Annexure 25: Impact Assessment Methodology ........................................................................... 591

Annexure 26: Air Dispersion Modeling Results and Isopleths ........................................................ 600

Annexure 27: Details of Injury to the Contract Workers in the Year 2012 ...................................... 618

Annexure 28: Letter from Regional Officer, MoEF regarding Certification of Compliance ................. 620

Annexure 29: NABET Certificate – Kadam Environmental Consultants (Sr. No. 84 on Nabet’s Website, as on Feb. 5, 2014) ................................................................................................................... 622

Annexure 30: Advertisement for Public Hearing ........................................................................... 625

Annexure 31: Copy of Letters issued by GPCB to Concerned Authorities for PH .............................. 628

Annexure 32: Proof of Executive Summary Distribution in 59 Villages ............................................ 635

LIST OF APPENDIX

Appendix 1: MoM of Public Hearing ............................................................................................ 641

Appendix 2: MSDS of Chemicals used in Unit – 1 ......................................................................... 878

Appendix 3: MSDS of Chemicals used in Unit – 2 ....................................................................... 1165

LIST OF TABLES

Table 1-1: Schedule of Proposed Project ....................................................................................... 19

Table 1-2: GNFC’s Top Management List....................................................................................... 21

Table 1-3: Brief Description of the Proposed Project ...................................................................... 21

Table 1-4: Statutory Clearances and Other Permissions ................................................................. 23

Table 1-5: Compliance with the Terms of Reference ...................................................................... 26

Table 2-1: Projected Demand Supply Gap for Urea (‘000 tonnes of material) ................................... 33

Table 2-2: Aniline Demand Projected by the End of 2015 ............................................................... 34

Table 2-3: Import and Indigenous Production of Aniline ................................................................. 34

Table 2-4: Latitude and Longitude of the Corners of the GNFC Complex .......................................... 36

Table 2-5: Product List with Existing and Proposed Capacity for Unit 1 and Unit 2 ............................ 40

Table 2-6: Details of Raw Material Requirement for Proposed New Plants (Unit-1) ........................... 43

Table 2-7: Details of Raw Material Requirement for Proposed New Plants (Unit-2) ........................... 45

Table 2-8: Fuel Consumption of Unit 1 .......................................................................................... 46



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Table 2-9: Fuel Consumption of Unit 2 .......................................................................................... 47

Table 2-10: Mass Balance for Ammonia (Proposed) ....................................................................... 54

Table 2-11: Mass Balance for Urea (Proposed) .............................................................................. 57

Table 2-12: Mass Balance for Aniline and Nitro Benzene (Proposed) ............................................... 63

Table 2-13: Mass Balance for TDI-MDI Blend (Proposed) ............................................................... 65

Table 2-14: Water Consumption details Existing and after Proposed Expansion (Unit-I) .................... 70

Table 2-15: Wastewater Generation for Existing and Proposed Expansion (Unit-I) ........................... 71

Table 2-16: Design Flow, Outlet Characteristics for the Existing Central ETP (Unit-I) ........................ 76

Table 2-17: Adequacy of Existing Central ETP based on Hydraulic Load (Unit-I) ............................... 79

Table 2-18: Analysis Results for Samples Collected from Existing Central ETP (Unit-I) ...................... 80

Table 2-19: Stage Wise Reduction after each Stage of Treatment of Central Aniline ETP (Unit-I) ...... 81

Table 2-20: Design Flow, Inlet and Outlet Characteristics for the Proposed STP (Unit-I) ................... 83

Table 2-21: Unit Sizes for Proposed Sewage Treatment Plant (Unit-I) ............................................. 86

Table 2-22: Water Consumption Details Existing and after Proposed Expansion (Unit-II) .................. 87

Table 2-23: Waste Water Generation Details Existing and after Proposed Expansion (Unit-II) ........... 88

Table 2-24: Design Flow, Inlet and Outlet Characteristics for the Existing Aniline ETP (Unit-II) ......... 92

Table 2-25: Adequacy of Existing Aniline ETP based on Hydraulic Load (Unit-II) .............................. 97

Table 2-26: Analysis Results for Samples Collected from Existing Aniline ETP (Unit-II) ..................... 99

Table 2-27: Stage Wise Reduction after each Stage of Treatment of Existing Aniline ETP (Unit-II) .... 99

Table 2-28: Design Flow, Inlet and Outlet Characteristics for the Proposed Aniline ETP (Unit-II) ..... 101

Table 2-29: Unit Sizes for Proposed Aniline Effluent Treatment Plant (Unit-II) ............................... 106

Table 2-30: Details of Existing and Proposed Flue Gas Stacks of Unit 1 ......................................... 108

Table 2-31: Details of Existing and Proposed Flare Stacks of Unit 1............................................... 108

Table 2-32: Details of Existing and Proposed Process Vents of Unit 1 ............................................ 109

Table 2-33: Details of Existing and Proposed Stacks of Unit 2 ....................................................... 110

Table 2-34: Details of Air Pollution Control Equipment at Unit-1 .................................................... 110

Table 2-35: Details of Air Pollution Control Equipment at Unit-2 .................................................... 112

Table 2-36: Sizing and Specifications of Ventuary Scrubber attached to Incinerator ....................... 113

Table 2-37: Specifications of Packed Bed Scrubber attached to Incinerator Stack ........................... 113

Table 2-38: Specifications of Air Pollution Control Equipments in Unit 2 ......................................... 117

Table 2-39: Details & Specifications of Proposed Air Pollution Control Equipment at Unit-1 ............. 118

Table 2-40: Details & Specifications of Proposed Air Pollution Control Equipment at Unit-2 ............. 118

Table 2-41: Daily Work Place Monitoring at GNFC ........................................................................ 119



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Table 2-42: Existing Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ........ 121

Table 2-43: Proposed Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ...... 125

Table 2-44: Summary Solid / Hazardous Waste Generation, Management and Disposal (Unit-I) ...... 126

Table 2-45: Adequacy of Hazardous Waste Storage Facility (Unit-I) .............................................. 128

Table 2-46: Existing Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ....... 129

Table 2-47 Proposed Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ...... 133

Table 2-48: Summary Solid / Hazardous Waste Generation, Management and Disposal (Unit-II) ..... 136

Table 2-49: Adequacy of Hazardous Waste Storage Facility (Unit-II) ............................................. 138

Table 2-50: Proximate Analysis of TDI Tar .................................................................................. 139

Table 2-51: Coordinates of Land Allocated for Proposed Plants ..................................................... 141

Table 2-52: Land Distribution Area Breakup for Proposed Plants (Unitwise) ................................... 145

Table 2-53: Operational Controls at Design Stage ........................................................................ 150

Table 3-1: Predominant Month-wise Wind Directions ................................................................... 155

Table 3-2: Average Meteorological Condition at Bharuch (1961 – 1976) ........................................ 156

Table 3-3: Monitoring Methodology of Meteorological Data .......................................................... 158

Table 3-4: Mean Meteorological Data for Summer Season 2013 .................................................... 159

Table 3-5: Synopsis of Land Use / Landcover Classification used for the Project ............................. 162

Table 3-6: GPS Readings Enumerating Land Features within Study Area ....................................... 164

Table 3-7: Land use / Landcover Pattern of the Study Area .......................................................... 165

Table 3-8: Area Statistic for Land Use / Land Cover Categories in the Study Area .......................... 166

Table 3-9: Important Feature within the Study Area .................................................................... 170

Table 3-10: Ambient Air Quality Monitoring Location Details and Justification ................................ 170

Table 3-11: Methodology of Ambient Air Monitoring..................................................................... 173

Table 3-12: Ambient Air Monitoring Results ................................................................................. 174

Table 3-13: Stack Monitoring Analysis Summary for Unit – 1 ........................................................ 178

Table 3-14: Stack Monitoring Analysis Summary for Unit – 2 ........................................................ 182

Table 3-15: Methodology of Noise Sampling & Monitoring ............................................................ 184

Table 3-16: Sampling Locations for Noise ................................................................................... 184

Table 3-17: Noise Level Readings (Unit – I) ................................................................................ 187

Table 3-18: Noise Level Readings (Unit – II) ............................................................................... 187

Table 3-19: Noise Level Readings (Study Area) ........................................................................... 187

Table 3-20: Ambient Noise Levels as per Noise Regulations.......................................................... 188

Table 3-21: Analysis Methodology of Ground Water and Surface Water ......................................... 189



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XVIII

Table 3-22: Surface Water Sampling Location (Pond & River) ....................................................... 190

Table 3-23: Analysis Results of Surface Water Samples ................................................................ 194

Table 3-24: Analysis Result of River Water Sample ...................................................................... 196

Table 3-25: Ground Water Sampling Locations ............................................................................ 197

Table 3-26: Analysis Report of Ground Water Samples ................................................................. 199

Table 3-27: Details of Samples Collected to assess impact of GNFC Waste Water Discharge on Water Quality of River ......................................................................................................................... 203

Table 3-28: Analytical Results of Surface Water samples collected along Garamia Nalla to assess impact of GNFC Waste Water Discharge on Water Quality of Nalla as well as Bhukhi River ............. 204

Table 3-29: Analytical results of Water samples Collected at Junction Point of Garamia Nalla & Bhukhi River ........................................................................................................................................ 207

Table 3-30: Comparison of GNFC Outlet with Discharge Norms Specified in Consent ...................... 209

Table 3-31: Geological Succession of Bharuch District .................................................................. 210

Table 3-32: Analysis Methodology of Soil .................................................................................... 214

Table 3-33: Soil Sampling Locations ........................................................................................... 214

Table 3-34: Soil Analysis Result .................................................................................................. 217

Table 3-35: Formulas for Analyzing Phyto-Sociological Characteristics of Vegetation ...................... 221

Table 3-36: Location of Quantitative Study of vegetation ............................................................. 221

Table 3-37: Quantitative Assessment of Vegetation ..................................................................... 224

Table 3-38: List of Flora in the Study Area .................................................................................. 225

Table 3-39: List of Birds with its Distribution and Migratory Status ................................................ 230

Table 3-40: List of Butterflies, Reptiles and Mammals with its Distribution and Migratory Status ...... 232

Table 3-41: Details of Sampling Locations ................................................................................... 234

Table 3-42: Phytoplankton Cell Count (No./Lit.) Across Sampling Locations ................................... 234

Table 3-43: Abundance of Phytoplankton .................................................................................... 234

Table 3-44: Zooplankton Standing Stock (No. /Lit)....................................................................... 235

Table 3-45: Abundance of Zooplankton....................................................................................... 235

Table 3-46: Presenting diversity (Shannon Weaver Index) Across Sampling Locations .................... 235

Table 3-47: List of Villages, Households and Population within the Study Area ............................... 237

Table 3-48: Gender Wise Population and Households Distribution ................................................. 238

Table 3-49: Number of SC/ST Population within the Study Area ................................................... 238

Table 3-50: Number of Villages having Educational Facilities within the Study Area ........................ 239

Table 3-51: Literacy Rate within the Study Area .......................................................................... 240

Table 3-52: Number of Villages having Health Facilities within the Study Area ............................... 240



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XIX

Table 3-53: Details of Drinking Water Facilities ............................................................................ 240

Table 3-54: Occupational Status of the Study Area ...................................................................... 242

Table 3-55: Number of Villages having Transportation Facilities within the Study Area ................... 242

Table 3-56: Communication Facilities within the Study Area ......................................................... 243

Table 4-1: Aspect – Impact Identification from Proposed Project .................................................. 245

Table 4-2: Impact Scoring Air Environment ................................................................................. 251

Table 4-3: Proposed Stacks of Unit – 1 ....................................................................................... 254

Table 4-4: Proposed Stacks of Unit – 2 ....................................................................................... 255

Table 4-5: Assumptions for Calculating Emission Estimate for Point Source ................................... 255

Table 4-6: Emission Estimate (Point Source) from Proposed Plants in Unit – 1 ............................... 256

Table 4-7: Emission Estimate (Point Source) from Proposed Plants in Unit – 2 ............................... 256

Table 4-8: Summary of Air Dispersion Modeling for Proposed Stacks ............................................. 258

Table 4-9: 24 Hr Average Incremental Increase in GLC from Proposed Project............................... 258

Table 4-10: Road Transportation Details for Raw Material (In) ..................................................... 263

Table 4-11: Road Transportation Details for Finished Product (Out) .............................................. 263

Table 4-12: Transportation Details for Unit 1 ............................................................................... 264

Table 4-13: Transportation Details for Unit 2 ............................................................................... 264

Table 4-14: Hourly Average Traffic Survey on NH-8 (Mumbai to Delhi) .......................................... 266

Table 4-15: Hourly Average Traffic on NH-8 (Delhi to Mumbai)..................................................... 266

Table 4-16: Hourly Average Traffic Survey on SH-6 (Dahej to Bharuch) ........................................ 266

Table 4-17: Hourly Average Traffic on SH-6 (Bharuch to Dahej) ................................................... 267

Table 4-18: Noise Modelling Calculation & Results for Long Duration Noise Sources ....................... 270

Table 4-19: Impact Scoring Noise Environment ........................................................................... 271

Table 4-20: Impact Scoring for Water Environment ..................................................................... 274

Table 4-21: Impact Scoring Land Use / Land Cover ..................................................................... 278

Table 4-22: Impact Scoring Soil Conservation ............................................................................. 280

Table 4-23: Impact Scoring – Solid Hazardous Waste Generation ................................................. 281

Table 4-24: Impact Scoring Ecology and Biodiversity ................................................................... 284

Table 4-25: Impact Scoring for Socio-Economic Environment ....................................................... 290

Table 4-26: Impact Scoring for Occupational Health and Risk to Surrounding Community ............... 290

Table 6-1: Environmental Monitoring Program for Air Environment ............................................... 298

Table 6-2: Environmental Monitoring Program for Noise Environment ........................................... 300

Table 6-3: Environmental Monitoring Program for Water Quality ................................................... 302



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XX

Table 6-4: Environmental Monitoring and Management Program for Soil Environment .................... 305

Table 6-5: Environmental Monitoring and Management Program for Solid Hazardous Waste Management ............................................................................................................................ 306

Table 6-6: Environmental Management Program for Ecological and Biodiversity Environment ......... 309

Table 6-7: Expenditure on Environmental Matters........................................................................ 310

Table 6-8: Summary of Environmental Monitoring Program .......................................................... 311

Table 7-1: Issues Rose during Public Hearing .............................................................................. 315

Table 7-2: Environment Related Key Issues for Proposed Plants and Commitment by GNFC ........... 316

Table 7-3: Positive Response from Nearby Villages ...................................................................... 317

Table 7-4: Population Data ........................................................................................................ 320

Table 7-5: Weather Condition Selected ....................................................................................... 320

Table 7-6: Event Classification ................................................................................................... 321

Table 7-7: Damage due to Radiation Intensity............................................................................. 323

Table 7-8: Overpressure Damage ............................................................................................... 323

Table 7-9: Chemicals with Storage Capacity, Storage Condition and Bund Dimension ..................... 326

Table 7-10: Radiation Level and Effect Distance due to release of Ammonia .................................. 328

Table 7-11: Overpressure Effect Distance due to the Release of Ammonia..................................... 328

Table 7-12: Effect Distance for Toxic Dose Due to Release of Ammonia ........................................ 329

Table 7-13: Radiation Level and Effect Distance Due to Release of Aniline ..................................... 330

Table 7-14: Overpressure Effect Distance Due to Release of Aniline .............................................. 330

Table 7-15: Radiation Level and Effect Distance Due to Release of Benzene .................................. 332

Table 7-16: Overpressure Effect Distance Due to Release of Benzene ........................................... 332

Table 7-17: Effect Distance for Toxic Dose Due to Release of Benzene .......................................... 332

Table 7-18: Radiation Level and Effect Distance Due to Release of Methanol ................................. 334

Table 7-19: Overpressure Effect Distance Due to Release of Methanol .......................................... 334

Table 7-20: Effect Distance for Toxic Dose Due to Release of Methanol......................................... 334

Table 7-21: Radiation Level and Effect Distance Due to Release of Nitrobenzene ........................... 336

Table 7-22: Overpressure Effect Distance Due to Release of Nitrobenzene .................................... 336

Table 7-23: Radiation Level and Effect Distance Due to Release of Toluene ................................... 337

Table 7-24: Overpressure Effect Distance Due to Release of Toluene ............................................ 337

Table 7-25: Effect Distance for Toxic Dose Due to Release of TDI ................................................ 339

Table 7-26: Conclusion .............................................................................................................. 340

Table 7-27: Failure Cases Input to PHAST Risk ............................................................................ 345



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXI

Table 7-28: Major Risk Contributors ........................................................................................... 353

Table 7-29: Fire Protection Facility at Site ................................................................................... 366

Table 7-30: Details of Checkup based on Exposure ...................................................................... 368

Table 10-1: Available Rainwater (Annual) for Harvesting in Unit-I ................................................. 381

Table 10-2: Available Rainwater (Maximum) for Harvesting in Unit-I ............................................. 381

Table 10-3: Available Rainwater (Annual) for Harvesting in Unit-II ................................................ 382

Table 10-4: Available Rainwater (Maximum) for Harvesting in Unit-II ............................................ 382

Table 10-5: Plant Species used for Landscaping around Offices and Residential Areas .................... 382

Table 10-6: Trees and Shrubs Species Planted in Various Locations of the Project Area .................. 383

Table 10-7: Proposed Plantation Schedule for next Five Years ...................................................... 385

Table 10-8: Allocation of Funds for CSR Activities in Last 5 Years.................................................. 385

Table 10-9: Proposed CSR Activities ........................................................................................... 386

Table 10-10: Traffic Management Plan ....................................................................................... 388

Table 10-11: Summary of EMP ................................................................................................... 390

Table 13-1: Status of Non and Partially compalances (Compliance Report – EC from MoEF-1) ......... 433

Table 13-2: Status of Non and Partially Compalances (Compliance Report – EC from MoEF-2) ........ 435

Table 13-3: Status of Non and Partially compalances (Compliance Report – EC from SEIAA) ........... 438

LIST OF FIGURES

Figure 2-1: Project Implementation Schedule ................................................................................ 48

Figure 2-2: Process Flow Diagram of Ammonia Plant (Proposed) .................................................... 50

Figure 2-3: Process Flow Diagram for Urea Plant (Proposed) .......................................................... 55

Figure 2-4: Process Flow Diagram for Water Soluble Fertilizers ....................................................... 58

Figure 2-5: Process Flow Diagram for Aniline Plant (Proposed) ....................................................... 61

Figure 2-6: Process Flow Diagram for TDI-MDI Blend (Proposed) ................................................... 64

Figure 2-7: Process Flow Diagram for CPSU (Proposed) ................................................................. 66

Figure 2-8: Existing Water Balance Diagram (Unit-I) ...................................................................... 72

Figure 2-9: Water Balance for Proposed Expansion of Ammonia and Urea Plant ............................... 73

Figure 2-10: Water Balance Diagram after Proposed Expansion (Unit-I) with Recycling and Reuse .... 74

Figure 2-11: Existing Water Balance Diagram (Unit-II) ................................................................... 89

Figure 2-12: Water Balance Diagram of Proposed Expansion (Unit-II) ............................................. 90



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXII

Figure 2-13: Water Balance Diagram after Proposed Expansion (Unit-II) ......................................... 91

Figure 2-14: Google Image of Site Showing Land Distribution of Proposed Plants .......................... 142

Figure 2-15: Site Location of Proposed Ammonia – Urea & CPSU Plants ........................................ 143

Figure 2-16: Site Location of Proposed Water Soluble Fertilizers (NPK) Plant ................................. 143

Figure 2-17: Site Location of Proposed Aniline Plant .................................................................... 144

Figure 2-18: Site Location of Propsoed ETP – Unit 2 .................................................................... 144

Figure 2-19: Site Location of Proposed TDI-MDI Blend Plant ........................................................ 145

Figure 2-20: Site Layout Plan for Proposed Ammonia and Urea Plants ........................................... 146

Figure 2-21: Site Layout Plan for Water Soluble Fertilizers (NPK) Plant .......................................... 147

Figure 2-22: Site Layout Plan for Proposed Aniline Plant............................................................... 148

Figure 2-23: Site Layout Plan for Proposed TDI – MDI Blend Plant ................................................ 149

Figure 3-1: Windrose Diagram for Summer Season ...................................................................... 160

Figure 7-1: Approach to QRA ..................................................................................................... 319

Figure 7-2: Late pool fire risk contour due to 50 mm Leak in Ammonia tank at weather 4.0/D ........ 329

Figure 7-3: Concentration risk contour - Catastrophic Rupture of Ammonia Tank at 4.0/D .............. 330

Figure 7-4: Late pool fire risk contour - Catastrophic Rupture in Aniline tank at 4.0/D .................... 331

Figure 7-5: Late Explosion overpressure risk contour catastrophic rupture of Aniline tank at 4.0/D .. 331

Figure 7-6: Late pool fire risk contour - Catastrophic Rupture in Benzene tank at 4.0/D .................. 332

Figure 7-7: Late Explosion overpressure risk contour - catastrophic rupture of Benzene tank at 4.0/D ............................................................................................................................................... 333

Figure 7-8: Concentration risk contour - Catastrophic Rupture of Benzene tank at 4.0/D ................ 333

Figure 7-9: Late pool fire risk contour - Catastrophic Rupture in Methanol tank at 4.0/D ................. 335

Figure 7-10: Late Explosion overpressure risk contour - Catastrophic rupture of Methanol tank at 4.0/D ............................................................................................................................................... 335

Figure 7-11: Late pool fire risk contour - Catastrophic Rupture in Nitrobenzene tank at 4.0/D ......... 336

Figure 7-12: Late Explosion overpressure risk contour - Catastrophic rupture of Nitrobenzene tank at 4.0/D ....................................................................................................................................... 337

Figure 7-13: Late pool fire risk contour - Catastrophic Rupture in Toluene tank at 4.0/D................. 338

Figure 7-14: Late Explosion overpressure risk contour - catastrophic rupture of Toluene tank at 4.0/D ............................................................................................................................................... 338

Figure 7-15: Concentration risk contour - Catastrophic Rupture of Toluene tank at 4.0/D ............... 339

Figure 7-16: Concentration risk contour - Catastrophic Rupture of TDI tank at 4.0/D ..................... 340

Figure 7-17: Criteria for Individual Risk ....................................................................................... 343

Figure 7-18: Criteria for Group Risk ............................................................................................ 344



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXIII

Figure 7-19: Iso-risk Contours-Overall Plant Area ........................................................................ 347

Figure 7-20: Iso-Risk Contour Enlarged View............................................................................... 348

Figure 7-21: Individual Risk ....................................................................................................... 349

Figure 7-22: FN Curve of Group Risk (on-site) ............................................................................. 351

Figure 7-23: FN curve of Group Risk (off-site) ............................................................................. 352

Figure 10-1: Hierarchy of Environment Management Cell ............................................................. 389

LIST OF PHOTOGRAPHS

Photograph 2-1: Photos of Central Effluent Treatment Plant (Unit-I) ............................................... 77

Photograph 2-2: ABB Analyzer system – EL3020.......................................................................... 112

Photograph 3-1: Meteorological Station set up at the Site ............................................................ 160

Photograph 3-2: Various Land uses of Study Area ....................................................................... 169

Photograph 3-3: AAQ Sampling Stations ..................................................................................... 171

Photograph 3-4: Noise Level Sampling Locations ......................................................................... 185

Photograph 3-5: Surface Water Sampling Locations ..................................................................... 192

Photograph 3-6: Ground Water Sampling .................................................................................... 198

Photograph 3-7: Photographs of Sampling at Garamia Nalla ......................................................... 210

Photograph 3-8: Soil Sampling Locations .................................................................................... 215

Photograph 3-9: Vegetation Cover and Sampling in Study area .................................................... 223

Photograph 3-10: Method of data collection used within the study area ........................................ 236

Photograph 3-11: Educational Facilities within the Study Area ...................................................... 239

Photograph 3-12: Animal Husbandry within Study Area................................................................ 241

Photograph 3-13: Places of Religious Importance Present within the Study Area ............................ 243

Photograph 7-1: Photographs of Public Hearing Publicity through Auto ......................................... 314

Photograph 7-2: Photographs of Public Hearing........................................................................... 318

Photograph 7-3: Rescue Tools Available ..................................................................................... 365

Photograph 7-4: Leak Detectors installed at Site.......................................................................... 366

Photograph 7-5: Photographs of Occupational Health Centre and Check up ................................... 372

Photograph 10-1: Existing Landscaping and Greenbelt with Project Premise .................................. 384

Photograph 12-1: Photographs showing EIA Team at Project Site and Study Area ......................... 397



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXIV

LIST OF MAPS

M- 2-1: Project Location Map ....................................................................................................... 37

M- 2-2: Satellite Image Showing the Project Site with Coordinates .................................................. 38

M- 2-3: Map Indicating Distance of Project site from Severely Polluted Area .................................... 39

M- 3-1: Study Area Map showing Nearby Industries, Habitation and Surface Water Bodies ............. 154

M- 3-2: Sampling Location Map .................................................................................................. 161

M- 3-3: Map Showing Land Use / Land Cover .............................................................................. 168

M- 3-4: Map Showing Extent of Garamia Nalla and Bhukhi River and Sampling Locations for Surface Water Samples collected ............................................................................................................ 208

M- 3-5: Geomorphology of Region .............................................................................................. 211

M- 3-6: Seismic Map of Gujarat State ......................................................................................... 212

M- 3-7: Soil Profile of Bharuch Region ........................................................................................ 213



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXV

ABBREVIATIONS

AAQM : Ambient Air Quality Monitoring

AAS : Atomic Absorption Spectroscopy

AERMIC : American Meteorological Society/Environmental Protection Agency Regulatory Model Improvement Committee

AERMOD : AMS/EPA Regulatory Model

ALARP : As Low As Reasonably Practicable

ANP : Ammonium Nitro Phosphate

APCM : Air Pollution Control Measures

APHA : American Public Health Association

BASF : Badische Anilin- und Soda-Fabrik

BATNEEC : Best Available Technology Not Entailing Excessive Costs

BEIL : Bharuch Enviro Infrastructure Limited

BHEL : Bharat Heavy Electricals Limited

BLEVE : Boiling Liquid Expanding Vapor Explosion

BOD : Biological Organic Demand

BSI : British Standards Institution

BVB : Bhartiya Vidya Bhavan

CAN : Calcium Ammonium Nitrate

CAS : Chemical Abstracts Service

CBM : Coal Bed Methane

CCA : Consolidated Consent and Authorization

CCE : Center for Credentialing and Education

CCTV : Closed Circuit Television

CETP : Central Effluent Treatment Plant

CAN : Concentrated Nitric Acid

CPCB : Central Pollution Control Board

CPSU : Cogeneration Power and Steam Unit

CO : Carbon Monoxide

COD : Chemical Oxygen Demand

CREP : Corporate Responsibility for Environment Protection

CSR : Corporate Social Responsibility

CTO : Consent to Operate

dB : Decibels

DCS : Distributed Control System

DG : Diesel Generator

DGVCL : Dakshin Gujarat Vij Company Limited

DM : De-mineralization

DMIC : Delhi-Mumbai Industrial Corridor

DMP : Disaster Management Plan

DNV : Det Norske Veritas

DPR : Detailed Project Report



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXVI

EAC : Expert Appraisal Committee

EC : Environmental Clearance

ECG : Electrocardiogram

EDTA : Ethylene-Diamine-Tetraacetic Acid

EIA : Environmental Impact Assessment

EMP : Environmental Management Plan

EMS : Environmental Management Systems

ERPG : Emergency Response Planning Guideline

ESP : Electro Static Precipitator

ETP : Effluent Treatment Plant

FAE : Functional Area Expert

FLOX : Flameless Oxidation

FRV : Fiber Reinforced Vinylester

GAIL : Gas Authority India Limited

GC : Gas Chromatography

GEPIL : Gujarat Enviro Protection & Infrastructure Limited

GHGs : Green House Gases

GIDC : Gujarat Industrial Development Corporation

GmbH : Gesellschaft mit beschränkter Haftung

GNFC : Gujarat Narmada Valley Fertilizers and Chemicals Limited

GoG : Government of Gujarat

GoI : Government of India

GPCB : Gujarat Pollution Control Board

GPS : Global Positioning System

GSFC : Gujarat State Fertilizers Company Limited

GSI : Geological Survey of India

GSPC : Gujarat State Petroleum Corporation Limited

GSPL : Gujarat State Petronet Limited

HB : Hemoglobin

HCs : Hydro-Carbons

HDPE : High-Density PolyEthylene

HF : Hydrogen Fluoride

HP / MP / LP : High Pressure / Medium Pressure / Low Pressure

HRSG : Heat Recovery Steam Generators

HRT : Hydraulic Retention Time

HSD : High Speed Diesel

HTAS : Haldor Topsoe

Hz : Hertz

IAA : Impact Assessment Authority

IAY : Indra Awas Yojna

IC : Incident Controller

ICDS : Integrated Child Development Services

IDLH : Immediately Dangerous to Life & Health



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXVII

IL&FS : Infrastructure Leasing & Financial Services Limited

IMD : India Meteorological Department

INR : Indian Rupees

IPP : Import Party Prices

IRC : Indian Roads Congress

IS : Indian Standards

ISLM : Integrating Sound Level Measurement

ISO : International Organization for Standardization

IUCN : International Union for Conservation of Nature

JV : Joint Venture

KBR : Kellogg Brown and Root

KEC : Kadam Environmental Consultants

KO : Knot Out

kPa : Kilo Pascal

kVA : Kilo Volt Amperes

LAC : Linde Ammonia Concept

LDO : Light Diesel Oil

LDPE : Low-Density PolyEthylene

LNG : Liquefied Natural Gas

LSIR : Location Specific Individual Risk

LSTK : Lump Sum Turn Key

MCAS : Maximum Credible Accident Scenario

MCC : Motor Control Center

MLSS : Mixed Liquor Suspended Solids

MMSCMD : Million Standard Cubic Feet per Day

MNREGS : Mahatma Gandhi National Rural Employment Guarantee Scheme

MTA : Metric Tons Per Annum

MTPD : Metric Tons Per Day

MDI : Methylene Diphenyl Diisocyanate

MoEF : Ministry of Environment & Forest

MSDS : Material Safety Data Sheet

MSU : Methanol Synthesis Unit

MW : Mega Watt

NABET : National Accreditation Board of Education & Training

NARDES : Narmadanagar Rural Development Society

NB : Nitrobenzene

NCPL : Narmada Chematur Petrochemicals Limited

NCSC : Narmada College of Science and Commerce

NEST : Narmada Education & Scientific Research Society

NG : Natural Gas

NH : National Highway

NH3 : Ammonia

NIHL : Noise Induced Hearing Loss



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXVIII

NIP : New Investment Policy

NITT : National Institute of Technical Training

NOC : No Objection Certificate

NOx : Oxides of Nitrogen

NPK : Nitrogen, Phosphorus & Potassium

NRHM : National Rural Health Mission

NRSA : National Remote Sensing Agency

ODCB : Ortho Di Chloro Benzene

ODS : Oxide Dispersion Stabilized

OHS : Occupational Health & Safety

OM : Office Memorandum

OMIFCO : Oman India Fertilizer Company

OSHAS : Occupation Health and Safety Assessment Series

P&ID : Piping and Instrumentation Diagram

PCM : Pollution Control Measures

PCPIR : Petroleum, Chemicals and Petrochemicals Investment Region

PCU : Passenger Car Unit

PDIL : Projects and Development India Limited

PEL : Permissible Exposure Level

PESO : Petroleum and Explosives Safety Organization

PFD : Process Flow Diagram

PFR : Pre-Feasibility Report

PFT : Pulmonary Function Test

pH : Power of Hydrogen

PHAST : Process Heating Assessment and Survey Tool

PM : Particulate Matter

PP : Polypropylene

PPE : Personal Protective Equipment

ppm : Parts per Million

PSA : Pressure Swing Adsorption

PUCC : Pollution Under Control Certificates

QCI : Quality Council of India

QRA : Quantitative Risk Assessment

GLC : Ground Level Concentration

GNFC : Gujarat Narmada Valley Fertilizers and Chemicals Limited

GSFC : Gujarat State Fertilizers Company Limited

RO : Regional Officer

RO : Reverse Osmosis

RLNG : Regasified Liquefied Natural Gas

RWH : Rain Water Harvesting

SAC : Sulphuric Acid Concentration

SAY : Sardar Awas Yojna

SEIAA : State Environmental Impact Assessment Authority



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXIX

SEZ : Special Economic Zone

SGPT : Serum Glutamic Pyruvate Transaminase (Liver Test)

SH : State Highway

SMC : Site Main Controller

SPL : Sound Pressure Level

SS : Suspended Solids

STP : Sewage Treatment Plant

TDI : Toluene Di-Isocyanate

TDS : Total Dissolved Solids

TEC : Toyo Engineering Corporation

TEFR : Techno-Economic Feasibility Report

TM Blend : TDI - MDI Blend

TOC : Total Organic Carbon

ToR : Terms of Reference

TSDF : Treatment, Storage and Disposal Facility

USEPA : United States Environmental Protection Agency

VOCs : Volatile Organic Compounds

VSCC : Vertical Submerged Carbamate Condenser

VTC : Vocational Training Center (VTC)

WNA : Weak Nitric Acid

ZSI : Zoological Survey of India



KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 XXX

LIST OF PERSONS AND INSTITUTIONS MET

GNFC Personnel

1 Mr. A. T. Patadia Executive Director

2 Mr. V. S. Sirohi General Manager

3 Mr. V. K. Nema General Manager

4 Mr. S. K. Mehta General Manager

5 Mr. P. G. Dave Additional General Manager

6 Mr. K. N. Jaggi Additional General Manager

7 Mr. V. C. Bhatt Additional General Manager

8 Mr. K. H. Patel Chief Manager

9 Mr. B. T. Golwala Chief Manager

10 Mr. P. K. Purohit Chief Manager

11 Mr. Y. C. Prajapati Sr. Manager

12 Mr. T.S Santa Sr. Manager

13 Mr. D.B. Shah Sr. Manager

14 Mr. V. N. Patel Sr. Manager

15 Dr. A. D. Thakkar Sr. Manager

16 Dr. J. B. Joshi Manager

17 Mr. Y. A. Patel Manager

18 Mr. S. R. Desai Manager

19 Mr. D. K. Patel Sr. Environmental Engineer

20 Mr. Anurag Srivastava NARDES - Manager

Others

1 Shri Jagdishbhai Patel Local Resident (Umraj Village)

2 Shri Madhusudan Patel Sarpanch (Umraj Village)

3 Shri Vasava Taraben Melabhai Sarpanch (Haldarva Village)

4 Shri Raijibhai Narsinhbhai Vasava Local Resident (Chavaj Village)

5 Shri Dahyabhai Premabhai Parmar Local Resident (Vadadla Village)

6 Smt Rashmika Parmar Local Resident (Vadadla Village)

7 Shri Ishwarbhai Ratanbhai Parmar Sarpanch (Vadadla Village)


EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 1

0 EXECUTIVE SUMMARY

0.1 PROJECT DESCRIPTION

0.1.1 About the Company and Project Proponent

GNFC is a joint sector enterprise promoted by the Government of Gujarat and the Gujarat State Fertilizer Company Ltd. (GSFC). It was set up in Bharuch, Gujarat in 1976. Located at Bharuch in an extremely prosperous industrial belt, GNFC draws on the resources of the natural wealth of the land as well as the industrially rich reserves of the area. For more than 30 years it is serving nation by making Fertilizers and Chemicals. It is a partner to the Nation's progress, its fertilizers playing a key role in enhancing agricultural output and its chemicals helping the Indian industrial revolution.

GNFC started its manufacturing and marketing operations by setting up in 1982, one of the world's largest single-stream ammonia-urea fertilizer complexes. Over the next few years, GNFC successfully commissioned different projects - in fields as diverse as chemicals, fertilizers and electronics.

GNFC has an enterprising, strategic view towards expansion and diversification. GNFC promoted Narmada Chematur Petrochemicals Limited. Now, it is merged as Unit – 2 in year 2007. As on date, Unit – 1 and Unit – 2 has separate Consent Orders from Gujarat Pollution Control Board (GPCB).

GNFC is run by experienced chairman, managing director, directors and executive directors with well qualified employees. GNFC has won various prestigious National and International awards with its state-of-the-art technology, high quality standards and productivity-conscious work-force. Recent award includes National Energy Conservation Award - 2013 in Fertilizer Sector. The award was bestowed to the MD-GNFC, Dr. Rajiv Kumar Gupta, IAS at the hands of Hon’ble President of India. Also, GNFC has won the prestigious FAI (Fertilizer Association of India) Award for the best production performance in Complex Fertilizer NP/NPK category for the year 2012-13.This award was given based on performance in production, specific energy consumption and P2O5 efficiency.

It intends to expand its manufacturing facilities for fertilizers and chemicals within its existing Fertilizer Complex at Bharuch.

0.1.2 About Project

Proposed project comprises of Brownfield Ammonia (2,800 MTD), Urea (3,850 MTD), various grades of Water Soluble Fertilizers (NPK) (5,000 MTA) and a 45 MW Co-generation Power & Steam Unit (CPSU) for Unit 1, whereas new Aniline (78,000 MTA) and TDI – MDI Blend (7,800 MTA) for Unit 2.

0.1.3 Regulatory Framework

The existing manufacturing facility has received environmental clearances for existing products from MoEF, New Delhi and SEIAA, Gujarat. Conditions as stipulated in valid consents are being complied with. Certification of compliance for environmental clearance conditions by MoEF, Bhopal has been received.

The proposed project is classified as Category “A” Project. Various components of the proposed expansion project lie under the following Project or Activity and Categories as per the schedule in EIA Notification 2006 amended till date:

1. 5(a) for Chemical Fertilizers : Category “A”


EIA & EMP REPORT FOR EXPANSION UNITS AT GNFC, BHARUCH EXECUTIVE SUMMARY

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2014 2

2. 5(f) for Synthetic Organic Chemicals Industries : Category “B” 3. 1(d) for Thermal Power Plants : Category “B”

Considering that the expansion projects are part of an integrated fertilizers and chemicals complex, these are submitted to the Impact Assessment Authority (IAA), Ministry of Environment and Forests (MoEF), New Delhi for consideration as an integrated project.

0.1.4 Location of the Project

The project site is located at Survey No. 5, 24/1-B, 99/3-A, 127, 38, 15 and 74 in Notified Industrial Area as per gazette notification enacted by Government of Gujarat (Ref. Map, M- 2-1). It is surrounded by Mumbai-Delhi National Highway (NH-8) at a distance of 0.5 km in East Direction and adjacent State Highway (SH – 6) connecting Dahej, a major sea port at approximately 48 km, Bharuch Railway Station is at ~3.9 km distance in SW direction, nearest airport is Surat Airport at a distance of 70.6 kms in SW Direction. The base elevation of site is at 19.2 m above mean sea level.

0.1.5 Project Cost

The estimated project cost INR 4,463 Crore includes environmental management cost ~ INR 153.67 Crore and recurring expenditure ~ INR 6.41 Crore per annum.

GNFC is engaged in the CSR activities like Education,

EIA & EMP Report for Expansion of Brownfield...

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