Eia MCFL 30112017 PDF

Environmental Impact Assessment
&
Environmental Management Plan
Report
for
1. Energy improvement project of Ammonia and Urea plant
2. 1 million t/y DAP/NPK project
3. Poly Carboxyl Ether project
By
At
Panambur, Mangalore - 575010
Submitted by:
EIA Consultant:
EQMS INDIA PVT. LTD. INDIA

304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower,
Community Centre, Karkardooma, Delhi – 110092
Phone: 011-30003200, 30003219; Fax: 011-22374775
Website: www.eqmsindia.com ; E-mail – eqms@eqmsindia.org
August-2017
Doc No.: EIA
Energy improvement project of Ammonia and Urea plant, 1 million Rev No. 0
t/y DAP/NPK project, Poly Carboxyl Ether project at Mangalore,
Karnataka Issue Date: 20.08.2017
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Contents
Executive Summary..............................................................................................................I-XII
Chapter 1. Introduction .................................................................................................... 7
1.1. Prelude ............................................................................................................................... 7
1.2. History of Existing Plant ...................................................................................................... 7
1.3. Justification for Proposed Projects ...................................................................................... 7
1.4. Need of the Study ............................................................................................................... 8
1.5. Project Location .................................................................................................................. 8
1.6. Scope of Study ................................................................................................................. 11
1.7. Regulatory Framework ..................................................................................................... 11
1.8. Approved ToR for EIA Study by MoEF- EAC .................................................................... 11
1.9. Methodology for Environmental Impact Assessment......................................................... 18
1.10. Contents of the EIA Report ............................................................................................... 19
Chapter 2. Project Description ....................................................................................... 21
2.1. Brief Overview of Existing Plant and Proposed Expansion................................................ 21
2.2. Energy improvement: Ammonia and Urea plants. ............................................................. 30
2.3. Process Description of existing Ammonia Plant ................................................................ 33
2.4. Revamp of Urea Plant ...................................................................................................... 38
2.7. Products with Capacities (Existing & Proposed) ............................................................... 51
2.8. Raw Materials (Existing & Proposed) ................................................................................ 52
2.9. Infrastructure& Utilities Required For Proposed Expansion Project................................... 52
2.10. Employment ..................................................................................................................... 57
2.11. Environmental Aspects: .................................................................................................... 57
Chapter 3. DESCRIPTION OF THE ENVIRONMENT ................................................... 69
3.1. Background and Salient Environmental Features of the Study Area ................................. 69
3.2. Environmental Setting and Salient Environmental Features of the Project Area ............... 69
3.3. Primary Data Collection: Monitoring Plan and Quality Assurance Procedures .................. 74
3.4. Physical Environment ....................................................................................................... 75
3.5. Meteorology ...................................................................................................................... 85
3.6. Ambient Air Quality ........................................................................................................... 88
3.7. Noise Environment ........................................................................................................... 92
3.8. Water Quality .................................................................................................................... 94
3.9. Soil................................................................................................................................. 100
3.10. Biological Environment ................................................................................................... 104
3.11. Socio-Economic Environment ......................................................................................... 116
3.12. Traffic Analysis ............................................................................................................... 131
Chapter 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION Measures134
4.1. Introduction..................................................................................................................... 134
4.2. Identification of Impacts .................................................................................................. 134
4.3. Impact on Topography .................................................................................................... 135
4.4. Impact on Climate ........................................................................................................... 136
4.5. Land Environment .......................................................................................................... 136
4.6. Air Environment .............................................................................................................. 138
4.7. Impact on Noise Levels .................................................................................................. 149
4.8. Impact on Water Quality ................................................................................................. 151
4.9. Solid / Hazardous Waste ................................................................................................ 154
4.10. Ecology........................................................................................................................... 155
4.11. Impact of Earthquake...................................................................................................... 157
4.12. Transport ........................................................................................................................ 157
4.13. Occupational Health and Risk......................................................................................... 157
Chapter 5. Analysis of alternatives (Site and Technology)........................................... 159
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5.1. Potential Location ........................................................................................................... 159

5.2. Technologies available ................................................................................................... 159
Chapter 6. Environmental Monitoring program ............................................................ 160
6.1. Objectives....................................................................................................................... 160
6.2. Proposed Environmental Monitoring Programme and Control ........................................ 160
6.3. Infrastructural Requirements for Monitoring .................................................................... 162
6.4. Environmental Organisational Setup............................................................................... 164
6.5. Submission of Monitoring Reports to Regulatory Authorities (MoEF&CC, CPCB,
KSPCB) ...................................................................................................................................... 165
Chapter 7. Additional Study ......................................................................................... 166
7.1. Introduction..................................................................................................................... 166
7.2. Scope of Work ................................................................................................................ 166
7.3. Objectives....................................................................................................................... 166
7.4. Methodology of HIRA...................................................................................................... 166
7.5. Hazardous Materials Bulk Storages at the MCF Plant .................................................... 167
7.6. Detailed QRA Approach: Rule Sets and Assumptions .................................................... 168
7.7. Effect & Consequence Analysis ...................................................................................... 171
7.8. Population Data .............................................................................................................. 172
7.9. Weather parameters ....................................................................................................... 174
7.10. Hazardous Incidents Impact ........................................................................................... 176
7.11. QRA Results ................................................................................................................... 182
7.12. Conclusions and Recommendations............................................................................... 186
7.13. Recommendations .......................................................................................................... 187
7.14. Occupational Health and Safety ..................................................................................... 187
7.15. Occupational Health – Proposal for Surveillance ............................................................ 189
7.16. Personal Protective Equipment (PPE) ............................................................................ 190
7.17. Disaster Management Plan............................................................................................. 193
7.18. Emergency Organization ................................................................................................ 196
7.19. Communication System .................................................................................................. 199
7.20. Pre-emergency activities ................................................................................................ 201
7.21. Causes of Emergency: ................................................................................................... 203
7.22. Off-Site Emergency Plan ................................................................................................ 204
7.23. Mock Drills and Records ................................................................................................. 205
Chapter 8. Environmental Management Plan .............................................................. 207
8.1. General........................................................................................................................... 207
8.2. Environmental Management Plan (EMP) comprises of ................................................... 207
8.3. Management Plan during Construction Phase ................................................................ 208
8.4. Management Plan during Operation Phase .................................................................... 210
8.5. Hazardous / Solid Waste Management ........................................................................... 213
8.6. Green Belt Development ................................................................................................ 216
8.7. Noise and Vibration ........................................................................................................ 219
8.8. Rain Water Harvesting System ....................................................................................... 219
8.9. Traffic Management Plan ................................................................................................ 220
8.10. Action Plans ................................................................................................................... 220
8.11. Socioeconomic Environment .......................................................................................... 222
8.12. Occupational Safety and Fire Fighting ............................................................................ 223
8.13. Environmental Policy of MCF .......................................................................................... 228
8.14. Measures for Protection of Environment ......................................................................... 228
8.15. Corporate Responsibility on Environmental Protection (CREP) ...................................... 231
8.16. The Fertilizer Association of India (FAI) Environmental Protection Award ....................... 231
8.17. CSR Activity ................................................................................................................... 232
Chapter 9. Summary and Conclusion .......................................................................... 234
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9.1. Summary and Conclusion ............................................................................................... 234

9.2. Regulatory Compliance .................................................................................................. 234
9.3. Baseline Conditions ........................................................................................................ 235
9.4. Environmental Impacts and Mitigation Measures ............................................................ 235
9.5. Recommendations .......................................................................................................... 235
Chapter 10. : DISCLOSURE OF CONSULTANTS ........................................................ 237
LIST OF TABLES
Table 1.1 Terms of Reference Compliance ......................................................................... 12
Table 2.1 : Salient Features (Existing & Proposed) ............................................................. 21
Table 2.2 : Co-ordinates (lat-long) of all four corners of the site ................................ 22
Table 2.3 Comparison of Fossil Fuel & Power consumptions between present and post
revamp conditions ........................................................................................................ 31
Table 2.4 Products with capacities (Existing & Proposed) ................................................... 51
Table 2.5 List of Raw materials required /Source /Transportation/Storage .......................... 52
Table 2.6 Land Distribution at Site (Acres) .......................................................................... 53
Table 2.7 Power Supply Details .......................................................................................... 53
Table 2.8 Stack Parameters and Emission Details of Proposed Sources ............................ 66
Table 2.9 Stack emission Rate – (Existing & Propose) ....................................................... 67
Table 3.1 : Salient Environmental Features of Proposed Site ............................................. 70
Table 3.2 Summary of Methodology for Primary/Secondary Baseline Data Collection ........ 74
Table 3.3 : Land use of the Study Area ............................................................................... 83
Table 3.4 : Long Term Meteorological Data of Mangalore (30 years average) .................... 85
Table 3.5 : No. of days with zero octas of cloud cover (Mangalore) .................................... 86
Table 3.6 : Monthly Percentages of Calm Periods (IMD Mangalore) ................................... 86
Table 3.7 : Site Specific Meteorological Data ...................................................................... 87
Table 3.8 : Ambient Air Quality Monitoring Locations .......................................................... 88
Table 3.9 : Ambient Air Quality Monitoring Results (24-hour average)................................ 89
Table 3.10 : Ambient Noise Quality Monitoring Locations ................................................... 93
Table 3.11 Ambient Noise Quality in the Study Area ........................................................... 93
Table 3.12 : Ground Water Sampling Locations .................................................................. 95
Table 3.13 : Ground Water Quality in the Study Area ......................................................... 96
Table 3.14 : Ground Water Quality in the Study Area ......................................................... 97
Table 3.15 : Surface Water Sampling Locations ................................................................. 99
Table 3.16 : Surface Water Quality in the Study Area ......................................................... 99
Table 3.17 : Soil Sampling Locations ................................................................................ 102
Table 3.18 : Physicochemical Characteristics of Soil ........................................................ 102
Table 3.19 : Abstract of various categories of forests in different ranges of Mangalore
division ....................................................................................................................... 104
Table 3.20 : List of the vegetation observed/ reported in the study area ........................... 108
Table 3.21 : List of the Mammals Recorded in Study Area ................................................ 111
Table 3.22 : List of Amphibians and Reptiles Recorded in Study Area .............................. 112
Table 3.23 : List of the Birds Surveyed / Recorded in the Study Area ............................... 112
Table 3.24 : Caste-wise Population Distribution of Study Area Villages ............................ 117
Table 3.25 : Male-female wise Literates & Illiterates ......................................................... 121
Table 3.26 : Distribution of Work Participation Rate .......................................................... 122
Table 3.27 : Village-wise Occupational Pattern in the Study Area ..................................... 124
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Table 3.28 : Composition of Non-Workers ................................................................... 126

Table 3.29 : Village wise Basic Amenities (Census Records 2011) .................................. 129
Table 3.30 : Abbreviations used in the Table 3.29 are as follows; ..................................... 129
Table 3.31 : Traffic Analysis Results ................................................................................. 132
Table 3.32 Traffic Analysis results..................................................................................... 132
Table- 4.1 Proposed activities during Construction phase ................................................. 135
Table 6.1 : Air Quality Monitoring Schedule ...................................................................... 160
Table 6.2 : Water And Wastewater Monitoring Schedule .................................................. 161
Table 6.3 List of Equipment in Laboratory ......................................................................... 162
Table 8.1 Air Pollution (Control & Treatment) .................................................................... 211
Table 8.2 Quantification of Waste Generation (Existing/Proposed) ................................... 214
Table 8.3 List of Equipment Required ............................................................................... 225
Table 8.4 Total estimated budget for implementation of EMP ........................................... 230
LIST OF FIGURES
Figure 1.1 Photograph of Project Site ................................................................................... 9
Figure 1.2 : Location of the Project Area............................................................................. 10
Figure 2.1 : Location on Topo Map ..................................................................................... 23
Figure 2.2 : Location on Google Map .................................................................................. 24
Figure 2.3 : Coordinates of Project boundary...................................................................... 25
Figure 2.4 : Plant Layout (All the Facility) ............................................................................ 26
Figure 2.5 : Plant Layout (Revamp of Urea & Ammonia Facility) ......................................... 27
Figure 2.6 : Plant Layout (DAP/NPK Facility) ...................................................................... 28
Figure 2.7 : Plant Layout (PCE Facility) .............................................................................. 29
Figure 2.8 Improvement in Specific Energy Consumption in Ammonia & Urea over the period
.................................................................................................................................... 31
Figure 2.9 Process Flow Diagram ....................................................................................... 35
Figure 2.10 Block Diagram of Urea Process ....................................................................... 38
Figure 2.11 Process Flow Diagram of NPK Plant ................................................................ 49
Figure 2.12 Process Flow Diagram ..................................................................................... 51
Figure 2.13 Water Balance Diagram (Existing).................................................................... 54
Figure 2.14 Water Balance Diagram (Expansion) ............................................................... 55
Figure 2.15 Urea Hydrolyser System .................................................................................. 60
Figure 2.16 Lamella clarifier ................................................................................................ 61
Figure 2.17 Infrastructure For Waste Water Treatment Facility In MCF ............................... 62
Figure 2.18 RO unit ............................................................................................................. 63
Figure 2.19 Sewage water treatment unit with MBR technology .......................................... 64
Figure 3.1 Google Map showing Site & Surrounding Environmental Features within 10 km
area ............................................................................................................................. 72
Figure 3.2 Location Map of Study area ............................................................................... 73
Figure 3.3 Environment sampling Location Map.................................................................. 76
Figure 3.4 Digital Elevation Map of Study Area ................................................................... 77
Figure 3.5 Drainage Map of Study Area .............................................................................. 78
Figure 3.6 Geological Map of the Mangluru ......................................................................... 79
Figure 3.7 : Depth of Ground Water Table in Dakshina Kannada District ............................ 80
Figure 3.8 Hydrogeology of Dakshin Kanada ...................................................................... 81
Figure 3.9 Seismic Zones Map ............................................................................................ 82
Figure 3.10 Land Use Map of the Study Area (10 km Radial Zone) .................................... 84
Figure 3.11 : Wind Frequency distribution (Winter Season) .......................................... 87
Figure 3.12 : Wind Rose (Winter Season) ......................................................................... 88
Figure 3.13 : Concentration of PM10 in the study area ....................................................... 90
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Figure 3.14 : Concentration of PM2.5 in the study area ...................................................... 91

Figure 3.15 : Concentration of SO2 in the study area ......................................................... 91
Figure 3.16 : Concentration of NOx in the study area ......................................................... 92
Figure 3.17 : Graphical representation of ambient Noise Level in the study area ................ 94
Figure 3.18 : Soil Map of Magalore District ....................................................................... 101
Figure 3.19 : Male-Female wise Population Distribution in the Study Area ....................... 119
Figure 3.20 : Male-Female wise Population Distribution in Mangalore (MC+OG) ............. 119
Figure 3.21 : Scheduled Caste Population Distribution ..................................................... 120
Figure 3.22 : Scheduled Tribes Population Distribution .................................................... 120
Figure 3.23 : Male-Female Wise Distribution of Literates & Illiterates ............................... 121
Figure 3.24 : Workers Scenario of the Study Area ............................................................ 123
Figure 3.25 : Composition of Main Workers ...................................................................... 125
Figure 3.26 : Composition of Marginal Workers ................................................................ 125
Figure 3.27 : Composition of Non-Workers ....................................................................... 126
Figure 4.1 Isopleths for Proposed Stack............................................................................ 144
Figure 4.2 Isopleths for Existing Stack .............................................................................. 145
Figure 6.1 Exiting Laboratory ............................................................................................ 163
Figure 6.2 NABL Certificate .............................................................................................. 164
Figure 7.1 Wind Rose Diagram for Mangalore .................................................................. 176
Figure 7.2 : Imported ammonia tank outlet line leak –Ammonia Dispersion....................... 178
Figure 7.3 : Imported ammonia tank outlet line leak –Ammonia Dispersion....................... 179
Figure 7.4 : New ammonia tank outlet line leak –Ammonia Dispersion ............................. 179
Figure 7.5 : Naphtha Tank Roof Failure – Full Surface Fire............................................... 180
Figure 7.6 : Naphtha Tank Roof Failure – Flash Fire ......................................................... 180
Figure 7.7 : Naphtha Tank Large Spill– Dyke Fire ............................................................. 181
Figure 7.8 : Naphtha Tank Large Spill– Flash Fire ............................................................ 181
Figure 7.9 : Methacrylic Acid Tank Large Spill– Dyke Fire ................................................ 182
Figure 7.10 : Iso-Risk Contours on MCF Plot Plan ............................................................ 183
Figure 7.11 : Iso-Risk Contours on MCF Plot Plan (Enlarged - 1) ..................................... 183
Figure 7.12 : Iso-Risk Contours on MCF Plot Plan (Enlarged - 2)...................................... 184
Figure 7.13 : Maximum Individual Risk at MCF Plant ........................................................ 185
Figure 7.14 : Societal Risk due to MCF Plant .................................................................... 186
Figure 8.1 Existing Green Belt area .................................................................................. 217
Figure 8.2 Photograph Green Belt area ............................................................................ 218
Figure 8.3 Rain Water Harvesting System ........................................................................ 220
Figure 8.4 Medical Facility Inside the MCF Plant ............................................................... 226
LIST OF ANNEXURE
Annexure I: NABET Certificate
Annexure II: Land Document
Annexure III: ToR Letter
Annexure IV: Compliance of Earlier EC Letter
Annexure V: Agreement with GAIL for Gas Supply
Annexure VI: Compliance of CREP Guideline
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CHAPTER 1. INTRODUCTION
This chapter provides background information of the project proponent, Need for
the EIA study as per prevailing legislation, location and brief description of the
project, methodology adopted for EIA study and structure of the report.
1.1. Prelude
Mangalore Chemicals & Fertilizers Ltd (MCF) is an 'Adventz' Group Company, a large
and diversified business house. The main products of MCF are Urea, Di-Ammonium
Phosphate (DAP), NP 20:20:00:13, Ammonium Bi-Carbonate (ABC) - Food grade,
Sulphuric Acid, Specialty Mixtures of Plant Nutrients consisting of Water Soluble
Fertilizers, Micronutrients & Soil Conditioners and an Industrial Product called
Sulphonated Naphthalene Formaldehyde (SNF) used in construction industry. MCF is
an ISO 14001, OHSAS 18001 and ISO 22000 certified Company.
1.2. History of Existing Plant

Construction of Ammonia and Urea plants commenced in 1972 and commercial
production started in 1976. Di-ammonium Phosphate (DAP) production commenced
during 1986. Commercial production of Ammonium Bicarbonate started in 1982.
Sulphuric Acid Plant was commissioned during March 2006. A new construction
chemical product Sulphonated Naphthalene Formaldehyde facility was installed in
2010 as part diversification. MCF also has installed a Specialty fertilizer plant to make
Water Soluble Fertilizers & Micronutrients in 2011.
1.3. Justification for Proposed Projects

Energy improvement project of Ammonia and Urea plant
Energy improvement Project of Ammonia & Urea plants by modernization and

capacity enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from
4,29,000 t/y to 5,69,400 t/y. :
Government of India announced new Urea policy No. 12012/1/2015-FPP dated 25-05-
2015 which mandated all Ammonia, Urea manufacturer to improve the energy norms
to particular levels by 2018-19. The norms prescribed for MCF vintage is 6.5 Gcal/t of
urea from present 6.9015 Gcal/t. As the operation profitability depends only on actual
energy consumption and payment of all subsidies are energy dependent, it becomes
necessary for manufacturers like MCF to bring down energy norms to best achievable
industry levels to continue profitable operation. Current energy consumption of Urea
production at MCF is 6.5 Gcal/t and MCF intends to do energy improvement revamp
of existing Ammonia / Urea plants to reduce its energy consumption from present
levels.
Also, Urea is an important fertilizer segment. The supply/demand gap is huge and
more than 8 million tons of urea imports are done as of now. The estimated total
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demand supply gap in 2015- 2016 was 8.2 Million MT of urea alone. Government of
India is bound to support this industry through conducive policies/subsidies. All
southern states of India namely Karnataka, Tamilnadu, Kerala and Andhra Pradesh
have enough demand for Urea. In view of this, MCF proposes capacity enhancement
of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to 5,69,400
t/y. The capacity enhancement proposed by MCF will help towards filling the
supply/demand gap.
New DAP/ NPK plant
There is increasing demand of DAP/NPK fertilizers in the country. The estimated total
demand supply gap of DAP/NPK would be 11 Million MT by 2017-2018. The proposed
expansion project of DAP/NPK would contribute in reducing the dependence on
import of DAP/NPK fertilizers.
New PCE Plant
Higher grade (> M45 Grade) concrete requires different type of admixtures known as
super plasticizers. Poly Carboxyl Ether (PCE) acts as Super plasticizers and is
currently being imported in the country. The proposed new facility within MCF plant
would be contributing in our country’s “Make in India” Program.
1.4. Need of the Study

As per the Ministry of Environment, Forest & Climate Change (MoEFCC),
Government of India EIA Notification 2006 and as amended on December 1, 2009,
the proposed Expansion Project need to take environmental clearance prior to
commissioning of the plant. The proposed project is covered under Category 'A' as
per the Schedule of EIA Notification and hence requires environmental clearance from
Environmental Impact Assessment Authority (EIAA) of MoEF, New Delhi.
This Environmental Impact Assessment (EIA) study undertaken is mainly focused on

identification of existing environmental conditions of the project, its impact on pre and
post commissioning. A detailed prediction of all environmental impacts associated
with the various activities during the construction and operation phases of the
proposed modernization – expansion plan suggesting suitable measures to navigate
the observed adverse environmental impacts. The study also aims at reflecting the
acceptability of the project to different stakeholders and at incorporating the concerns
raised by them into impact assessment and of the subsequent Environmental
Management Plan (EMP). These all mentioned above are part of the Environment
Impact Assessment (EIA) project Study.
1.5. Project Location

The factory is located at Panambur, 9 km north of Mangalore City, along the National
Highway 66, opposite to the New Mangalore Port Trust.
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DAP Plant PCE Plant
Ammonia Plant Urea Plant

Figure 1.1 Photograph of Project Site
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Source: EQMS
Figure 1.2 : Location of the Project Area
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1.6. Scope of Study

The EIA shall be generally as per the “TOR” approved for the proposal by EAC, Delhi.
The report will examine the sustainability of proposal and adequacy of mitigation
measures. The detailed environment management plan will be prepared which will
include collection of baseline data about. Air, Noise, Water, soil for one season and
data related to Land, ecology and biodiversity and Socio-economy and hazardous and
non-hazardous solid wastes, risk associated with handling of hazardous chemicals.
For environmental assessment, areas within 10 km radial zone of the project have
been studied and classified as study Area. Following methodology has been adopted
for the EIA study:
 Identification of sources of pollution during construction and operation phases
of the project at the proposed site
 Identification of utilisation of resources obtained during construction and
operation phases of the project
 Assessment of extent of pollution and resource utilisation in the proposed area
 Recommend measures to optimise resource utilisation
 Develop an environmental monitoring plan to ensure effective implementation
of the environmental management plan
1.7. Regulatory Framework
The plant operation has been subjected to other procedural and compliance
monitoring programme viz. annual consents under Water (Prevention and Control of
Pollution) Act, 1974; Air (Prevention and Control of Pollution) Act, 1981; authorization
under Hazardous Waste (Management & Handling) Rules, 1989/ 2000; Environment
(Protection) Act, 1986; requirements and statutory norms as per Karnataka Pollution
Control Board etc. The production level of this plant has been as per the
clearances/consents.
In addition to environmental regulatory compliance, MCFL is also complying with
following other statutory rules and regulations:
 Fuels and other hazardous (Inflammable & Explosives) materials storages (As
per Petroleum and Explosive Safety Organization, Nagpur; rules and guide
lines)
 Labour laws as per Labour Commissioner, Government of Karnataka,
 Boilers regulation and Safety guidelines as per Directorate of Factories, Boilers,
Industrial Safety & Health, Govt of Karnataka
1.8. Approved ToR for EIA Study by MoEF- EAC
As per the Environmental Impact Assessment Notification, S.O. 1533, 14th September
2006, Schedule – I, the proposed industry falls under the Category 5 (A).
Based on the application submitted to MoEF and presentation made in 11th EAC held
on 20th and 21st July 2016 at MoEF has issued TOR on 23rd September 2016 vide its
letter no J-1011/159/2016-IA II (I) The EIA study has been conducted in-line with the
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approved ToR by EAC (MoEF) and taking into consideration the structure of the report
given in the EIA Notification 2006. The compliance to the approved TOR has been
presented in Table 1.1:
Table 1.1 Terms of Reference Compliance
S.
ToR Points Tor Compliance
No.
1. Executive Summary Enclosed with EIA Report
Introduction
I. Details of the EIA Consultant including NABET Enclosed as an Annexure I.
2. accreditation
II. Information about the project proponent Importance Details are given section 1.1 & 1.2 of
and benefits of the project. chapter 1.
Project Description
Section 2.11.6 of Chapter 2.
i. Cost of project and time of completion.
Existing and proposed capacity of plant
ii. Products with capacities for the proposed project.
is given in Table 2.4 of chapter 2.
iii. If expansion project, details of existing products with
Existing and proposed land distribution
capacities and whether adequate land is available for
is given Table 2.6 of Chapter 2.
expansion, reference of earlier EC if any.
Existing and proposed raw material
iv. List of raw materials required and their source along
details are given Table 2.5 of Chapter
with mode of transportation.
2.
Detailed bulk storage with item and
v. Other chemicals and materials required with quantities
quantity is given in Table 7.1 of Chapter
and storage capacities
7.
vi. Details of Emission, effluents, hazardous waste Detailed environmental aspect covered
generation and their management. in section 2.11 of Chapter 2.
vii. Requirement of water, power, with source of supply, Details of infrastructure, Power, water
status of approval, water balance diagram, man-power etc are given in section 2.9 of chapter
requirement (regular and contract) 2.
viii. Process description along with major equipment and
From section 2.3 to 2.6 all process
machineries, process flow sheet (quantitative) from raw
3. details are given in chapter 2.
material to products to be provided
ix. Hazard identification and details of proposed safety Details are given different section of
systems. chapter 7.
x. Expansion/modernization proposals:
a. Copy of all the Environmental Clearance (s) including
Amendments thereto obtained for the project from
MOEF/SEIAA shall be attached as an Annexure . A
certified copy of the latest Monitoring Report of the
Regional Office of the Ministry of Environment and
Forests as per circular dated 30th May, 2012 on the
status of compliance of conditions stipulated in all the Details are given in Annexure IV.
existing environmental clearances including
Amendments shall be provided. In addition, status of
compliance of Consent to Operate for the on-going
existing operation of the project from SPCB shall be
attached with the EIA-EMP report.
b. In case the existing project has not obtained
environmental clearance, reasons for not taking EC
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under the provisions of the EIA Notification 1994

and/or EIA Notification 2006 shall be provided .
Copies of Consent to Establish/No Objection
Certificate and Consent to Operate (in case of units
operating prior to EIA Notification 2006, CTE and
CTO of FY 2005-2006) obtained from the SPCB shall
be submitted. Further, compliance report to the
conditions of consents from the SPCB shall be
submitted
Site Details
I. Location of the project site covering village, Justification of project is given in
Taluka/Tehsil, District and State, Justification for section 1.3 and Site Details are given
1.5 of chapter 1.
selecting the site, whether other sites were considered .
II. A toposheet of the study area of radius of 10-km and
site location on 1:50,000/1: 25,000scales on an A3/A2 Location map on Topo sheet is given in
sheet. (including all eco-sensitive areas and Figure 2.1 of chapter 2.
environmentally sensitive places)
Sufficient site is available in Existing
III. Details w.r.t. option analysis for selection of site
premises
Details are given in Figure 2.3 of
IV. Co-ordinates (lat-long) of all four corners of the site.
Chapter 2.
Details are given in Figure 3.1 of
V. Google map-Earth downloaded of the project site.
chapter 3.
VI. Layout maps indicating existing unit as well as proposed
unit indicating storage area, plant area, greenbelt area, Detailed plant layout with all upcoming
utilities etc. If located within an Industrial and existing facility is given in Figure
area/Estate/Complex, layout of Industrial Area indicating 2.4 of chapter 2.
location of unit within the Industrial area /Estate.
VII. Photographs of the proposed and existing (if applicable)
4. Site photograph is given in Figure 1.1
plant site. If existing, show photographs of
of chapter 1.
plantation/greenbelt.
VIII. Land use break-up of total land of the project site
(identified and acquired), government/ private - There is no land acquisition in this
agricultural, forest, wasteland, water bodies, project. The proposed project is coming
settlements, etc shall be included. (not required for in the existing facility of MCF
industrial area)
IX. A list of major industries with name and type within
The major industries near the project
study area (10km radius) shall be incorporated. Land
site are given in Figure 3.1 of chapter 3.
use details of the study area
X. Geological features and Geo-hydrological status of the Details are given in section 3.4 of
study area shall be included. Chapter 3.
XI. Details of Drainage of the project up to 5 .0-km radius of
study area. If the site is within 1.0-km radius of any
major river, peak and lean season river discharge as
The environments near the project site
well as flood occurrence frequency based on peak
are given in Figure 3.1 of chapter 3.
rainfall data of the past 30 years . Details of Flood Level
of the project site and maximum Flood Level of the river
shall also be provided. (mega green field projects)
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XII. Status of acquisition of land. If acquisition is not

complete, stage of the acquisition process and expected The proposed project in coming in
existing premises of MCF.
time of complete possession of the land.
XIII. R&R details in respect of land in line with state
There is no R&R involve in this project.
Government policy
Forest and wildlife related issues (if applicable):
I.
Permission and approval for the use of forest land
(forestry clearance), if any, and recommendations of
the State Forest Department. (if applicable).
II. Land use map based on High resolution satellite
imagery (GPS) of the proposed site delineating the
forestland (in case of projects involving forest land
more than 40 ha)
III. Status of Application submitted for obtaining the
stage I forestry clearance along with latest status
shall be submitted.
IV. The projects to be located within 10 km of the
5. Not Applicable
National Parks, Sanctuaries, Biosphere Reserves,
Migratory Corridors of Wild Animals, the project
proponent shall submit the map duly authenticated by
Chief Wildlife Warden showing these features vis-à-
vis the project location and the recommendations or
comments of the Chief Wildlife Warden-thereon.
V. Wildlife Conservation Plan duly authenticated by the
Chief Wildlife Warden of the State Government for
conservation of Schedule I fauna, if any exists in the
study area
VI. Copy of application submitted for clearance under the
Wildlife (Protection) Act, 1972, to the Standing
Committee of the National Board for Wildlife
Environmental Status:
I. Determination of atmospheric inversion level at the
project site and site-specific micro-meteorological Detailed metrology data given in
data using temperature, relative humidity, hourly wind section 3.5 of chapter 3.
speed and direction and rainfall.
II. AAQ data (except monsoon) at 8 locations for PM10,
PM2.5, SO2, NOX, CO and other parameters
relevant to the project shall be collected . The
Detailed ambient air quality data is
6. monitoring stations shall be based CPCB guidelines
given in Section 3.6 of chapter 3.
and consider the pre-dominant wind direction,
population zone and sensitive receptors including
reserved forests.
III. Raw data of all AAQ measurement for 12 weeks of all
stations as per frequency given in the NAQQM
Notification of Nov. 2009 along with - min., max., The air monitoring was conducted at 8
locations in the study area.
average and 98% values for each of the AAQ
parameters from data of all AAQ stations should be
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provided as an annexure to the EIA Report .

IV. Surface water quality of nearby River (100m
upstream and downstream of discharge point ) and Detailed surface quality of water is
other surface drains at eight locations as per CPCB/ given in section 3.8 of chapter 3.
MoEF& CC guidelines.
V. Whether the site falls near to polluted stretch of river
identified by the CPCB / MoEF & F & CC, if yes give Not Applicable
details.
VI. Ground water monitoring at minimum Eight (08) Detailed ground water quality is given
locations shall be included. in section 3.8 of chapter 3.
VII. Noise levels monitoring at 8 locations within the study Ambient Noise monitoring sampling
location along with result is given in
area.
section 3.7 of chapter 3.
A detail of soil sampling location along
VIII. Soil Characteristic as per CPCB guidelines . with result is given in section 3.9 of
chapter 3.
IX. Traffic study of the area, type of vehicles, frequency
of vehicles for transportation of materials, additional Detailed traffic study is given in section
traffic due to proposed project, parking arrangement 3.12 of chapter 3.
etc.
X. Detailed description of flora and fauna (terrestrial and
aquatic) existing in the study area shall be given with
special reference to rare, endemic and endangered Detailed biological environment is given
species. If Schedule-I fauna are found within the in section 3.10 of chapter 3.
study area, a Wildlife Conservation Plan shall be
prepared and furnished.
Detailed Socio Economic is given in
XI. Socio-economic status of the study area.
section 3.11 of chapter 3.
Impact and Environment Management Plan
i. Assessment of ground level concentration of pollutants
from the stack emission based on site-specific
meteorological features. In case the project is located
on a hilly terrain, the AQIP Modeling shall be done using
inputs of the specific terrain characteristics for
The Detailed modeling along with
determining the potential impacts of the project on the
isopleths and ground level
AAQ. Cumulative impact of all sources of emissions
concentration is given in section 4.6 of
(including transportation) on the AAQ of the area shall
Chapter 4.
be assessed. Details of the model used and the input
data used for modelling shall also be provided. The air
quality contours shall be plotted on a location map
7.
showing the location of project site, habitation nearby,
sensitive receptors, if any.
ii. Water Quality modelling - in case of discharge in water
Not applicable
body
iii. Impact of the transport of the raw materials and end
products on the surrounding environment shall be
assessed and provided. In this regard, options for
Details are given in section 4.12 of
transport of raw materials and finished products and
chapter 4.
wastes (large quantities) by rail or rail-cum road
transport or conveyor-cum-rail transport shall be
examined.
iv. A note on treatment of wastewater from different plant Details are given in Section 4.8 of
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operations, extent recycled and reused for different chapter 4.

purposes shall be included. Complete scheme of
effluent treatment. Characteristics of untreated and
treated effluent to meet the prescribed standards of
discharge under E (P) Rules.
Stack details with pollution control
v. Details of stack emission and action plan for control of
measures are given in section 8.4 of
emissions to meet standards.
chapter 8.
vi. Measures for fugitive emission control
vii. Details of hazardous waste generation and their
storage, utilization and management. Copies of MOU
regarding utilization of solid and hazardous waste in
Details are given in section 8.5 of
cement plant shall also be included. EMP shall include
chapter 8
the concept of waste-minimization,
recycle/reuse/recover techniques, Energy conservation,
and natural resource conservation.
viii. Proper utilization of fly ash shall be ensured as per Fly
Ash Notification, 2009. A detailed plan of action shall be Not Applicable
provided.
ix. Action plan for the green belt development plan in 33 %
area i.e. land with not less than 1,500 trees per ha.
Giving details of species, width of plantation, planning
schedule etc. shall be included. The green belt shall be No addition green belt is required.
around the project boundary and a scheme for greening
of the roads used for the project shall also be
incorporated.
x. Action plan for rainwater harvesting measures at plant
site shall be submitted to harvest rainwater from the roof
tops and storm water drains to recharge the ground The details of rain water harvesting are
water and to use for the various activities at the project given in section 8.4.5 of chapter 8.
site to conserve fresh water and reduce the water
requirement from other sources.
xi. Total capital cost and recurring cost/annum for
Approximate 56 Cr as a capital cost
environmental pollution control measures shall be
along with 3 Cr as recurring cost.
included.
Detailed action plan for post
xii. Action plan for post-project environmental monitoring
environmental monitoring is given in
shall be submitted.
Chapter 6.
xiii. Onsite and Offsite Disaster (natural and Man-made)
Preparedness and Emergency Management Plan The detailed DMP along with
including Risk Assessment and damage control. Quantitative risk assessment report is
Disaster management plan should be linked with District given in chapter 7
Disaster Management Plan
Occupational health
i. Plan and fund allocation to ensure the occupational

health & safety of all contract and casual workers
ii. Details of exposure specific health status evaluation of
worker. If the workers' health is being evaluated by pre-
designed format, chest x rays, Audiometry, Spirometry,
8.
Vision testing (Far & Near vision, color vision and any
other ocular defect) ECG, during pre-placement and
periodical examinations give the details of the same.
Details regarding last month analyzed data of above MCF is having all the facility inside the
mentioned parameters as per age, sex, duration of primes. The details are given in section
exposure and department wise. 8.12 of chapter 8.
iii. Details of existing Occupational & Safety Hazards. What
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are the exposure levels of hazards and whether they are

within Permissible Exposure level (PEL)?If these are not
within PEL, what measures the company has adopted to
keep them within PEL so that health of the workers can
be preserved,
iv. Annual report of health status of workers with special
reference to Occupational Health and Safety.
9) Corporate Environment Policy
i. Does the company have a well laid down Environment
Policy approved by its Board of Directors? If so, it may
be detailed in the EIA report.
ii. Does the Environment Policy prescribe for standard
operating process / procedures to bring into focus any
infringement / deviation / violation of the environmental
or forest norms / conditions? If so, it may be detailed in
the EIA.
9. Detailed environmental policy of MCF is
iii. What is the hierarchical system or Administrative order
given in Section 8.13 of chapter 8.
of the company to deal with the environmental issues
and for ensuring compliance with the environmental
clearance conditions? Details of this system may be
given.
iv. Does the company have system of reporting of non-
compliances/ violations of environmental norms to the
Board of Directors of the company and / or shareholders
or stakeholders at large? This reporting mechanism
shall be detailed in the EIA report
Details regarding infrastructure facilities such as sanitation, At the time of construction, the local
10. fuel, restroom etc. to be provided to the labour force during worker will be involve and in operation
construction as well as to the casual workers including truck phase exiting facility will be use for
drivers during operation phase. Truck drivers.
Enterprise Social Commitment (ESC)
v. Adequate funds (at least 2.5 % of the project cost) shall
MCF is involved so many CSR activity
be earmarked towards the Enterprise Social
Mangala Akshara Mitra’, Project Eye
11. Commitment based on Public Hearing issues and item-
Care, Mangala Rytha Suraksha Vima
wise details along with time bound action plan shall be
Yojana etc.
included. Socio-economic development activities need to
be elaborated upon.
Any litigation pending against the project and/or any
direction/order passed by any Court of Law against the
project, if so, details thereof shall also be included. Has the
12. unit received any notice under the Section 5 of Environment There is no litigation is pending.
(Protection) Act, 1986 or relevant Sections of Air and Water
Acts? If so, details thereof and compliance/ATR to the
notice(s) and present status of the case.
A tabular chart with index for point wise compliance of above Details are given in Table 1.1 of
13.
TOR. chapter 1.
Details on requirement of energy and water along with its Details are given in section 8.14 of
14.
source and authorization from the concerned department chapter 8.
Energy conservation in ammonia synthesis for urea Detailed are given in section 8.14 of
15.
production and comparison with best technology. chapter 8
Details quantitative risk assessment
16. Details of ammonia storage and risk assessment thereof along with storage details are given in
chapter 7.
There will not be any increase in
Measures for control of urea dust emissions from prilling pollution load due to increase in
17.
tower production. This is achieved by the
energy improvement schemes which
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will be implemented in the plant.

The water is supplied by Mangalore
City Corporation. No additional water
drawl is required for the proposed
18. Measures for reduction of fresh water requirement. plants. The marginal increase in the
water requirement after the
commissioning of the plants will be met
by effluent water recovery unit installed.
Details of proposed source-specific pollution control schemes Details are given in section 4.6 of
19.
and equipments to meet the national standards for fertilizer. chapter 4.
Details of fluorine recovery system in case of phosphoric acid
20. plants and SSP to recover fluorine as hydrofluorosilicicacid There is no production SSP.
(H2SiF6) and its uses
Management plan for solid/hazardous waste including
storage, utilization and disposal of bye products viz., chalk, The detailed management plan is given
21.
spent catalyst, hydro fluoro silicic acid and phosphor gypsum, in section 8.10 of chapter 8.
sulphur muck,etc.
Details on existing ambient air quality for PM10, PM2.5, Urea
dust*, NH3*, SO2*, NOx*, HF*,F*,Hydrocarbon ( Methane and
Non-Methane) etc., and expected, stack and fugitive Detailed Air quality is given in section
22.
emissions and evaluation of the adequacy of the proposed 3.6 of chapter 3.
pollution control devices to meet standards for point sources
and to meet AAQ standards.(*as applicable
Details on water quality parameters in and around study area
such as pH, Total Kjeldhal Nitrogen, Free Ammonical
Detailed ground water quality is given
23. Nitrogen, free ammonia, Cyanide, Vanadium, Arsenic,
in section 3.8 of chapter 3.
Suspended Solids, Oil and Grease, *Cr as Cr+6, *Total
Chromium, Fluoride, etc.
24.
25. 2
Public Consultation shall be done as per provisions of the EIA
Yet to be done
Notification,
5 2006.
26. 2
Video recording of proposed location to be submitted. Yet to be done
6
27. Layout
2 Plan earmarking space for 10 m wide green belt This is old site and more than 33%
around
7 periphery of the plant to be submitted. green belt already developed.
Most of the by product will be reuse in
Hazardous storage area shall not be toward human the process. Only used oil and
28. habitation. Plan for minimum storage of Hazardous materials discarded containers will be sent to
to be submitted. recyclers. Details are given in section
8.5 of chapter 8.
29. 2
Recommendation from SCZMA to be submitted. Not Applicable
9
30. 3 This is the ZLD based process. No
Submit a cost-benefit report w.r.t. ZLD implementation.
0 additional water will be use.
Proposed project is coming inside the
31. 3
Alternate site analysis to be done. exiting premises of MCF. No Additional
1
land will be required.
1.9. Methodology for Environmental Impact Assessment
The methodology adopted for carrying out the Environmental Impact Assessment for
the proposed expansion project is based on the Guidelines issued by Ministry of
Environment, Forest and Climate Change (MOEF&CC) and EQMS’s experience of
similar jobs. An effective environmental assessment calls for establishing sufficient
background data on various environmental components through reconnaissance
survey, sampling and available literature survey etc.
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The methodology adopted in preparing this EIA report is outlined in the following
sections:
Project Setting and Description: In this section, Environmental setting of the
existing plant and details of proposed facilities will be defined. The description also
gives details of effluents (gaseous/liquid/solid/noise) generation sources. Coverage on
environmental setting of the proposed plant in terms of site details, project description,
products, its storage, existing pollution control devices/measures, emission summary,
hazardous waste / chemicals management, etc. will be described.
Identification of Impacts: To identify the impacts comprehensively, all the activities
associated with the proposed project during the construction as well as operational
phase are identified and listed. The environmental impacts associated with the
proposed project on various environmental components such as air, water, noise, soil,
flora, fauna, land, socioeconomic, etc. Shall be identified using Impact Identification
Matrix.
Baseline Data Collection: Once the affected environmental parameters are
identified, various environmental parameters of concern are identified to establish its
baseline quality. M/s JP Test and Research Center (A NABL recognized Laboratory)
was entrusted for carrying out environmental baseline data collection from 1st
December 2016 to 28th February 2017. Data thus collected has been utilized here to
establish baseline quality of various environmental parameters.
Environmental Impact Prediction & Evaluation: In this part of the report, the
sources of emissions (Gaseous, Liquid, Solid, Noise) due to the proposed activities
have been identified and based on their emission loads their impacts are to be
predicted. Such predictions are then superimposed on baseline quality (wherever
there is an additional impact) and quantitative/qualitative assessments have been
made for the impacts and synergistic impact is evaluated using the matrix method.
The resultant matrix attempts to give an objective assessment to identify the
mitigation measures needed for abatement of various impacts.
Environment Management Plan (EMP): To mitigate or minimize the negative
impacts (if any) of the proposed project, an effective EMP is delineated. Therefore, in
the final part of the report, the planning and implementation of various pollution
abatement strategies including the proposed monitoring/surveillance network has
been described. Detailed Environment Management Plan (EMP) with specific
reference to details of air pollution control system, water & wastewater management,
monitoring frequency, responsibility and time bound implementation plan for mitigation
measure is formulated.
Qualitative and Quantitative risk assessment was also carried out using the latest
Phast 6.6 and finds considered for safe operation planning.
1.10. Contents of the EIA Report
An “Executive Summary” indicating a brief note on various chapters of EIA report is
prepared which provides a statement on various environmental issues. Further, the
contents and its coverage are explained below:
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Chapter-1: Introduction: This chapter provides background information of the

proposed expansion, scope, frame work & methodology of the study.
Chapter-2: Project Description: This chapter presents the details of the proposed
project in terms of location, project configuration of existing and proposed, utilities &
off sites, description of the resources required and emissions, solid waste and
wastewater anticipated to be generated.
Chapter-3: Description of Environment: This chapter describes the existing baseline
status of environment components collected in a pre-defined study area based on
primary and secondary data collection.
Chapter-4: Anticipated Environment Impacts and Mitigation Measures: This chapter
describes the potential impacts of the proposed project and evaluates their
significance based on parameters such mathematical models were used to quantify
the intensity and spatial extension of the impacts. Impact avoidance and mitigation
measures are delineated.
Chapter-5: Analysis of Alternatives (Sites and Technology): This chapter indicates the
justification for selection of project sites and Technology.
Chapter-6: Environment Monitoring Programme: This chapter describes the details of
the monitoring schedule to be implemented for checking the effectiveness of
mitigation measures. It covers the parameters and its, frequency.
Chapter-7: Additional Studies: (Risk Assessment) This chapter assesses the potential
risks involved in the construction and operation of proposed facilities from this project
and provides broad guidelines for updating existing Disaster Management Plan (DMP)
of proposed plant.
Chapter-8: Environment Management Plan (EMP): This chapter describes the
existing environmental management system, existing CSR, impact analysis &
mitigation measures for various components of environment. It also includes
organizational structure and resources planned for implementing the mitigation
measures and monitoring schedule.
Chapter-9: Summary and Conclusions: This chapter summarizes the conclusions,
management of release of pollutants, greenbelt development plan and CSR
Chapter-10: Disclosure of Consultants: This chapter contains the details of various
functional areas in which the consultant is expertise as per Quality Council of India
(QCI) to conduct Environment Impact Assessment (EIA) studies as per the MoEF&CC
Guidelines.
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CHAPTER 2. PROJECT DESCRIPTION
This chapter provides overview and technical details of existing plant and
proposed expansion along with land, input materials, utilities and pollution
control measures. This chapter includes the following section namely- brief
summary, overview of the project, site location and features, existing plant and
proposed expansion details, input material with its transportation and storage
details, utilities, waste management and pollution control details.
2.1. Brief Overview of Existing Plant and Proposed Expansion

Proposed plant area profile is given in the following Table 2.1:
Table 2.1 : Salient Features (Existing & Proposed)
Details
S.No. Features
Existing Proposed
A. Location Details
Coordinates 12°56'8.99"N, 74°49'25.08"E
Village: Panambur
Village, Tehsil, District, State Tehsil/Taluk: Mangalore
District: Dakshina Kannada
Nearest Railway Station Railway Station: Mangalore – 10 km
1
Nearest Highway NH-66
Nearest City, Town Mangalore – 10 km
Nearest Airport Bajpe International Airport- 10 km
Lakes/Reservoir/Dams/River Gurupura River – 1.0 km
Sensitive Places None within 10 km radius
B. Technical Details
Products & Handling of Fertilizers (t/y)
Ammonia 2,47,500 3,28,500
Urea 4,29,000 5,69,400
DAP/NPK (Multi-grade) 4,01,500 14,01,500
2
Poly Carboxyl Ether (PCE) - 18,000
Sulphuric Acid 1,46,000 No Change
Ammonium Bicarbonate
24,750 No Change
(ABC)
Sulphonated Naphthalene
85,000 No Change
Formaldehyde
Specialty mixtures of plant
2,21,000 No Change
nutrients
No Additional requirement,
3 Total Plot Area 192 Expansion is coming in Existing
Premises
4 Water Requirement (KLD) 9000 No Additional Water Required
48 MW through Existing capacity will meet the
5 Power
Captive power additional Power required for
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plant. Proposed project

6 Manpower Requirement 680 Additional 200
7 Green belt 64 Acres No Change
Project cost including Project Cost Rs 1547 Cr &
8 Environmental controlling ---- Environmental Equipment cost Rs
equipment 56 Cr
Recurring cost/ annum for
10 environmental pollution Recurring Cost approx. Rs 3 Cr
control measures
Baikampady Industrial Area &
N
NMPT Colony
Kudremukh Iron ore company
S
11 Neighbouring Features limited (KIOCL)
Kudremukh Iron & Steel Company
E
(KISCO)
W New Mangalore Port Trust
(Source: Site Visit/PFR)
The coordinates of the project site boundary are given in Table 2.1 and Figure 2.2 below.
Table 2.2 : Co-ordinates (lat-long) of all four corners of the site
Location Latitude Longitude

KIOCL 12°55′45.4″N 74°49′33.3″E
Behind SNF 12°56′15.1″N 74°49′37.8″E
18 MG security gate 12°56′25.4″N 74°49′22.7″E
Railway crossing 12°56′12.0″N 74°49′10.8″E
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Figure 2.1 : Location on Topo Map
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Figure 2.2 : Location on Google Map
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Figure 2.3 : Coordinates of Project boundary
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Figure 2.4 : Plant Layout (All the Facility)
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Figure 2.5 : Plant Layout (Revamp of Urea & Ammonia Facility)

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Figure 2.6 : Plant Layout (DAP/NPK Facility)

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Figure 2.7 : Plant Layout (PCE Facility)

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2.2. Energy improvement: Ammonia and Urea plants.

2.2.1. Brief on environmental impact of Energy Improvement Projects of Ammonia Plant:
The energy improvement project of Ammonia plant is aimed at reducing energy
consumption. This is done by recovery of heat from flue gas and condensate streams,
flash steam recovery by two stage stripping, replacement of vintage compressor with new
one, steam optimization etc. The improvement will ultimately reduce input requirement
such as reduction in fuel for firing in primary reformer and fired heaters, boilers, reduced
power consumption etc. Hence the proposed project will decrease pollution load in spite
of increase in production. Comparison of feed, fuel and power consumptions in present
and post revamp cases are provided in table-1
Capacity of Ammonia plant will increase from 2,47,500 t/y to 3,28,500 t/y on natural gas
based operation. On naphtha operation, plant capacity will remain unchanged.
The proposed revamp schemes in this project reduce the liquid effluent generation
(process condensate) from the ammonia plant. The plant will continue to remain zero
liquid effluent discharge plant as the process condensate is used as cooling tower make
up. One of the major proposed schemes – replacement of present low-pressure
condensate stripper with medium pressure (MP) stripper will ensure removal of Ammonia
from process condensate. The stripped ammonia in off gases of the MP stripper will be
carried by the steam going to primary reformer, nullifying gaseous emission too.
2.2.2. Brief on environmental impact of capacity enhancement of Urea Plant:
Prilling tower is the only source of dust emission in Urea Plant. Prilling tower in Urea plant
facilitates formation of droplets of urea melt by a prill bucket and distributing them across
cross section of prill tower and cooling of the same with counter current to form urea
prills. It is estimated that existing prilling tower and installed ID Fans of MCF Urea plant
are adequate for prilling of additional load created from proposed expansion. Since the ID
Fan flow is maintained at same rate as today, and due to optimization of process
parameters such as inlet temperature of urea melt, the dust generation in prilling tower
will be maintained at same level.
Urea Hydrolyser desorber system will treat the effluent water from ammonia and Urea
plants and treated water containing less than 10 ppm ammonia is used as cooling tower
make up. Flow of this treated effluent going to cooling tower will also come down from
present 540 t/d to 460 t/d post revamp.
The effluent generated in the plant shall be treated in the existing effluent treatment
facility and recycled back to the system.
In total, the Energy Improvement of Ammonia plant and capacity enhancement of Urea
plant will have positive impact on environment as they are intended to reduce feed and
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Table 2.3 Comparison of Fossil Fuel & Power consumptions between present and post
revamp conditions
Present Post Revamp

Unit of
Sl.No Product measurement (Naphtha Naphtha NG
Operation) Operation Operation
1 Ammonia t/y 240900 240900 328500
2 Urea t/y 419750 419750 569400
4 Feed (Naphtha/NG) t/d 341 341 411
5 Fuel (Naphtha/NG) t/d 165 127 159
Total t/d 505 468 570
6 Furnace Oil t/d 54 50 0
Total Fuel (Equivalent to NG) t/d 500 463 570
7 Electrical Power MWh/d 778 549 700
8 Total Energy Consumption Gcal/d 7614 6671 8274
Sp Energy Consumption
(including shutdown & Start Gcal/t
up) 6.62 5.80 5.50
Figure 2.8 Improvement in Specific Energy Consumption in Ammonia & Urea over the
period
2.2.3. Past measures on upgradation of Ammonia & Urea Plants
MCF has continuously upgraded its Ammonia-Urea plants of 1976 vintage with
significant investment to improve reliability and energy consumption. Further
improvement is possible only with major technological modifications involving large

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investment. The proposed revamp of the Ammonia – Urea plants will take up their
performance in terms of energy consumption to best operating plants in India. Some of
the major schemes implemented so far are listed below:
 Purge Gas Recovery Unit (PGRU) was installed in 1984 for recovery of Hydrogen
from purge gas
 Captive Power Plant was installed in 1985 for reliable power source
 Axial type ICI Ammonia Converter basket internals were replaced with S-200 axial
type of HTAS design in 1994 for Lower loop pressure and higher Ammonia
conversion per pass.
 Reformer Tube replacement (new material), Reformer wall refractory was upgraded
from castable to new ceramic modules lining to reduce heat losses and to increase
reformer tube life due to lower skin temperature.
 Replacement of Reformer Burners with Low NOx burners.
 Replacement of make gas boiler with improved design.
 Replacement of Packing and internals of CO2 absorber.
 Implementation of Distributed Control System (DCS) and Advanced Process Control
(APC)
 VAM Chiller installation to supply chilled cooling water to for syngas compressor
suction chilling.
 Burner Management System (BMS) for fired heaters F210 & F202 to improve safety
of operation.
 Installation of Seal Gas recovery unit to Syngas compressor.
 Safe shut down PLC for improved safety.
 Ammonia plant and Power plants NG conversion to use Natural Gas as feed and
fuel.
 Hydraulic Power Recovery Turbine in CO2 removal section
 Urea Hydrolyser stripper installation to reduce ammonia in effluent stream.
 Urea reactor trays replacement with high efficiency trays and relining of Autoclave.
 Pre evaporator and LP scrubbers were installed.
 Change of material of construction of HP stripper & HP condensers were to Safurex.
 Medium Pressured scrubbing section was introduced for improved reliability.
 MCF has installed urea hydrolyser stripper at a cost of Rs. 8.5 crores in 1990 for the
treatment of effluent streams from ammonia process, urea process and condensates
from urea plant compressors. The urea hydrolyser stripper system consists of
hydrolyser, which hydrolyzes urea in feed stream into ammonia and carbon di
oxides. Ammonia thus formed is separated in the second desorption column. The
bottom outlet (liquid) of second desorption column contains less than 10 ppm of
ammonia and urea. The overhead gas (ammonia vapors) from second desorption
column is fed to first disrober. The disrober overhead vapors (essentially ammonia &
CO2) are condensed in a condenser and reused in Urea plant. The treated effluent

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from the second desorber which contains about 10 ppm of ammonia is used as
cooling tower makeup water.
2.3. Process Description of existing Ammonia Plant

Brief description of the process of existing Ammonia plant of 247500 t/y capacity is given
below:
Ammonia plant has the following sections:

 Naphtha Pre-treatment
 Reforming
 Shift Conversion
 CO2 Removal
 Methanation
 Compression
 Synthesis
 Purge Gas Recovery
a. Naphtha Pre-treatment Section:

In this section the feed naphtha is purified of sulfur from 200 ppm to <1 ppm. The
naphtha is heated to 380°C and reacted with hydrogen to convert all the sulfur into
hydrogen sulfide in the reactor filled with CoMox Catalyst of volume. H2S rich stream is
separated from naphtha and mixed with fuel in primary reformer.
b. Reforming section:
Steam Reforming of the feed naphtha is carried out in primary and secondary reformer.
In the primary reforming, de-sulphurised naphtha is reacted with the steam in the
reformer tubes where the hydrocarbon is converted to hydrogen, methane, carbon
dioxide, carbon monoxide in the presence of the nickel catalyst. The overall reaction is
endothermic and heat is supplied by means of burners on the top of the reformer. There
are total 224 catalyst filled tubes arranged in 4 rows (of 56 tubes each) in which reaction
takes place 60 burners in 5 rows (each having 12 burners). In the secondary reformer,
process gas from the primary reformer is made to react with the preheated air. Here the
methane content is reduced to 0.30% and the nitrogen which is required for the
ammonia synthesis is added to the process.
c. Shift Conversion:
The hot process gas from secondary reformer gives heat for steam generation in the
waste heat boilers and enters the high temperature and the low temperature shift
conversion vessels where Carbon monoxide in the process gas reacts with steam and
converts to carbon dioxide while producing Hydrogen, in two steps. The catalyst used is
copper promoted iron oxide. At the end of the shift conversion, the CO in the process
gas is reduced below 0.20%.

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d. CO2 Removal Section:

In this section, Benfield process is adopted. The gas coming out of the shift converter
contains hydrogen, nitrogen, carbon dioxide, carbon monoxide, methane, argon and
excess of the steam added in the reformer. Only hydrogen and the nitrogen are
desirable for the production of the ammonia. CO₂ is separated from gas mixture in this
section in absorption – stripping process using Benfield solution (potassium carbonate)
as solvent and sent to the urea plant where it is used as one of the raw materials.
Process gas, called Synthesis gas here after, containing H2 and N2 in desired ratio,
essentially free of CO-CO2 goes to methanation.
e. Methanation:
In this process the residual, Carbon monoxide and CO2 slipped in CO2 removal process
are converted to methane in the nickel catalyst bed as these are poisons for the
synthesis catalyst.
f. Compressors:
Synthesis gas compressor increases the pressure of the make-up gas to the synthesis
pressure as well as it is used to recirculate the recycle gas. The synthesis section
operates at pressure of 200 kg/cm² as the ammonia reaction is favored by high
pressure.
Air compressor is used to compress the air and supply it to the secondary reformer.
A refrigeration compressor is used to cool the synthesis convertor outlet gases to
condense and separate the product ammonia.
g. Synthesis:
Haldor Topsoe make S200 Synthesis converter is installed in Synthesis. Here the
process gas containing hydrogen and nitrogen in the molar ratio of 3.0 is passed over
the iron catalyst in the two beds arranged in series with intercoolers and quenches to
control the reaction temperatures. The conversion to ammonia is only partial and hence
the unconverted reactants are recirculated to converter after separation of product.
h. Purge gas recovery:

As the process in synthesis section is a circulating process, to avoid build up inert, purge
gas is taken from circulating stream. Purge gas recovery is a cryogenic process, where
in the hydrogen from the purge gas is recovered and recycled to the compressor suction.
This helps to increase the process efficiency.

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Figure 2.9 Process Flow Diagram
2.3.2. Revamp Schemes in Ammonia Plant.

The proposed revamp schemes will reduce energy consumption of the plant as well as
increase capacity enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y
The plant is currently operating with naphtha as feed and fuel and operates with an
energy consumption of around 9.6 GCal/t. The plant is already converted in year 2014 to
operate on Natural gas as feed and fuel. In the revamped process, production of the
ammonia plant will be increased with a decrease in the energy consumption to around

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8.0 Gcal/t when operated on natural gas. However, the plant can be operated on
Naphtha also and in naphtha based operation, plant capacity will remain at present level,
but energy consumption will reduce to 8.5 Gcal/t.
The revamping process will include the following modifications:

a) Reformer section:
In the reformer section in the convection side two coils will be added. One is for
preheating the feed NG before it enters the fired heater and the other is to heat the NG
and the steam mixture before it enters the primary reformer. This will increase the inlet
temperature to the primary reformer by heat recovered from flue gases thereby bringing
down firing and the heat flux in the tubes. This calls for the replacement of the cross over
line and the inlet pig tails. It also calls for replacement of some of the coils in the super
heater section and replacement of the tubular combustion air heater with a plate heat
exchanger. The temperature to stack will be brought down to 136°C versus the current
value of 170°C.
b) CO2 removal section:
The current CO2 removal section with UOP Benfield process consists of a single stage
regeneration consumes around 1100 Kcal energy per Nm³ of CO2 separated. Whereas
going forward using the GV low heat two stage regeneration the regeneration energy
can be brought down to around 700 Kcal/Nm³ of CO2 separated. It calls for an additional
regenerator operating at very low pressure (1.05 kg/cm² a) and the current one will
operate at close to 2.0 Kg/cm²a. In addition to this a blower will be required to boost the
CO2 from the low pressure regenerator. The CO2 will be available to the urea plant at
1.40 kg/cm2a compared to the current value of 1.25 Kg/cm2a.
c) Compression section:
i. Synthesis gas compressor
A completely new set of compressor and drive turbine will replace existing Motor +
turbine driven compressor.
ii. Air compressor
The new compressor purchased for the gas conversion project along with the existing
compressor will be adequate for the revamped requirements.
iii. Refrigeration compressor
To optimize the load on the refrigeration compressor, additional high pressure ammonia
chiller, an interstage cooler and a parallel flash drum will be added.
d) Synthesis section:
An Additional synthesis converter will be added in series (downstream) with the existing
S200 converter. The synthesis loop will operate at 186 kg/cm2a. The additional
converter will be of a single bed with a feed-effluent cooler and will have catalyst volume

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of 45m³. This additional converter will increase the per pass conversion. This converter
will be a cold walled. Additional BFW heater is provided for heat balance.
e) PGRU
The current PGRU though may not be able to take the additional load and hence will be
left untouched. The additional purge will be used as fuel in the primary reformer.
f) Naphtha Pre-treatment:
The whole revamp is considered with the NG as feed and fuel, hence the pretreatment
of Naphtha section is not considered for any change.
g) MP stripper:
Process condensate from the plant will be stripped using a medium pressure stripper.
The treated condensate produced from this stripper can be used as a make up to the de-
aerator thereby bringing down the fresh DM water requirement for Boiler feed water.
2.3.3. UREA Plant

Urea is produced by reacting liquid ammonia and gaseous carbon dioxide at about 180-
185°C and 140-150 kg/cm2a according the following reactions:
2 NH3 + CO2 <====> NH2COONH4 + heat (1)
NH2COONH4 <====> NH2CONH2 + H2O (2)
In the first reaction carbon dioxide and ammonia are converted into ammonium
carbamate. This reaction is fast and exothermic. In the second reaction, which is slow
and endothermic, the ammonium carbamate dehydrates to produce urea and water.
Urea Plant is designed based on CO2 striping process licensed by Stamicarbon BV
Netherlands. Ammonia (NH3) and Carbon Dioxide (CO2) are the main raw materials for
Urea production.
Initially, NH3 and CO2 are passed through a High Pressure Condenser where
Ammonium Carbamate is formed. This is sent to autoclave where a portion of it is
converted to Urea. The unconverted Ammonium Carbonate is stripped into NH3 and
CO2 gases in a High Pressure Stripper using fresh CO2 and recycled back to the HP
condenser along with fresh Ammonia and dilute Ammonium Carbamate to again form
concentrated solution of Ammonium Carbamate. This cycle thus continues. The Urea
solution thus coming from the Stripper is separated and concentrated in low pressure
section consisting of a rectification column, a flash vessel, Pre-evaporator and two
stages of evaporation.
The molten Urea solution coming from the final evaporator is sent to a revolving prill
bucket at the top of the Prill Tower. The Urea solution is sprayed in the form of fine
droplets by rotation of the prill bucket. The droplets solidified into prills before reaching

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the bottom of the Prill Tower as they come in contact with an upward flow of air. The
prills are collected at bottom and conveyed to bagging plant or for storage in silo.
Figure 2.10 Block Diagram of Urea Process

2.4. Revamp of Urea Plant
The revamp schemes are designed to Increase the current plant capacity from 4,29,000
t/y to 5,69,400 t/y and reduction of the steam consumption from the current consumption
of 850 kg/t to about 550-600 kg/t (400°C, 38 bar).
Stamicarbon being the process licensor has come up with a new concept called
EVOLVE for revamp and shall be adopted. Main objectives of the revamp are:- a)
Reduce HP steam consumption in HP stripper - using Stamicarbon low energy concept

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to achieve 550 - 600 kg/t (38 bar A & 400° C). b) Capacity expansion from 4,19,750 t/y
to 5,69,400 t/y. c) To improve the quality of the prilled Urea product.
Process retrofit concepts to fulfil the revamp objectives
Urea is produced by reacting liquid ammonia and gaseous carbon dioxide at about 170 -
185 C and 135 - 145 bar according to the following reactions:
2 NH3 + CO2 <=====> NH2COONH4 (1)
NH2COONH4 <=====> NH2CONH2 + H2O (2)
In the first reaction, carbon dioxide and ammonia are converted into ammonium
carbamate. This reaction is fast and exothermic. In the second reaction, which is slow
and endothermic, the ammonium carbamate dehydrates to produce urea and water.
Ammonia and Carbon dioxide compression
Liquid ammonia is supplied from battery limits to the high pressure ammonia pump and
compressed to about 165 bar. It is then sent to the pool condenser via the high pressure
ammonia ejector. Additional ammonia is supplied to the MP section. As the normal
operating pressure of the MP section is lower than the supply pressure of the ammonia,
this is done via a let-down valve. In case of increased pressure in the MP section, a new
MP NH3 pump is foreseen to transfer ammonia to the MP section. Carbon dioxide from
battery limits is supplied, together with a small amount of air, to the carbon dioxide
compressor before it is compressed to synthesis pressure. A hydrogen converter is
integrated in the carbon dioxide compressor. In this converter the hydrogen, present in
the carbon dioxide, is removed by catalytic combustion. A portion of the supplied air is
used for this catalytic combustion while the remainder being used to passivate the
equipment of the synthesis section and so prevent corrosion. The dehydrogenated
carbon dioxide is introduced into the bottom part of the high pressure stripper. Additional
carbon dioxide is supplied to the LP section via the newly installed LP CO2 compressor.
Additional air is supplied to this compressor and a hydrogen converter is placed in the
discharge. The two feedstocks, ammonia and carbon dioxide, are fed to the synthesis
section at a molar ratio of 2 : 1.
Synthesis
The dehydration of ammonium carbamate into urea and water takes place in the
poolcondenser and subsequently in the reactor. The reactor effluent is partially
distributed over the tubes of the high pressure stripper, which is a falling film type shell
and tube heat exchanger. Here, the reactor effluent is contacted counter-currently with
carbon dioxide, causing the partial ammonia pressure to decrease and the carbamate to
decompose. The heat, required for this purpose, is supplied by passing saturated high
pressure steam around the tubes of the high pressure stripper. A part of the liquid from
the reactor is bypassing the stripper and is sent directly to the MP section. By means of
the pressure of the HP steam to the stripper and the ratio between liquid sent to the

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stripper and liquid that bypasses the stripper, the ammonia concentration in the liquid to
the MP section is controlled at about 15% by weight.
The urea solution from the high pressure stripper, flows to the low pressure recirculation
section whilst the high pressure stripper off gases are sent to the poolcondenser which is
special design U-tube type heat exchanger. In the pool condenser condensation of
stripgasses takes place through the principle of poolcondensation, i.e. the gases are
dispersed into a pool of liquid, where the heat of condensation is being dissipated by
submerged heat exchanger tubes. This heat of condensation is used for two purposes:
1: to dissociate carbamate from the urea solution in the MP stage (in the lower bundle).
2: to generate low pressure steam of 4.5 bar (in the upper bundle). This steam is used
for heating and desorption as well as for the vacuum ejector. The steam pressure at the
tube side of the high pressure carbamate condenser is controlled by a pressure control
valve in the steam discharge line of the steam drums. A change in this pressure will
change the steam condensate temperature and hence the temperature difference
between the shell side and the tube side. The steam drum pressure is set to such a
value that the synthesis pressure is about 145 bar.
The pool of liquid in the poolcondenser allows for a considerable amount of urea
formation to take place here. The formed urea, non-converted carbamate, excess
ammonia and some non-condensed ammonia and carbon dioxide are subsequently
introduced into the bottom of the reactor where further conversion of carbamate into
urea takes place. The reactor volume allows sufficient residence time for the reaction to
approach equilibrium. The heat, required for the conversion and for heating the solution
in the reactor, is supplied by additional condensation of ammonia and carbon dioxide.
The reactor contains a number of high efficiency trays to ensure that the flow of liquid
through the reactor approaches piston flow. Moreover the trays are designed such that
negative effects (such as back-mixing, by-passing and stagnant zones in the reactor) are
avoided. The reactor effluent goes through the downcomer to the high pressure stripper.
The inert, introduced with the carbon dioxide and part of the unreacted ammonia and
carbon dioxide, go overhead to the high pressure scrubber which contains a shell and
tube heat exchanger in the lower part and a packed bed in the upper part. In the lower
part of the high pressure scrubber the bulk of the ammonia and carbon dioxide are
condensed, the heat of condensation being dissipated into tempered cooling water. This
heat is recovered in the pre-evaporator. In the upper part of the scrubber the gases,
leaving the bottom section, are contacted counter currently with the carbamate solution
coming from the medium pressure recirculation section. The gases, substantially
consisting of nitrogen and oxygen and containing only small amounts of ammonia and
carbon dioxide, are vented to the atmosphere via a LP absorber. The carbamate solution
from the high pressure scrubber flows to the high pressure ammonia ejector. The
ammonia feed pressure is such as to induce sufficient head in the high pressure
ammonia ejector to convey the carbamate solution from the high pressure scrubber to
the high pressure carbamate condenser.

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Medium pressure recirculation section
Liquid leaving the stripper is flashed to MP conditions. The liquid from this flash is led
through the bottom bundle of the pool condenser where the supplied heat enables the
dissociation of carbamate into ammonia and carbon dioxide. The gas from this
dissociation is combined with the off gas from the flash and is led to the first stage
evaporation heater, which acts as a MP carbamate condenser. The heat of
condensation of the carbamate is used to evaporate water from the urea solution. The
formed carbamate is sent to the HP scrubber. Small amounts of non-condensed
ammonia and carbon dioxide as well as inerts are vented to the existing LP absorber.
Liquid, leaving the dissociation heater is counter-currently contacted with the off gas
from the MP flash and then discharged to the existing LP section.
Low pressure recirculation section
In this section essentially all of the small amounts of non-converted ammonia and
carbon dioxide are recovered from the urea/ carbamate solution, leaving the MP section.
This solution is expanded to about 4 bar. As a result a portion of the carbamate, left in
the solution, decomposes and evaporates. The remaining liquid is divided onto a bed of
Pall rings in the rectifying column. The urea/ carbamate solution is sent from the bottom
of the rectifying column to a new heater where its temperature is raised to about 135 C
in order to decompose the remaining carbamate. The heat required is supplied by low
pressure steam. In the separator (i.e. the bottom part of the rectifying column) the gas
phase is separated from the liquid phase. The gases are sent to the rectifying column
where they are cooled by the colder urea/ carbamate solution. This causes a portion of
the water vapour contained in the gases to condense. The gases leaving the rectifying
column are introduced into the bottom part of the low pressure carbamate condenser
where they are condensed almost completely. The heat of condensation is dissipated
into tempered cooling water. Process condensate is also supplied to the low pressure
carbamate condenser together with the condensed overhead vapours from the first
desorber and from the atmospheric section in order to control the water concentration in
the carbamate solution. The optimum ammonia/ carbon dioxide ratio allows the water
concentration to be as low as 31 % by weight. The pressure in the low pressure
carbamate condenser is controlled at about 3.3 bar. From the level tank of the low
pressure carbamate condenser, the carbamate solution flows to the medium pressure
carbamate pump where its pressure is raised and from where the carbamate solution is
carried to the MP section. The urea solution, leaving the bottom of the rectifying column,
flows to the atmospheric flash separator via a level control valve. Due to the adiabatic
flash to about atmospheric pressure, a portion of the water evaporates and some
ammonia, carbon dioxide and inert are liberated. These vapours are partly condensed in
the flash separator condenser and the remaining vapours are sent to the condensers of
the evaporation section. Condensate from the flash separator condenser is recycled to
the LP carbamate condenser.

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Pre-evaporation and evaporation
The solution from the atmospheric flash separator is sent to the flash separator heater. A
portion of the water in the solution is evaporated so as to increase the urea
concentration. The heat of evaporation is taken from the tempered cooling water system.
Finally, the urea solution is sent to the urea solution tank. The urea solution is pumped
from the urea solution tank to the evaporators, where it is concentrated to about 99.5 %
by weight. In the separator of the evaporator, the outlet from the evaporator heater is
separated into a gas phase and a liquid phase. The vapour, leaving this separator, is
condensed in the evaporator condenser together with the vapours from the separator
pre-evaporator. The urea solution from the evaporation separator flows to the suction
side of the urea melt pump and is sent to the prilling tower. The condensate, leaving the
evaporator condenser is sent to the ammonia water tank via a barometric leg.
Process condensate treatment
Process condensate from the evaporator condenser, containing ammonia, carbon

dioxide and urea, is collected in the ammonia water tank and used as absorbent in the
LP absorber and the atmospheric absorber. Next, the process condensate is pumped
from the ammonia water tank to the first desorber via a desorber heat exchanger. In the
first desorber the bulk of the ammonia and carbon dioxide is stripped off by means of the
overhead vapours of the second desorber and hydrolyser. The bottom effluent of this
first desorber is pumped via a hydrolyser heat exchanger, where this condensate is
heated, to the top of the hydrolyser column. In the hydrolyser, the urea is decomposed
into ammonia and carbon dioxide while being heated by means of live high pressure
steam. To obtain very small urea concentrations in the hydrolyser effluent, the process
condensate is countercurrently contacted with the live steam. On leaving the hydrolyser
the process condensate, containing traces of urea, goes via the hydrolyser heat
exchanger to the second desorber. The overhead vapours of the hydrolyser being sent
to the first desorber. After cooling the hydrolyser effluent in the hydrolyser heat
exchanger, this condensate is fed to the top of the second desorber. Here, the remaining
ammonia and carbon dioxide is stripped off by means of live low pressure steam. The
process condensate, leaving the second desorber, is cooled in the desorber heat
exchanger and subsequently in the waste water cooler. It contains very small amounts of
urea and ammonia and can be used for several purposes i.e. for boiler feed water or
cooling water make up. The overhead gases from the first desorber are first partially
condensed in a pre-reflux condenser and after that in the reflux condenser and are
transferred as a carbamate solution to the low pressure carbamate condenser. The non-
condensed vapours are sent to the atmospheric absorber.
2.5. 1 million t/y DAP/NPK project.
DAP/NPK plants mainly involve solid processing, hence dust generation is a major
issue. To handle the dust generation, emphasis is given to collect the dust at source.
The dry dust will be passed through Cyclone separators for dust separation and cleaned

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gas will be scrubbed in venturi type scrubber. Wet gases will be directly scrubbed in
venturi scrubbers. Venturi scrubber outlet will be again scrubbed in final tail gas scrubber
before letting to atmosphere.
The technology also incorporates special scrubbing scheme like Dual Mole Scrubbing
System and Dedusting system. Air pollution control equipment viz. Cyclone, Scrubber,
Mist eliminator etc of adequate capacity shall be installed during the commissioning of
the plant itself.
There will be no liquid waste and solid waste generation from the plant. All liquid
spillages shall be collected and recycled back to the process.
The flow of gaseous emission from the stack (3 No. 45 m each) is expected to be
maximum 720000 Nm³/hr, particulate Matter 50 Mg/Nm³, fluorine 20mg/Nm³ and
Ammonia 150mg/Nm³.
Considering the sufficient pollution control measures incorporated in the process
technology and plant design towards reducing emissions and maintaining the emissions
within specified norms, the proposed project will not have any significant adverse impact
on the existing environment.
2.5.1. Process description of 1 MILLION t/y DAP / NPK PROJECT
NH3 + H3PO4  NH4H2PO4 + Q2A (1)
Ammonia + Phosphoric Acid -> Mono Ammonium + Heat
Phosphate
NH4H2PO4 + NH3  (NH4)2HPO4 + Q2B (2)

Mono Ammonium + Ammonia  Di Ammonium + Heat
Phosphate Phosphate
a) Dry Section
With reference to the simplified process flow diagram for the Dry Section of the Slurry
Process, a detailed description is furnished as follows:

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Phosphoric acid, gaseous Ammonia, and scrubber liquor enter into the Preneutralizer
where it is controlled at a specific gravity of 1.53 and a mole ratio of 1.5, which
corresponds to moisture content in the slurry of 18%. The Preneutralizer is maintained at
a mole ratio of 1.5 to ensure maximum solubility of the slurry. The Ammonium
Phosphate slurry is pumped from the Preneutralizer to the Pipe Reactor where it is
combined with strong phosphoric acid, and gaseous Ammonia and sprayed onto the bed
of the Rotary Granulator at a mole ratio of 1.5 and moisture of 10%. Underneath the bed

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in the Granulator is the Ammonia sparger that supplies liquid Ammonia to raise the mole
ratio of the fertilizer up to the desired value.
The material leaves the Granulator and enters into the Rotary Dryer where the DAP is
dried, using hot gases leaving the Combustion Chamber, to a moisture of 1.0-1.5% or
even lower if needed. After exiting the Dryer the material enters into the Primary Elevator
to be distributed over the Oversize Screens. The Oversize Screens are double deck
screens where the oversize is sent to the chain mills, the undersize falls onto the
Recycle Belt along with the crushed material, and the product size material is sent to the
Product Screen Elevator for distribution on the Product Screens.
The purpose of the Product Screens is to remove the remaining fines that were not
removed by the Oversize Screens. The fines fall onto the Recycle Belt and the on spec
material enters into the Fluidized Bed Cooler or is recycled for control of the recycle
ratio. The air entering into the Fluidized Bed Cooler can be chilled using the Ammonia
Air Chiller which will be discussed later.
Once leaving the Fluidized Bed Cooler the material enters into the Product Elevator and
is distributed onto the Polishing Screens. The on spec material then enters into the
Coating Drum and is then conveyed to the storage building. The gases leaving the
Dryer, Product Cooler, and Dedusting system are each sent through a separate set of
cyclones. After the dedusting system offgas exits the cyclones it is sent through a
baghouse to be sent to the Combustion Chamber.
If this method of recycling dedusting offgases is not in place then the gases are sent to
the RG Scrubber. The gases leaving the Dryer Cyclones go to the Dryer Scrubber and
the gases leaving the Cooler Cyclones go the Tail Gas Scrubber.
b) Wet Section
With reference to the simplified process flow diagram for the Wet Section of the Slurry
Process, a detailed description is furnished as follows:
Ammonia laden gases exiting the Preneutralizer and Granulator first enter into the
Prescrubber where they are scrubbed with liquor at a mole ratio of 1.4 where 60-70% of
the Ammonia is absorbed. Once exiting the Prescrubber the gases enter into the
Reactor Granulator Scrubber (RG Scrubber) where the gases are scrubbed with liquor at
a mole ratio of 0.7. The gases exiting the Dryer go through a cluster of cyclones and
enter into the Dryer Scrubber where the gases are scrubbed with the same liquor that is
used in the RG Scrubber. The liquor that is used in the RG Scrubber and the Dryer
Scrubber is circulated from the Scrubber Tank. Gases from the RG Scrubber and Dryer
Scrubber along with the gases that exit the Cooler Cyclones enter into the Tail Gas
Scrubber and then exit into the atmosphere. The circulating liquor in the Tail Gas
Scrubber is sent through a kettle type heat exchanger to vaporize Ammonia.

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c) Pipe Reactor used in conjunction with Preneutralizer

The purpose of the Pipe Reactor is to supply Ammonium Phosphate slurry at a low
moisture content thereby reducing fuel requirements in the drying step. The Pipe
Reactor mixes high strength Phosphoric acid, gaseous anhydrous Ammonia, and reactor
slurry from the Preneutralizer and sprays it onto the bed of the Granulator. The reason
the Pipe Reactor can operate at such a low moisture is because of the high temperature
and pressure which keeps the slurry fluid. Under atmosphere pressure the slurry
reaches a minimum moisture content of 18% and in the Pipe Reactor it can be as low as
10%. The moisture content in the Pipe Reactor is reduced by vaporizing water from the
high heat of reaction of Phosphoric acid and Ammonia. Another reason why the Pipe
Reactor is economical is because it reduces Citrate Insoluble P2O5. Citrate Insoluble
P2O5 increases with increased retention time and since the retention time of a Pipe
Reactor is very low there is virtually no Citrate Insoluble P2O5 produced in the Pipe

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Reactor. The average Citrate Insoluble P2O5 can be reduced by 0.2% when a Pipe
Reactor is used. The Preneutralizer mixes Phosphoric acid, Ammonia, and Scrubber
liquor to be sent to the Pipe Reactor or directly to the Granulator. The Phosphoric acid
and Scrubber liquor are fed through the top of the reactor while the gaseous anhydrous
Ammonia is fed through spargers located at the bottom.
The process uses the reduced retention time Preneutralizer where the diameter at the
bottom of the tank is smaller than the top. The advantage of this design is that the
Citrate Insoluble losses are decreased while still maintaining the liquid level necessary to
absorb Ammonia and not to entrain liquid in the exiting gas. The Citrate Insoluble losses
increase with increased retention time so it is necessary to minimize the liquid volume in
the Preneutralizer. The Preneutralizer is much simpler to operate than the Pipe Reactor
and when used in conjunction with the Pipe Reactor it gives the plant a stable baseline
and increased controllability.
Using a Preneutralizer reduces the amount of water that is vaporized in the Granulator
by the Pipe Reactor. If less water is vaporized in the Granulator then less air is needed
to keep the gas leaving the Granulator below the saturation point. For a 120 MT/hr.
plant, the required airflow in the Granulator when a Pipe Reactor and Preneutralizer are
installed is 44,000 ACFM and when there is only a Pipe Reactor present is 88,000
ACFM. This reduced airflow reduces the size of the Granulator, Prescrubber, RG
Scrubber, RG Fan, Scrubber Pump and the Tail Gas Scrubber and Pump.
d) Dual Mole Scrubbing
Dual Mole Scrubbing is a two stage process where gases from the Preneutralizer and
Granulator are scrubbed with a high N/P mole ratio liquor followed by scrubbing at a low
mole ratio. The gases first enter the Prescrubber, which operates at a mole ratio of 1.4,
where about 60-70% of the Ammonia is removed. Next the gases enter into the Reactor
Granulator (RG) Scrubber where the rest of Ammonia as well as the fluorine are
removed and this scrubber operates at a mole ratio of 0.7.

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e) Recycling Dedusting System Offgas to the Combustion Chamber
Recycling Dedusting system off gas to the Combustion Chamber takes the heat given off
by the DAP throughout the plant and reuses it in the Dryer. There are various dedusting
pickup points within a DAP plant which mainly come from the belt conveyors, screens,
and elevators.

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Figure 2.11 Process Flow Diagram of NPK Plant

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2.6. Poly Carboxyl Ether (PCE) project of 18,000 t/y capacity.

There will not be any gaseous emissions from the proposed PCE project.
There will be no liquid effluent generated in the plant. The spillages if any from the plant
floor will be collected in and recycled back to soil conditioners section.
There is no solid waste from the plant. The spillages if any from various points in the
plant are effectively collected and recycled back to the system.
2.6.1. Process Description of Poly Carboxyl Ether (PCE) project
Manufacture of Poly carboxylates is essentially a batch operation and comprises of two
main steps, i.e.
 Esterification
 Polymerization
The basic raw materials for Poly carboxylate production are Methoxy Poly Ethylene
Glycol (MPEG / PEGM 2000) and Meth acrylic Acid. The overall chemical reactions
involved in the above mentioned (a) & (b) process steps are schematically shown in
Figure 1A and 1B below

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Figure 2.12 Process Flow Diagram

2.7. Products with Capacities (Existing & Proposed)
The present EIA study is for the Expansion of fertilizer plant for Energy Improvement
Project of Ammonia & Urea Plants by modernization and capacity enhancement of
Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to 5,69,400 t/y.
The list of products and by products shown in Table 2.4
Table 2.4 Products with capacities (Existing & Proposed)
S. No. Plant Capacity(TPA) Methodology

Existing Additional Total
1. Ammonia 2,47,500 81,000 3,28,500 Revamp
2. Urea 4,29,000 1,40,400 5,69,400 Revamp
3. DAP/NPK (Multi 4,01,500 10,00,000 14,01,500 Additional Production
grade) stream
(16:20 & 20:20)
4. Poly Carboxyl Ether ---- 18,000 18,000 New plant
(PCE)

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5 Sulphuric Acid 1,46,000 --------------- 1,46,000 Inside Existing Plant

6 Ammonium Inside Existing Plant
24,750 ------------- 24,750
Bicarbonate (ABC)
7 Sulphonated Inside Existing Plant
Naphthalene 85,000 ------------- 85,000
Formaldehyde
8 Specialty mixtures of Inside Existing Plant
2,21,000 ------------- 2,21,000
plant nutrients
2.8. Raw Materials (Existing & Proposed)

Each product is unique in nature and application/ use, process of manufacture and raw
material requirement. As such MCF has a long list of raw materials. Raw materials
required along with estimated quantity, likely source of material and mode of transport of
raw material is mentioned in Table 2.5 below
1. The transportation of raw materials will be done by road complying with all safety
requirements as per MSIHC rule.
2. The raw materials will be procured and stored / inventory will be maintained as per
market requirement of the products and production schedule. Some of the key raw
materials are:
Table 2.5 List of Raw materials required /Source /Transportation/Storage
S. Raw materials Existing After Mode of transportation

No. Expansion
1. Naphtha 1,85,000 t/y 1,71,000 t/y Through pipeline from IOC
terminal
2. Furnace Oil (for Boiler) 19,500 t/y 18,100 t/y Through pipeline from IOC
terminal
3. Furnace Oil (for Power 65,300 t/y 47,000 t/y Through pipeline from IOC
Plant) terminal
4. NG - 2,75,000 t/y Only after the availability of NG at
Mangalore
5. Ammonia 88,300 t/y 3,20,000 t/y Imported through Ships. Stored in
IAT.
6. Phosphoric Acid 1,92,000 t/y 6,60,000 t/y Imported through Ships. Stored in
IAT.
7. Sulphuric Acid for DAP 15,444 t/y 1,46,000 t/y Captive production
8. MOP, Filler, Urea for 1,30,000 t/y 4,10,000 t/y Ships, Trucks
DAP/Multigrade
9. Methoxy polyethylene - 19,365 t/y Tankers
glycol
10. Methacrylic acid - 830 t/y Drums
2.9. Infrastructure& Utilities Required For Proposed Expansion Project
2.9.1. Land Requirement

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The proposed project site is located within the boundary of Mangalore Chemicals and
Fertilizers Ltd., Mangalore. No additional land will be required for this project.
Table 2.6 Land Distribution at Site (Acres)
S. Land Breakup- Land Breakup-

Area Description
No. Existing After Expansion
1 Ammonia Plant/Urea/Utilities/ETP 20 20
2 DAP/ NPK (Existing) 3 3
New DAP/ NPK plant including RM & product
3 0 15
storage, bagging plant and Utilities
4 PCE Plant 0 2
Other Plant (Sulfuric Acid, , ABC, SNF, Speciality
5 8 8
Fertilizers & CPP)
6 Green Belt 64 64
7 Area for Expansion 51 34
8 Area for Administrative Block + Engineering Building 6 6
Buildings, Roads, Bagging, Storage,
9 Weighbridge, Parking, Water Reservior & Railway 40 40
siding
Total 192
Imported Ammonia Terminal 4
Site layout is shown in Figure 2.2.
2.9.2. Power
The present power requirement is 36MW. After implementation of proposed projects, power
requirement for Ammonia and Urea plants will reduce by about 6 MW. This will cater to the
requirement of the new DAP/NPK and PCE plants.
So no additional power will be required for this project.
Table 2.7 Power Supply Details
New project Power

Requirement Source
Ammonia Power requirement will be reduced as compare Captive power plant
to present scenario (24.594 MW to 15.85 MW)
Urea Additional Power 0.79 MW Captive power plant

DAP/NPK 6.106 MW Grid / CPP
PCE 0.125 MW Grid / CPP
2.9.3. Water Requirement
The water is supplied by Mangalore City Corporation. No additional water drawl is required for
the proposed plants. The marginal increase in the water requirement after the commissioning of
the plants will be met by effluent water recovery unit installed.

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Figure 2.13 Water Balance Diagram (Existing)

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Figure 2.14 Water Balance Diagram (Expansion)

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2.9.4. Fuel
Naptha / FO will be used as fuel. Comparison of fuel in present and post revamp
conditions are given in table 2.1Control Measures provided in the tank farm area:
 Underground pipelines are protected from corrosion by protective coating and
over ground pipelines by painting.
 Pipelines are periodically inspected and hydraulic testing of underground
pipelines is done as per preventive maintenance schedule.
 Jumper connections are provided across the flanges of Naphtha carrying
pipelines to prevent buildup of static electricity.
 Storage tanks are constructed as per API 650 standards.
 The tanks are provided with level indicators, temperature indicators and earthing
arrangements.
 Raw Naphtha tank is a floating roof tank. Swivel joints are provided for roof drain,
which are inspected periodically. Double earthing protection is provided for the
pontoon. Breather valve with flame arrestor is provided to avoid buildup of
pressure / vacuum in the tank.
 Sweet Naphtha tank is provided with Nitrogen blanket. Low Nitrogen flow alarm
is provided. Relief valve with flame arrestor is provided to prevent excessive
buildup of pressure in the tank.
 Fuel oil storage tanks are provided with a vent with a flame arrestor. Steam
heating coil is provided to maintain the Fuel oil/LSHS at the proper temperature
to facilitate easy handling.
 Regular draining of the tanks is done to avoid contamination of the contents with
water.
 Periodic inspection of raw naphtha tanks, tank seals, inspection of pipeline
supports, phased replacement of flanged bolts and gaskets would ensure
prevention of any leaks and emergencies.
 Tanks are provided with containment dykes and fire break walls as per relevant
standards, rules and regulations.
 Oil water separators and fire seals are provided to avoid contamination of storm
water drains with Naphtha and Fuel oil spills.
 Adequate firefighting facilities are provided which include TAC approved fire
hydrant system. One fire tender and one trolley mounted fire pump are available
at site.
 Both the Raw Naphtha tanks are provided with 10 fixed foam pourers each and
furnace oil with 2 fixed foam pourers. 2 Nos fixed foam pourers for sweet
Naphtha tank. 2 nos. foam compound tanks with a capacity of 10,000 litres are
provided at the tank farm area. 1000 litres of foam is kept available at the fire

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station. In addition 10,000 litres of foam is maintained spare for mutual aid with
MRPL.
2.10. Employment
The unit proposes to provide employment to various skilled and unskilled persons. The
existing employment at the site is 680 no of persons and proposed employment
generation from the project is estimated to be 200 no of persons including contract labor
during operation phase.
2.11. Environmental Aspects:
2.11.1. Liquid Effluent
 Ammonia Plant
There is no additional liquid effluent generation from the plant and will remain zero liquid
effluent discharge plant. It is proposed to replace the present low pressure stripper with
medium pressure (MP) stripper which will ensure removal of Ammonia from process
condensate. The gases from the MP stripper will go to primary reformer along with
steam. The effluent generated in the plant shall be treated in the existing effluent
treatment facility and recycled back to the system.
 Urea Plant
There will not be any additional effluent generation because of the proposed expansion.
Because of the various energy improvement schemes, effluent generation will reduce.
For the existing system, MCF has installed and commissioned urea hydrolyser stripper
and operated for the treatment of effluent streams from ammonia plant process, urea
plant process and condensates from urea plant compressors. The urea hydrolyser
stripper system consists of hydrolyser, which is operated at high temperature' and high
pressure, where urea gets hydrolyzed to ammonia and carbon dioxide. Ammonia thus
produced is separated in the second desorption column. The liquid outlet of second
desorption column contains less than 10 ppm of ammonia and urea. The ammonia
vapours from the second desorption column is fed to the first desorber. The desorber
overhead vapours are condensed in a condenser and reused in Urea plant.
 DAP/NPK Plant
No trade effluent generation from the proposed DAP/NPK plant. No solid waste will be
generated. Any spillage will be recycled and reused in the proposed plant. The marginal
increase in the water requirement after the commissioning of DAP/NPK plant will be met
 Poly carboxyl ether (PCE) Plant
floor will be collected and recycled back.

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Mangalore Chemicals & Fertilizers Ltd. (MCFL) has given top priority to its effluent
treatment and disposal system right from the design stage of its plants.
TRADE EFFLUENT TREATMENT SYSTEM
In Mangalore Chemicals & Fertilizers Ltd., (MCF), the Liquid Effluent streams generated
are only from Ammonia, Urea and Water Treatment Plants. The Ammonium Bi-
carbonate and Di-Ammonium Phosphate Plants are designed to have zero effluent
discharge. In Di-Ammonium Phosphate (DAP) Plant a part of ammonia and urea bearing
effluent from Urea/Ammonia plant is used as process condensate. MCF already installed
the ETP in existing plant and the same will be used for the treatment of additional
effluent generated in the proposed projects.
MCF has installed and commissioned urea hydrolyser stripper at the cost of Rs.8.5
crores in 1990 and same is being operated for the treatment of effluent streams from
ammonia plant process, urea plant process and condensates from urea plant
compressors. The urea hydrolyser stripper system consists of hydrolyser, which is
operated at high temperature and high pressure where urea gets hydrolysed to ammonia
and carbon dioxide. Ammonia thus produced is separated in the second desorption
column. The liquid outlet of second desorption column contains less than 10 ppm of
ammonia and urea. The ammonia vapours from the second desorption column is fed to
the first desorber. The desorber overhead vapours are condensed in a condenser and
reused in Urea plant. The treated effluent from urea hydrolyser stripper is reused as
Urea Hydrolyser Stripper:
Urea Hydrolyser stripper system consists of mainly first Desorption column, Urea
Hydrolyser, Second desorption column, Reflux condenser and Level tank reflux
condenser.
Pre-Desorber or First desorber: Process condensate (design = 11% NH3) from
ammonia water tank is fed to desorption column through heat exchanger. Process
condensate from Urea plant oil separator is also fed to desorption column after
preheating to 128oC. Steam, water vapour from urea hydrolyser and 2nd desorption
column are introduced to the bottom part of desorption column as stripping medium.
The desorption column is operated at 2.6 Kg/cm2 and in this a part of ammonia and CO2
in the solution is stripped off. To control the water percentage at about 46% in the top of
the first desorber, reflux is added to the top tray of first desorption column. The reflux
comes from level tank reflux condenser.
The pre-desorbed solution at a temperature of 140 oC from the bottom of desorption
column is pumped upto 20 Kg/cm2 and after heating to about 182 oC in the hydrolyser
heat exchanger; it is fed to the hydrolyser.

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Hydrolyser: In the hydrolyser, most of the urea is hydrolysed into NH3 and CO2 at an
average temperature of about 200 oC at 16.5 Kg/cm2. The feed flow to hydrolyser
exchanges heat with the bottom effluent of the hydrolyser in hydrolyser heat exchanger.
The feed temperature increases from 138 oC to about 189 oC. The feed inlet is at the first
tray. The column has 16 sieve trays to ensure a good contact between the process liquid
and vapours. The column is almost completely filled with liquid except for the space
above the first tray.
The heat required for hydrolysation and maintaining a temperature of about 189 oC in the
top of the hydrolyser is supplied by 38Kg/cm2 steam with a temperature of about 390 oC.
The temperature of the bottom effluent is about 208 oC before hydrolyzer heat
exchanger exchanges heat with the feed flow thereby decreasing the temperature to
about 146 oC.
Second desorption column: The effluent is then fed to the top of 2nd desorption column
for final stripping. Process condensate from Ammonia plant is also introduced into
second desorption column after preheating to about 146 oC, with second desorption
column outlet liquid stream.
In the second desorber, operated at 2.8 Kg/cm2, L.P. steam is used to strip the residual
ammonia and CO2 and is fed underneath tray 41. Separated hot ammonia and CO2
gases with water vapour are sent to the first desorption column. Second desorber is a
vertical column consisting of 41 Nos. of double flow sieve trays each with 538 holes of
12.7 mm diameter.
The second desorber liquid discharge, which contains less than 10 ppm of ammonia and
urea (Guaranteed 30 ppm NH3 and 30 ppm urea) at a temperature of 143 oC is
extracted from the bottom of second desorber and is split into two steams. One stream
after heat exchange with process condensate feed from NH3 plant is sent to cooling
tower. The other stream after heat exchange with process condensate feed from urea
plant oil separator and with process condensate from ammonia water tank is cooled at
40 oC with cooling water in coolers and this also is sent to cooling tower.
Block diagram is attached.

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Figure 2.15 Urea Hydrolyser System

Wastewater recovery plants:
As corporate social responsibility, with the aim of reusing the entire treated effluent and
to achieve the target of zero effluent discharge MCF has installed Effluent Water
Recovery Units during 2009-2010 by investing about Rs.7.0 crores for treating the
effluent streams consisting of the following:
 Sand filter back wash water from water treatment plant and cooling tower
 Water treatment plant resin regeneration effluent - acidic and alkaline
 Cooling tower blow down.
Based on the characteristics of the effluent streams, trade effluents are categorized and
are treated as given below:
Lamella Clarifier Technology:
Sand filter back wash water from water treatment plant and cooling tower containing
high suspended solids effluent is treated by using Lamella Clarifier technology.
Static mixer, Lamella clarifier, centrifuge and sand filter are major equipment for treating
the high suspended solids effluent streams. Back wash water of sand filter and
activated carbon filter from water treatment plant and cooling tower side stream filter are
treated in this unit. Lamella clarifier are proven equipment and technically suitable for
treating the above streams. The treated water is reused in cooling tower as makeup.

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The Lamella Clarifier consists of a series of inclined overlapping plates, which are
arranged to form a sedimentation chamber. Before entering to Lamella clarifier, water is
first fed to Flocculation tank through Static mixer.
Chemicals like Alum, Polymer and Chlorine are added prior to static mixer in which
zigzag vanes are provided for proper mixing of chemicals in water. Water from static
mixer enters in flocculation chamber in which paddle type agitator is provided for gentle
mixing. Polymer is added for flocculation of coagulated particles. Sufficient residence
time is provided in this chamber for particles to become heavy before entering into
Lamella Clarifier. The pretreated feed stream enters the Lamella and transverses
through feed ducts longitudinally, along each side of the Lamella plates, through a
bottomless distribution duct. As the feed stream moves upwards, solids settle down.
The backwash water from clarifier is recycled to static mixer. The slurry containing solids
is pumped to a centrifuge for separating liquid which is recycled to static mixer. The
thickened slurry is used in DAP plant.
SF B/W
ACF B/W
LAMELL
FLOCUL
STATIC A
ATION SLURRY TO
MIXER CLARIF
TANK CENTRIFUGE
IER
SOLIDS TO
DAP PLANT
LIQUID TO
POLYMER STATIC MIXER
CLARIF
DOSING
IED
WATER
COAGULA TANK MGF
COOLI NT
NG DOSING
TOWE
R
BLOW
DOWN
PIT
COOLIN RECOV
G ERED
TOWER WATER
SS FOR
FILTER REUSE
B/W Figure 2.16 Lamella clarifier
WATER

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MEMBRANE BIO REACTOR - SEWAGE

LAMELLA CLARIFIER UHS
TREATMENT
RO TECHNOLOGY - EFFLUENT WATER

UF & RO WASTEWATER RECOVERY UNIT
RECOVERY
Figure 2.17 Infrastructure For Waste Water Treatment Facility In MCF

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Reverse Osmosis (RO) Technology:

Water treatment plant resin regeneration and cooling tower blow down effluents
containing high dissolved solids is treated by Reverse Osmosis technology.
The high dissolved solids effluent stream containing water treatment plant resin
regeneration effluent and cooling tower blow down is passed through clarifier, pressure
sand filter and Ultra Filtration (UF) units to remove suspended solids and colloidal
particles. Then it is treated in Reverse Osmosis (RO) units to remove dissolved solids.
Treated water is reused in cooling tower as makeup.
The high dissolved solids effluent streams are collected in an equalisation tank. This
stream after dosing with NaOCl, Coagulant, Lime, Dolomite & Polymer will be pumped to
High Rate Solids Contact Clarifier (HRSCC). The clarified water from HRSCC is passed
through Multi Grade filter for reduction of suspended solids. Then the filtered water is fed
into the Ultra filtration unit (UF) to remove colloidal silica and related colloids of iron and
aluminium in water causing fouling, scaling and poor performance of the plant. The
stream which is free from suspended and colloidal particles will be passed through
Reverse Osmosis unit (RO). The Dissolved solids are removed in 2 stages of RO unit. In
the first stage RO1 about 75 % of desired quality water will be recovered and reject is fed
to second stage RO2 wherein further 10% is recovered. The RO2 reject containing high
dissolved solids is used in DAP plant. The sludge collected in the HRSCC is pumped to
centrifuge to remove water. The separated liquid is recycled to equalizing tank and
sludge is used in DAP plant.
SAC REGN.
EFFLUENTS
POLYMER CLARIFIED
CLARIFIER CLARIFIER WATER
FEED TANK STORAGE TANK
NaOCl
REGN. COAGULANT
EFFLUENT
SOLIDS TO DAP
WATER TANK CT BLOWN DOWN WATER SLURRY TO CENTRIFUGE
CLARIFIER FEED PLANT
PUMPS
LIQUID TO
SBMS DOSING FEED TANK
MB/SBA/WBA
REGN.
EFFLUENTS UF
ANTISCALANT PERMEATE U.F
HCl DOSING
TANK
MULTI GRADE
FILTER
RO SKID
RO REJECT
RECOVRED DAP PLANT
WATER
WATER FOR
REUSE IN
COOLING
TOWER
Figure 2.18 RO unit

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Sewage Treatment Plant

MCF has put up a centralized sewage treatment unit with the capacity of 300KLD. The
combined sewage from the factory is collected in the sump tanks and pumped to the bar
screen chamber and oil trap to remove floating solids and oil traces respectively. After
this preliminary treatment the effluent is fed to equalization tank.
Effluent from the equalization tank is fed to the Membrane Bio-Reactor (MBR) tank at
constant flow rate. In MBR tank, MLSS (mixed liquor suspended solids) in the range of
10,000 mg/l is maintained. The high amount of bacteria gives better and complete
removal of organic matter from the raw effluent in relatively small area. Aeration is done
both to the equalization and MBR tanks through diffuser membranes by using blowers.
The suction pumps directly sucks permeate and the filtration is carried out by the
membrane. The suspended solids, turbidity, bacteria and viruses in permeate water are
removed to the levels required for reusing treated water. The treated water is reused in
cooling tower as makeup.
Figure 2.19 Sewage water treatment unit with MBR technology

2.11.2. Emission Control System: Emission Points, Stack and Control Strategy
Ammonia Plant
There will not be any increase in pollution load due to increase in production. This is
achieved by the energy improvement schemes which will be implemented in the plant.
The total firing in the primary reformer will be lower resulting in reduction of fuel
consumption. Also there will be reduction in steam and power requirement for the plant.
Urea Plant

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There will not be any significant increase in pollution load after the implementation of
energy improvement project. Capacity of Urea plant will be increased from 4,29,000 t/y
to 5,69,400 t/y after the availability of NG in Mangalore.
The emission of Particulate matter from the urea prill tower will be about 110 mg/Nm3
which is well within standard of 150 mg/Nm³.
The Ammonia / Urea revamp project will not have impact on Environment as energy
norms will improve further there by reducing the consumption norms on fuel resulting in
reduction of emissions. The proposed project will not have any adverse impact on the
existing environment as sufficient pollution control measures are incorporated in the
process technology. Additional CO2 required for Urea production will be recovered from
reformer flue gas by Carbon dioxide Recovery (CDR) unit which inturn reduces the
emission of CO2, a greenhouse gas.
DAP/NPK Plant.
The proposed project will not have any significant adverse impact on the existing
environment as sufficient pollution control measures are incorporated in the process
technology and plant design. The technology also incorporates special scrubbing
equipment like Dual Mole Scrubbing System and also Dedusting system. In DAP / NPK
plant Air pollution control equipment viz. Cyclone, Scrubber, Mist eliminator etc. shall be
installed during the commissioning of the plant itself.
The flow of gaseous emission from the stack (3 no. 45 m each) is expected to be
maximum of 720000 Nm³/hr., particulate Matter 50 mg/Nm³, fluorine 20 mg/Nm³ and
Ammonia 150 mg/Nm³.
POLY CARBOXYL ETHER (PCE) Plant
There will not be any gaseous emission from the proposed plant.
The details of stacks and vents along with height, type of fuel, fuel consumption rate,
control measure etc. is referred in Table below

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Table 2.8 Stack Parameters and Emission Details of Proposed Sources
Discharge, Exit Gas Exit

Dia, Height, Nm³/h Velocity, m/s Temperature, °C
Tag Name
m m Existin
Existing New Existing New New
g
IJT Boiler IJT Boiler Stack F-931 1.9 43 45000 45000 6.3 6.30 190 190.00
BHEL Boiler BHEL Boiler Stack F-902 1.4 43 41000 41000 12.4 12.40 210 210.00
Reformer S-201 Reformer Stack 2.26 38 120,000 100900 12.1 10.21 190 126
Raw Naphtha Heater
F-101 0.61 17.9 8700 0 8.2 0.00 430 -
(Pretreatment)*
F-4202 Air Preheater 0.91 23 16000 5875 6.9 6.46 430 430
F-210 Naphtha Vaporizer* 1.04 33 22000 0 7.1 0.00 380 -
F-4210 Feed NG Heater ** 1 34 0 3900 0 2.52 - 226
Sulphuric Acid
Sulphuric Acid Plant Stack 0.95 50 8200 8200 3.7 3.7 70 70
plant stack
42500 42500
CPP DG Sets CPP DG Sets 8 Nos. 1.4 44 14.8 14.80 240 240
each each
DAP Plant Stack (Existing
DAP Plant stack 2.4 45 210000 210000 15.5 15.5 60 60
plant)
DAP Plant Stack (New 720000
DAP Plant stack 2.73 45 0 0 0 60
Plant)(3 No,) (Total)
Urea Plant Prill
Prill Tower Fan ducts 1.7 72 500000 500000 17.7 17.70 70 70
Tower
* These stacks will be removed after expansion.
** New stack after expansion

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Table 2.9 Stack emission Rate – (Existing & Propose)
Sox, Nox, NH3, SPM, HF,

Tag Name mg/N m³ mg/Nm³ mg/N m³ mg/N m³ mg/N m³
Existing New Existing New Existing New Existing New Existing New
IJT Boiler IJT Boiler Stack F-931 815 10 112 112 Nil Nil 32 32 Nil Nil
BHEL Boiler BHEL Boiler Stack F-902 860 10 103 103 Nil Nil 30 30 Nil Nil
Reformer S-201 Reformer Stack 14 10 250 250 Nil Nil 33 33 Nil Nil
F-101 Raw Naphtha Heater (Pretreatment)* 13 0 250 0 Nil Nil Nil Nil
F-4202 Air Preheater 13 10 250 250 Nil Nil Nil Nil
Negligible
F-210 Naphtha Vaporizer* 11 0 250 0 Nil Nil Nil Nil
F-4210 Feed NG Heater ** 0 0 0 250 Nil Nil Nil Nil
Sulphuric Acid plant Sulphuric Acid Plant Stack 640 640 Nil Nil Nil Nil Nil Nil Nil Nil
CPP DG Sets CPP DG Sets 8 Nos. 910 10 1180 1180 Nil Nil 32 32 Nil Nil
DAP Plant stack DAP Plant Stack (Existing plant) Nil Nil Nil Nil 60 60 80 80 2 2
DAP Plant stack DAP Plant Stack (New Plant) Nil Nil Nil Nil 0 150 0 50 0 <10
Urea Plant Prill Tower Prill Tower Fan ducts Nil Nil Nil Nil 150 150 95 110 Nil Nil
* These stacks will be removed after expansion.
** New stack after expansion

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2.11.3. Noise Environment

The proposed project will have various machines and equipment which will generate
noise. The equipment and machines will have adequate provision to minimize the noise
generation. The manufacturing process is batch process.
 Plant personnel working in the noisy area will be provided with earplug.
 Installation of the plant machinery will be done after due consideration to design
noise levels and noise mitigation measures.
 The green belt developed helps in reducing noise levels generated due to plant
operations.
 There will be few major sources of industrial noise; minor noise generated from
the industrial operations will be controlled by proper maintenance.
 Proper mitigation measures will be taken in addition to above for the reduction of
noise levels i.e. use of acoustic enclosures and providing personal protective
equipment etc. to the workers.
 Periodical monitoring for noise will be carried out on regular basis.
 Proper maintenance, oiling and greasing of machines at regular intervals is done
to minimize generation of noise at source.
 The D.G. sets are provided with acoustic enclosures.
2.11.4. Solid and Hazardous waste
The hazardous waste is generated at various stages of the manufacturing activity. The
domestic and industrial wastewater generated will be segregated. The effluent
generated will go to the Effluent Treatment Plant (ETP). Minor quantities of construction
waste will be generated in the form of packaging material and construction waste.
Proper care will be taken for handling and reduction of the solid waste generated during
construction phase. During the operation phase the solid waste generated will be resued
as filler material in the proposed DAP/NPK plant. Hazardous wastes like used oil, waste
oil, spent catalyst and discarded containers will be handled as per the Hazardous and
other wastes (Management and Trans-boundary movement) rules, 2016.
2.11.5. Green Belt Development
MCF has already developed and maintained a green belt covering an area of about 64
acres. The green belt contains around 63,000 trees of different species viz. Mangium,
Casurina, Subabul, Acacia, Gulmohar, Jack, Cashew, Mango, Banyan, Peepal, etc.
2.11.6. Project Cost & Implementation schedule:
The cost and implementation schedule is given below.
Sl.N Plant Capital Environmental Implementation
o Cost Cost (Cr) Schedule
(Cr)
1. Urea and Ammonia Plant 540 30.0 24 months
2. Di Ammonium Phosphate 987 25.0 30 month
(DAP) / NPK Multi-grades
3. Poly Carboxyl Ether (PCE) 20 1.0 12 Month
Total Cost 1547 56.0
EQMS INDIA PVT LTD

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CHAPTER 3. DESCRIPTION OF THE ENVIRONMENT
This Chapter describes the baseline environmental conditions around the proposed MCF
project site for various environmental attributes, i.e. physical, biological and socio-economic
conditions, within the 10-km radial zone of the proposed project site, which is termed as the
study area. Topography, drainage, meteorology, air, noise, water, soil and land constitute
the physical environment, where as flora and fauna constitute the biological environment.
Demographic details and occupational pattern in the study area constitute socio-economic
environment.
3.1. Background and Salient Environmental Features of the Study Area

Generation of environmental baseline of a project area is an important phase of any
Environmental Assessment process. Baseline data provide vital information on the
existing environmental quality in which a development is planned. It is also useful for
delineating environmental sensitive areas and for preparing an Environmental Sensitivity
Map for contingency planning. In this study, the environmental characteristics of the
project area (10 km study area) were established through extensive literature search,
field sampling/measurements, laboratory analysis, consultation and data interpretation.
Secondary data from literature search were also obtained from the Govt. sources i.e.
Meteorological Department, CPCB publications; Forest Department and other Govt.
Sources. The baseline environmental data generation has been done for the period from
1st December 2016 to 28th Feb 2017. M/s JP Test & research centre, Sahibabad, Uttar
Pradesh with EQMS Team, carried out sampling and testing. The study area within a 10-
km radius around the proposed plant site has been considered as impact zone for EIA
study. Primary and secondary data has been collected for 10 Km radius of the project
site.
3.2. Environmental Setting and Salient Environmental Features of the Project

Area
Mangalore Chemicals and Fertilizers Ltd proposes for energy improvement of Ammonia
and urea plant, expansion of DAP/NPK plant and Poly Carboxyl Ether (PCE) plant at the
existing premises of MCF Ltd. Located at Mangalore taluk of Dakshina Kannada district,
Karnataka state. The Existing MCF plant is in coastal belt of Arabian Sea in Mangalore
taluk of Dakshina Kannada district, Karnataka state. The MCF complex occupies an
area of 192 Acre. The proposed developments / facilities are planned within the existing
MCF premises and no additional land shall be acquired for the project.
Mangalore town is located about 10 km south of the plant site. Eddap ally-Panvel
highway is passing along the western boundary of the plant. Sea coast is located about
2.0 km west of the plant site. Nearest settlement is Kulur located about 2.0 km southeast
of the project site. Nearest railway station is Thokur railway station which is located
about 4.0 km north in direction. Mangaluru Central Railway station is located about 10.0
km in south direction. Nearest Airport is Mangaluru International Airport located at 8.0
from the site in north east direction. Nearest city is Mangalore which is located about
10.0 km from the site in southeast direction. Gurpura River is passing about 1.0 km
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southeast of the project site. Netravathi River is flowing at more than 10 km from site in
south direction. Panambur beach is located at about 3.0 km west of the site.
There are no environmentally sensitive components such as National Park, Wildlife

Sanctuary, Elephant / Tiger Reserve, migratory routes of fauna and wet land present
within 10 Km radius of plant site. There are no Reserve and protected forest present
within 10 km area of the site. Location map, showing site and surrounding environment
features within the 10-km area is provided in Figure 3.1 and Google map provided in
Figure 3.2. The Salient Environmental Features of plant site within 500m, 2 Km and 10
Km radius is summarized at Table 3.1.
Table 3.1 : Salient Environmental Features of Proposed Site
Within 500 m Within 2 km area Within 10 km

S.
Environmental Features area around around project area around
No.
project site site project site
1 Ecological Environment
Presence of Wildlife
A Sanctuary/ National None None None
Park/Biosphere Reserves
Reserved /Protected
B None None None
Forests
Wetland of state and
C None None None
national interest
Migratory route for wild
D None None None
animals
Presence of schedule-I
E None None None
Fauna
G Critically polluted Area None within 10 km study area
2. Physical Environment
Eddapally- Panel Eddapally- Panel Eddapally- Panvel
H Road connectivity
highway highway highway
Thokur rail stn. –
4.0 km, north
I Rail connectivity None None Mangaluru
Central Station-
10.0 km, south
J Defence Installation None None None
Mangalore town
K Densely Populated Area None None
~10.0 km, S
Other village close to Nearest settlement is Kulur located about 2.0 km southeast
L
plant site of the project site.
Plain, elevation of Flat to undulating
Plain, elevation
site ranges elevation ranges
M Topography ranges between 6
between 19 to 27 between 0 to121
to 38 amsl
amsl amsl.
M Seismicity Seismic zone-III (Moderate Risk Zone)
Gurupura river –
Gurupura river –
Surface Water 1.0km SE,
N None 1.0 km SE, Sea
Resources (Rivers) Netravathi river-
coast-2.0 km west
more than 10 km
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about 82% area fall in safe category and and 18% area falls
O Groundwater
in critical category
Silty loam sandy
Silty loam sandy
clay loam,
Silty loam clay loam,
Vegetation,
P Soil and Land-use Industrial,
industrial,
Industrial settlement and
settlement, water
mixed-use area
body ect.
3. Social Environment
Industrial, Rural &
S Physical Setting Industrial Mixed use
Urban
Physical Sensitive School, Hospitals, School, Hospitals,
T None
Receptors Temple etc. Temple etc.
Archaeological
U None None None
Monuments
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Figure 3.1 Google Map showing Site & Surrounding Environmental Features within 10 km area
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Figure 3.2 Location Map of Study area
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3.3. Primary Data Collection: Monitoring Plan and Quality Assurance

Procedures
Primary baseline data has been collected as per the TOR prescribed by MOEF during 1st
December 2016 to 28th February 2017 for one complete season. The study period and
methodology for primary data collection is summarized in Table 3.2. Sampling location
map provided in Figure 3.3.
Table 3.2 Summary of Methodology for Primary/Secondary Baseline Data

Collection
No. Of
Frequency
Parameters sampling Remark
/ season
locations
Ambient Air Quality
AAQ monitoring was carried out at
8 locations (representing upwind,
Twice a
downwind and sensitive locations).
PM10, PM2.5, SO2, NOx, 8 Week
24 hours sampling at each location
CO, NH3, HC, HF locations For winter
was carried out as per CPCB guide
season
lines (CPCB Gazette notification
dated 18.11.2009 on AAQ).
Meteorology
Temperature, Humidity, Hourly for Met station was established close
One
Wind speed, Direction, winter to the site to record the site-specific
location
Rainfall etc. season hourly met data.
Ground Water Quality
Ground water: Sampling was
conducted at 8 locations. Samples
8
Physical, chemical and were preserved, transported and
locations
biological parameters as per Once in a analyzed for different parameters
in study
IS 10,500 season based on APHA methods. Temp,
area
conductivity and pH which were
measured instantly at site itself.
Surface Water Quality
Surface Water: Sampling was
conducted at four locations.
3 Samples were preserved and
Physical, chemical and locations Once in a transported for analysis for different
biological parameters as per in study season parameters based on APHA
IS: 10,500 area methods. Temp, conductivity, DO
and pH which were measured
instantly at site itself.
Soil
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No. Of
Frequency
Parameters sampling Remark
/ season
locations
Texture, bulk density, pH, 6
conductivity, cation locations Soil samples were collected at six
Once in a
exchange capacity, organic in study locations within the study area and
season
matter, Total N, P, K, and area analyzed as per IARI method
Heavy metals etc
Noise
8 Noise monitoring was conducted
locations within the 10-km area of project
Once in
Noise profiling for 24 hrs. in study site for noise profiling for 24 hrs
season
area using integrated sound level meter,
as per CPCB guidelines.
Ecology (Flora & Fauna)
Primary survey and Secondary
Flora & Fauna Once
sources
Demography & Socio-economics
Demography & Primary survey/ Secondary
- Once
Socioeconomic sources
Standard methods and procedures have been strictly adhered to during this study.
QA/QC procedures were strictly followed which covers all aspects of the study, and
includes sample collection, handling, laboratory analysis, data coding, statistical
analysis, presentation and communication of results. All analysis was carried out in
NABL/MoEF accredited/recognized laboratory.
3.4. Physical Environment
3.3.1 Topography
The topography of proposed site is almost plain. The site elevation ranges between 19
to 27 amsl. Topography around 10 km area of the proposed site is slightly undulating.
The average elevation in 10 km area around the site ranges between 0 to121 metres
above mean sea level. The eastern and south-eastern part of the study area is hilly.
Digital elevation map of the study area is provided in Figure3.4.
3.3.2 Drainage
The study area falls in Netravathi and Gurpura river basin. Drainage pattern of the study
area is mainly controlled by Gurpura River and Netravathi River. The Nethravati and
Gurupur rivers originate in the Western Ghats and flows towards the Arabian Sea. The
area is sloping towards sea coast and all the drainage of the study area is towards sea.
Drainage map of study area is presented in Figure 3.5.
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Figure 3.3 Environment sampling Location Map
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Figure 3.4 Digital Elevation Map of Study Area
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Figure 3.5 Drainage Map of Study Area
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3.3.3 Geology & Hydrogeology

Geo-morphologically the study area lies in Coastal plain. The Coastal plain is a narrow,
thickly populated and intensely cultivated area adjoining the coast. There is considerable
extent of barren land along the coast partly because it is sandy, rocky, and marshy.
The study area falls in Netravathi and Gurupura river basin. Gurupura river basin lies in
the south-western part of the Dharwar Craton i.e., coastal stretch of the Western
Dharwar Craton (Fig. 3.6). The coastal stretch and the adjacent Western Ghats are
composed of Precambrian (Archean) rocks and the Phanerozoic formations.
Figure 3.6 Geological Map of the Mangluru

Geologically the Netravathi and Gurpur river basin is composed of rock types belonging
to tertiary to quaternary eras. The geological set-up of the study area is represented by
Cenozoic lithounits which comprises of major rocks as recent sub recent alluvium,
quarternary pebble beds, tertiary laterites, Rhyodacite-Granophyre and Saint Mary
dacite.
The other major lithounits represents are Peninsular Gneiss/Archean Tonalitic-

Trondhjemitic-Granodioritic (TTG) gneiss. The greenstone-amphibolitic facies
metamorphic rocks and granulites could be seen in patches.
3.3.4 Depth to Ground Water Table
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The study area falls in Mangluru block of Dakshina Kannada District. The depth to water
level in study area during pre-monsoon season varies from 2 m bgl to 10 m bgl and in
post monsoon season depth to water tableranges 0 m to 10 m. Depth to water table in
District is provided in Figure 3.7.
Project Site Project Site
Source: (CGWB ground Water Voucher, Dakshin Kanada)
Figure 3.7 : Depth of Ground Water Table in Dakshina Kannada District

3.3.5 Hydrogeology
Weathered and fractured gneiss, granite and schist are the major water bearing
formations. Alluvial formation of limited thickness and aerial extent is found along the
courses of major rivers. The groundwater occurs under phreatic (water table) condition
in weathered zones of gneiss, schist and granite and under semi-confined to confined
conditions in joints and fractures of these rocks at deeper levels. Weathered and
fractured gneiss is the predominant aquifer found in the district followed by schistose
and granitic aquifers, which occur as isolated patches in some taluks. In study area
gneiss and alluvium are the major water bearing formations (refer Figure3.8).
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Figure 3.8 Hydrogeology of Dakshin Kanada

3.3.6 Ground Water Resources
The 10-km study area falls in Mangalore block of Dakshina Kannada District. Net ground
water resources based on water level fluctuation method is estimated to be 8068.14
hams. Existing gross ground water draft for all use is 5234.90 hams and over all stage of
development is 64.88%. Overall about 82% area fall in safe category and 18% area falls
in critical category.
3.3.7 Seismicity of the Study Area

Based on tectonic features and records of past earthquakes, a seismic zoning map of
India has been prepared by a committee of experts under the auspices of Bureau of
Indian Standard (BIS Code: IS: 1893: Part I 2002). As per Seismic map of India the
study area falls in Zone-III (moderate damage Risk Zone). The seismic zone map of
study area is shown in Figure3.9.
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Figure 3.9 Seismic Zones Map

3.3.8 Land use
Land use analysis was carried out using remote Sensing Data. Interpretation approach
based on systematic digital imaging was used for delineating the land use classes. The
demarcation of boundaries falling under different land use/land cover units is done using
different colours assigned to different land use/land cover units of satellite imagery1.
The site is located in the Karnataka Industrial Area Development Board notified
Baikampady/ Panambur industrial area, Mangalore, Dakshina Kannada (Mangalore
Industrial Cluster) for industrial land use. Most of the land within the 10-km area of the
project site is Water body and Vegetation/Plantation. As per the land use based on
satellite image, about 30% land in study area is under Vegetation\Plantation, about 39%
of land is under water body, about 21% land is under settlement, only 5% of the land is
under agricultural and rest of the land is under other uses (Refer Figure3.10 and Table
3.3).
1 The satellite Imagery of Indian Remote Sensing Satellite (IRS- ID, sensor P6, LISS III) of 24 m resolution was used. The Swath of the imagery is 141 Km x 141
Km. Band used are 4, 3, 2 and 5. LANDSAT imagery of 30 meter resolution and 185 x 185 km swath is also used for the comparative and overall analysis of the
area. LISS III imagery and LANDSAT 4-5 TM imagery were used for the complete coverage of the study area
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Table 3.3 : Land use of the Study Area
Class Area (SQ KM) %

Agricultural Land 16.88 5
Vegetation\Plantation 103.00 30
Water body 133.95 39
Settlement 70.34 21
Marshy Land 4.66 1
Barren Land 13.46 4
Total 342.29 100
(Source: satellite data analysis)
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Source: Interpretation of Satellite image
Figure 3.10 Land Use Map of the Study Area (10 km Radial Zone)
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3.5. Meteorology
Historical meteorological data was obtained from nearest IMD station located at district
headquarter Mangalore (Bajpe- A). The predominant wind direction is from east,
southeast and west. Details provided in Table 3.4.
Table 3.4 : Long Term Meteorological Data of Mangalore (30 years average)
Relative Predominant Cloud

Temperature Wind
Humidity Rainfall Wind Direction Calm Period Amounts
Month (°C) daily Speed
(%) (mm) (From) Octas
Km/hr
Max Min Max Min 08:30 17:30 08:30 17:30
January 31.7 21.7 70 65 0.2 E, SE W, NW 0 0 2.6 9.1
February 31.7 22.7 73 68 3.6 E, SE W, NW 3 0 2.4 9.2
March 31.9 24.4 74 70 2.5 E, NE W, NW 3 0 2.5 8.9
April 32.8 25.7 72 71 35.0 E, NE W, NW 5 0 3.4 9.1
May 32.3 25.4 76 73 199.5 E, NE W, NW 6 0 4.9 9.8
June 29.9 23.7 87 82 955.8 E, SE W, SW 7 3 6.7 8.3
July 28.6 23.1 90 86 1160.3 E, SE W, SW 6 4 7.5 8.7
August 28.5 23.1 89 85 792.6 E, SE W, SW 6 0 7.2 8.6
September 29.2 23.1 86 83 331.5 E, SE W, SW 4 0 6.1 7.8
October 30.4 23.4 83 80 184.0 E, SE W, SW 4 1 5.2 7.6
November 31.7 23.0 74 71 75.2 E, SE W, SW 1 0 3.5 7.8
December 32.0 22.4 69 67 33.9 E, SE W, NW 1 1 3.2 8.4
(Source: IMD)
Temperature– December, January and February constitutes winter months with daily
mean minimum temperature around 21.7°C and daily mean maximum temperature
around 32.0°C. Daily mean minimum temperature at 25.4°C.
Relative Humidity– The air is generally dry in the region except during monsoonDec,
2016 and Feb 2017 with relative humidity ranges between 74-70%. The maximum
humidity during rainy season is 90%.
Rainfall–The annual total rainfall is 3774.1 mm (for which year). Over 77% of the total
annual rainfall is received during the monsoon period between June to August.
Cloud Cover – In the study area, clear weather prevails in most of the time during post
monsoon, winter and summer seasons. Only during monsoon months of June July and
August moderate to heavy clouds are observed. Relevant details about the number of
days with zero octas of cloud cover (all clouds) for all months are presented in Table 3.5.
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Table 3.5 : No. of days with zero octas of cloud cover (Mangalore)
Time Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
08:30 1 3 3 1 0 0 0 0 0 0 1 1
17:30 5 7 5 1 1 0 0 0 0 0 1 2
(Source: IMD Mangalore)
Wind Speed– The mean wind speed ranges from 8.4 to 9.2 kmph during winter season,
8.3 to 8.6 kmph during monsoon and 8.9 to 9.8 kmph in pre-monsoon season.
Wind Direction– The predominant wind direction at Mangalore is from E, SE morning

time in all the months. The second most predominant wind direction is from W, NW
evening time.
Calm Periods– The calm period constitute an important factor in the dispersion of air
pollution. The calm period is more during 8:30 AM compared to 17:50 PM. The maximum
calm period occurs during October to February months. Monthly calm period values
obtained from nearest IMD is shown in Table 3.6.
Table 3.6 : Monthly Percentages of Calm Periods (IMD Mangalore)
Calm (%) Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
08:30 0 3 3 5 6 7 6 6 4 4 1 1
Time
17:30 0 0 0 0 0 3 4 0 0 1 0 0
(Source: IMD Mangalore)
Special Weather Phenomena- The occurrence of thunderstorm is 12.2 days per year,
mostly spread across the months of May to September. Annual Dust Storm is 0 day.
Annually 0.8days have visibility less than 1 km, 22.7 days has visibility in the range of 1 -
4 km, 61 days have visibility in the range of 4 -10 km, 154.9 days between 10 - 20 km
and 125 days have visibility above 20 km. No dust storm or thunderstorm occurred during
the study period.
Met Data Generated at Site
Met data for 1st December 2016 to 28th February 2017 month was generated at site. An
automatic weather monitoring station was installed near Project site, keeping the sensors
free exposed to the atmosphere and with minimum interference with the nearby
structures. The micro-meteorological data like wind speed, wind direction, temperature,
relative humidity and atmospheric pressure were collected using the weather stationed
cloud cover was recorded manually for the study period.
The wind directions, wind speed, temperature, rainfall and humidity recorded at site
during study period are presented in Table 3.7. Site specific wind rose diagram for study
period (Dec-16 to Feb-17) is presented in Figure3.13.
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Table 3.7 : Site Specific Meteorological Data
Month Temperature Relative Wind speed Predominant Calm

(deg C) Humidity, % wind Direction Period
Min Max Min Max (m/s) (from ) %
Dec 2016 20 35 26 100
Jan 2017 20 36 21 94 0.5 to >4.5 E, ESE and W 14.63
Feb 2017 20 36 18 94
(Source: Field Survey)
Temperature – During the study period daily mean minimum temperature was 20°C and
daily mean maximum temperature was 36.0°C.
Relative Humidity –The maximum humidity during study period was 100 % and
minimum was 21 %. High humidity is found during daytime and low humidity values
during night time.
Wind Speed– The wind speed ranges between 0.5 to 4.5 m/s during study period except
calm conditions. Most of the time wind speed ranges between 1.5 to 3.5 m/s. Wind
frequency distribution during the study period is presented inFigure 3.12.
Wind Direction – The predominant wind direction at site is from E, SE and W direction.
Wind rose diagram is presented in Figure 3.13.
Calm Periods – Calm period is more during night time than day time. Percentage calm
periods during study period was 14.63%.
Figure 3.11 : Wind Frequency distribution (Winter Season)
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Figure 3.12 : Wind Rose (Winter Season)

3.6. Ambient Air Quality
CPCB guidelines were applied for selecting the appropriateness of monitoring locations.
The location and height of the stations were so selected (>5 m from base) to avoid the
capture of re-suspended road dust and fugitive domestic emissions due to burning. All
the ambient air analysis with respect to each parameter was analyzed as per CPCB
guidelines. AAQ monitoring was done at eight locations within the study area considering
dominant wind direction, populated area and sensitive receptors. Details of monitoring
locations are shown in Table 3.8. Monitoring Location map is shown in Figure3.3. The
summary of Ambient Air quality results is presented inTable 3.9.
Table 3.8 : Ambient Air Quality Monitoring Locations
Direction wrt
S.No. Location Terrain Features Tentative Geo-coordinates
Plant site
AAQ-1 Project Site -- Flat terrain, industrial 12°56′11.11″N,74°49′27.36″E
Undulating, urban area,
AAQ-2 Lalbagh 5.6km,S located in cross wind 12°53′6.40″N,74°50′17.96″E
direction
Flat terrain, mixed use
AAQ-3 Kulur 2.0 km, SE area, located in upwind 12°55′30.77″N,74°49′49.40″E
wind direction
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Flat terrain, rural area,

located in
AAQ-4 Marakada 4.6km, E 12°55′54.56″N,74°52′0.13″E
upwind/downwind
direction
AAQ-5 Kodikal 2.6km,N area, located in cross 12°54′41.60″N,74°49′32.79″E
wind direction
AAQ-6 Kulai 3.5 km,NW area, located in down 12°57′48.45″N,74°48′21.48″E
wind direction
Flat terrain, rural area,
AAQ-7 Purkodi 6.5km,NE located in crosswind 12°58′17.53″N,74°52′6.52″E
direction
Flat terrain, Industrial
AAQ-8 Baikampady 2.5km,N 12°56′51.54″N,74°49′17.25″E
area
Table 3.9 : Ambient Air Quality Monitoring Results (24-hour average)
Location PM2.5 (g/m3) PM10 (g/m3)

Code Location
Min Max Mean 98%tile Min Max Mean 98%tile
AAQ-1 Project Site 24 41 32 40 56 85 74 85
AAQ-2 Lalbagh 20 34 27 34 48 69 58 68
AAQ-3 Kulur 22 39 30 37 53 82 64 78
AAQ-4 Marakada 18 36 25 34 44 73 57 72
AAQ-5 Kodikal 18 28 23 27 40 69 54 67
AAQ-6 Kulai 21 37 28 35 46 76 59 74
AAQ-7 Purkodi 20 34 26 33 41 72 56 70
AAQ-8 Baikampady 23 46 36 45 58 92 78 91
NAAQ Standard: PM2.5 (60 g/m3), PM10 (100 g/m3)
Location SO2 (g/m3) NOx (g/m3)

Code Location
Min Max Mean 98%tile
Min Max Mean 98%tile
AAQ-1 Project Site 6.7 10.2 8.6 10.2 13.8 17.7 16.0 17.5
AAQ-2 Lalbagh 5.0 9.4 7.2 9.3 8.5 14.3 12.5 14.3
AAQ-3 Kulur 4.1 7.4 6.1 7.3 11.5 15.2 13.0 14.9
AAQ-4 Marakada 5.0 8.6 6.9 8.6 8.7 14.5 12.3 14.4
AAQ-5 Kodikal 4.0 6.8 5.3 6.8 10.1 14.8 12.1 14.8
AAQ-6 Kulai 4.3 8.2 6.4 8.1 10.2 16.5 13.0 16.4
AAQ-7 Purkodi 4.3 7.7 6.0 7.6 8.3 13.4 11.0 13.2
AAQ-8 Baikampady 5.5 9.8 7.8 9.7 11.4 18.6 15.7 18.4
NAAQ Standard: SO2 (80 g/m3), NOx (80 g/m3)
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CO, HC (µg/m³)
mg/m3 HF
NH3 (µg/m³) None-
Location (1hrs Methane (µg/m³)
Location methane
Code Conc.)
98 Mean Mean Mean Mean
Min Max Mean
%tile Value Value Value Value
AAQ-1 Project Site 14.2 29.7 22.1 29.0 <0.1 <0.1 <0.1 <0.1
AAQ-2 Lalbagh 10.0 19.2 13.4 18.8 <0.1 <0.1 <0.1 <0.1
AAQ-3 Kulur 10.8 21.6 15.6 20.9 <0.1 <0.1 <0.1 <0.1
AAQ-4 Marakada 10.4 23.0 14.0 21.9 <0.1 <0.1 <0.1 <0.1
AAQ-5 Kodikal 9.2 21.2 13.6 20.8 <0.1 <0.1 <0.1 <0.1
AAQ-6 Kulai 10.0 24.4 17.5 23.7 <0.1 <0.1 <0.1 <0.1
AAQ-7 Purkodi 9.1 18.6 12.2 18.3 <0.1 <0.1 <0.1 <0.1
AAQ-8 Baikampady 11.5 27.4 19.2 26.8 <0.1 <0.1 <0.1 <0.1
NAAQ Standard: NH3 (400 g/m3), CO (4 mg/m3)
(Source: Primery Data Collection and analysis during study period by Laboratory)
3.3.9 Observations on Ambient Air Quality

Particulate Matter (PM10): The highest PM10 level were found at Baikampady (92 µg/m³)
and lowest PM10 level at Kodikal (40 µg/m³) were observed at Project Site while the mean
conc. of all location ranges between 54-78 µg/m³. The PM10 level in all the monitoring
locations was found well within the National Ambient Air Quality Standards i.e. 100 µg/m³.
Figure 3.13 : Concentration of PM10 in the study area

Particulate Matter (PM2.5): The highest PM2.5 level was found at Baikampady (46 µg/m³)
and lowest PM2.5 level was observed at Markada and Kodikal (18 µg/m³) while the mean
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conc. of all location ranges between 23-36 µg/m³. The PM2.5 level in all the monitoring
locations was found well within the National Ambient Air Quality Standards i.e. 60 µg/m³.
Figure 3.14 : Concentration of PM2.5 in the study area

Sulphur Dioxide (SO2): The highest SO2 level were found at Project Site (10.2 µg/m³)
and lowest SO2 level were observed also at Kodikal (4.0 µg/m³) while the mean conc. of
all location ranges between 5.3-8.6 µg/m³. The SO2 level in all the monitoring locations
was found well within the National Ambient Air Quality Standards i.e. 80 µg/m³.
Figure 3.15 : Concentration of SO2 in the study area
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Oxides of Nitrogen (NOx): The highest NOx level was found at Baikampady (18.6
µg/m³) and lowest NOx level were observed at Purkodi village (8.3 µg/m³) while the mean
conc. of all location ranges between 11.0-16.0 µg/m³. The NOx level in all monitoring
location was found well within the National Ambient Air Quality Standards i.e. 80 µg/m³.
Figure 3.16 : Concentration of NOx in the study area

No abnormal values have been found in the dust of ambient air. The concentration of
NH3, range between 9.1 µg/m³ to 29.7 µg/m³was found well within the National Ambient
Air Quality Standards. No abnormal values regarding CO, HC and HF have been
observed in ambient air of the study area. Overall the ambient air quality of the study area
is meeting the prescribed National Ambient Air Quality Standard at all locations.
3.7. Noise Environment

Noise after a certain level can have a very disturbing effect on the people and animals
exposed to it. Hence, it is important to assess the present noise quality of the area to
predict the potential impact of future noise levels due to the proposed project. Ambient
noise measurements were taken at 8 locations, represented in Table 3.10. Location wise
result for day time and night time is presented in Table 3.11.
The monitored levels were compared against the Noise Pollution (Regulation and
Control) Rules 2000, as amended through the Noise Pollution (Regulation and Control)
Amendment Rules 2010 dated 11th January 2010. The project site falls in designated
industrial area and the noise levels at all the locations were found within the ambient
noise standards.
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Table 3.10 : Ambient Noise Quality Monitoring Locations
S. Location Direction wrt Category Tentative Geo-coordinates

No. Plant site with
approx. distance
N-1 Project Site Site Industrial 12°56′11.11″N,74°49′'27.36″E
N-2 Lalbagh 5.6km,S Residential 12°53′6.40″N,74°50′'17.96″E
N-3 Kulur 1.0 km, SE, Commercial 12°55′30.77″N,74°49′49.40″E
N-4 Marakada 4.6km E Residential 12°55′54.56″N,74°52′0.13″E
N-5 Kodikal 2.6km,N Residential 12°54′41.60″N,74°49′32.79″E
N-6 Kulai 3.5km,NW Residential 12°57′48.45″N,74°48′21.48″E
N-7 Purkodi 6.5km,NE Residential 12°58′19.28″N,74°52′6.12″E
N-8 Eddapally- 2.5 km,NW Commercial 12°56′27.58″N,74°48′56.62″E
Panvel Highway
Table 3.11 Ambient Noise Quality in the Study Area
dB(A) Standard dB(A) Standard

S.
Locations Leq dB(A) Leq dB(A)
No.
Day time Leq Night time Leq
N-1 Project Site 57.6 75 47.2 70
N-2 Lalbagh 53.1 55 43.3 45
N-3 Kulur 53.0 65 42.0 55
N-4 Marakada 50.2 55 41.8 45
N-5 Kodikal 51.2 55 42.7 45
N-6 Kulai 52.1 55 41.6 45
N-7 Purkodi 49.4 55 41.0 45
N-8 Eddapally- Panvel Highway 64.3 65 55.6 55
(Source: Analysis during study period, EQMS)
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Figure 3.17 : Graphical representation of ambient Noise Level in the study area
Observation on Ambient Noise Quality
The ambient noise quality of the study area is within the prescribed National Ambient
Noise Quality Standards prescribed for industrial (Standards - 75 dBA during day time
and 70 dBA during night time) residential area (Standards - 55 dBA during day time and
45 dBA during night time) and commercial area (Standards - 65 dBA during day time and
55 dBA during night time). However, the night time noise level (dB(A) Leq) at Eddapally-
Panvel Highway is slightly high than the Standards i.e.55 dBA due to vehicular
movement.
3.8. Water Quality

Eight ground water samples and three surface water sample were collected from different
locations around the site during study period. The water samples were examined for
physic-chemical parameters and bacteriological parameters. The samples were collected
and analyzed as per the procedures specified in Standard Methods. Samples for
chemical analyses were collected in polyethylene carboys. Samples for bacteriological
analyses were collected in sterilized bottles. Temperature, pH, conductivity and dissolved
oxygen were measured at site itself. Surface water sample were analyzed for various
parameters and assessed using the water quality standards for coastal waters marine
Outfalls (EPA Rule 1986).
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The name of sampling locations is presented in Table 3.12. The analysis results of
surface water and groundwater are presented in Table 3.13 and Table 3.14.
Table 3.12 : Ground Water Sampling Locations
S. Location Tentative Geo-coordinates Distance from Plant site

No.
Ground Water Sampling Location
GW-1 Project Site 12°56′11.11″N, 74°49′27.36″E Site
GW-2 Lalbagh 12°53′6.40″N 7, 4°50′17.93″E 5.6km,S
GW-3 Kulur 12°55′30.76″N, 74°49′49.39″E 2.0 km, SE
GW-4 Marakada 12°55′54.53″N, 74°52′0.12″E 4.6 km, E
GW-5 Kodikal 12°54′41.58″N, 74°49′32.77″E 2.6 km,N
GW-6 Kulai 12°57′48.43″N, 74°48′21.46″E 3.5 km,NW
GW-7 Purkodi 12°58′17.52″N, 74°52′6.51″E 6.5 km,NE
GW-8 Baikampady 12°56′51.53″N, 74°49′17.24″E 2.5 km,N
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Table 3.13 : Ground Water Quality in the Study Area
S.N. Parameters Project Lalbagh Kulur Markada Method Desired Limit /Permissible
site Limit
1 pH Value 6.91 7.23 6.87 7.10 APHA-4500 6.5-8.5/ No relaxation
2 Temperature 0C 25.0 25.3 25.2 25.1 Part 9 --
3 Conductivity, mhos/cm 152 140 302 244 APHA-4500 --
4 Turbidity (NTU) 0.26 0.38 0.46 0.30 APHA-2030B 1-5
5 Total Dissolved solids mg/l 93 88 196 143 APHA-2540B 500/2000
6 Total Suspended solids mg/l 0.6 0.8 0.9 0.4 APHA-2540D --
7 Total Hardness as CaCO3 50 32 84 56 APHA-2340C 200/600
mg/l
8 Chloride as Cl mg/l 18 17 42 46 APHA-4500B 250/1000
9 Total Alkalinity mg/l 56 50 92 74 Part -23 200/600
10 Sulphates as SO4 mg/l 02 02 15 04 APHA-4500E 200/400
11 Nitrates as NO3 mg/l 0.8 0.6 1.0 0.8 APHA-4500 45/No relaxation
12 Fluoride as F mg/l 0.14 0.11 0.16 0.24 APHA-4500D 1/1.5
13 Iron as Fe mg/l 0.22 0.30 0.38 0.25 APHA-3111B 0.3/No relaxation
14 Zinc as Zn mg/l <0.1 <0.1 <0.1 <0.1 APHA-3111B 5/15
15 Calcium as Ca mg/l 11 6 28 13 APHA-3500B 75/200
16 Magnesium as Mg mg/l 5.4 4.2 3.4 5.7 APHA-3500B 30/100
17 Sodium as Na mg/l 10 8 12 9 APHA-3500 --
18 Potassium as K mg/l 2.3 2.8 2.2 2.6 APHA-3500 --
KB
19 Cadmium as Cd mg/l <0.003 <0.003 <0.003 <0.003 APHA-3111B 0.003/No relaxation
20 Copper as Cu mg/l <0.02 <0.02 <0.02 <0.02 APHA-3111B 0.05/1.5
21 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.02/No relaxation
22 Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.01/No relaxation
23 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001
24 Chromium (Total as Cr) <0.05 <0.05 <0.05 <0.05 APHA-3111B 0.5/No relaxation
mg/l
25 Arsenic as As mg/l <0.01 <0.01 <0.01 <0.01 APHA-3114 0.01/0.05
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26 Phenolic compound mg/l <0.001 <0.001 <0.001 <0.001 Part 43 0.001/0.002

27 Total coliform MPN/100ml Absent Absent Absent Absent APHA-9230B Nil
Table 3.14 : Ground Water Quality in the Study Area
S.N. Parameters Kodikal Kulai Pukodi Baikampady Method Desired Limit

/Permissible Limit
1 pH Value 6.56 6.82 6.68 6.87 APHA-4500 6.5-8.5/
No relexation
2 Temperature 0C 25.0 25.4 24.5 25.2 Part 9 --
3 Conductivity, mhos/cm 212 132 258 288 APHA-4500 --
4 Turbidity (NTU) 0.24 0.22 0.20 0.46 APHA-2030B 1-5
5 Total Dissolved solids mg/l 124 84 152 182 APHA-2540B 500/2000
6 Total Suspended solids 0.6 0.6 0.8 0.9 APHA-2540D --
mg/l
7 Total Hardness as CaCO3 42 28 68 74 APHA-2340C 200/600
mg/l
8 Chloride as Cl mg/l 39 18 50 39 APHA-4500B 250/1000
9 Total Alkalinity mg/l 65 48 58 98 Part -23 200/600
10 Sulphates as SO4 mg/l 05 03 8 14 APHA-4500E 200/400
11 Nitrates as NO3 mg/l 0.8 0.5 0.9 1.1 APHA-4500 45/No relaxation
12 Fluoride as F mg/l 0.34 0.12 0.22 0.45 APHA-4500D 1/1.5
13 Iron as Fe mg/l 0.26 0.26 0.24 0.34 APHA-3111B 0.3/No relaxation
14 Zinc as Zn mg/l <0.10 <0.10 <0.10 <0.10 APHA-3111B 5/15
15 Calcium as Ca mg/l 10 6.0 16 24 APHA-3500B 75/200
16 Magnesium as Mg mg/l 4.1 3.2 6.8 3.4 APHA-3500B 30/100
17 Sodium as Na mg/l 8 6 13 14 APHA-3500 --
18 Potassium as K mg/l 3.0 2.8 2.5 2.8 APHA-3500 KB --
19 Cadmium as Cd mg/l <0.003 <0.003 <0.003 <0.003 APHA-3111B 0.003/No relaxation
20 Copper as Cu mg/l <0.02 <0.02 <0.02 <0.02 APHA-3111B 0.05/1.5
21 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.02/No relaxation
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22 Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.01/No relaxation

23 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001
24 Chromium (Total as Cr) <0.05 <0.05 <0.05 <0.05 APHA-3111B 0.5/No relaxation
mg/l
25 Arsenic as As mg/l <0.01 <0.01 <0.01 <0.01 APHA-3114 0.01/0.05
26 Phenolic compound mg/l <0.001 <0.001 <0.001 <0.001 Part 43 0.001/0.002
27 Total coliform MPN/100ml Absent Absent Absent Absent APHA-9230B Nil
(Source: Water Analysis during study period)
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Table 3.15 : Surface Water Sampling Locations
S. Location Tentative Distance

No. Geo-coordinates from
Plant site
Gurupura River (500 mtr.
SW-1 12°56′19.07″N,74°49′51.13″E 1.0 km,NE
Upstream)
Gurupura River (500 mtr.
SW-2 12°55′27.58″N 74°49′39.73″E 1.0 km,SW
Downstream)
SW-3 Sea Water (Panambur Beach) 12°56′8.32″N 74°48′16.79″E 2.5 km,NW
Table 3.16 : Surface Water Quality in the Study Area
S. Parameters Units Gurupura River Sea water (Near

No. Upstream Downstream Panambur Beach)
1 pH Value - 7.24 7.67 8.01
2 Temperature 0C 24.3 24.5 24.0
3 Turbidity NTU 12 16 18
4 Total Suspended mg/l 41 49 58
Solids
5 Total Dissolved mg/l 42685 42571 47790
Solids
6 Salinity % 25.6 26.4 28.2
7 Dissolved Oxygen mg/l 5.8 6.0 6.4
8 B.O.D (27°C, 3 mg/l 4.8 4.4 4.2
days)
9 C.O.D. mg/l 18 17 15
10 Oil & Grease mg/l <1.0 <1.0 <1.0
11 Nitrite mg/l 0.32 0.35 0.36
12 Nitrate mg/l 0.18 0.19 0.19
13 Phosphates mg/l 0.20 0.22 0.24
14 Silicates mg/l 3.8 3.5 3.9
15 Lead as Pb mg/l 0.04 0.05 0.06
16 Mercury as Hg mg/l 0.04 0.05 0.07
17 Cadmium as Cd mg/l 0.04 0.04 0.05
18 Total Coliform MF Count.
1.3 x 103 1.1 x 103 1.1 x 103
/100ml
Observation on Ground Water Quality:
The pH value of drinking water is an important index of acidity or alkalinity. pH value of

the sample varies from 6.56 to 7.23 in all locations, which is well within the specified
standard of 6.5 to 8.5.
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Electric Conductivity levels vary from 132 to 302µmho/cm. Total dissolved solids range
from 84 to 196 mg/l which is within desirable limit.
The total hardness is an important parameter of water quality. The hardness values in
ground water of the study area ranges between 28 to 84 mg/l which is well within the
desirable limit. The calcium and magnesium values in ground water of the study area are
well within the specified desirable limit of Indian drinking water standard.
The chloride values in ground water of the study area ranges between 17 to 50 mg/l
which is well within the desirable limit.
No biological and metallic contamination has been found in any of the ground water
sample of the study area.
Overall the parameters in ground water sample were well within the desirable limit of
Indian Standard IS: 10500-2012.
Observation on Surface water Quality:
The sea water quality parameters are compared with water quality standards for coastal
waters marine Outfalls (EPA Rule 1986). The sea water quality is complying with the
Class SW-II of coastal waters marine Outfalls (EPA Rule 1986) which suits for Contact
Water Sports and Commercial marine fishing.
3.9. Soil
Soils may be defined as a thin layer of earth's crust that serves as a natural medium for
the growth of plants. It is the unconsolidated mineral matter that has been subjected to
and influenced by genetic and environmental factors. Soils serve as a reservoir of
nutrients for plants and crops and provide mechanical anchorage and favorable tilts. Soil
is our most important natural resource and a natural resource is anything that comes from
the earth and is used by us. We depend on the soil for food, clothing, shelter, minerals,
clay & water. Soil is the seat of many macro & micro flora like algae, fungi, earthworms,
bacteria etc. These are very beneficial in promoting soil reactions and decomposing the
organic matter by which essential nutrients for plants are liberated. Most of the soils are
made-up of two main parts:
Tiny bits of mineral particles which come from larger rocks, and humus, which is dark
brown in color and consists of decaying remains of plants and animals.
Soil also contains water, air and living organisms, such as fungi, bacteria, earthworms,
roundworms, insects, etc. More living organisms live in the soil than above it.
For general characterization of soil a few random samples from the study area to the
depth of about 15-cm may be sufficient. Deeper soil samples may be needed only for the
study of soil profile.
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General Characteristics of the Soil in Mangalore District
The soil in the district is mostly lateritic type, found distributed in the Pedi plain area
characterized by high iron and aluminum content. Lateritic soil is mostly red in color and
yellow loamy, pale to bright red colors are also seen. Red lateritic soil is the most
dominant soil type in the area. Soil Map of Mangalore District in Karnataka is shown as
Figure3.19.
(Source-
http://maps.icrisat.org/gallery/RSGIS_gallery/GIS/Images/Soils/Karnataka_atlas/DKannada/DKannadaBoron.jpg
)
Figure 3.18 : Soil Map of Magalore District

Cropping Pattern
As per the satellite imagery in study area there is only 5 % of the land is under
agriculture. The common crops grown in the area are cash crops like coconut, mango
etc. the other crops grown in the study area are paddy and vegetable crops.
Selection of Sampling Locations
Soil sampling was conducted once during the study period of winter season. Six (06) soil
samples were collected from selected locations near the proposed project. For studying
soil quality in the study area, sampling locations were selected to assess the existing soil
conditions in and around the site area representing various land use conditions. The
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samples collected from all the locations were homogeneous representatives of each
location. At random five sub-locations were identified at each location and soil samples
were collected from 5 to15-cm below the surface. It was uniformly mixed before
homogenizing the soil samples. The samples about 500-gms were packed in polythene
bags labelled in the field with location & number and sent to the laboratory for the
analysis of major physicochemical parameters. The homogenized samples were
analysed for physicochemical characteristics. Soil sampling locations with their distance
& directions with respect to the proposed project site are presented in Table: 3.17.
Table 3.17 : Soil Sampling Locations
Sampling Code Sampling Locations Distance, km Co-ordinates

S-1 Project Site - 12°56′11.11″N74°49′27.36″E
S-2 Kulai 3.5 km,NW 12°57′48.43″N 74°48′21.46″E
S-3 Purkodi 6.5 km, NE 12°58′17.52″N 74°52′6.51″E
S-4 Marakada 4.6 km E, 12°55′54.53″N 74°52′0.12″E
S-5 Kulur 2.0 km SE, 12°55′30.76″N 74°49′49.39″E
S-6 Kodikal 2.6 km, N 12°54′41.58″N 74°49′32.77″E
Soil Quality
The soil samples were examined for various physicochemical parameters, to determine
the existing soil characteristics of the study area. Soil samples were collected from the
vicinity of project site. Physicochemical characteristics of soil are presented inTable: 3.18.
Table 3.18 : Physicochemical Characteristics of Soil
S. Parameters Unit Project Kulai Purkodi Marakada Kulur Kodikal

No. Site
Physical Characteristics
1. Colour - Reddish Reddish Reddish Reddish Reddish Reddish
2. Texture USDA Silty Silty Silty Silty Sandy Sandy
Loam Loam Loam Loam Clay Loam Clay
Loam
3. Porosity % 47.6 49.1 46.8 45.3 43.8 46.0
4. Bulk Density gm/cc 1.39 1.35 1.41 1.45 1.49 1.43
5. Water Holding % 31.8 28.6 29.5 28.9 30.2 30.4
Capacity
6. Particle Size Distribution
i) Sand % 16 17 20 22 55 49
ii) Silt % 66 62 58 62 18 26
iii) Clay % 18 21 22 16 27 25
7. Permeability cm/hr 1.46 1.08 0.94 1.65 0.36 0.47
Chemical Characteristics
8. pH 1: 5 Soil 6.2 6.5 7.0 6.9 6.6 6.8
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Suspension
9. Conductivity µmhos/cm 136.2 139.6 133.4 166.4 128.7
(EC) 145.5
10. CEC Meq/100gm 19.5 16.6 18.8 17.4 22.8 17.5
11. Organic %
0.66 0.69 0.72 0.48 0.55 0.62
Carbon
12. Organic Matter % 1.14 1.19 1.24 0.83 0.95 1.07
13. Chlorides as Cl mg/kg 46.8 34.7 45.6 55.8 35.3 44.5
14. Iron as Fe mg/kg 5.15 4.75 8.34 6.25 5.28 4.78
15. Copper as Cu mg/kg 8.2 6.9 7.5 6.5 9.2 10.8
16. Zinc as Zn mg/kg 11.5 16.2 14.8 21.6 18.4 14.6
17. Manganese as mg/kg 6.25 5.44 3.77 7.52 5.88 8.15
Mn
18. Boron as B mg/kg 0.62 0.85 0.98 0.74 1.82 1.55
19. Available Nutrients
i) Nitrogen as N kg/ha 265.6 298.2 374.8 285.4 365.4 288.5
ii) Phosphorus as kg/ha
16.1 14.5 15.8 15.2 16.6 12.5
P
iii) Potassium as kg/ha
148.6 106.2 135.8 112.4 159.4 164.6
K
(Source: JP Test House)
Observation on Soil Quality
Physical Properties
Reddish colour soils are observed in the study area. Texturally the soils of study area are
observed as Silty Loam and Sandy Clay Loam Soils. The bulk density of the soils was
found in the range of 1.35 to 1.49-gm/cm3. Water holding capacity of the study area soil
was observed as 28.6 to 31.8%.
Chemical Properties
The soil pH ranges from 6.2 to 7.0, thereby indicating the soils are slightly acidic to
neutral. The Organic Carbon content of soil varied from 0.48 to 0.72 %( 0.83 to 1.24% as
Organic Matter) thereby implying that soils are low to medium in organic content.
Available nitrogen content in the surface soils ranges between 265.6 & 374.8-kg/ha,
thereby indicating that soils are low to medium in available nitrogen content. Available
phosphorus content ranges between 12.5 & 16.6-kg/ha, thereby indicating that soils are
medium in available phosphorus content. Available potassium content in these soils
ranges between 106.2 & 164.6-kg/ha, thereby is indicating that the soils are medium in
potassium content. The available manganese content in surface soils were recorded as
3.77 to 8.15-mg/kg, as the critical limit of available manganese is <2.0-mg/kg. As per the
critical limit of available zinc is <0.5-mg/kg, most of the study area soils are more than
sufficient in available zinc near the project. The available boron content in the soils
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ranges from 0.62 to 1.82-mg/kg. The critical limit for deficiency of the available boron is
<0.5-mg/ kg. Based on the above physicochemical properties it is revealed that overall
moderate Soil fertility potential is observed in the study area.
3.10. Biological Environment

The Botanical and wildlife species in an area depend on the availability of suitable habitat
for survival. Habitat loss and increasing habitat fragmentation are the primary causes of
species decline in these environments. This section provides an overview of flora and
fauna observed in study area during site visit.
Introduction
The study area (10 km area around the plant site) falls within Mangaluru Forest Division.
Mangalore Division was reorganized vide GO. No.AFD-80-FEG-66, Bangalore dated 13-
9-1966. Mangalore forest division at present consists of eight ranges, namely, Mangalore,
Bantwal, Belthangadi, Uppinangadi, Puttur, Sullia, Panja and Subramanya spread over 5
revenue taluks of Mangalore, Bantwal, Belthangadi, Puttur and Sullia. The division
comprises of three sub-divisions, namely, Mangalore, Puttur and Sullia. Forests account
for about 23 % of the total land area of the Maglore forest division. The forest types found
in the division vary from coastal scrub type to wet evergreen Ghat forests. They are
unevenly distributed, being mostly confined to a continuous stretch of area along the
western slopes of the ghats and being scarce in the densely populated areas towards the
coast. The productivity per hectare is very low which is inherent due to heterogeneous
character of these forests where only certain species are valuable.
Forest
The total area of notified forests in Mangalore division is 112816.01 hectares and these
are distributed in seven ranges. The range headquarters is at Hoiga Bazaar in
Mangalore. There are no notified forests in Mangalore range. The study area falls in this
range of the division. Various categories of forest in different range of Mangalore Forest
Division are given in Table 3.19.
Table 3.19 : Abstract of various categories of forests in different ranges of

Mangalore division
Sl Name of the As per notification under, Indian Total Other Total

No. range forest Act and KFA (Area in ha.) notified Govt. forest
Section- Section- Section- forests lands area
16 17 4
1 Bantwal - 1888.68 315.63 2204.31 245.40 2449.71
2 Belthangadi - 10667.30 1317.79 11985.09 3054.01 15039.10
3 Mangalore - - - - 334.35 334.35
4 Panja - 11908.52 546.60 12455.12 455.93 12911.05
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5 Puttur 8874.46 3033.36 970.89 12878.71 1379.33 14258.04

6 Subramanya 520.74 30386.05 - 30906.79 232.11 31138.90
7 Sullia 14263.13 1907.48 78.00 16248.61 1134.62 17383.23
8 Uppinangadi 24750.72 384.83 1001.83 26137.38 1344.41 27481.79
Total 48409.05 60176.22 4230.74 112816.01 8180.16 120996.17
(Source: Forest Working Plan Mangaluru Forest Division)
Composition of Forest
The forests of the division exhibit rich diversity. Because of their distribution in widely
varying conditions of locality and many external factors of the ecosystem to which they
are subjected, the forest types of the division are diverse and complex. The present
vegetation is the result of inter-action of several contributing factors of varying intensities.
Variations in climatic, edaphic, topographic and biotic factors have led to variations in the
nature and growth of the vegetation.
The principal forest types of the area dealt in Mangalore Forest Division are
classified\according to the revised survey of the forest types of India by Sir Harry G.
Champion and Sri S.K. Seth are evergreen forest consists 0.5%, Semi evergreen forest
consists 54%, Moist deciduous forest consists 42%, and other forest 3.5%.
Forest Type in Study Area:
The study area falls in Mangalore range and there are no notified forests in Mangalore
range. The vegetation type mostly comprises of Lateritic scrub vegetation. This type of
vegetation is confined to the reserves towards the coast where the soil is dry, shallow and
lateritic due to denudation and exposure, although the climate is otherwise conducive to
growth of semi-evergreen or even evergreen species. The trees are of deciduous nature
and stunted growth, forming open scrub vegetation. The undergrowth is thin including
xerophytic evergreens.
Flora of Study Area (10 km study Area)
Vegetation at proposed Plant site: The proposed expansion shall be done within the
existing plant premises of Mangalore Chemicals & Fertilizers limited. There is no national
park, wildlife sanctuary, biosphere reserve, reserved & protected Forests, notified forest
is present within the 10-km radius of the proposed plant site.
There is no forest present at proposed site. The identified land is open scrub land and
presently few trees are present in the proposed land. The vegetation type present on the
identified land is scrub vegetation along with Albizia lebback, Acacia auriculiformis and
cassia fistula plantation.
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Type of vegetation on identified land for proposed project

Vegetation in Study Area (10 Km study Area):
The study area comprises of open scrub, dense scrub, dense scrub hillocks, ravines,
rivulets/river system, flat terrain and sea coast/beach. The natural vegetation of ever
green/decidua’s forest species in the form of dense scrub, open scrub degraded
vegetation in the hilly area are observed along with rural agriculture, semi- urban and
industrial development towards the coast. Accordingly, the survey was planned based on
Topography, land use, vegetation pattern etc.
The natural vegetation of the area may be broadly noted under two types: the hilly
vegetation and river bed vegetation, apart from roadside and avenue trees. Observations
on the Trees, Shrubs, Herbs, climbers, grasses, agricultural fields, medicinal plants, and
social plantations were made for the study area considered. The vegetation cover falls
into following broad categories:
 Natural vegetation
 Greenbelt Plantation
 Agriculture Fields / commercial plantation
 Pilikula Nisarga Dhama (Biological Park)
 Mangroves
Aquatic flora
Natural Vegetation:The natural vegetation in the

study area is mainly comprises of Areca catechu,
Cocos nucifera, Acacia concinna, Anacardium
occidentale, Tectona grandis, Casuarina
equisitifolia, Acacia Auriculiformis,Alstonia scholoris,
Bombax ceiba, Cassia fistula, Terminalia arjuna,
Acacia nilotica, Ficus hispida, Roystenia vegia
Casuarina equisitifolia, Bauhinia recemosa, Cassia
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siamea etc. were observed. Shrubs like Lantana camara, Jatropha curas, Annona
squamosa, Alangium salvifolium, Hibiscus cannabinus and Sesbania grandiflora are
found densely in this region. Herbs like Mimosa pudica was found maximum, while
Datura metal and Evolvulus alsinoides were moderately seen.
Greenbelt Plantation: Various types of plantations

have been experimented in Mangaluru. Plantations of
Rubber, Cashew, Casuarina, Ailanthus, Hopea,
Acacia auriculiformis, Nutmeg, Teak, Cane and
Mangrove species.Greenbelt plantations in industrial
areas road sides and townships include various
ornamental plants like Nerium indicum, Polyalthia
longifolia, and Bougainvillea glabra and trees like
Acacia nilotica, Azadirachta indica, Saraka indica and
Leucena lucocephala.
Lantana Camara
Agriculture Fields and Commercial Plantation:
There are many villages in the study area where agriculture is the main occupation.
Paddy is the main crop of the study area. However, vegetables and fruits are also grown
in the study area. Commercial crops viz. Areca nut, Coconut, Pepper, Cashew nut, Clove,
fruits like Banana, Pineapple and jack fruit are grown in the study area.
Pilikula Nisarga Dhama (Biological Park): Pilikula Nisarga Dhama is a multifaceted

biological park developed near Mudashedde village on the bank of Gurupur River. In local
language Pili means tiger and Kulameans pond. In olden days, tigers used to come to
this lake to drink water. Hence, this lake came to be known as Pilikula.
A significant Biological Park is established in Pilikula Nisarga Dhama Society has major
focus on the wildlife species of Western Ghats and it has now become the hot spot for
people who are looking for scenic beauty & peace. The park is named as Dr. Shivaram
Karanth Biological Park. The park consists of an area of 380 Acre land. In accordance
with prevailing laws, the central Zoo Authority of India has recognized the park. As per
modern Zoological practices, the animal enclosures have been designed to closely
resemble its natural habitat. The park has now become the hot spot for people who are
looking for scenic beauty & peace.
Pilikula has a huge lake & beautifully laid gardens encircling the entire lake. One can see
swans & ducks moving around in the lake & sometimes they even move into the gardens.
Boating facilities are available in the lake. One can either use pedaling boats (mostly
preferred by couples) or bigger boats carry about 10 to 15 persons.
Pilikula Zoo has been classified as a Major Zoo by the Central Zoo Authority of India. It is
the only zoo recognized as a breeding centre for King Cobras. It is also functioning as a
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rescue centre for wounded wild life. Today Pilikula Zoo has 400 animals, reptiles and
birds and most of the species are breeding.
An arboretum (a garden comprising woody species of plants, i.e. trees and shrubs)
extending over an area of 35 ha has been established at Pilikula Nisarga Dhama where
about 60,000seedlings belonging to 236 taxa of flowering plants of Western Ghats,
spread over 60 families have been planted randomly as well as family clusters. They
include 70 taxa endemic to the Western Ghats region. The arboretum has a focus on the
conservation of the plants of the Western Ghats. It not only contains manythreatened
species, but also a few Re-discovered species that were extinct earlier. The arboretum
also includes 6 acres devoted to medicinal plants with more than 460 varieties, often
visited by students of botany and Ayurvedic medicine. 9 aquatic Ponds containing aquatic
plants like Lotus, Lilies etc. are seen here.
Mangroves: The major ecological role of

Mangroves is the stabilization of the shoreline
and prevention of shore erosion. The
mangroves help in feeding and provide
breeding and Nursery grounds for commercially
important fishes. This helps in sustaining
coastal fisheries. The seaboard in the coastal
Mangalore is very much influenced by tidal Scattered Mangroves near Gurpura
River the 10 km area is Gurupura
rivers or backwater creeks. The principal estuary within
estuary. In the study area, Gurupura estuary zone consist of mangroves in discrete
patches, in which Avicennia alba was found to be dominant species.
Aquatic flora: Aquatic plants are plants that have adapted to living in aquatic
environments (saltwater or freshwater). They are also referred to as hydrophytes or
macrophytes. These plants require special adaptations for living submerged in water, or
at the water's surface. The common aquatic plants observed in the study area are
Nelumbo nucifera, Nymphaea stellata, Cyperus rotundus, Nymphoides hydrophylla,
Colocasia esculenta, Azolla pinnata, Pistia stratiotes, Eichhornia crassipes and Salvania
molesta. The list of the vegetation observed/ reported in the study area is presented in
Table 3.20.
Table 3.20 : List of the vegetation observed/ reported in the study area
S. Botanical Name Family Vernacular Name

No.
Tree
1 Acacia auriculiformis Mimosaceae Ear-pod wattle
2 Acacia concinna Fabaceae Seege
3 Acacia leucophloea Mimosaceae Bellada, bili-jali
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4 Acacia nilotica Fabaceae Babli

5 Acacia arabica Fabaceae Bauli
6 Albizia lebbeck Fabaceae Fabaceae
7 Alangium salvifolium Cornaceae Ankola
8 Alstonia scholaris Apocynaceae Hale mare, Dodapala
9 Anacardium occidentalis Anacardiaceae Goddambi
10 Annona squamosa Annonaceae Sitaphal
11 Anogeissus latifolia Combretaceae Indian gum tree
12 Areca catechu Arecaceae Areca palm
13 Artocarpus heterophyllus Moraceae Halasina hannu
14 Atalantia monophylla Rutaceae Kuruntam
15 Atalantia racemosa Rutaceae Kumuntam
16 Azadirachta indica Meliaceae Bevu
17 Bombax ceiba Bombacaceae Burga
18 Buchanania latifolia Anacardiaceae Chironji
19 Bauhinia malabarica Caesalpiniaceae Basavanapada
20 Bauhinia Variegata Caesalpiniaceae Kachanr/Orchid tree
21 Borassus flabellifer Arecaceae Tody palm
22 Bosewellia serrata Sapindaceae Indian frankincense
23 Beutea monosperma Leguminoseae Palas
24 Cassia fistula Fabaceae Amaltas
25 Caryota urens Arecaceae Fish tail palm
26 Casuarina equisetifolia Casuarinaceae Kyasurina
27 Cocos nucifera Crucifere Coconut
28 Dalbergia latifolia Fabaceae Beete
29 Delonix regia Fabaceae Gulmohar
30 Eucalyptus globules Myrtaceae Nilagirienne tailam
31 Emblica officinalis Euphorbiaceae Betta neli
32 Ficus benghalensis Moraceae Vatavruksha
33 Ficus hispida Moraceae Athi
34 Ficus religiosa Moraceae Arayal
35 Ficus elastic Moraceae Rubber tree
36 Flacourtia indica Salicaceae Governors plum
37 Gymnosporia Montana Celastraceae Mountain spike
38 Gardenia latifolia Rubiaceae Papra
39 Hibiscus cannabinus Malvaceae Dasawala
40 Jatropha gossypifolia Eurphorbiaceae Bellyache Bush
41 Kigelia pinnata Bignoniaceae Sausage
42 Lagerstroemia speciosa Lythraceae Holenandi
43 Mangifera indica Anacardiaceae Mavina mara
44 Michellia champaca Magnoliaceae Sonchapha
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45 Peltophorum pterocarpum Caesalpiniaceae Copper pod

46 Phoenix sylvestris Arecaceae Date palm
47 Pulmeria alba Apocynaceae Frangipani
48 Polyalthia longifolia Annonaceae Ashok
49 Pongamia pinnata Fabaceae Karanj
50 Roystenia regia Arecaceae Royal Palm
51 Senna siamea Fabaceae Senna
52 Spondias mangifera Anacardiaceae Ambatte mara
53 Stereospermum suaveolens Bignoniaceae Billmara, Bodhi
54 Syzygium cumini Myrtaceae Kadunerale
55 Sterculia urens Sterculiaceae Gum karaya
56 Tectona grandis Lamiaceae Saguvani
57 Terminalia arjuna Combreta ceae Nirmatti
58 Tamarindus indicus Caesalpiniaceae Imli
59 Terminalia tomentosa Combreteaceae Matti
60 Terminalia bellirica Combreteaceae Bahera, Shanthimara
61 Thespesia populnea Malvaceae Bugarimara
62 Ziziphus jujube Rhamnaceae Soorimullu
Shrubs
63 Calotropis gigntea Asclepiadaceae Rui/ milk weed
64 Casia alata Fabaceae Candle bush
65 Cassia tora Fabaceae Stinking cassia
66 Hemidesmus indicus Asclepiadaceae Sarsaparilla
67 Ipomea camara Convolvulaceae Morning glory
68 Lantana camara Verbenaceae Big Sage
69 Murraya koenigii Rutaceae Curry leaf
70 Mimosa pudica Mimosaceae Touch me not
71 Narium indicum Apocynaceae Kaner
72 Nyctanthus arbortristis Oleaceae Coral Jasmine / Parijat
73 Sida acuta Malvaceae Morning mallow
74 Thevetia peruviana Apocynaceae Yellow oleander
75 Vitex negundo Verbenaceae Nekki, Lakkigida
Herbs, climber and grasses
76 Asparagus recemosus Liliaceae Shavitri
77 Bougainvillea glabra Nyctaginaceae Bougainvillea
78 Cassia occidentalis Caesalpiniaceae Coffee senna
79 Clitoria annua Fabaceae Bombay bean
80 Crotolaria juncea Fabaceae Sun hemp
81 Cyprus rotundus Cyperaceae Nut grass
82 Parthenium hysteophorus Asteraceae Congress grass
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83 Denrocalamus membranaceous Poaceae Bamboo

84 Bambusa vulgaris Poaceae Bamboo
85 Tridex procumbens Asteraceae Coat button
86 Wedelia trilobata Asteraceae Creeping daisy
Threatened Plant Species: Threatened taxa are those species which are vulnerable to
endangerment soon. Threatened status of any taxa is not a single category but is a group
of three categories, critically endangered, endangered and vulnerable. On the application
of different criteria of IUCN for the assessment of conservation status of taxa, no taxa
were found threatened in the study area. The reported taxa have also not been enlisted in
the Red Data Book of Indian plants (Nayar and Shastry, 1988).
Rare and Endangered Plant Species in the Study Area: No rare and endangered plant
species was observed in the study area (Source: Red Data Book of Indian Plants, N.P
Nayar and A. P. K. Sastry, B.S.I. 1988).
Faunal Biodiversity
Most of the land around the study area (10 km radius around the proposed Plant site) is
under settlement, industrial, agriculture, and vegetation uses. No national parks, wild life
sanctuary, biosphere reserve, Reserve, Protected and any other notified forests forest is
present within 10 km area of the project site. Speedy industrial development and
urbanization has left the area devoid of any significant faunal species or wildlife. During
the preliminary survey, the sighting of wild animals was negligible in the entire study area.
The assessment of wild life fauna has been carried out based on information collected
from the secondary sources (Forest Officer, Fisheries Department, and local inhabitants).
List of fauna found in the study area is presented in Table 3.21 & 3.22. The listed fauna
has been cross-checked with Red Data Book of Indian Animals (Zoological Survey of
India). There is no endangered or critical faunal species in the study area.
Mammals: No significant carnivorous and herbivorous wild animals are found in the area.
Amphibian & Reptiles: Frog, Indian bull frog, snake like Indian cobra (Naja naja); Krait
(Bungarus coeruleus), and lizard are encountered at various places in study area.
Table 3.21 : List of the Mammals Recorded in Study Area
Feeding Schedule
Common Name Scientific Name
Status
1. Striped s squirrel Funambulus pennanti H IV
2. Field rat Bandicota bangalonsis H V
3. Jungle cat Felis chaus C II
4. Mongoose Herpestes edwardsi C IV
5. Bat Cyanopterus gigenticus C -
H – Herbivorous, C – Carnivorous, O – Omnivorous
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Table 3.22 : List of Amphibians and Reptiles Recorded in Study Area
S. Common Scientific Vernacular Feeding Schedule

Family
N. Name Name Name Status
Amphibians
1. Frog Rana tigrina - - C IV
Reptiles
2. Binocellate Naja naja Nag Elapidae C II
cobra
3. Indian Krait Bungarus - Elapidae C IV
coeruleus
4. Russell’s Vipera russellis - Crotalidae C II
Viper
5. Rat snake Ptyas mucosus Dhaman Colubridae C II
6. Garden Calotes - Agamidae C II
Lizard versicolor
7. Brooks geeko Hemidactylis - Gekkonidae C II
brooki
C – Carnivorous
Avifaunal Investigation
Avifauna is an important part of the ecosystem playing the various roles as scavengers,
pollinators, predators of insect, pest, etc. They are also one of the bio indicators of
different status of environment and affected by urbanization, industrialization and human
interference. They can be used as sensitive indicators of pollution and malfunction of
ecosystem.
There is a wide range of avifauna observed in the study area. The study area is inhabited
by forty-four species of birds belonging to 19 families. The list of avifauna observed in the
study area is given in Table 3.23.
Table 3.23 : List of the Birds Surveyed / Recorded in the Study Area
S.No English name Scientific Name Distribution Family Status

Vanellus indicus Paddy feilds,
1 Red-wattled Lapwing Charadriidae R
ponds, lakes
River, stream,
2 Wood Sandpiper Tringa glareola Scolopacidae M
sea cost
Tringa River, stream,
3 Common Sandpiper Scolopacidae M
hypoleucos sea cost
widespread
4 Indian Pond-Heron Ardeola grayii Ardeidae R
resident
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Cattle Egret widespread

5 Bubulcus ibis Ardeidae R
resident
Human
6 Rock Pigeon Columba livia Columbidae R
settlement
Pond, marshes,
7 Lesser pied kingfisher Ceryle rudis Cerylidae R
river
widespread
8 Common Kingfisher Alcedo atthis Alcedinidae R
resident
Indian Roller Coracias Gardens,
9 Coraciidae R
benghalensis woodlands
Merops Pond, marshes,
10 Blue tailed bee- eater Meropidae M
Philippinus river
Little Green Bee- Merops
11 Paddy fields Meropidae R
eater orientalis
Centropus Gardens,
12 Greater Coucal Centropodidae R
sinensis plantation
Eudynamys Gardens,
13 Asian Koel Cuculidae R
scolopacea plantation
Brahminy Kite widespread
14 Haliastur indus Accipitridae R
resident
Human
15 Black kite Milvus migrans Accipitridae R
settlement
16 Grey Junglefowl Gallus sonneratii Forest Phasianidae R
Indian Peafowl Jungle,
17 Pavo cristatus Phasianidae R
cultivation
Marshes,
18 Grey breasted Prinia Prinia hodgsonii Cisticolidae R
grassland
Plain Prinia Marshes,
19 Prinia inornata Cisticolidae R
grassland
House Crow Corvus Human
20 Corvidae R
splendens habitation
Corvus Forest, Human
21 Jungle crow Corvidae R
macrorphyncos habitation
Dendrocitta Near vegetation,
22 Rufous Treepie Corvidae R
vagabunda parks
Dicrurus Near vegetation,
23 Black Drongo Dicruridae R
macrocercus parks
Dicrurus Near vegetation,
24 White billed drongo Dicruridae R
caerulescens parks
Gardens,
Eurasian Golden
25 Oriolus oriolus plantations, Corvidae R
Oriole
forests
Saxicoloides Garden, local
26 Indian Robin Muscicapidae R
fulicata resident
Nectarinia Garden, human
27 Purple Sunbird Nectarinidae R
asiatica settlement
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Motacilla
Woodlands,
28 Large pied Wagtail maderaspatansis Motacillidae R
plantation
House Sparrow Passer Human
29 Passeridae R
domesticus settlement
Ploceus Paddy field,
30 Baya Weaver Ploceidae R
philippinus cultivations
Paddy fiels,
Common Myna Acridotheres
31 human Sittidae R
tristis
settlements
human
32 Black Kite Milvus Migrans Accipitridae R
settlements
Brahminy kite Sturnus Streams, sea
33 Sturnidae R
pagodarum coast
Falco Grassland, open
34 Common Kestrel Falconidea M
tinnunculus area
Charadrius
35 Little ringed Plover Dry open areas Charadridae R
dubilus
Turdoides
36 Common Babbler Scrub jungle Leiothrichidae R
caudatus
Turdoides Plantation scrub
37 Jungle Babbler Leiothrichidae R
striatus jungle
Phylloscopus Plantation scrub
38 Greenish Babbler Leiothrichidae R
trochiloides jungle
Megalaima
39 Brown headed barbet Gardens, forest Megalaimidae R
zeylanica
Megalaima widespread
40 Coppersmith Barbet Megalaimidae R
haemacephala resident
Psittacula Paddy fields,
41 Alexandrine Parakeet Psittacidae R
eupatria cultivation
Psittacula Paddy fields,
42 Rose-ringed Parakeet Psittacidae R
krameri cultivation
Plum Headed Psittacula Paddy fields,
43 Psittacidae R
Parakeet cyanocephala cultivation
Spotted Owlet Human
44 Athene brama Strigidae R
settlement
Woodland,
45 Hoopoe Upupa epops Upupidae R
grasslands
Gardens, parks,
46 Red vented Bulbul Pycronotus cafer Pycnonotidae R
plantation
Pycronotus Gardens, parks,
47 Red whiskered Bulbul Pycnonotidae R
jocosus plantation
Marshes,
Grey-breasted Prinia Prinia hodgsonii Cisticolidae
48 grasslands R
Lonchura Cultivations,
Black-headed Munia
49 malacca grasslands, Passeridae R
gardens
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Childonias Sea cost, back

50 Whiskered tern Laridae R
hybridus water, marshes
Sea cost, back
51 Little tern Sterna albifrons Laridae R
water
Fisheries
Mangalore district is known for marine fishing and the
export of fish as well as fish products. Fisheries
constitute the major economic and characteristic feature
of the district. Besides Udupi and Uttar Kannada,
Dakshina Kannada is the only district endowed with a
coastal line. The district is known for marine fishing and
the export of fish and fish products. With a considerably
large coastal line, the district has a rich continental shelf
which abounds with pelagic fisheries in addition to a rich
prawn fishery. The estuaries of the rivers are noted for
the richness of their fish fauna. In view of the
abundance of Mackerels, this part of the west coast is
popularly known as the Mackerel Coast.
However, with preponderance of marine
fisheries, the inland fisheries hold a
secondary place. The fishermen adopt
the traditional method for catching the
fish. A major position of fish landing is
sold on the spot to local consumers and
the traders. All along the coast there are
several curing yards, cold storage
facilities and ice plants.
There are 63 ice plants, 19 freezing plants and 10 cold storages in the district. The district
has a fishermen population of 58,218. Out of which 27,597 are active fishermen. The
district ranks at 3rd place in the State in terms of active fishermen. There are 103 fish
market in the district and all are departmental. Apart from the above there are 23 fishing
co-operative societies in the district. From the point of view of developments, the state
government has introduced various welfare schemes such as saving cum relief scheme,
group accident insurance for the active fishermen, development of model villages for
fishermen, establishment of district relief fund with a view to improve the socio-economic
condition of the fishermen. Shoaling fishes like sardines and mackerel’s, tuna, seer
fishes, lacarius, pomfrets, silver bellies, scianids sharks, cat fishes etc. are commonly
fished out.
There are fresh water fishes also found in the study are mainly Minnow (Barilius barila),
Common carp (Cyprinus carpio), Sucker head (Garra gotyla), South Indian barb (Esomus
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barbatus), Ticto barb (Puntius ticto), Glass fish (Ambassis ambassis), Tilapia
(Oreochromis mossambicus) and Guppy (Poecilia reticulata).
3.11. Socio-Economic Environment

Demography:
Demography is one of the important indicators of environmental health of an area. It
includes population, sex ratio, number of households, literacy, population density, etc. To
assess the demographic features of the study area, census records of Dakshin Kannada
district of Karnataka for the year 2011 have been compiled and analysed. The entire
study area falls in Dakshin Kannada district of Karnataka comprising 18 revenue villages
and 10 towns including Mangalore (MC) as major part of the study area.
Economy of the District
Fisheries constitute the major economic and characteristic feature of the district. The
district is known for marine fishing and the export of fish and fish products. Though
Dakshina Kannada does not rank amongst the industrially advanced districts of the State,
manufacturing industry makes a significant contribution to the economy of the district.
Agriculture is also an important livelihood for the people of Dakshina Kannada besides
fishing. Paddy is the principal agricultural crop of the district. Sugarcane is confined to the
coastal taluk’s. Cashew nut, areca nut, pepper, cloves and coconut are the important
cash crops in the district. It is in fact, renowned to produce tiles, beedis and cashew
besides chemical and fertilizers. The most important industry of the district is the
Mangalore Refineries and Petrochemicals Limited, popularly known as MRPL. Another
important industry of the district is cashew industry.
Demography of the District:
As per the district census Handbook, 2011, the total population of the district is observed
as 20, 89,649 persons. Male-female wise population was observed as 10, 34,714 and 10,
54,935 persons respectively. The population of the district is further distributed as 10,
93,563 living in rural areas and 9,96,086 in urban areas, constituting 52.3 & 47.7% of
rural and urban population respectively. The population in the age-group of 0-6 years is
reported as 2, 08,297. This constitutes as 53.3% in rural areas and 46.7% in urban areas.
The proportion of child population is 9.97% to the total population of the district. Dakshina
Kannada district was recorded growth rate as 10.1% during the decade 2001-11. The
decadal growth rate in rural areas is decreased by 6.4%. The decadal growth rate in
urban areas is recorded as 36.9%. As such, the population density recorded as per the
Census records 2011, is 430 persons per sq.km. As per the Census records 2011, the
sex ratio of the district is recorded as 1020 females for every 1000 males. The literacy
rate for Dakshina Kannada district is 88.8% in 2011 as against 83.4% in 2001. Total
Scheduled Castes (SCs) population reported in the district is 1, 48,178 persons,
constituting about 7.1% to the total population of the district. The decadal growth rate of
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Scheduled Castes as per the Census records 2011 is observed as 12.97%. The growth
rate of Scheduled Tribes (STs) during the decade 2001-11 is observed as 30.7% and
about 3.9% of the district’s total population is Scheduled Tribes. The decadal change in
the growth rate of SCs and STs in urban areas has reported to be high compared to the
growth rate in rural areas. (Source-District Census Handbook 2011)
Methodology
To assess the Demographic & Socio-economic features of the 10-km radius study area
based on Socio-economic surveys and public consultations undertaken during the
baseline field study period and Census records 2011, for the concerned district Dakshin
Kannada in Karnataka State was compiled and placed in the form of tabulation and
graphical representation. Entire study area is predominantly urban except few revenue
villages. About 45% part of the study area is occupied by Arabian Sea in Westwards.
Population Distribution in the Study Area
There are about ten (10) numbers of census towns, one major city (Mangalore city) and
28 villages fall within the study area. As per the census records 2011, the total population
of the study area were recorded as 595733 persons comprise 296554 males and 299179
females. Total number of ‘Households’ was observed as 135462 in the 10-km radius
study area. Caste-wise population distribution of the entire study area is shown in Table
3.24.
Table 3.24 : Caste-wise Population Distribution of Study Area Villages
Total Population Scheduled Castes Scheduled Tribes Tehsil

Name of Village No of Households Persons Male Female Male Female Male Female
Kulur 184 778 369 409 30 33 29 30 Mangalore
Madya 387 1624 802 822 101 118 58 62
Chelliru (OG) 729 3278 1556 1722 194 207 1 2
Panja 99 418 208 210 30 20 10 10
Surinje 613 3098 1564 1534 19 22 23 23
Kilenjur 143 658 305 353 3 5 0 0
Delanthabettu 314 1464 702 762 49 51 4 6
Tenkayekkar 738 3445 1660 1785 66 60 25 29
Permude 492 2242 1117 1125 0 0 8 20
Hosabettu 498 2260 1095 1165 86 71 49 58
Kuthethur (OG) 1030 3791 2089 1702 84 72 16 18
Bala (OG) 663 2637 1324 1313 29 24 30 22
Kavathar 357 1529 724 805 124 134 59 77
Attur 314 1478 710 768 81 64 4 5
Nadugodu 326 1454 694 760 22 27 6 2
Boliyar 1036 5753 2854 2899 98 108 13 12
Kolambe (CT) 1239 5592 2761 2831 187 187 26 24
Kenjar (CT) 1135 5338 2718 2620 217 239 12 5
Thokur-62 (CT) 1396 7433 4074 3359 101 113 16 18
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Bajpe (CT) 1976 9701 5179 4522 166 137 58 49

Kandavara 725 3347 1639 1708 99 96 29 21
Adyapady 448 2089 1043 1046 107 111 25 31
Malavoor 778 3468 1721 1747 340 339 81 83
Mudushedde (CT) 1832 8155 3922 4233 205 197 87 92
*Mangalore
(MC + OG) 115036 499487 247903 251584 10585 11033 3744 3665
Alike 1041 5840 3206 2634 116 111 441 433 Bantval
Navoor (CT) 1131 5365 2596 2769 169 201 51 50
Bandaru 802 4011 2019 1992 184 186 9 7 Beltangadi
TOTAL 135462 595733 296554 299179 13492 13966 4914 4854
Source-Census Records 2011
*Mangalore City (MC+OG)-About forty nine (49) locations namely as Kodikal , Mukka ,
Srinivasnagar, Dodda Kopla, Krishanapura, Kuthluru, Naithangadi, Katipalla, Kana,
Surathkal, Purkodi, Jokatte, Mandarabail, Kotikani, Kuntikan, Urwa, Lalbagh, Chilambi,
Kapikad, Kudroli, Yeyyadi, Bikarnakatte, Kaikamba, Kulashekara, Mallikatte, Kodailbail,
Dongerkerry, Azziuddin, Hampankatta, Kankandy, Marnamikatte, Suharda Nagar, Kulai,
Baikampady, Bondel, Marakada, Pudukodi, Kasba Bengre, Derebail, Bolpugudde,
Conchaddy, Vamanjoor, Thiruvali, Gurunagar, Kottara, Balmatta, Bendoor, Padil, Bejai
etc falls within the administration of Mangalore city Municipality corporation.
Sex Ratio
The ‘Sex Ratio’ of the study area is a numeric relationship between females and males of
an area and bears paramount importance in the present-day scenario where the un-
ethnic pre-determination of sex and killing of female foetus during pregnancy is practiced
by unscrupulous medical practitioners against the rule of the law of the country. It is
evident that by contrast the practice of female foeticide is not prevalent in the study area.
As per the census records 2011, the entire study area is falling in Dakshin Kannada
district of Karnataka. The ‘Sex Ratio’ was observed as 1020 females per 1000 males in
the District. The same was recorded as 1009 females for every 1000 males in the study
area. The child sex ratio of the district was observed as 944 female children per 1000
male children. The village wise male-female population distribution for the study area and
Mangalore (MC+OG) is depicted and shown by graphical representation in Figure3.21.
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Total Population in Study Area
600000
500000
400000
300000
200000
100000
0
Total Population Male Population Female Population
Total Population in Study Area
Figure 3.19 : Male-Female wise Population Distribution in the Study Area
Total Population in Mangalore

(MC & OG)
500000
400000
300000
200000
100000
0
Total Population Male Population Female Population
Total Population in Mangalore(MC & OG)
Figure 3.20 : Male-Female wise Population Distribution in Mangalore (MC+OG)

Scheduled Caste & Scheduled Tribe Population
Based on the village/town wise SC & ST population distribution of the study area during
2011, the ‘Scheduled Castes’ population was observed as 27458 persons consisting of
13492 males and 13966 females respectively in the study area which accounts as 4.6%
to the total population (595733 persons) of the study area. ‘Scheduled Tribes’ population
was observed as 9768 persons, accounting as 1.6% to the total population of the study
area consisting of 4914 males and 4854 females. It implies that the rest 93.8% of the total
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population belongs to the General category. Male-female wise distribution of ‘SC’ &‘ST’
population in the study area is graphically shown in Figure3.22& 3.23 as follows.
Total SC Population
30000
25000
20000
15000
10000
5000
0
Total SC Population Male SC Population Female SC Population
Total SC Population
Figure 3.21 : Scheduled Caste Population Distribution
Total ST Population
10000
8000
6000
4000
2000
0
Total ST Population Male ST Population Female ST Population
Total ST Population
Figure 3.22 : Scheduled Tribes Population Distribution

Literacy Rate
Literacy level is quantifiable indicator to assess the development status of an area or

region. Male-Female wise literates and illiterate’s population is represented in Table 3.25.
Total literate’s population was recorded as 502723 persons (84.4%) in the study area.
Table 3.25 reveals that Male-Female wise literates are observed as 256776 & 245947
persons respectively, implies that the ‘Literacy Rate’ is recorded as 84.4% with male-
female wise percentages being 43.1% & 43.0% respectively. The total illiterate’s
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population was recorded as 93010 persons (15.6%) in the study area. Male-Female wise
illiterates were 39778 (6.7%) and 53232 (8.9%) respectively. The Male-Female wise
graphical representation of literates & illiterate’s population in study area villages/town is
shown inFigure3.24.
Literates and Illiterates Population
6,00,000
5,00,000
4,00,000
3,00,000
2,00,000
1,00,000
0
Total Literates Male Literates Female Total Male Female
Literates Illiterates Illiterates Illiterates
Literates and Illiterates Population
Figure 3.23 : Male-Female Wise Distribution of Literates & Illiterates
Table 3.25 : Male-female wise Literates & Illiterates
Literates Illiterates
Name of Village Total Population Person Males Female Person Male Female
Kulur 778 649 326 323 129 43 86
Madya 1624 1320 672 648 304 130 174
Chelliru (OG) 3278 2771 1362 1409 507 194 313
Panja 418 314 162 152 104 46 58
Surinje 3098 2524 1295 1229 574 269 305
Kilenjur 658 548 270 278 110 35 75
Delanthabettu 1464 1177 603 574 287 99 188
Tenkayekkar 3445 2695 1341 1354 750 319 431
Permude 2242 1812 946 866 430 171 259
Hosabettu 2260 1876 942 934 384 153 231
Kuthethur (OG) 3791 3065 1758 1307 726 331 395
Bala (OG) 2637 2137 1100 1037 500 224 276
Kavathar 1529 1187 603 584 342 121 221
Attur 1478 1192 599 593 286 111 175
Nadugodu 1454 1156 594 562 298 100 198
Boliyar 5753 4272 2261 2011 1481 593 888
Kolambe (CT) 5592 4480 2322 2158 1112 439 673
Kenjar (CT) 5338 4150 2261 1889 1188 457 731
Thokur-62 (CT) 7433 6017 3409 2608 1416 665 751
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Bajpe (CT) 9701 7940 4372 3568 1761 807 954

Kandavara 3347 2683 1385 1298 664 254 410
Adyapady 2089 1614 872 742 475 171 304
Malavoor 3468 2639 1377 1262 829 344 485
Mudushedde (CT) 8155 6468 3276 3192 1687 646 1041
Mangalore (MC+OG) 499487 426286 216154 210132 73201 31749 41452
Alike 5840 4819 2820 1999 1021 386 635
Navoor (CT) 5365 4075 2115 1960 1290 481 809
Bandaru 4011 2857 1579 1278 1154 440 714
TOTAL 595733 502723 256776 245947 93010 39778 53232
Economic Structure
Most people in rural sector are cultivators & agricultural labors which indicates dominant
agricultural economy. A small section of people is engaged as workers in household
industries. But in urban sector the existing scenario is completely reversed as most of the
people there are engaged in non-agricultural activity especially in local hotels/restaurants
and as drivers some people also operates their vans/jeeps/cars as tourist vehicle.
Annual income helps in identifying families below poverty line. During the field survey,
income of a household through all possible sources was recorded. Agriculture and allied
activities was reported to be the major source of income followed by non-farm wage
labor, business, Government and Private Service etc. The other important sources of
income include government pension and income from selling of fodder.
Workers Scenario
Occupational Pattern’ was studied to assess the skills of people in the study area.
Occupational pattern helps in identifying major economic activities of the area. The main
and marginal workers population with further classification as casual, agricultural,
households and other workers is shown in Table 3.26.In the study area, the Main and
Marginal Workers population was observed as 236519 (39.7%) and 19053 (3.2%)
respectively of the total population (595733) while the remaining 340161 (57.1%) persons
were recorded as non-workers. Thus, it implies that the semi-skilled and non-skilled work-
force required in study area for the project is available in aplenty.
Occupation Pattern wise distribution of Population and Graphical representation of

‘Workers Scenario’ of the study area are shown below&Figure3.25.
Table 3.26 : Distribution of Work Participation Rate
Occupation Class 2011 Occupation Class 2011

Main Workers 236519 (39.7%) Female 8055 (42.3 %)
Male 162599 (68.8 %) Non-Workers 340161 (57.1%)
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Female 73920 (31.2 %) Male 122957 (36.1 %)

Marginal Workers 19053 (3.2%) Female 217204 (63.9 %)
Male 10998 (57.7 %)
Total Population 173282
Source: Census of India Records, 2011
Workers Scenario of the Study Area
Main
Workers
Non- 39.7%
Workers
57.1%
Marginal
Workers
3.2%
Figure 3.24 : Workers Scenario of the Study Area
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Table 3.27 : Village-wise Occupational Pattern in the Study Area
MAIN MAIN_CL MAIN_AL MAIN_HH MAIN_OT MARG MARG_CL MARG_AL MARG_HH MARG_OT
Name of the Village WORK_P _P _P _P _P WORK_P _P _P _P _P
Kulur 349 77 17 104 151 66 1 1 4 60
Madya 619 42 3 177 397 193 1 4 41 147
Chelliru (OG) 1478 82 67 356 973 177 1 13 6 157
Panja 185 48 23 36 78 42 0 2 0 40
Surinje 1105 56 6 230 813 205 2 7 9 187
Kilenjur 320 37 0 135 148 13 1 0 0 12
Delanthabettu 825 100 49 269 407 28 0 3 2 23
Tenkayekkar 1047 70 28 250 699 460 6 78 131 245
Permude 921 122 22 124 653 31 2 8 5 16
Hosabettu 909 95 45 123 646 128 4 0 81 43
Kuthethur (OG) 1842 88 24 283 1447 201 1 23 28 149
Bala (OG) 1022 0 2 64 956 8 2 0 0 6
Kavathar 751 74 99 173 405 121 6 42 24 49
Attur 739 30 18 195 496 13 0 0 2 11
Nadugodu 721 86 26 207 402 9 0 2 0 7
Boliyar 2655 87 108 993 1467 321 6 44 179 92
Kolambe (CT) 2319 67 42 502 1708 334 23 41 39 231
Kenjar (CT) 2417 95 50 462 1810 259 13 9 23 214
Thokur-62 (CT) 3015 12 12 126 2865 325 8 4 15 298
Bajpe (CT) 3964 38 37 327 3562 311 8 14 15 274
Kandavara 1519 64 9 428 1018 72 7 20 10 35
Adyapady 1081 89 22 349 621 29 6 6 1 16
Malavoor 1441 57 60 227 1097 320 8 18 96 198
Mudushedde (CT) 4090 38 54 812 3186 360 0 9 45 306
Mangalore (MC+
OG) 193772 1067 863 11419 180423 14738 221 271 1368 12878
Alike 2233 294 395 438 1106 62 17 3 4 38
Navoor (CT) 2816 129 98 1076 1513 36 0 5 6 25
Bandaru 2364 200 12 743 1409 191 3 1 22 165
TOTAL 236519 3244 2191 20628 210456 19053 347 628 2156 15922
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Composition of Main Workers
The ‘Main Workers’ were observed as 236519 persons (39.7%) to the total population of
the study area and its composition is made-up of Casual laborers as 3244 (1.4%),
Agricultural laborers as 2191 (0.9%), Household workers 20628 (8.7%) and other workers
as 210456 (89.0%) respectively. Composition of Main workers is shown below
asFigure3.26.
Composition of Main Workers Population

MAIN_AL_P
MAIN_CL_P 0.9% MAIN_HH_P
1.4% 8.7%
MAIN_OT_P
89.0%
Figure 3.25 : Composition of Main Workers

Composition of Marginal Workers:
The total marginal workers are observed as 19053 which constitute 3.2% of the total
population (595733) comprise of Marginal Casual Laborers as 347 (1.8%), Marginal
Agricultural Laborers as 628 (3.3%), Marginal Household laborers as 2156 (11.3%) and
marginal other workers were also observed as 15922 (83.6%) of the total marginal
workers respectively. Composition of Marginal workers is shown in Figure3.27 as follows.
Composition of Marginal Workers Population

MARG_AL_P
MARG_CL_P
3.3%
1.8%
MARG_HH_P
11.3%
MARG_OT_P
83.6%
Figure 3.26 : Composition of Marginal Workers

Composition of Non-Workers:
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The total Non-workers population was observed as 340161 which constitute 57.1% to the
total population (595733) of the study area. Male-female wise Non-workers population
was recorded as 122957 Males (36.1%) and 217204 Females (63.9%) respectively.
Details about total Non-workers of the study area with Graphical representation are
tabulated belowand shown in Figure 3.28.
Table 3.28 : Composition of Non-Workers

Non-Workers Population
Persons Males Females
340161 122957 (36.1%) 217204 (63.9%)
400000
300000
200000
100000
0
Total Non-Workers Male Non-Workers Female Non-
Workers
Figure 3.27 : Composition of Non-Workers
Basic Amenities Availability Status
A review of Basic infrastructure facilities (Amenities) available in the study area has been
done based on the Field survey and Census records, 2011 for the study area inhabited
revenue villages of mainly Three (03) tehsils namely Mangalore, Bantval and Beltangadi
of Dakshin Kannada District in Karnataka. The study area has good level of basic
infrastructure facilities like educational, medical, potable water, power supply, and
transport & communication network. Entire study area is predominantly urban except few
revenue villages.
Education Facilities
As per the Census Records of India 2011, there are a total twenty-eight (28) revenue
villages/towns of Dakshin Kannada District in Karnataka. All the revenue villages/towns
are mainly under three (03) tehsils namely Mangalore, Bantval and Beltangadi of Dakshin
Kannada District in Karnataka. There are about twenty-seven (27) Primary Schools
existing in the rural part/revenue villages of the study area. Middle schools are thirteen
(13 no’s) in the rural part of the study area. Only seven (07 no’s) Higher Secondary
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Schools are available in the rural part of the study area. Senior Secondary School facility
is not available in the rural part of the study area. The educational facilities have been
further strengthening now and many private public schools and colleges are also
functioning in the surroundings of the study area. Besides, there are Engineering and
Medical colleges available in Towns and District headquarters only. Higher education
facilities are available in Towns of the area. There is considerable improvement in
educational facility. The villages/towns of the study area have no such facilities can reach
within 5.0 to 10.0-km range. Majority of the villages are little far from their nearest town.
More than 99% of villages of the district have education facility, transport and
communication.
Medical Facilities
The medical facilities are provided by different agencies like Govt. & Private individuals
and voluntary organizations in the study area. As per the district census handbook
information of 2011, Two (02) primary health center / PHC exists in the study area; most
of the study area villages depend upon the towns / district HQ of the study area having
such facility. Fourteen (14) Primary Health Sub-centers /PHSC are exists in the rural part
of the study area. Mother &Child Welfare Centre / MCWC are available in Attur and
Boliyar village of the study area. Family welfare centre (FWC) exists in fourteen (14)
villages of the study area. Overall study area villages are served by good medical
facilities. Specialized medical facilities are available in towns and District Headquarter
(HQ) only.
Potable Water Facilities
Potable water facility is available in most of the villages/towns of the study area. The
entire study area has plenty of good potable water facilities. Most of the villages (about
100%) having Hand Pumps (HP) as potable water facility. Out of total twenty-eight (28)
revenue villages/towns eleven (11) villages (39.3%) are served with River/Canal water in
the study area. As per the census records of 2011, about Six (6) villages (21.4%) are
being served with Tank/Pond/Lake in the study area. In most of the villages, hand pumps
are commonly observed in the study area. Good potable water facilities are available in
the study area.
Communication, Road & Transport Facilities
Apart from Post &Telegraph (P & T) services, transport is the main communication
linkage in the study area. About five (05) villages (17.9%) out of twenty-eight (28) are
served with Post Office facilities in the study area, remaining villages are depending upon
these five (05) villages and towns of the study area. The study area has average rail and
road network, passes from the area. Two (02) villages named Madya and Delanthabettu
itself are served with railway station facility in the study area and remaining villages
depend upon these villages/towns with this facility. Nearest town/city is Mangalore (MC)
at about 10.0-km away from the project site. Bajpe Airport is about 10-kms away from the
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proposed site in East direction. Most of the villages are served with Pucca road facility in
the study area. The villages in the study area which do not have such facility can reach
within 5 to 10-km range. Mainly five (05) towns named Mulki (TP), Mangalore (MC),
Mudbidri (TMC), Bantval (TMC) and Beltangady (TP) are available within the distance
range of 5 to 26-kms from the villages of the study area. Approach by pucca road facility
is available to 100% of villages of the district. Post office facility is available for 81.6% of
villages in the district. The study area has almost all the schedule commercial banks with
ATM facility at urban areas and the district HQ. Majority of the villages have banking
facility at a distance of 5-10 km.
Power Supply
It is revealed from the compiled information on Amenities availability as per the census
record of 2011; most of the villages and towns (about 100%) are electrified for all purpose
in the study area. Village/town wise ‘Basic Amenities’ availability data for the entire study
area is compiled and presented in Table 3.29.
Village/town wise ‘Basic Amenities’ availability data for the entire study area is compiled
and presented in Table 3.29.
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Table 3.29 : Village wise Basic Amenities (Census Records 2011)
Village Name Educational Medical Drinking Water P&T Communication Approach to Power Nearest Town &
Village Supply Distance, km
P M SS PHC PHSC MCWC FWC T W HP TW R Tk PO Tele. Mob. BS RS PR KR FP EA
Kulur 1 0 0 0 1 0 1 1 2 1 1 2 2 2 1 1 1 2 1 1 1 1 Mulki ,5.0km
Madya 1 1 1 0 1 0 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 Mangalore, 25.0km
Chelliru (O.G) Urban Part
Panja 1 0 0 0 0 0 0 2 2 1 1 1 1 2 1 1 2 2 1 1 1 1 Mulki, 16.0km
Surinje 1 1 1 0 1 0 1 2 2 1 1 1 2 2 1 1 1 2 1 1 1 1 Mangalore, 15.0km
Kilenjur 1 1 0 0 0 0 0 2 2 1 1 2 1 2 1 2 2 2 1 1 1 1 Mulki, 9.0km
Delanthabettu 1 0 0 0 1 0 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 Mangalore, 17.0km
Tenkayekkar 2 1 0 0 1 0 1 2 2 1 1 1 1 2 1 1 2 2 1 1 1 1 Mulki, 13.0km
Permude 2 1 0 0 1 0 1 2 2 1 1 2 2 1 1 1 1 2 1 1 1 1 Mulki, 15.0km
Hosabettu 2 0 1 0 2 0 2 2 2 1 1 2 2 1 1 1 2 2 1 1 1 1 Mudbidri, 10.0km
Kuthethur (OG) Urban Part
Bala (OG) Urban Part
Kavathar 1 0 0 0 1 0 1 1 2 1 1 2 1 2 1 1 1 2 1 1 1 1 Mulki, 4.0km
Attur 1 1 1 1 0 1 0 2 2 1 1 1 2 2 1 1 2 2 1 1 1 1 Mulki, 16.0km
Nadugodu 1 1 1 0 0 0 0 2 2 1 1 1 2 2 1 1 1 2 1 1 1 1 Mulki, 9.0km
Boliyar 3 2 0 1 0 1 0 2 1 1 1 1 2 1 1 1 1 2 1 1 1 1 Bantval, 12.0km
Kolambe (CT) Urban Part
Kenjar (CT) Urban Part
Thokur-62 (CT) Urban Part
Bajpe (CT) Urban Part
Kandavara 2 0 0 0 2 0 2 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 Mudbidri, 20.0km
Adyapady 1 1 1 0 1 0 1 2 2 1 1 1 1 2 1 1 1 2 1 1 1 1 Mudbidri, 24.0km
Malavoor 2 2 0 0 1 0 1 1 1 1 1 2 2 2 1 1 2 2 1 1 1 1 Mangalore, 6.0km
Mudushedde (CT) Urban Part
Mangaluru (MC & OG) Urban Part
Aliake Urban Part
Navoor (CT) Urban Part
Bandaru 4 3 1 0 1 0 1 2 2 1 1 1 2 1 1 1 1 2 1 1 1 1 Beltangady,26.0km
TOTAL 27 13 7 2 14 2 14 Status for Availability and Non-Availability is shown as A (1) & NA (2) respectively
Source-http://www.censusindia.gov.in/2011census/dchb/DCHB.html
Table 3.30 : Abbreviations used in the Table 3.29 are as follows;

Educational Facilities, P-Primary School ,M-MiddleSchool, HSS-Higher Secondary Schools, Medical Facilities, Post, Telegraph and Telephone Facilities, PO- Post Office, Tel. - Telephone Connection, Communication Facilities,
MCWC-Maternity and Child Welfare Centre, PHC-Primary Health Centre , PHSC-Primary Health Sub-Centre BS- Bus Services, RS- Railways Services, NW- Navigable Waterway Available, Approach to Village, PR- Paved Roads,
,FWC-Family Welfare Centre, Drinking Water Facilities, T-Tap Water, W-Well Water, Tk-Tank Water ,TW- Tube KR-Kuchha Road, FP- Foot Path, Power Supply, EA- Electricity for All Purposes
Well Water, HP-Hand Pump, R-River Water
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Brief description of Places of Religious, Historical or Archaeological Importance and

Tourist interest in Villages and Towns of the District;
Panambur Beach (Mangalore Taluk): is a good picnic spot and holiday resort in the
vicinity. The Panambur New Mangalore Port is also located at about 10-km away from
Mangalore and this is an “All Weather Port.”
Someshwara Beach (Mangalore Taluk):This Beach is a good picnic spot and moreover
beautiful sunset view can be seen from this beach. Fishing is another attraction in this
beach. Somanatheshwara temple near the beach is another religious center.
Gorakhnath Temple Kudroli (Mangalore Taluk): This Temple is situated at 3.0-km from
the heart of the city Hampanakatta, and dedicated to Lord Shiva. This temple was
constructed by Sri Narayana Guru in 1912 AD.
Kadri Manjunatha Temple (Mangalore Taluk): This Temple is dedicated to lord

Manjunathaswamy. The idol of shrine is said to have oldest bronze in South Indian
Temples. It was installed in 1068 A.D.
Maha Ganapathi Temple at Sharavu (Mangalore Taluk): This Temple is dedicated to

Lord Ganesha. This is one of the ancient temples near Hampanakatta.
Mangaladevi Temple (Mangalore Taluk): This Temple is situated at a place called

Bolar, 3.0-km away from the heart of the city Hampanakatta. The Ballala of Attavara are
said to have constructed a temple and enshrined it with an image of Shakti, which was
inaugurated by Goraknath, a disciple of Matsyendranath, sometime in the early years of
the 10th century A.D.
Shreemanth Bai Memorial Government Museum (Mangalore Taluk): This Museum is

about 4.0-km away from the heart of the city Hempanakata. This museum has objects of
art, archaeology and national history.
St. Aloysius Church Chapel & Museum (Mangalore Taluk): This Church was
constructed in 1885 A.D. by Rev. Fr. Joseph Willy. It has a marvelous gallery of painting
done by Br. Anthony Moschemi from 1902-1904 A.D.
St. Milegris Church (Mangalore Taluk): This Church was established in 1834 A.D., is
one of the Christian momentums of the city.
St. Rosario Cathedral (Mangalore Taluk): Situated 1.0-km away from the heart of city
Hampanakatta, the dome of the St. Rosario Cathedral built in 1910 A.D. is said to have
been modeled on St. Peter’s Basilica in Rome.
Sultaan Bathery (Mangalore Taluk): This fort situated at Boloor, 4.0-km away from the
heart of city Hampanakatta. Sulthan Bathery a watch tower, built by rough blocks of

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laterite, in the last remaining bastion of Tippu Sultan’s fort built by him to block the entry
of British warships through the Gurpur river.
Light House Hill Idgah (Mangalore Taluk): This Idgah was built by Tippu Sultan.
Village: Kulai Village:Surathkal
Village:Baikampady
3.12. Traffic Analysis

Traffic analysis was conducted on NH-66 for 24 hours on dated 22.02.2017 for up and
down counts. Results are provided in Table3.31 and 3.32.
 Name of the Location: NH-66 (Near MCF Main Gate)

 Direction of Vehicles: Mangalore to Suratkal
 Date of Monitoring: 22.02.2017
 Road width: 15 meters
 Road Lane: 4

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Table 3.31 : Traffic Analysis Results
Time (Hrs.) Two wheelers Three and Four wheelers Light vehcals Bus Heavy vehicals Total
6:00 128 119 38 95 134 514
7:00 206 242 55 166 178 847
8:00 344 308 68 235 208 1163
9:00 370 441 104 311 312 1538
10:00 428 516 132 188 206 1470
11:00 526 318 95 202 286 1427
12:00 432 241 145 84 335 1237
13:00 678 405 98 150 405 1736
14:00 616 510 164 126 258 1674
15:00 348 424 202 98 219 1291
16:00 306 491 142 182 242 1363
17:00 512 602 106 209 145 1574
18:00 488 505 167 194 130 1484
19:00 519 782 226 155 126 1808
20:00 441 530 153 232 170 1526
21:00 278 416 87 164 95 1040
22:00 226 304 72 104 175 881
23:00 147 218 119 95 195 774
0:00 68 105 144 66 164 547
1:00 25 78 59 46 128 336
2:00 31 46 15 34 70 196
3:00 16 30 34 18 45 143
4:00 56 82 48 54 75 315
5:00 144 155 84 105 112 600
Total 7333 7868 2557 3313 4413 25484
 Name of the Location: NH-66 (Near MCF Gate)
 Direction of Monitoring: Suratkal to Mangalore
 Date of Monitoring: 22.02.2017
 Road width: 15 meters
 Road Lane: 4
Table 3.32 Traffic Analysis results
Time (Hrs.) Two wheelers Three and Four wheelers Light vehicles Bus Heavy vehicles Total
6:00 110 148 30 122 142 552
7:00 134 206 50 172 190 752
8:00 322 345 93 188 228 1176
9:00 409 457 121 318 344 1649
10:00 500 258 135 260 207 1360
11:00 408 504 155 186 311 1564
12:00 336 378 117 172 344 1347
13:00 502 425 176 140 406 1649
14:00 399 406 145 108 253 1311
15:00 531 328 80 124 234 1297
16:00 408 540 73 246 244 1511
17:00 381 515 127 144 161 1328
18:00 492 416 140 75 160 1283

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19:00 431 605 163 132 141 1472

20:00 341 481 211 208 180 1421
21:00 202 375 177 156 97 1007
22:00 185 282 94 190 174 925
23:00 146 194 207 125 212 884
0:00 81 95 170 98 158 602
1:00 36 65 63 55 163 382
2:00 30 32 17 30 71 180
3:00 14 20 29 25 54 142
4:00 68 60 61 56 91 336
5:00 134 124 80 118 122 578
Total 6600 7259 2714 3448 4687 24708

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CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES
This chapter provides the study of impacts which are likely to be caused by the proposed
project and their suggested mitigation measures. To study the intensity of impacts on
environment during operation phase modeling process was carried out at the proposed
project site.
4.1. Introduction
One of the important elements of EIA study is the identification of impacts, as it helps in
quantification and evaluation of impacts. Although, in general, a number of impacts have
been identified while describing the baseline environmental status, it is necessary at this
stage to identify the critical impacts positive/negative on various components of the
environment that are likely due to installation of proposed fertilizer plant.
Generally, the environmental impacts can be categorized as either primary or secondary.
Primary impacts are attributed directly to project activities whereas secondary impacts
are indirectly induced and typically include the associated investment and changed
patterns of social and economic activities due to the proposed project activities.
The construction and operational phase of the proposed expansion project at MCF;
Mangalore, Karnataka comprises various activities, each of which may have either
positive or negative impact on some or other environmental attributes.
The proposed project activities would impart impact on the environment in two distinct
phases:
 During construction phase which may be regarded as temporary or short term and
reversible effect; and
 During operational phase which may have long term effects.
The evaluation of environmental impacts due to installation of main plants namely
Ammonia and Urea within a radius of 10 km around the MCF; Mangalore, Karnataka
fertilizer complex and the mitigation measures are as under:
4.2. Identification of Impacts

The likely impacts due to proposed activities are described for the following
environmental components:
 Topography
 Climate
 Land Environment
 Air Environment

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 Noise Environment
 Water Environment
 Solid Waste Generation
 Terrestrial & Aquatic Ecology
The impact of the proposed activities on each of the above environmental components is
discussed in following paragraphs.
4.3. Impact on Topography

4.3.1. Construction Phase
The construction phase can be broadly classified into four different periods viz., pre-
construction, site work, permanent facilities and project close out. The various activities
may be summarised as under:
Table- 4.1 Proposed activities during Construction phase

Construction Construction
Potential Environmental Impact
Phase Activity
The soil investigation is limited to construction of bore
wells/holes which will have no impact on the
Soil Investigation
Pre- topography and environment. The study will furnish
Environmental
construction lithological information. The running unit of MCF is full
Monitoring
of shrubs and herbs all along the boundary wall. No
leveling and fencing is required.
The proposed project site is practically free and clear
land devoid of any permanent structure. Only wild
shrubs and herbs shall be cleared and composted for
its use in green belt area. This will have negligible
Clearing & grading impact. Existing facilities like approach roads, sheds,
Temporary facilities sanitary facilities etc. shall be utilized. Hence, no
such as sheds, impact is envisaged. Water requirement during
approach roads, construction period shall be met through existing water
sanitary facilities supply. Excavation and demolition of old and damaged
Earth work structures shall be carried out through MSTC as per C
Site Work
comprising of & D waste Rules, 2016 in consultation with local
excavation, guarding Municipal Corporation authorities and State Pollution
and trenches Control Board. Demolition material shall be used for
Foundation work, leveling and stabilization of the surface in plant area. A
piling and drainage little impact within sustainable limits has been
system envisaged for a limited period.
Dust emission and noise pollution cannot be ruled.
Proper de-dusting arrangement (water spray) shall be
strictly followed. New Generation machines for piling
and other construction works shall be utilised.
Permanent Landscaping, Decreased soil erosion, increased water infiltration
facilities Temporary seeding, and positive visual impact Makes the surfaces
comprising of permanent seeding impervious Increase in Noise level and alarming

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building, Construction of safety condition

ware-houses Permanent structure
and storages Mechanical erection
etc of process plant and
Removal of
Project temporary facilities,
Dust and solid generation
Close-out finish grading,
cleaning etc.
The installation activities include excavation of soil from the proposed site. The excavated
loose soil shall be utilized for leveling of low lying areas and maintenance of existing
dominant drainage pattern in the plant premises. The demolition and construction
material along with loose soil shall be used for stabilization and mulching of raw material
storage yard area. Thus, the impact on topography during construction phase is
insignificant.
4.3.2. Operation Phase
As the proposed expansion project would be installed within premises of MCF fertilizer
plant and the operation will be confined within plant premises, no impact is envisaged on
the topography during operation phase.
4.4. Impact on Climate

The proposed fertilizer plant shall be set up within the existing plant premises of MCF
unit. The proposed site is almost plain and full of wild shrubs & herbs. For site
preparation, all the shrubs & herbs would be cleared.
The removed shrubs and herbs shall be composted and re-used in green belt area as
organic manure. Removal of shrubs and herbs would not alter the existing climatic
condition and no impact is envisaged on the present climatic condition during
construction phase.
During operation, a little green house gases as well as air pollutants namely PM10,
PM2.5, Urea dust, NOx and ammonia shall be emitted in to the environment.
4.5. Land Environment

4.5.1. Sources of Impact
The sources of impacts due to proposed project are as follows:
 The study area falls in Netravathi and Gurupura river basin. Gurupura river basin lies
in the south-western part of the Dharwar Craton i.e., coastal stretch of the Western
Dharwar Craton.
 The proposed fertilizer project does not involve acquisition of land as the proposed
plants would be established within existing factory premises of Fertilizer unit of MCF.
Hence, there shall be no change in land use pattern.

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 The proposed expansion is based on recent BAT with NG as feedstock which is

supposed to be one of the cleanest processes. There will be no solid waste
generation except spent catalysts, activated carbons, metal scraps etc. which will be
generated periodically and can be managed safely.
 Liquid waste generated in proposed project during normal operations shall be treated
in the in-plant treatment systems so that the same can be recycled / neutralized in
the plant. The treated wastewater shall be reused within plant premises.
 The proposed project does not involve handling of materials resulting into generation
of garbage.
4.5.2. Prediction of Impacts
The impacts of the proposed project during construction and operation stages are as
follows:
 As the proposed plants shall be established within plant premises of existing MCF,
Mangalore, no impact on natural drainage or topography is envisaged.
 Solid waste i.e excavated soil generated in the form of construction waste shall be
utilized in leveling, dressing and maintenance of natural drainage pattern. Hence, no
impact on the land environment is envisaged with respect to disposal of construction
waste.
 Solid waste in the form of spent catalyst generated during operation shall be sent to
authorised recyclers.
 No additional Wastewater generated during upset conditions is envisaged to be
collected separately and treated in the existing ETP for reuse within plant premises.
 Concept of ZLD shall be implemented. Thus, no impact due to disposal of liquid
waste is envisaged.
4.5.3. Mitigation Measures:
The following measures will be adopted:
 After completion of the construction, the surplus earth will be utilized to fill up the low
lying areas, the rubble will be cleared and all un-built surfaces will be reinstated;
 The top soil from the excavated areas will be preserved for re-use during plantation;
4.5.4. Impact of the transport of raw materials and end products on the surrounding
environment
The raw material for this project i.e. NG shall be received through proposed pipeline laid
by M/s GAIL. Hence, no impact is envisaged on the surrounding environment due to
transport of raw material.
About 90% of end products i.e. Urea/ NPK/ DAP shall be transported through rail wagons
and about 10% through trucks to different locations. The proposed project site is well
connected to road network and shall be maintained properly to prevent fugitive
emissions, if any. The trucks engaged for transportation of end products shall be BS-III/IV

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compliant. In case of dust emission in the command area of the factory, shall be
controlled by sprinkling water with or without chemicals / de-dusting agent.
It is, therefore, concluded that the proposed facilities shall have a little impact on land
environment, during construction & operation phase which shall remain well within the
buffering limit of the environment.
4.6. Air Environment

The production of Ammonia-Urea using NG is the cleanest, established and one of the
best available technology on global basis. The existing environmental impact due to air
pollutants has been calculated on the basis of 24 nos. of samples collected from 08
sampling stations spread over a radius of 10 km around the proposed project site. The
baseline data generation with respect to air environment has been conducted for three
months period from 1st December 2016 to 28th Feb 2017.
4.6.1. Emission Sources from Proposed Plants
Construction Phase
The main sources for impact of air quality during construction is due to movement of
vehicles and construction equipment at site, dust emitted during leveling, grading,
earthmoving, foundation works, transportation of construction material etc. Dust would be
generated during activities such as loading and unloading, top soil removal, movement of
vehicles over dirt roads and windblown dust from exposed project site. Hence, during the
construction phase, dust generated from the concentration material would be the main
pollutants. The emissions from vehicles and construction equipment could also be of
some concern on a local level.
Air Pollution Mitigation Measures:
The dust generated is fugitive in nature, which is controlled by sprinkling of water. The
impacts will be localized in nature and the areas outside the project Site area are not
likely to have any major adverse impact with respect to ambient air quality.
There will not be any major leveling operations required as the plant site is plain. Hence,
no significant excavation in the area except for foundations for civil constructions and
foundations of equipment is proposed. However, it is necessary to control the dust
emissions. This is achieved by regular water sprinkling all over the area under
construction to arrest the emissions. SO2 and NOx emissions may increase in ambient air
due to operation of construction machinery such as bulldozers, pay loaders, trucks etc.
However, increase in levels of these emissions is expected to be marginal since these
machines will be operated intermittently and the equipment being on the move there will
not be concentration of emissions at a single location. Nevertheless, it will be ensured
that both petrol and diesel powered construction vehicles are properly maintained to
minimize exhaust emissions and only the vehicles whose emissions are within the
pollution limits would be allowed to operate with in the plant area.

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4.6.2. Emission Standards

The Ministry of Environment & Forests ( Department of Environment, Forest & Wildlife) in
its Notification dated 19th November, 1986 has laid down under the ENVIRONMENT
(PROTECTION) RULES, 1986 and there amendment in 2015, the following stack
emission standards for nitrogenous Fertilizer Industry:
B-Emission Standard
(i) Straight Nitrogenous
(a) Ammonia Reformer
Oxide of Nitrogen (as NO2) 400 mg/Nm³ (at 3% O2)
(b) Urea Plant-Prilling Tower
Pre 1982 units 150 mg/Nm³
Particulate Matter
Post 1982 unites 50 mg/Nm³
(ii) Ammonium Nitrate/Calcium Ammonium Nitrate/NPK Plant
Particulate Matter 50 mg/Nm³
Ammonium as NH3 Existing Plant 300 mg/Nm³
New 150 mg/Nm³
Plant Expansion
Total Fluoride as F 50 mg/Nm³ (Only NPK Plant)
(iii) Phosphatic Fertilizer Plant- Phosphoric Acid Plant/Rock Grinding and Acidulation in
SSP Plant
Particulate Matte 125 mg/Nm³
Total Fluoride as F 20 mg/Nm³
(iv) Nitric Acid Plant
Oxides of Nitrogen (as NO2) 400 mg/Nm³
4.6.3. Air Environment: Operation Phase
Air emissions of various pollutants like PM10, SO2, NOx, and NH3, due to operation of
proposed plants are mentioned below:
 Ammonia plant reformer
 Urea Prill tower
 Captive Power plant
 DAP/ NPK plant
Emissions due to Vehicular Movement
This kind of emissions will principally arise from the vehicles used for the transport of
construction materials and equipment, for the transport of raw materials to the site and for
the transportation of finished products from the site. There will be a chance that, the
workers on the site would get exposed to this type of emission from the vehicles.
However their effect will be localized and transient in nature and will principally affect the
localities adjacent to the access road.
The major air emissions from the proposed plant operations are particulate matter,
ammonia, sulphur dioxide and nitrogen oxides from the point sources. These include the
stacks attached to plants and the captive power plant. While the impact of fugitive

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emissions will be within the project area, the effect of emissions from the point sources is
a major concern as it will have impact on the ambient air quality in the surrounding area.
An atmospheric dispersion modeling and the prediction of ground level pollutant
concentration has great relevance in estimating the impact of these pollutants.
The prescribed emission norms nevertheless assessment of ground level concentrations
(GLC) of the possible pollutants is carried out for control purposes. The significant point
sources that contribute to the air pollution incidence from the proposed plant are provided
below in Table. 4.1.
Air Dispersion Modeling Methodology (Modeling Approach)
The assessment methodology for the air dispersion modelling exercise follows the
guidance specified in the United States Environmental Protection Agency (USEPA). The
detailed model recommended for air dispersion modelling in the ambient air is AERMOD.
The model of selection was the commercially available AERMOD View dispersion model,
developed by Lakes Environmental. This model is used extensively to assess pollution
concentration and deposition from a wide variety of sources. AERMOD View is a true,
native Microsoft Windows application and runs in Windows applications. The AMS/EPA
Regulatory Model (AERMOD) was specially designed to support the EPA’s regulatory
modeling programs.
AERMOD is a regulatory steady-state plume modeling system with three separate
components:
 AERMOD (AERMIC Dispersion Model), AERMAP (AERMOD Terrain Preprocessor),
and
 AERMET (AERMOD Meteorological Preprocessor). The AERMOD model includes a
wide range of options for modeling air quality impacts of pollution sources, making it
a popular choice among the modeling community for a variety of applications. Some
of the modelling capabilities of AERMOD include the following:
 The model may be used to analyze primary pollutants and continuous releases of
toxic and hazardous waste pollutants.
 Source emission rates can be treated as constant or may be varied by month,
season, hourof- day, or other optional periods of variation. These variable emission
rate factors may be specified for a single source or for a group of sources. For this
project all emission rates were treated as constant.
 The model can account for the effects of aerodynamic downwash due to buildings
that are nearby point source emissions.
Receptor locations can be specified as gridded and/or discrete receptors in a
Cartesian or polar coordinate system.
 For applications involving elevated terrain, the U.S. EPA AERMAP terrain
preprocessing program is incorporated into the model to generate hill height scales
as well as terrain elevations for all receptor locations.

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 The model contains algorithms for modeling the effects of settling and removal
(through dry and wet deposition) of large particulates and for modeling the effects of
precipitation scavenging for gases or particulates.
 AERMOD requires two types of meteorological data files, a file containing surface
scalar parameters and a file containing vertical profiles. These two files are provided
by the U.S. EPA AERMET meteorological preprocessor programme
Model Inputs (Source Emissions)
A critical step for conducting air dispersion modeling is to quantify the emissions from the
sources at the facility. The emission rates from the sources identified were estimated in
accordance with the standard guideline.
Meteorological Data
The AERMOD model requires hourly surface data values for wind speed, wind direction,
temperature, rainfall, relative humidity, pressure, cloud cover and ceiling height and solar
radiation and at least once daily mixing height data.
The data files for the surface and mixing heights were then used to generate the
meteorological file required by the AERMOD dispersion model using the AERMET
meteorological preprocessor programme. The AERMET programme has three stages to
process the data. The first stage extracts meteorological data and assesses data quality
through a series of quality assessment checks. The second stage merges all data
available for 24-hour periods and writes these data together in a single intermediate file.
The third and final stage reads the merged meteorological data and estimates the
necessary boundary layer parameters for dispersion calculations by AERMOD.
Model Domain, Receptor Network and Terrain Considerations
The selected model domain was 10 km in both the east-west and north-south directions,
with the centre of the domain being the centre of the proposed facility site, with
coordinates 12°56′11.11″N and 74°49′27.36″E with 19 to 27 amsl. Figure 4.1 shows the
model domain that was utilized in the project, including the receptor grid and the plant
boundary. The model domain is overlain on a Google image.
Receptor Network
The selection and location of the receptor network are important in determining the
maximum impact from a source and the area where there is significant air quality impact.
Impacts were assessed at locations beyond the site boundary. Consequently, the
receptor locations were selected as a multi-tier grid that is defined by discrete Cartesian
receptors, square in shape and uniform polar grid receptors, circular in shape and with
origin at the centre of the proposed facility.
The entire receptor network locations include a 100-meter spaced grid within 10 km from
the subject source. A total of 621 receptors were considered, and receptor grid is
graphically depicted in Figure 4.1.

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Terrain Considerations
The classification of the land use in the vicinity of the proposed facility is needed because
dispersion rates differ based on the land use type. The topography in the region of the
proposed fertilzer manufacturing facility is defined as either simple terrain (terrain lying
below the stack top elevation) or complex terrain (terrain above the top of the stack).
Measurements of the terrain in the area surrounding the proposed facility were made
using terrain data obtained from Digital Elevation Maps derived from the United States
Geological Survey (USGS).
The terrain data obtained was shown in the Figure 4.2. It was determined that the
topography from the west to the eastern directions up to 10 km have terrain elevations
above 19 to27 m .Therefore, since terrain elevations extend above the facility’s highest
top stack elevation, complex terrain algorithms were included as part of the dispersion
modeling analysis.
Model Results and Impact Assessment
With the various sources identified, a model domain established of 10 km in the North
East direction and 10 km in the north-south direction and centred in the middle of the
proposed facility, and the necessary input files created, model predictions were made for
the pollutants SO2, NOx, PM10 and NH3 for averaging periods for which there are
National Ambient Air Quality Standards.
4.2.3 Post Project Scenario (Projected)
Predicted maximum ground level concentrations considering micro meteorological data of
Winter 2016-17 are superimposed on the maximum baseline concentrations obtained
during the study period to estimate the post project scenario, which would prevail at the
post operational phase. The overall scenario with predicted concentrations over the
maximum baseline concentrations is shown in the following Table 4.2 & 4.3.
Table–4.2 Ground Level Concentrations (GLCs)
S.No. Parameters Max (µg/m3) Distance (Km.) Direction
Existing Stack
1 SOx 14.7 2.4 NNE
2 NOx 12.3 1.0 E
3 NH3 6.7 1.5 E
4 SPM 14.4 1.0 E
5 HF 0.2 0.2 E
Proposed Stack
1 SOx 2.8 1.5 NNE
2 NOx 12.4 0.337 NE
3 NH3 9.4 0.8 E
4 SPM 6.2 1.2 E
5 HF 0.6 1.0 E

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The Summary of cumulative GLC by the proposed project for Sox, PM, NOx, NH3 and
HF observed 18.8 µg/m3 (Baikampady), 97.3 µg/m3 (Lalbag), 36.6 µg/m3 (Project Site)
and HF was not detected in base line as well as proposed project mostly in North East
direction.
The predicted ground level concentrations obtained when superimposed on the maximum
baseline concentrations observed during study period resultant concentrations are within
the prescribed NAAQ Standards. The details are as per Table 4.3 below
AERMOD Output
The isopleths representing pollutant concentrations representing 10 km x 10 km grid are
presented in Figures – 4.3 to 4.5
The existing emission load from stack already covered at the time of base line data
collection. The Maximum predicted GLC by the proposed project for Sox, SPM, NOx,
NH3 and HF observed 2.8 µg/m3 (Baikampady), 6.2 µg/m3 (Kulur), 12.4 µg/m3 (Project
Site) 6.5 µg/m3 (Kulur) and 0.4 µg/m3 (Project Site) detected in base line as well as
proposed project mostly in North East direction
The Summary of predicted GLC by the proposed project with baseline data for Sox, SPM,
NOx, NH3 and HF observed 5.9 µg/m3 (Lalbag), 92.1 µg/m3 (Lalbag), 19.8 µg/m3
(Project Site) 23.8 µg/m3 (Project Site) and 0.4 µg/m3 (Project Site) detected in base line
as well as proposed project mostly in North East direction
The predicted ground level concentrations obtained when superimposed on the maximum
baseline concentrations observed during study period resultant concentrations are within
the prescribed NAAQ Standards. The details are as per Table 4.3 below
National Ambient Air Quality Standards (2009)
Pollutants Time Concentration in Ambient Air
Weighted Industrial, Residential, Ecologically
Average Rural, other areas Sensitive Area
(Notified by MOEF)
Sulphur Dioxide (SO2), Annual * 50 20
μg/m3 24 Hours ** 80 80
Nitrogen Dioxide (NO2), Annual * 40 30
μg/m3 24 Hours ** 80 80
PM10, μg/m3 Annual * 60 60
24 Hours ** 100 100
PM2.5, μg/m3 Annual * 40 40
24 Hours ** 60 60
Lead (Pb) μg/m3 Annual * 0.50 0.50
in particulate matter 24 Hours ** 1.0 1.0
Arsenic (As), ng/m3 Annual * 06 06
in particulate matter
Nickel (Ni), ng/m3 Annual * 20 20
in particulate matter

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SPM SOX HF
NOx NH3
Figure 4.1 Isopleths for Proposed Stack

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HF NH3 SPM
NOx SOx
Figure 4.2 Isopleths for Existing Stack

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Table 4.3 Overall Scenario of GLCs predictions

S.No. Locations Monitored Value Prediction from Existing stack Prediction from New stack
(µg/m3) (µg/m3) (µg/m3)
Sox SPM Nox NH3 HF Sox SPM Nox NH3 HF Sox SPM Nox NH3 HF
A1 C1 D1 E1 A2 B2 C2 D2 E2 A3 B3 C3 D3 E4
B1
1 Near Purkodi 6.0 85 11.0 12.2 0.1 3.2 2.3 2.4 0.4 0.0 0.1 1.0 0.5 0.8 0.0
2 Kulai 6.4 69 13.0 17.5 0.1 4.7 2.1 1.9 2.2 0.0 1.1 2.5 3.6 3.0 0.2
3 Baikampady 7.8 82 15.7 19.2 0.1 5.5 0.8 2.6 0.7 0.0 2.8 0.9 2.0 2.1 0.1
4 Project Site 8.6 73 16.0 22.1 0.1 8.2 8.5 8.6 4.2 0.1 2.0 3.8 12.4 5.9 0.4
5 Kulur 6.1 69 13.0 15.6 0.1 5.3 6.6 6.5 4.0 0.0 0.5 6.2 4.6 6.5 0.3
6 Marakada 6.9 76 12.3 14.0 0.1 4.4 2.1 2.0 1.4 0.0 0.3 1.7 1.7 2.7 0.1
7 Kodikal 5.3 72 12.1 13.6 0.1 2.0 1.6 1.4 1.3 0.0 0.1 1.5 1.3 2.5 0.1
8 Lalbagh 7.2 92 12.5 13.4 0.1 1.6 2.3 2.0 2.3 0.0 0.3 2.4 2.9 3.8 0.2
 Cumulative values
S.No. Locations Cumulative values (µg/m3)

Sox SPM Nox NH3 HF
A1-A2+A3 B1-B2+B3 C1-C2+C3 D1-D2+D3 E1-E2+E3
1 Near Purkodi 2.9 83.7 9.1 12.6 0.1
2 Kulai 2.8 69.4 14.7 18.3 0.3
3 Baikampady 5.1 82.1 15.1 20.6 0.2
4 Project Site 2.4 68.3 19.8 23.8 0.4
5 Kulur 1.3 68.6 11.1 18.1 0.4
6 Marakada 2.8 75.6 12 15.3 0.2
7 Kodikal 3.4 71.9 12 14.8 0.2
8 Lalbagh 5.9 92.1 13.4 14.9 0.3
*Existing stack emission covered under the baseline data collection.The only incremental load come from the proposed stack.

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4.6.4. Air Pollution Control Equipment (Existing)

DAP Plant:
DAP plant is predominantly a solid handling plant. Therefore, escape of solid particles
into the atmosphere through various gas streams has to be effectively controlled. For this
purpose the designers of DAP plant, M/s Toyo Engineering Corporation, Japan have
incorporated adequate arrangements in the plant for the recovery of dust from various
gas streams before letting them into the atmosphere.
Accordingly the DAP plant is provided with suitably designed cyclones, wet scrubbers,
Mist Eliminator and venturi scrubbers. In order to minimize dust in the DAP plant, suction
fans are provided to suck the air along with dust from locations such as belt outlets,
screens, elevators etc., where dust formation is expected and this dust laden air is
passed through cyclones to recover the dust and then scrubbed in a spray tower before
letting it out into the atmosphere.
The design incorporates provision of independent cyclones for the dryer, cooler and
dedusting system so that the performance of each section is maximized. Further, they
are provided with high efficiency knockers and screw conveyers to ensure uninterrupted
high performance.
The gas streams containing ammonia vapours are scrubbed in various scrubbers with
dilute phosphoric acid solution to recover ammonia and DAP dust particles if any. The
scrubbed phosphoric acid solution is recycled into the process along with the phosphoric
acid feed.
The gas stream from the venturi scrubber passes through a final gas treatment chamber,
consisting of mist eliminator before entering the stack. The gases from the cyclones of
cooler and de-dusting system are scrubbed in a spray tower with acidic solution before
letting into the stack.
Effluent from the urea/ammonia plants and wastewater is used for making up the
scrubbing liquor for the final gas treatment operation as well as for wet scrubbing and
then it is recycled back into the system.
Scrubbed gases are let out into the atmosphere through a 45 M high stack well above the
DAP plant building.
Sulphuric Acid Plant:
1. Alkali scrubbing system
Alkali scrubber has been provided in Sulphuric Acid plant to scrub SO 2 from tail gas
during plant start up. This equipment will be on line during plant start ups and shutdowns
to scrub SO2 gas in alkali solution. The alkali scrubber is a vertical vessel. The tower
contains a polypropylene distributor for uniform distribution of alkali onto the packing. The
tower is provided with a demister pad. The alkali scrubber ensures emission of SO2 within
stipulated limits during plant startup.

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2. Acid Mist Eliminator:

Mist eliminator of hanging type candle filters designed and supplied by CECO Filters
India private limited ( A subsidiary of CECO Filters, USA) have been provided in the Inter
Pass Absorption Tower and in the Final Absorption Tower. In drying tower demister pads
have been provided to prevent acid mist and moisture carryover into the system.
In the Inter Pass Absorption Tower and Final Absorption Tower, 4 nos. and 3 nos. of
Chemical grade fibre glass candle filters are provided respectively. The acid mist is
trapped in these mist eliminators (candle filters) and recycled back to the tower. So the
gases coming out of the final tower is acid mist free. The exit gas coming out of these
mist eliminators are vented through a stack of 50 M height, which is much above the
required height.
Urea Plant:
The original prill bucket was replaced with modified design prill bucket supplied by M/s.
The Stamicarbon, Netherlands, OEM. The modified prill bucket known as the “Tuttle prill”
bucket has special features in the spray hole orientation which gives prills of very uniform
size of improved crushing strength and thereby helps in reducing the dust formation
inside the prilling tower. Also the configuration of louvers with well-maintained induced
draft fans has ensured adequate flow and temperature control. Prill Tower having internal
diameter of 17 m and free fall height of 49.14 M has been provided for prilling. The
highest point of the structure is 72 M from the ground level.
4.6.5. Mitigation Measures
The Proposed Fertilizer Plant shall contribute insignificant amount of pollutants to
atmosphere such as SO2, and NOX. During the design phase all efforts have been made
to adopt latest state of art technology, install adequate pollution control measures and
control possible fugitive emission sources. The following mitigation measures will be
employed during operation period to reduce the pollution level to acceptable limits:
 Ensure that all the pollution control facilities envisaged at the design stage are
implemented and functioning properly.
 Stack monitoring to ensure proper functioning of different pollution control facilities
attached to major stacks.
 Air monitoring in the Work-zone to ensure proper functioning of fugitive emission
control facilities.
 Adequate plantation in and around different units.
 Vehicles and machineries would be regularly maintained so that emissions
confirm to the applicable standards.
 Monitoring of ambient air quality through online AAQ monitoring system with in and
around plant premises so as to reduce the pollution level to acceptable limit
 Design of the plant system to meet the OISD requirements.
 Regular monitoring and review to ensure safe operation.

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 Provisions of the Safety Systems in the design with redundancy, reliability and
defense in depth are considered.
 Regular monitoring by Environmental Cell to demonstrate the compliance with
Statutory limits in the public domain.
 Mitigation measures of Fugitive Emissions:
The following measures shall be adopted to control fugitive emissions:
 Bagfilter with extraction system shall be provided at raw material area. Scrubber
system shall be installed at product bagging area
 All vehicles and their exhausts will be well maintained and regularly monitored for
emission generated from the vehicle exhaust;
 Venturi Scrubber and cyclones will be provided in the process plant
 Regular dust suppression with water sprinkler on the haul roads will be practiced
 The green belt development in the plant will be undertaken.
4.7. Impact on Noise Levels

The noise generation during construction phase may have impact on the existing ambient
noise levels. The major works associated with installation/ construction activities would be
carried out during day time. The construction equipment may result in high noise levels,
which may affect the personnel in the work zone. However, use of Personal Protective
Equipments (PPE) such as earplugs, ear muffs will mitigate any adverse impact of the
noise on working personnel.
The noise likely to be generated during excavation of earth, loading/unloading and
transportation of construction materials will be in the range of about 80 to 90 dB(A) and
this will occur only when all the equipments operate simultaneously. There is remote
possibility of such occurrence. The workers engaged in construction activities, in general,
are likely to be exposed to an equivalent noise level of 70-75 dB(A). Therefore, use of
protective equipments in the form of ear muffs/ earplugs in high noise level areas shall
mitigate adverse impact, if any.
Sound Propagation
Sound propagation from a source to a receiver depends upon the properties of the
atmosphere and the presence of any object or barrier in the transmission path. The
sound pressure level generated by a noise source decreases with increasing distance
mainly due to wave divergence. There is an additional decrease, called excess
attenuation, in sound pressure level, with distance from the source due to atmospheric
effects or interference with objects in the transmission path. For a sound source of
strength LW, located above a flat rigid surface, the radiation pattern is approximately
hemispherical, and the sound pressure level,

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LP, at a distance r from the source is expressed by

LP = LW - 20 log r - Ae - 8 ------ (1)
Often, the sound power of a source is not known, but the sound pressure level
LP1 at a distance r1 from the source is known. The sound pressure level LP2 at
a distance r2 from the source can then be calculated from the equation:
LP2 = LP1 - 20 log r2/r1 - Ae1,2 -------- (2)
Where Ae1,2 is the excess attenuation along the path r2-r1 between observers 1 and 2. In
environmental noise assessment, Eqn (2) is of more general use since the sound power
of a source is seldom known.
Multiple Sound Sources
In environmental noise problems, generally more than one noise sources are
encountered, and total noise at an observer's location due to all sources is to be
evaluated. Since, the sound pressure level is logarithmic, decibel values are not additive
in nature. To determine resultant dB level, it is necessary to convert decibel values to
sound pressures, add these pressures, and then reconvert resultant ratio to decibel
value.
Sources of Noise
Major noise sources are moving/ rotating machineries like, Air Compressors, Feed
Pumps, ID Fans, Cooling Towers, FD Fans, etc.
4.7.3. Prediction of Impacts
Some of the important impacts due to environmental noise pollution may be
Hypertension, stress, annoyance, sleep disturbance, hearing loss, tinnitus, cardio-
vascular impact, cognitive impairment in child but the most important impact as reported
in the study area are sleep disturbance and annoyance. Impacts have been
mathematically calculated on the basis of the data generated during the study period
which have been quantified by mathematical expression.
From the above assessment, it is envisaged that the existing environmental noise in the
study area is well within the standards of AAQ for noise.
Noise Levels Mitigation Measures:
The noise control measures during the construction phase include provision of caps on
the construction equipment and regular maintenance of the equipment. Equipment will be
maintained appropriately to control the noise level within 75 dB(A). Wherever possible,
equipment will be provided with silencers and mufflers. High noise producing construction
activities will be restricted to day time only. Greenbelt development will be undertaken
from the construction stage itself. Further, workers deployed in high noise areas will be
provided with necessary protective devices such as ear plug, ear-muffs etc. Overall, the
impact of increase in noise on the environment would be insignificant, and localized and

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confined to the day hours. The general mitigation measures for the attenuation of noise
are given below:
 Noise will be reduced by preventing leakages from steam lines, compressed air
lines and other high pressure equipment.
 Suitable padding will be provided at required locations to avoid rattling due to
vibration
 Noise generating equipment will be encased to control noise.
 Noise proof cabins will be provided to operators wherever remote control for
operating noise generating equipment is feasible.
 The air compressor, process air blower, pneumatic valves etc, will be provided with
acoustic enclosure;
 Design/installation precautions will be taken as specified by the manufacturers with
respect to noise control and will be strictly adhered.
 High noise generating sources will be insulated adequately by providing suitable
enclosures.
 Sound attenuation panels will be installed wherever required around noise
generating equipment.
 Noise control will form an integral part of the plant design.
 Other than the regular maintenance of various equipment, ear plugs/muffs will be
provided to personnel working close to the noise generating units.
 All openings like covers and partitions will be designed properly
 Inlet and outlet mufflers will be provided wherever required.
 All rotating equipment / parts will be well lubricated and provided with enclosures
as far as possible to reduce noise transmission.
4.8. Impact on Water Quality

4.8.1. Impact during Construction Phase
During construction phase, about 70-80 labourers would be engaged by the contractors.
During peak period of construction, small quantity of water will required, which will be met
through water supplied by Mangalore City Corporation.
Water Pollution Mitigation Measures:
The earth work includes cutting and filling will be avoided during rainy season and will be
completed during the winter and summer seasons. Stone pitching on the slopes and
construction of concrete drains for storm water to minimize soil erosion in the area will be
undertaken. Settling pond is planned for storage and recycling of surface water for use in
the plant area. The development of green belt in and around plant will be taken up during
the monsoon season. Toilets with septic tanks are available at site for construction
workers. The overall impacts on water environment during construction phase due to
proposed activity are temporary and marginal.
Effluent Treatment and Maintaining discharge standard:

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A comprehensive waste water management system shall be provided in the Fertilizer

Plant to treat the liquid effluent to meet the EC / State Pollution Control Board
requirements. The waste water treatment plant at Fertilizer Plant shall be designed based
on combining physical, chemical and biological treatment systems to effectively control
the quality of effluent.
4.8.2. Impact during Operation Phase
The water is supplied by Mangalore City Corporation. No additional water drawl to the
proposed plants. The marginal increase in the water requirement after the
commissioning of the plants will be met by the effluent water recovery unit installed.
Wastewater Generation
The proposed project will not have any adverse impact on the existing environment as
sufficient pollution control measures are incorporated in the process technology like
medium pressure scrubber in ammonia.
Zero discharge concepts have been conceived for proposed fertilizer plant. The
wastewater generation from different plants shall be properly treated and reused. The
details of wastewater generation and treatment from different plants are as under:
(A) Ammonia Plant

There will not be any increase in pollution load due to increase in production.
There is no additional liquid effluent generation from the plant. The plant will remain
zero liquid effluent discharge plant. It is proposed to replace the present low pressure
stripper with medium pressure (MP) stripper which will ensure removal of Ammonia
from process condensate. The gases from the MP stripper will be carried by the
steam going to primary reformer. The effluent generated in the plant shall be treated
in the existing effluent treatment facility and recycled back to the system.
(B) Urea Plant

MCF has installed and commissioned urea hydrolyser stripper and same is being
operated for the treatment of effluent streams from ammonia plant process, urea
stripper system consists of hydrolyser, which is operated at high temperature' and
high pressure, where urea gets hydrolyzed to ammonia and carbon dioxide.
Ammonia thus produced is separated in the second desorption column. The liquid
outlet of second desorption column contains less than 10 ppm of ammonia and urea.
The ammonia vapours from the second desorption column is fed to the first
desorber. The desorber overhead vapours are condensed in a condenser and
reused in Urea plant. The treated effluent from urea hydrolyser stripper is reused as

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There will not be any additional effluent generation by the proposed energy
improvement project. Wastewater generation will reduce because of the
implementation of various energy improvement schemes.
Water treatment plant ion exchange regeneration effluent streams, the cooling tower
blow down and backwash water effluent from water treatment plant sand filter and
cooling tower side stream filter were treated in the wastewater recovery unit and
treated water is reused as cooling water makeup.
(C) DAP/NPK Plant

There will not be any additional water drawl from the Mangalore City Corporation due
to requirement of proposed project. The marginal increase in the water requirement
after the commissioning of DAP/NPK plant will be met by effluent water recovery unit
installed.
No trade effluent generation from the proposed DAP/NPK plant. All liquid spillages
shall be collected and recycled back to the process.
(D) Poly Carboxyl Ether (PCE) Plant

There will be no liquid effluent generated in the plant. The spillages if any from the
plant floor will be collected in and recycled back.
Wastewater Generation/Disposal
Reusing the entire treated effluent and to achieve the target of zero effluent discharge
MCF has installed Wastewater Recovery Units during 2009-2010 by treating the effluent
streams consisting of the following:
 Sand filter back wash water from water treatment plant and cooling tower
 Water treatment plant resin regeneration effluent - acidic and alkaline
 Cooling tower blow down.
 Domestic effluent
Based on the characteristics of the effluent streams, trade effluents are categorized and
is treated as given below:
 Sand filter back wash water from water treatment plant and cooling tower containing
high suspended solids effluent is treated by using. Lamella Clarifier technology.
Static mixer, Lamella clarifier, centrifuge and sand filter are major equipment for treating
the high suspended solids effluent streams. Back wash water of sand filter and activated
carbon filter from water treatment plant and cooling 'tower side stream filter are treated in
this unit. The treated water is reused in cooling tower as makeup. The slurry containing
solids is pumped to a centrifuge for separating liquid which is recycled to static mixer.
The thickened slurry is used in DAP plant.

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 Water treatment plant resin regeneration and cooling tower blow down effluents
The high dissolved solids effluent stream containing water treatment plant resin
regeneration effluent and cooling 'tower blow down is passed through clarifier, pressure
sand filter and Ultra Filtration (UF) units to remove suspended solids and colloidal
particles. Then it is treated in Reverse Osmosis (RO) units to remove dissolved solids.
Treated water is reused in cooling tower as makeup.
The high dissolved solids effluent streams are collected in an equalization tank. This
stream after dosing with NaOCI, Coagulant, Lime, Dolomite & Polymer is pumped to
High Rate Solids Contact Clarifier (HRSCC). The clarified water from HRSCC is passed
through Multi Grade' filter for reduction of suspended solids.
Then the filtered water is fed into the Ultra filtration unit (UF) to remove colloidal silica
and related colloids of iron and aluminium in water causing fouling, scaling and poor
performance of the plane the stream which is free from suspended and colloidal particles
will be passed through Reverse Osmosis unit (RO). The Dissolved solids are removed in
2 stages of RO unit. In the first stage R01 about 75 % of desired quality water will be
recovered and reject is fed to second stage R02 wherein further 10% is recovered. The
R02 reject containing high dissolved solids is used in DAP plant.
The recovered water is used in cooling tower as makeup. The sludge collected in the
HRSCC is pumped to centrifuge to remove water. The separated liquid is recycled to
equalizing tank and thickened slurry is used in DAP plant.
4.9. Solid / Hazardous Waste

Solid Waste
The solid waste generated during the construction may include waste oil, welding gas
and paints. These materials would be stored and handled according to the guidelines
specified under Hazardous and Other Wastes (Management and Trans-boundary
Movement) Rules, 2016 of MoEF. Some of the precautions for storage and handling of
the hazardous materials includes the following:
 Dyked enclosures would be provided wherever necessary for storage of hazardous
materials.
 Waste oil and other fuels would be stored in separate dyke enclosures.
 On-site recycling of all waste solvents / thinners & oils and off-site recycling of
paint thinner solvent wastes & waste oil.
 Separate storage for waste paints and thinners, contaminated rags and brushes to
facilitate recycling and reuse. Rags could be laundered for reuse.
 Vehicle maintenance area to be selected properly to prevent contamination of soil
and ground water by accidental spillage of oil and other wastes.
4.9.1. Hazardous Waste

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As per Hazardous and Other Wastes (Management and Trans-boundary Movement)

Rules, 2016 the following items under Schedule-I [See Rule 3(I), “List of Processes
Generating Hazardous Waste” been declared hazardous waste for the chemical fertilizer
industry:
Schedule-I [Rule 3(1)]
List of Process Generating Hazardous Waste
S.No. Processes Hazardous Waste

18.1 Spent Catalyst
Production of nitrogenous and 18.2 Spent Carbon
(18)
complex fertilizers 18.3 Sludge/ residue containing Arsenic
18.4 Chromium sludge from cooling tower
According to above criteria, the following wastes are considered to be hazardous from
proposed projects:
Table- 4.24 Details of Hazardous Wastes
HW
Hazardous Waste Source
Sl.No.
No additional
18.1 Spent Catalyst Amm. Plant
quantity
No additional
18.2 Spent Carbon DM Plant
quantity
18.3 Sludge/ residue containing As
No Source of generaton
18.4 Chromium sludge from water cooling tower
4.10. Ecology
4.10.1. Terrestrial Ecology
The floristic component of the study area does not include any rare or endangered
species. Thus, impact on rare and endangered species of flora is not envisaged. The
project does not envisage destruction or displacement of any fauna species. Thus,
indirect impact on fauna due to loss of habitat is not foreseen.
The impact of proposed project on vegetation in the study area may occur through two
ways:
 Clearing of vegetation from the proposed site for plant setup
 Effects on terrestrial ecosystem due to stack emissions.
Construction Phase
The proposed expansion plants would be installed within premises of MCF Unit. The
land earmarked for proposed project is full of small herbs & shrubs. Clearing of land will
lead to generation of biodegradable waste which shall be composted for use in green
belt maintenance in the plant premises. No fruit bearing and costly/timber trees exist

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within the plant premises hence, clearance during construction period is not required.
Removal of small shrubs & herbs shall not impart adverse impact on terrestrial ecology
during construction phase.
Operation Phase
The impact on terrestrial ecology due to marginal increase in the concentration of air
pollutants from the proposed project will be in the form of solid pollutants namely PM 10 &
PM2.5 and there will be a drastic reduction in the emission level of gaseous pollutants
such as SO2 and NOx due to the usage of Natural Gas as feed/ fuel in the ammonia
plant.
But on the whole, the ambient air and water quality will not change significantly. Thus, no
impact on terrestrial ecology is envisaged.
4.10.2. Aquatic Ecology
The effluent from different plants shall be suitably treated in wastewater recovery unit.
Zero Liquid Discharge (ZLD) concepts shall be implemented for the proposed project.
The treated effluent shall be recycled and re-utilized within the premises for de-dusting
and maintenance of green-belt. Thus, no impact on the aquatic ecology is envisaged.
4.11 Impact on Socio-economic Environment
The development due to proposed project will have marginal impacts on local socio-
economic condition of the people residing in the area. The construction of different
plants would provide temporary employment to the people residing in adjoining villages.
This would improve the socio-economic condition of the local population.
The operation of the proposed project would result in positive impacts such as industrial
and economic development, generation of employment opportunity.
Reduction in import of Urea will save the foreign currency of the country. General Public
will be attracted towards rural area due to the use of fertilizer which will enhance the
crop production and thus, the living conditions in the area.
The impact of the proposed plant on socio economic conditions of the study area
expected to be positive as follows.
 Increase in floating population.
 Increase in demand of services including hotels, lodges, public transport (including
taxis), etc.
 Economic up-liftment of the area.
 Rising of infrastructure and financial aspects in the study area.
 Beneficiation of the civil construction and transportation companies as they are
procured from the local area.
 Expanding of services like retail shops, banks, automobile workshops, school,
healthcare facilities, etc.

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The local population will have employment opportunities in related service activities like
petty commercial establishments, small contracts/sub-contracts and supply of
construction materials for buildings and ancillary infrastructures etc. consequently, this
will contribute to economic up liftment of the area.
The construction activity will benefit the local population in a number of ways, which
include the increase in requirement of construction skilled, semi-skilled and un-skilled
workers, tertiary sector employment and provision of goods and services for daily needs
including transport. In line with the above, following recommendations are made:
Local people will be given preference for employment depending on their suitability; All
the applicable guidelines under the relevant Acts and Rules related to labour welfare and
safety will be implemented during the construction phase;
4.11. Impact of Earthquake

The district falls in low Earthquake Zone (Zone-III). However, seismic considerations
shall be taken during design stage itself to sustain the impact of seismic effects. Source:
NDMA(Govt. of India)
4.12. Transport
NG shall be received through pipeline proposed to be laid by GAIL (INDIA). The finished
products urea shall be dispatched from plant premises through rail networks. Hence,
transportation of raw material and finished products shall not produce any measurable
adverse impact on the environment as well as existing traffic network.
Mitigation measures for traffic
The trucks transporting raw materials and finished goods will be covered.
 It will be assured that vehicles are PUC certified.
 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.
 Temporary new approach road can be constructed, if required, for smooth and
hassle free movement of personnel;
 Ensuring the availability of valid Pollution Under Control Certificates (PUC) for all
vehicles used on site.
4.13. Occupational Health and Risk

General Safety Measures
Proposed plants will require installation of different storage tanks to store liquid
chemicals, located in tank-farm area. The liquid chemicals will be received through
tankers and trucks to storage-tanks. No specific liquid chemicals will stayed in any tank
for longer period, and there will be no possibility of adverse effect to any person,
surrounding atmosphere in ordinary circumstances. However, considering the various
chemicals handled and stored at site; following safety measures will be provided at the

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site. The following safety measures need to be taken while handling the chemicals.
Requisite personnel Protective Equipment shall be provided to the workers.
Instruction/Notice to wear the same will be displayed. Further, it will be insisted to use
the same while at work.
 Provision of water shower with Eye washer and display of notice accordingly.
 MSDS of all hazardous chemicals will available at Office and responsible persons.
 Antidotes for all chemicals being used as per MSDS will be kept ready at the site.
 Booklet on “Disclosure of Information on Hazardous Chemicals to the workers” will
be prepared and educated them.
 Provisions of First Aid Box and trained person in first aid.
 Prohibition on eating or drinking at work-area.
 Any leakage/spillage of liquid chemical shall be immediately attended and
provision of urgent cleaning.
 Work area will be monitored to maintain work environment free from any
dust/chemicals fumes/ vapours and keep within below permissible limit.
 Provision of adequate Fire Extinguishers at site and training will be imparted to the
workers also.
 Maintaining the Fire-Protection System adequately.
 Availability of Self Breathing Apparatus at site.
 Provisions of immediate accident/incident reporting and investigation.
 Instructions on Emergency/Disaster will be displayed.
 Safety Posters and slogans will be exhibited at conspicuous places.
 Arrangement of Periodical Training to workers/operatives, supervisors.
 Work permit systems will be strictly followed.
 Safety Committee will be constituted and safety, health and environmental
matters/issues will be discussed in the meeting and enlighten the participants in
these respect.
The occupational health care and safety plan incorporated in the EMP and the
Emergency Preparedness Plans will ensure that the probability of undesired events and
consequences are taken care. The overall impact on human health will be minimum.

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CHAPTER 5. ANALYSIS OF ALTERNATIVES (SITE AND TECHNOLOGY)
This Chapter provides an alternative analysis, including site and technology, considered
for the proposed expansion project.
Mangalore has special strengths in Chemical and mineral related industries, now
diversifying into machineries and other manufacturing industries. Regional wise, industrial
accumulation as well as population concentration can be found in major cities.
5.1. Potential Location

Aprox 192 Acres land already under the possession of MCF and expansion project is
coming in same premises of MCF. So, there is no additional land is required for the
proposed Project.
5.2. Technologies available

The Energy Improvement Study were carried out by two reputed Ammonia technical
licensors viz., M/s. Kellogg Brown & Root Inc. (KBR) and M/s. Haldor Topsoe A/S
(HTAS). KBR provides the most energy efficient ammonia and fertilizer plant designs
through advanced technology development and superior fertilizer complex integration.
HTAS and KBR conducted study in December 2015 - January 2016 and submitted the
final reports in June - July 2016. The modification and schemes proposed by KBR are
techno-economically superior compared to those proposed by HTAS. Hence, it was
decided to carry out Energy Improvement Project as per KBR’s proposal.
Reasons for selecting KBR’s proposal:
 Specific energy consumption reduction is 2% higher than others.

 Less number of proprietary equipment.
 Lower project cost.
 Scheme proposed by KBR are flexible for dual feed stock and more suitable for
implementation in existing plant layout.
 KBR has proven technology operating in more than 250 plants globally. They have
fully functional Engineering facility in India.
Hence, proposal of KBR is adopted for execution of the energy improvement project of
Ammonia plant.

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CHAPTER 6. ENVIRONMENTAL MONITORING PROGRAM
This chapter provides the proposed environmental monitoring programme for the
proposed project to access the environmental attributes for both the construction and
operation stages
6.1. Objectives
Regular monitoring program of the environmental parameters is essential to take into
account the changes in the environment. The monitoring program for the proposed
project will allow for prompt implementation of effective corrective measures. The main
objectives of environmental monitoring are:
 To assess the change in the environmental conditions,
 To monitor the effective implementation of mitigation measures,
6.2. Proposed Environmental Monitoring Programme and Control

The environmental monitoring program encompasses location, duration, frequency of the
parameters that has to be monitored. Monitoring of environmental components during
operation phase is a part and parcel of the environmental mitigation measures. Only
frequent monitoring can assess the functioning and efficiency of all pollution control
equipment. The monitoring activity for air quality, water quality, soil quality and noise
levels data will be submitted to Karnataka State Pollution Control Board (KSPCB) at
regular intervals.
6.2.1. Air Quality Monitoring

Air quality monitoring includes ambient air quality monitoring, stack gas emissions and
meteorological conditions. The monitoring will be carried out as per Central Pollution
Control Board (CPCB) guidelines and in consultation with Karnataka SPCB and standard
procedures like CPCB are followed for sample collection and analysis. Proposed
monitoring schedule with monitoring plan during operation of proposed project is given in
Table-6.1.
Table 6.1 : Air Quality Monitoring Schedule
Sr. Monitoring Number of Frequency of Proposed Monitoring

No. Stations Monitoring Monitoring Program During Operation
Stations of Proposed Project
1 Continuous One Continuous Wind speed, Wind direction,
Meteorology Temperature, Relative
station Humidity, Rain fall
2 Continuous One Continuous PM10, PM2.5, SO2, NOx, CO,
Ambient Air stations O3, Benzene+Toluene, NH3,
EQMS INDIA PVT LTD, New Delhi

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Sr. Monitoring Number of Frequency of Proposed Monitoring

No. Stations Monitoring Monitoring Program During Operation
Stations of Proposed Project
Quality monitoring
station
3 Ambient Air Four Twice in a week PM10, PM2.5, SO2, NOx, NH3
Quality monitoring round the year
stations
(Reparable dust
sampler) around
plant
4 Continuous Stack 3 stacks Continuous (Urea, Particulate matter, SO2, HF
Emission DAP and Sulphuric and NH3
Acid plant Stacks)
5 Stack monitoring All the Once in a month Particulate matter, SO2, Acid
through iso kinetic stacks by in-house NABL Mist, and HF
sampling accredited
laboratory
6.2.2. Water Quality Monitoring
Water quality monitoring includes Source (surface) water, ground water, treated plant
effluent and sewage treatment plant effluent. The monitoring is carried out as per CPCB
guidelines and in consultation with Karnataka SPCB. Standard procedures of
CPCB/BIS/ASTM/APHA are followed for sample collection and analysis. Proposed
monitoring schedule with monitoring plan during operation of proposed plant in Table-6.2.
Table 6.2 : Water And Wastewater Monitoring Schedule
Number of Proposed Monitoring

Sr. Water Quality Frequency of
Monitoring Program During Operation
No. Monitoring Monitoring
Stations of Proposed for Plant
1. Surface Water Not Applicable Not Applicable There is no discharge outside
Quality the boundary.
2. Ground Water Two Stations- Monthly Physico-chemical and
Quality Nearby villages Bacteriological parameters
Quarterly Heavy Metals - Quarterly

3 ETP/STP One Daily Physico-chemical parameters
and BOD as per consent

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* All Plant discharges including blow downs, cooling water blow down etc. are routed
through combined effluent treatment plant. Hence during normal operation of plant, the
system as such is Zero Liquid Discharge (ZLD) basis.
6.2.3. Noise Quality Monitoring
Ambient Noise monitoring includes monitoring during day time as well as night time. The
monitoring shall be carried out as per CPCB guidelines and in consultation with
Karnataka SPCB using standard instruments and methodology. The noise monitoring in
work zone and at surrounding villages shall be done once in 6 months.
6.3. Infrastructural Requirements for Monitoring

MCF have a well-established NABL accredited in-house Environment laboratory
equipped with sophisticated modern Analytical Instruments for carrying out various
environmental monitoring parameters in water, wastewater and air emissions. The
laboratory is headed by JGM- QC & E and has well qualified, trained and experienced
officers. Testing laboratory also got necessary attributes like testing manuals, high quality
chemicals, filter papers and glass wares, fully equipped safety system (First aid box,
safety shower, personal protective equipment etc.) and library.
The key activities carried out in environmental testing laboratory are as follows:
a. Monitoring liquid samples of water treatment plant.
b. Monitoring influent and treated effluent samples of Wastewater treatment plant.
c. Monitoring influent and treated effluent samples of Sewage treatment plant.
d. Monitoring Ambient Air Quality around MCF premises as per CPCB standards.
e. Monitoring Noise level around MCF boundary level.
f. Monitoring Ground water samples.
g. Monitoring of stack emissions as per CPCB standards.
The MCF is having the NABL approved laboratory for chemical testing, the copy of the
certificate is given in Figure 6.1. Details of testing equipment available for monitoring
Water, Wastewater and Air / Emissions. For Water and Wastewater testing:
Table 6.3 List of Equipment in Laboratory
Analytical Balance Hot plate Turbidity meter

(0.01 mg)
Autoclave Membrane Filtration Water Distillation Atomic Absorption
Assembly assembly Spectrophotometer
Bacteriological pH meter Colour Bio-assay test facility
Incubator comparator
BOD incubator Precision Balance (1.0 mg) Flame Gas Chromatography (GC)
photometer
COD digester Refrigerator Laminar Air flow UV – Visible
assembly Spectrophotometer
Conductivity meter Spectrophotometer Microscope Walk in cooler

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Hot air oven Thermometer Muffle furnace Water purification system

with (ultra pure)
For Air/ Emission testing:
Analytical Balance (0.01 PM 2.5 sampler Water purification system
mg)
Conductivity meter Precision Balance (1.0 mg) Carbon monoxide analyzer
Desiccators RDS (Respirable Dust sampler) Gas Chromatography (GC)
Flue gas analyzer Refrigerator Ozone analyzer
Hot air oven Sound level meter (Integrated) UV – Visible
Spectrophotometer
Hot plate Spectrophotometer (visible) Water purification system
Micro Analytical Balance Stack monitoring kit
pH meter Atomic Absorption Spectrophotometer
Figure 6.1 Exiting Laboratory

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Figure 6.2 NABL Certificate
6.4. Environmental Organisational Setup

An Environmental Management Group consisting of competent workforce headed by
JGM level was established by the proponent to deal with various environmental aspects
including follow-up with Karnataka SPCB, Regional MoEF&CC and CPCB and to interact
with inter-disciplinary groups responsible for maintenance and operation of pollution

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control equipment. The group reports to head of the station. The same group will continue
as nodal department for the proposed project also when in operation, with following
functions.
 Obtaining Consent Order from SPCBs;
 Environmental monitoring;
 Analysis of environment data, reports preparation and transmission of report to
statutory authorities and Corporate Centre etc.;
 Compliance with guidelines and statutory requirements;
 Coordination with statutory bodies, functional groups of the station, Corporate level
etc.;
 Interaction for evolving and implementation of modification programs to improve the
availability / efficiency of pollution control devices / systems;
 Environmental Appraisal (Internal) and Environmental Audit;
6.5. Submission of Monitoring Reports to Regulatory Authorities (MoEF&CC,

CPCB, KSPCB)
As per the requirements, the status of environmental clearance stipulation
implementation will be submitted to MoEF&CC in hard and soft copy by 1st December for
the period from April to September and by 1st June for the period from October to March
of every year. The conventional pollutants will be monitored on monthly basis and reports
will be submitted to SPCB, as per the requirements.

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CHAPTER 7. ADDITIONAL STUDY
This Chapter provides the details about the Risk Assessment, Disaster Management
Plan (DMP) and on-site emergency plan as proposed for the proposed project.
7.1. Introduction
The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of
Environment and Forests (MoEF). An emergency occurring in the proposed Energy
improvement project of Ammonia and Urea plant 1 million t/y DAP/NPK project, Poly
Carboxy Ether (PCE) project of 18000 t/y, at Mangalore, Karnataka is one that may affect
several sections within it and / or may cause serious injuries, loss of lives, extensive
damage to environment or property or serious disruption outside the plant. It will require
the best use of internal resources and the use of outside resources to handle it
effectively.
It may happen usually as the result of a malfunction of the normal operating procedures.
It may also be precipitated by the intervention of an outside force such as a cyclone,
flood, earthquake or deliberate acts of arson or sabotage. This chapter deals with the
risks associated with the Plant, its mitigation and the Disaster Management Plan.
7.2. Scope of Work

The scope of the study is to model and appraise the risks associated with all toxic and
flammable hazards resulting from potential loss of containment accident scenarios from
MCF Operations and developing a Disaster Management Plan.
7.3. Objectives
The specific objectives of the study are to identify:
 Hazardous materials associated with the project
 Potential consequences of identified threats
 Recommend risk prevention and reduction measures to ensure that all risks are
within ALARP.
 Defines the actions to be taken in case of emergencies.
7.4. Methodology of HIRA

Hazard Identification and Risk Assessment:
Hazard is defined as a chemical or physical conditions those have the potential for
causing damage to people, property or the environment. In this chapter the
hazards associated with only the proposed expansion project have been
discussed.

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The primary step of the Hazard identification is the risk analysis and entails the process
of collecting information on:
 the types and quantities of hazardous substances stored and handled at the plant,
 the location of storage tanks & other facilities, and
 Potential hazards associated with the spillage and release of hazardous chemicals.
7.4.1. Identification of Hazards
The main hazard potentials in the proposed Plant are categorized as below:
 Material hazards; Associated with Hazardous Materials Storage Facilities.
 Process hazards due to loss of containment during handling of hazardous
materials or processes resulting in fire, explosion, etc
 Mechanical hazards due to "mechanical" operations such as welding,
maintenance, falling objects etc. - basically those NOT connected to hazardous
materials.
 Electrical hazards: electrocution, high voltage levels, short circuit, etc.
Out of these, the material and process hazards are the one with a much wider damage
potential as compared to the mechanical and electrical hazards, which are by and large
limited to very small local pockets.
7.5. Hazardous Materials Bulk Storages at the MCF Plant

The major hazardous chemical to be stored at the MCF site given below in the Table 7.1:
Table 7.1. Bulk Storages
Material
S.No Area Type of Tank Capacity Pressure Temperature
Stored
Raw
1 Floating Roof Tank 2 x 10,770 KL Atmospheric Ambient
Naphtha
Sweet
2 Cone Roof Tank 1 x 2,016 KL Atmospheric Ambient
Naphtha Tank Farm
3 Furnace Oil Cone Roof Tank 1 x 2,279 KL Atmospheric 60 °C
4 Furnace Oil Cone Roof Tank 1 x 3,000 KL Atmospheric 60 °C
5. Diesel Cone Roof Tank 1 x 50 KL Atmospheric 30 °C
Liquid Ammonia Existing Ammonia
6 1 x 1,500 MT 3.5 kg/cm2g 0.9 °C
Ammonia Plant Storage Sphere
Imported
Liquid Double wall, double
7 Ammonia 1 x 10,000 MT 500 mm WG (-)33 °C
Ammonia integrity
Terminal
New DAP
Liquid Double wall, double
8 Plant 1 x 10,000 MT 500 mm WG (-)33 °C
Ammonia integrity
(Proposed)
Methacrylic PCE Plant
9 Cone Roof Tank 1 x 250 MT Atmospheric 30 °C
Acid (Proposed)

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7.5.1. Hazardous Analysis of Bulk Storage Materials

MCF will be using a number of raw materials but only few are stored in bulk and few
chemicals are listed under “List of hazardous and Toxic Chemicals” category under
MSIHC Rules, 1989. The raw materials coming under hazardous category as specified
by MSIHC Rules, 1989 (including subsequent amendments). The materials used in MCF
plant and their hazardous nature is as below:
Table 7.2. : Products and hazardous nature
Flammable Properties Toxic Properties
Name Normal Auto

Flash ERPG- ERPG-
Boiling LFL UFL Ignition ERPG-1 IDLH
Point 2 3
Point Temp.
(C) (C) (%) (%) (C) (ppm) (ppm) (ppm) (ppm)
Ammonia (-)33 - 15 28 651 30 160 1100 300
Carbon (-)192 - 12.5 74 609 83 83 330 1200

monoxide
Hydrogen (-)252 - 4.0 75.0 500 - - - -
Naphtha 60 (-)22 1.1 7.7 270 - - - -
Methacrylic Acid 162 77 1,6 8.7 365 6.7 61 220 NA
7.6. Detailed QRA Approach: Rule Sets and Assumptions

Identification of hazards and likely scenarios (based on Level-1 and Level-2 activities) calls
for detailed analysis of each scenario for potential of damage, impact area (may vary with
weather conditions / wind direction) and safety system in place. Subsequently each incident
is classified according to relative risk classifications provided in Table below as Table 7.3:
Table 7.3. Risk Classification
Stage Description
High A failure which could reasonably be expected to occur within the expected life
(> 10-2/yr.) time of the plant.
Examples of high failure likelihood are process leaks or single instrument or valve
failures or a human error which could result in releases of hazardous materials.
Moderate A failure or sequence of failures which has a low probability of occurrence within
(10-2 --10- the expected lifetime of the plant.
4
/yr.) Examples of moderate likelihood are dual instrument or valve failures,
combination of instrument failures and human errors, or single failures of small
process lines or fittings.
Low A failure or series of failures which have a very low probability of occurrence
(<10-4) within the expected lifetime of plant.
Examples of ‘low’ likelihood are multiple instruments or valve failures or multiple

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Stage Description
human errors, or single spontaneous failures of tanks or process vessels.
Minor Impact limited to the local area of the event with potent for ‘knock – on- events’
Incidents
Serious One that could cause:
Incident 1. Any serious injury or fatality on/off site;
2. Property damage of $ 1 million offsite or $ 5 million onsite.
Extensive One that is five or more times worse than a serious incident.
Incident
Assigning a relative risk to each scenario provides a means of prioritising associated risk
mitigation measures and planned actions.
7.6.1. Thermal Hazards
In order to understand the damages produced by various scenarios, it is appropriate to
understand the physiological/physical effects of thermal radiation intensities. The thermal
radiation due to tank fire usually results in burn on the human body. Furthermore, inanimate
objects like equipment, piping, cables, etc. may also be affected and also need to be
evaluated for damages. Tables 7.4, 7.5 and Table 7.6 (below), respectively give tolerable
intensities of various objects and desirable escape time for thermal radiation.
Thermal hazards could be from fires or explosion. Fire releases energy slowly while
explosion release energy very rapidly (typically in micro seconds). Explosion is rapid
expansion of gases resulting in rapidly moving shock wave. Explosion can be confined
(within a vessel or building) or unconfined (due to release of flammable gases).
BLEVE (boiling liquid expanding vapour explosion) occurs if a vessel containing a liquid at
a temperature above its atmospheric boiling point ruptures. The subsequent BLEVE is the
explosive vaporisation of large fraction of its vapour contents; possibly followed by
combustion or explosion of the vaporised cloud if it is combustible range.
Thermal hazards have been considered for various scenarios including: Fire in fuel storage
tank.
Table 7.4. Effects due to Incident Radiation Intensity
Incident Radiation
Damage Type
kW/m2
0.7 Equivalent to Solar Radiation
1.6 No discomfort on long duration
Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn
4.0
are likely).
9.5 Pain threshold reached after 8 sec. Second degree burn after 20 sec.
Minimum energy required for piloted ignition of wood, melting of plastic
12.5
tubing etc.
Minimum Energy required for piloted ignition of wood, melting, plastic
25
tubing etc.
37.5 Sufficient to cause damage to process equipment.

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62.0 Spontaneous ignition of wood.

Table 7.5. Thermal Radiation Impact to Human
Exposure Radiation Energy {1% Radiation Energy for Radiation Energy for
Duration lethality; kW/m2} 2nd degree burns; 1st degree burns;
kW/m2 kW/m2
10 sec 21.2 16 12.5
30 9.3 7.0 4.0
Table 7.6. Tolerable Intensities for Various Objects

Sl. No Objects Tolerable Intensities (kw/m2)
1 Drenched Tank 38
2 Special Buildings (No window, fire proof doors) 25
3 Normal Buildings 14
4 Vegetation 10-12
5 Escape Route 6 (up to 30 sec.)
6 Personnel in Emergencies 3 (up to 30 sec.)
7 Plastic Cables 2
8 Stationary Personnel 1.5
1. Damage due to Explosion
The explosion of a dust or gas (either as a deflagration or detonation) results in a reaction

front moving outwards from the ignition source preceded by a shock wave or pressure
front. After the combustible material is consumed the reaction front terminates but the
pressure wave continues its outward movement. Blast damage is based on the
determination of the peak overpressure resulting from the pressure wave impacting on the
object or structure.
As a safety measure MCF is storing highly hazardous raw materials in isolated places with
full safety measures. Damage estimates based on overpressure are given in Table 7.7
below:
Table 7.7. Damage due to Overpressure
Sl. No Overpressure (psig / Damage
bar)
1. 0.04 Loud Noise / sonic boom glass failure
2. 0.15 Typical pressure for glass failure
3. 0.5 – 1 Large and small windows usually shattered
4. 0.7 Minor damage to house structure
5. 1 Partial demolition of houses, made uninhabitable.
6. 2.3 Lower limit of serious structure damage
7. 5–7 Nearly complete destruction of houses
8. 9 Loaded train box wagons completely demolished
9. 10 Probable total destruction of houses

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10. 200 Limits of crater lip

7.6.2. Toxic Release
Hazardous materials handled and stored in bulk in MCF complex are toxic gases/
chemicals (as detailed in Table 7.1 and other raw materials as defined in MSHIC rules and
indicated in Table 7.2. Some of these chemicals are stored in bulk (in tank farm).
Damage criteria: For toxic release the damage criteria considered is IDLH concentration (if
data are available). In the absence of non-availability of IDLH, ‘Inhalation Toxicity (IT) data
for rats’ are considered.
7.7. Effect & Consequence Analysis

As a part of risk assessment study, maximum credible accident analysis (MCA) is carried
out to determine the maximum loss scenario from this analysis. It is an eventuality, which is
possible and will have maximum consequential distances for the particular hazardous
chemicals under evaluation.
The selection of the accident scenarios is based on the engineering and professional
judgment, accident descriptions of the past in similar type of plants & the expertise in risk
analysis studies.
7.7.1. Likely Failure Scenarios
Few likely failure scenarios have been selected after critical appraisal of raw materials and
storage inventories. Failure scenarios selected are as given in Table 7.8 below:
Table 7.8. Generic Failure Rate Data for Equipment Items
Failure rate
Tank Description Failure scenario (per tank
year)
Refrigerated Storage Tanks
Double containment tank Tank connecting pipe leak 1.0E-05
Catastrophic failure 2.5E-08
Atmospheric Storage Tanks (Floating/ Fixed Roof)
Liquid spill outside tank 2.8E-03
Fixed/ floating roof tank Full surface fire 9.0E-05
Tank rupture 3.0E-06
Leak size
Equipment Item
5 mm 25 mm 100 mm
2" Pipe 1.80E-05 7.00E-06 0
6" Pipe 8.50E-06 2.70E-06 6.00E-07
2" Flange 7.60E-06 4.00E-06 0
6" Flange 1.10E-05 3.00E-06 2.00E-06
2" Valve (Manual) 7.70E-06 4.90E-06 0
6" Valve (Manual) 1.20E-05 4.70E-06 2.40E-06
2" Valve (Actuated) 7.30E-05 3.00E-05 0
6" Valve (Actuated) 6.60E-05 1.90E-05 8.60E-06
Instrument Connection 6.80E-05 2.50E-05 0

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Pressure Vessel 2.00E-04 1.00E-04 5.10E-05

Centrifugal Pump 1.00E-03 2.90E-04 5.40E-05
Reciprocating Pump 1.20E-03 7.40E-04 5.00E-04
Reciprocating Compressor 8.00E-03 2.60E-03 8.80E-04
-5
Note: Failure rate notation: 1.0E-05 per year means 1.0 x 10 per year
7.8. Population Data
The total number of persons (employees and contractors) working in MCF plant is about
750. The distribution of personnel in the plant areas is shown in Table 7.9.
Table 7.9. Distribution of People in MCF Plant Area

Number of Persons
Department
General Shift Each Shift
MCF EMPLOYEES
Administration Services 2
Ammonia Plant 6 14
Chemical Marketing 2
CPP-Electrical 13 1
CPP-Mechanical 23 4
Director's Office (Admn Bldg.) 2
Distribution(Logistics Section) 8 5
Electrical MPSS (Main plant substation) 14 3
Electrical DAP Plant 9 1
Electrical Workshop 6
Engineering & Inspection (Technical Bldg.) 11
Environment 1
Finance (Admn Bldg.) 15
GM-Maintenance & Eng. Office (Admn Bldg.) 1
GM-Production Office (Admn Bldg.) 3 1
Human Resources (Admn Bldg.) 9
Imported Ammonia Terminal 1 2
Instrumentation 25 2
Learning & Development (Technical Bldg.) 33 2
Machinery Group 5
Maintenance - Mechanical
Zone1(Ammonia and SNF) 9
Zone 2(Urea and utilities) 9
Zone 3(DAP and SAP) 8
Zone 4(Bagging) 9
Maint. Personnel per shift for entire complex 2
Workshop 15
Occupational Health Centre 2 1
Phosphatic/DAP Plant 3 5

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Number of Persons
Department
Process Technology & Engg. (Admn Bldg.) 3
Procurement (Admn Bldg) 13
Projects (Admn Bldg) 3
Quality Control & Environment 12 4
Safety 9 4
Security 4 5
Shutdown, Planning & Contracts (Technical Bldg.) 8
SNF-Production 2 4
Speciality Fertilizers 5
Stores 13
Sulphuric Acid Plant 2 2
Support Services (Admn Bldg.) 2
Systems (Admn Bldg.) 1
Urea Bagging 1 4
Urea Plant 3 7
Water Treatment/Utilities 3 7
CONTRACTORS
Mechanical ( in General shift)
Ammonia 5
Urea 5
Utilities 5
DAP 10
SAP 5
Bagging 5
Speciality fertilizer 5
CPP 5
IAT 5
Civil (in General shift)
Ammonia 5
Urea 5
Utilities 5
DAP 5
Bagging 5
CPP 5
Painting 10
Electrical (In General shift) 20
Janitorial services 40
Garden and Green belt 10
Railway 10
Contractors Per Shift
SNF 10
DAP 10
Bagging 5

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Number of Persons
Department
Speacilitly ferilizer 10
CPP 3
Security 15
Canteen 15
Loaders 25
Railway 2
Payloader operators 7
The population in surrounding area is estimated as about 10,000 over 1 km radius.
7.9. Weather parameters

Weather parameters play a significant role in dispersion analysis. The notable
parameters for assessing the atmosphere are wind speed, atmospheric stability, ambient
temperature, humidity and topographic parameters.
Atmospheric stability represents the vertical turbulence in the air due to temperature
differentials caused by heating of the earth by solar radiation. Atmospheric stability
effects are represented through Pasquill parameters as follows shown in Table 7.10.
Table 7.10. : Pasquill parameters
Stability Class Atmospheric Condition Stability Class Atmospheric Condition
A Very Unstable D Neutral
B Unstable E Stable
C Slightly Unstable F Very Stable
The general correlation between wind speed and atmospheric stability is shown in
Table 7.11.
Table 7.11. Relationship between wind speed and atmospheric stability
Wind speed Day-Time: Night-Time
Solar Radiation Cloud Cover
(m/s) Strong Medium Slight Thin Medium Overcast
<3/8 >3/8 >4/5
<2 A A-B B - - D
2-3 A-B B C E F D
3-5 B B-C C D E D
5-6 C C-D D D D D
>6 C D D D D D
Category D (neutral) is the most probable at sites in moderate climates and may occur
for up to 80 % of the time at relevant sites. Stability F (very stable) represents the most
adverse condition in which dispersion extends over longer distances horizontally.
Normally, stability F occurs for short periods in the year, mainly during winter nights.

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Weather data (monthly average maximum & minimum temperature and rain fall) for
Indore are indicated in Table 7.12.
Table 7.12. : Monthly average weather data for Mangalore
Month Temperature (°C) Relative Humidity (%)
Daily Max. Daily Min. Highest in the Lowest in the Max. Min.
Month Month
January 31.4 21.7 34.1 19.5 71 61
February 31.1 22.8 33.9 20.9 75 66
March 31.7 24.5 33.7 22.2 75 67
April 32.4 26.1 33.6 22.9 73 69
May 32.1 26.0 33.6 22.4 77 72
June 29.4 23.9 32.1 22.0 89 85
July 28.5 23.5 30.7 21.9 91 88
August 28.5 23.6 30.1 22.1 91 87
September 28.7 23.5 30.1 22.1 89 83
October 29.8 23.8 32.0 21.9 85 79
November 31.1 23.2 33.5 20.7 77 69
December 31.7 21.9 33.6 9.2 69 62
Wind rose diagram for distribution of direction from which wind is blowing and wind
speed is shown in Figure 7.1.
January February March
April May June
July August September

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October November December
Figure 7.1 Wind Rose Diagram for Mangalore

The representative combinations of weather parameters for the site are considered in
this study are listed in Table 7.13.
Table 7.13. : Weather Parameters for Risk Analysis

Description #1 #2
Temperature (C) 30 25
Wind speed (m/s) 3 2
Atmospheric Stability D D
7.10. Hazardous Incidents Impact

The identified failure scenarios in Table7.10 have been analysed (Using Phast) for the
impact zones considering damage due to thermal and toxic impacts. Similar impacts are
considered for expansion units. Each incident will have Impact on the surrounding
environment which in extreme case may cross plant boundary. The impact zones for
various scenarios are given in Table 7.14
Table 7.14. Hazards Scenario Impact

Leak
Material & Temp. Pressure
S.No. Description Leak size Frequency
Phase (C) (kg/cm2g)
(per year)
Outlet pipe
2.0E-04
25mm leak
Existing
Liquid Outlet pipe
1. Ammonia 1 °C 3.5 1.0E-05
Ammonia failure
Storage Sphere
Catastrophic
1.0E-06
Failure of Tank
Outlet pipe
2.0E-04
Atmospheric 25mm leak
Ammonia Tank Liquid 500 mm Outlet pipe
2. (-)33 1.0E-05
(Imported Amm. Ammonia WG failure
Terminal) Catastrophic
2.5E-08
Failure of Tank
Atmospheric Liquid 500 mm Outlet pipe
3. (-)33 2.0E-04
Ammonia Tank Ammonia WG 25mm leak

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Leak
Material & Temp. Pressure
S.No. Description Leak size Frequency
Phase (C) (kg/cm2g)
(per year)
(Proposed Tank Outlet pipe
1.0E-05
in new DAP failure
Plant) Catastrophic
2.5E-08
Failure of Tank
Dyke spill 2.8E-03 each
Naphtha Tank
4. Naphtha 30 Atm. Full surface fire 9.0E-05 each
Farm
Tank failure 6.0E-06
Dyke spill 2.8E-03 each
Furnace Oil
5. Furnace Oil 50 Atm. Full surface fire 9.0E-05 each
Tanks
Tank failure 6.0E-06
Amm. Receiver 5 mm Leak 9.0E-04
Liquid
6. (Storage 40 15 25 mm Leak 4.0E-04
Ammonia
Refrigeration) 100 mm Leak 9.0E-05
5 mm Leak 1.2E-03
Ammonia Liquid
7. (-)33 29 25 mm Leak 3.5E-04
Transfer Pump Ammonia
100 mm Leak 7.0E-05
Methacrylic Acid Dyke spill 2.8E-03
Methacrylic
8. Tank (proposed 30 Atm. Full surface fire 9.0E-05
Acid
PCE Plant) Tank failure 6.0E-06
Table 7.15. Results of Consequence Analysis for MCF Plants
S. No. Description Down Wind Distance (m)
Weather Category → D; 3 m/s D; 2 m/s
1. Imported Ammonia Tank – Liquid Outlet Pipe Leak (25 mm)
Ammonia Cloud Footprint
Gas IDLH concentration (300 ppm) 230 100
Dispersion ERPG-3 concentration (1100 ppm) 50 35
2. Imported Ammonia Tank – Transfer Pump Discharge Pipe Leak (25 mm)
3. New Ammonia Tank in DAP Plant – Liquid Outlet Pipe Leak (25 mm)
4. Naphtha Storage Tank – Roof Failure
Tank Radiation Intensity
Surface Fire 4 kW/m2 56 52
12.5 kW/m2 19 18
37.5 kW/m2 Not reached Not reached
Flash Fire Flash fire envelope
LFL concentration (1.05%) 54 59
5. Naphtha Storage Tank Failure
Dyke Fire Radiation Intensity
4 kW/m2 129 120
12.5 kW/m2 52 52
37.5 kW/m2 Not reached Not reached
Flash Fire Flash fire envelope
LFL concentration (1.05%) 163 173

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6. Methacrylic Acid Tank Failure

Dyke Fire Radiation Intensity
4 kW/m2 30 29
12.5 kW/m2 18 17
37.5 kW/m2 9 9
(1) Imported Ammonia Tank – Liquid Outlet Pipe Leak (25 mm): Cloud Foot Print: IDLH
(300 ppm) & ERPG-3 (1100 ppm)
Figure 7.2 : Imported ammonia tank outlet line leak –Ammonia Dispersion
(2) Imported Ammonia Tank Transfer Pump – Discharge Pipe Leak (25 mm): Cloud Foot
Print: IDLH (300 ppm) & ERPG-3 (1100 ppm)

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Figure 7.3 : Imported ammonia tank outlet line leak –Ammonia Dispersion
(3) New Ammonia Tank (Proposed) – Liquid Outlet Pipe Leak (25 mm)
Cloud Foot Print: IDLH (300 ppm) & ERPG-3 (1100 ppm)
Figure 7.4 : New ammonia tank outlet line leak –Ammonia Dispersion

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(4) Raw Naphtha Tank – Roof Failure
Figure 7.5 : Naphtha Tank Roof Failure – Full Surface Fire
Figure 7.6 : Naphtha Tank Roof Failure – Flash Fire

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(5) Raw Naphtha Tank – Large Spill in Dyke
Figure 7.7 : Naphtha Tank Large Spill– Dyke Fire
Figure 7.8 : Naphtha Tank Large Spill– Flash Fire

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(6) Methacrylic Acid Tank – Large Spill in Dyke
Figure 7.9 : Methacrylic Acid Tank Large Spill– Dyke Fire

7.10.2. Review of Consequence Analysis Results
Results of consequence analysis using Phast software indicate the following:
 Effects of fire radiation and flash fire due to release of flammable material from
naphtha storage tanks are mostly contained within the plant boundary.
 Toxic ammonia dispersion footprints due to leak in Imported Ammonia Terminal
storage tank liquid outlet line and transfer pump discharge line extend beyond
the Terminal boundary.
 Toxic ammonia dispersion footprints due to leak in liquid outlet line from the new
Ammonia storage tank in the proposed DAP plant Ammonia are within the
boundary.
7.11. QRA Results
The detailed results of QRA for MCF Capacity Enhancement Project available as
outputs from Phast Risk software are presented in this section.
7.11.1. Individual risk
The iso-risk contours for MCF Capacity Enhancement are shown in Figure 7.10.

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1E-06 per year
1E-05 per year
1E-04 per year
Figure 7.10 : Iso-Risk Contours on MCF Plot Plan

Enlarged diagram showing iso-risk contours for MCF Capacity Enhancement Project are
shown in Figures 7.11 & 7.12.
1E-06 per year
Figure 7.11 : Iso-Risk Contours on MCF Plot Plan (Enlarged - 1)

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1E-06 per year
1E-05 per year
1E-04 per year
Figure 7.12 : Iso-Risk Contours on MCF Plot Plan (Enlarged - 2)

Individual Risk to Public
In the main plant area the iso-risk contour of 1.0E-06 per year is within the plant
boundary. However, in the Imported Ammonia Terminal area, area the iso-risk contour of
1.0E-06 per year extends outside the Terminal boundary. Individual risk at the boundary
of Imported Ammonia Terminal is measured as 2.20E-06 per year.
Therefore the maximum individual risk to members of the public outside the plant
boundary is 2.20E-06 per year.
Individual Risk to Plant Personnel
The highest iso-risk contour inside the plant area is 1.0E-04 per year.
Iso-risk contour indicates location-specific individual risk (LSIR) for a person standing at
the location all the time during a year.
However, any individual person is present in the plant location only for a limited period in
a year. The individual-specific individual risk (ISIR) is calculated taking into account the
fraction of time the individual stays at the location. Normally the plant personnel work in
daily shift of 8 hours. Therefore the maximum individual-specific individual risk,
ISIR = LSIR x (Average hrs. present at the location in a shift /8) x (8/24) per year.
Table 7.16. : Individual-Specific Individual Risk at MCF Plant
Location Location-specific Avg. time in a shift Individual-specific
individual risk (LSIR) present at the individual risk (ISIR)
per year location (hrs.) per year
Naphtha tank farm area 1.0E-04 4 1.7E-05
Imported Ammonia Terminal 8.0E-06 8 2.7E-06
New Ammonia Tank – DAP 8.0E-06 4 1.4E-06

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Plant
The maximum value of individual risk to plant personnel in the MCF Capacity
Enhancement Project is 1.7E-05 per year.
The values of maximum individual risk to public and plant personnel in MCF Capacity
Enhancement Project in comparison with the risk tolerance criteria are shown in Figure
7.13.
Acceptable Risk
Figure 7.13 : Maximum Individual Risk at MCF Plant

7.11.2. Societal Risk
The FN Curve for societal risk due to proposed projects is shown in Figure 7.14. It
indicates the potential frequency per year of incidents which may cause single and
multiple fatalities.

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Figure 7.14 : Societal Risk due to MCF Plant

It is seen that the societal risks for multiple fatalities due to proposed projects is in the
Acceptable Risk region.
7.12. Conclusions and Recommendations

The scope of this QRA study covers the proposed new facilities in the Capacity
Enhancement Project of Mangalore Chemicals and Fertilizers Limited.
The conclusions of QRA study are as follows.
 Maximum individual risk to the public is 2.7 E-06 per year which is in the lower
part of ALARP region close to the Acceptable Risk level.
 Maximum individual risk to personnel working in the MCF plant after

commissioning of proposed projects is 1.70E-05 per year, which is in the lower
part of ALARP region.
 Societal risk of multiple fatalities due to proposed projects is in Acceptable

region.
Based on the above results of QRA it is concluded that the proposed projects layout
conforms to the specified tolerance criteria for risk to persons working in the plants and
people around the facility.
Results of consequence analysis indicate the following:
 Effects of fire radiation and flash fire due to release of flammable material from
naphtha storage tanks are mostly contained within the plant boundary.

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 Toxic ammonia dispersion footprints due to leak in Imported Ammonia Terminal

storage tank liquid outlet line and transfer pump discharge line extend beyond
the Terminal boundary.
 Toxic ammonia dispersion footprints due to leak in liquid outlet line from the new
Ammonia storage tank in the proposed DAP plant Ammonia are within the
boundary.
Ammonia storage sphere represents significant risk because of the large inventory of
liquid ammonia under pressure. On the other hand, double wall double integrity tank
provides high degree of safety for storage of liquid ammonia close to atmospheric
pressure. It is therefore commendable that the existing Horton sphere storage tank will
not be used after taking the new double wall tank in the DAP plant into service.
7.13. Recommendations
Based on the results of this QRA study, the following recommendations are made to
ensure that the risks at proposed projects are maintained at low level.
1. In order to limit the quantity of ammonia released due to accidental leak, it is
necessary to provide ammonia leak detectors and emergency push buttons to
stop the ammonia transfer pumps and close the shut-off valve at tank outlet.
2. Mechanical integrity assurance is critical to prevent leakage of hazardous
material from equipment, tanks and piping. This includes the following systems:
o Maintenance system to ensure use of correct material and procedure
covering fittings, gaskets, welding etc.
o Monitoring of equipment and piping with non-destructive testing (NDT), leak
detection & repair (LDAR), etc.
3. The following safety and fire protections measures are to be ensured for the
Naphtha tanks as per OISD standards.
o Hydrocarbon gas detectors and medium expansion foam generators for dyke.
7.14. Occupational Health and Safety

Safety in the workplace is critical to the success of running a business, no matter what size
it is.
All safety gears will be provided to workers and care will be taken by MCF that these are
used properly by them. All safety norms will be followed.
Toxic Vapours, Dusts & Fibres
There will not be any Ammonia release during normal operation. Release of Ammonia will
takes place in case of accidental condition only. When an insulated vessel is stripped for
maintenance purposes, particular care should be taken to avoid inhaling dusts or fibres
from the insulating material.

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Handling of Heavy Bags

Handling of heavy bags of the final products may lead to occupational injuries like strains,
sprains and cramps. This can be avoided by going for mechanical handling of the product
or minimizing the weight for manual handling.
Table 7.17. Summary of Occupational Health & Safety in MCF
Occupational Health
i. Plan and fund allocation to ensure the Periodical medical examination is conducted
occupational health & safety of all contract for the contract and casual workers every year.
and casual workers. Treatment- both emergency and illness is
provided for the contract/casual workers at
OHC free of cost.
The annual budget of OHC is about Rs.13 lacs.
(for medicines and consumables).
ii. Details of exposure specific health status Pre placement medical examination is
evaluation of worker. If the workers health is conducted for all the selected candidates which
being evaluated by pre-designed format, includes general physical examination,
chest X-Rays, Audiometry, Spirometry, systemic examination and laboratory
Vision testing (Far & Near vision and any investigations including chest X-ray, ECG,
other ocular defect) ECG, during pre Audiometry, Vision test, etc. All the details are
placement and periodical examinations give entered in pre-designed format. Periodical
the details of the same. Details regarding medical examination is conducted for all the
last month analyzed data of above employees which includes general physical
mentioned parameters as per age, sex, examination, systemic examination and
duration of exposure and department wise. laboratory investigations. Special tests like
Spirometry, Audiometry and vision test are
conducted for the employees who are exposed
dust, chemicals, sound, etc. The details are
entered in the pre-designed format.
iii. Details of existing occupational & Safety Details given in the below table.
Hazardous. What are the exposure levels
of hazardous and whether they are within
Permissible Exposure level (PEL). If these
are not within PEL, what measures the
company has adopted to keep them within
PEL so that health of the workers can be
preserved.
iv. Annual report of health status of workers The details of the health status are entered in
with special reference to Occupational the Health Register-Form No.16 and submitted
Health and Safety. to the Certifying Surgeon.
Plant / Area Nature of Hazard and Measures taken by MCFL

Permissible Exposure Level
(Time weighted average
concentration, 8 hrs)
Ammonia Ammonia (18 mg/m³) Ammonia leakage detection sensors, Canister
Exposure to high noise Masks, PPEs.
Acoustic enclosures, Noise cancelling ear buds.
Urea  Ammonia (18 mg/m³) Ammonia leakage detection sensors, Canister
Masks, PPEs.

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Plant / Area Nature of Hazard and Measures taken by MCFL

Permissible Exposure Level
(Time weighted average
concentration, 8 hrs)
Import Ammonia (18 mg/m³) Ammonia leakage detection sensors, Canister
Ammonia Masks, PPEs.
Terminal
ABC Plant Ammonia (18 mg/m³) Ammonia leakage detection sensors, Canister
Masks, PPEs.
DAP Plant Dust Dust masks
Sulphuric Acid SO2 (5 mg/m³) PPEs. Canister Masks
Plant
Product Dust Dust masks.
handling
CPP Exposure to high noise Acoustic enclosures, Noise cancelling ear buds.
SNF Formaldehyde leakage (1.5 PPEs., Canister Masks
mg/m³)
Specialty Dust Dust masks.
mixture of
plant nutrients
Plant
7.15. Occupational Health – Proposal for Surveillance

The choice and the implementation of specific measures for preventing workplace injury
and ill health in the work-force of the MCF depend on the recognition of the principal
hazards, and the anticipated injuries and diseases, ill health and incidents. Below are the
most common causes of injury and illness:

Slips, trips and falls on the same level; falls from height; unguarded
machinery; falling objects;
 Engulfment; working in confined spaces; moving machinery, on-site transport,
forklifts and cranes;
 Exposure to controlled and uncontrolled energy sources; exposure to mineral
wools and fibers; inhalable agents (gases, vapors, dusts and fumes);
 Skin contact with chemicals (irritants acids, alkalis), solvents and sensitizers);
contact with hot objects;
 Fire and explosion; extreme temperatures; radiation (non-ionizing, ionizing);
 Noise and vibration; electrical burns and electric shock;
 Manual handling and repetitive work; failures due to automation; ergonomics;
 Lack of OSH training; poor work organization;
 Inadequate accident prevention and inspection; inadequate emergency first-
aid and rescue facilities; lack of medical facilities and social protection
 Working near heavy noise generating equipments may cause hearing and
blood pressure related diseases
 Continuous working and improper working position leading to pain &
exhaustion.
Plan of evaluation of health of workers

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 By pre designed format during pre-placement and periodical examinations.

 Proper schedule will be devised and followed with help of occupational health
experts and doctors.
Schedule of medical check-up during operational phase
 Comprehensive Pre-employment medical checkup for all employees
 General check up of all employees once every year.
 Local hospitals and Govt. health monitoring system will be engaged.
 Dispensary and ESI facility will be provided to all workers as applicable
All safety gears will be provided to workers and care will be taken by MCF that these
are used properly by them. All safety norms will be followed
7.16. Personal Protective Equipment (PPE)

General Provisions
As a supplementary protection against exposure to hazardous conditions in MCF, where
the safety of workers cannot be ensured by other means, such as eliminating the hazard,
controlling the risk at source or minimizing the risk, suitable and sufficient PPE, having
regard to the type of work and risks, and in consultation with workers and their
representatives, should be used by the worker and provided and maintained by the
employer, without cost to the workers.
 Items of PPE provided should comply with the relevant national standards and
criteria approved or recognized by the competent authority.
 Those responsible for the management and operation of the personal protection
programme should be trained in the selection of the proper equipment, in assuring
that it is correctly fitted to the people who use it, in the nature of the hazards the
equipment is intended to protect against, and provide adequate comfort, and in the
consequences of poor performance or equipment failure.
 PPE should be selected considering the characteristics of the wearer and
additional physiological load or other harmful effects caused by the PPE. It should
be used, maintained, stored and replaced in accordance with the standards or
guidance for each hazard identified at the facility and according to the information
given by the manufacturer.
 PPE should be examined periodically to ensure that it is in good condition.
 Different PPE & their components should be compatible with each other when
worn together.
 PPE should be ergonomically designed and, to the extent practicable, should not
restrict the user’s mobility or field of vision, hearing or other sensory functions.
 Employers should ensure that the workers who are required to wear PPE are fully
informed of the requirements and of the reasons for them, and are given adequate
training in the selection, wearing, maintenance and storage of this equipment.

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 When workers have been informed accordingly, they should use the equipment
provided throughout the time they may be exposed to the risk that requires the use
of PPE for protection.
 The PPE should not be used for longer than the time indicated by the
manufacturer.
 Workers should make proper use of the PPE provided, and maintain it in good
condition, consistent with their training and be provided with the proper means for
doing so.
Head Protection
 Any helmet that has been submitted to a heavy blow, even if there are no evident
signs of damage, should be discarded.
 If splits or cracks appear, or if a helmet shows signs of ageing or deterioration of
the harness, the helmet should be discarded.
 Where there is a hazard of contact with exposed conductive parts, only helmets
made of non-conducting material should be used.
 Helmets for persons working overhead should be provided with chin straps.
 In addition to safety, consideration should also be given to the physiological
aspects of comfort for the wearer.
 The helmet should be as light as possible, the harness should be flexible and
should not irritate or injure the wearer and a sweatband should be incorporated.
 All protective headgear should be cleaned and checked regularly.
Face & Eye Protection
 Face shields or eye protectors should be used to protect against flying particles,
fumes, dust and chemical hazards.
 Face shields should be used in boiler operations and other hot work involving
exposure to high-temperature radiation sources. Protection is also necessary
against sparks or flying hot objects. Face protectors of the helmet type and the
face-shield type are preferred.
 With the use of face and eye protectors, due attention should be paid to greater
comfort and efficiency.
 The protectors should be fitted and adjusted by a person who has received training
in this task.
 Comfort is particularly important in helmet and hood type protectors as they may
become almost intolerably hot during use. Air lines can be fitted to prevent this.
 Face and eye protectors should give adequate protection at all times even with the
use of corrective vision devices.
 Eye protectors, including corrective lenses, should be made of appropriate high-
impact material.
Respiratory Protective Equipment
 When effective engineering controls are not feasible, or while they are being
implemented or evaluated, respirators, appropriate to the hazard and risk in
question, should be used to protect the health of the worker.

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 When the hazard and risk cannot be assessed with sufficient accuracy to define
the appropriate level of respiratory protection, employers should make positive
pressure air supplied respiratory protective devices available.
 When selecting respirators, an appropriate number of sizes and models should be
available from which a satisfactory respirator can be selected. Different sizes and
models should be available to accommodate a broad range of facial types.
Workers should be fit-tested for respirators.
 Respirators should be cleaned and sanitized periodically. Respirators intended for
emergency use should be cleaned and sanitized after each use.
 The user should be sufficiently trained and familiar with the respirator in order to be
able to inspect the respirator immediately prior to each use to ensure that it is in
proper working condition. Inspection may include the following :
 tightness of connections;
 the condition of the respiratory inlet and outlet covering;
 head harness;
 valves;
 connecting tubes;
 harness assemblies;
 hoses;
 filters;
 cartridges;
 end of service life indicator;
 electrical components;
 shelf life date;
 The proper function of regulators, alarms and other warning systems.
 Respirators should be properly stored. Damage may occur if they are not protected
from physical and chemical agents such as vibration, sunlight, heat, extreme cold,
excessive moisture or damaging chemicals.
 Each respirator should be used with an understanding of its limitations, based on a
number of factors such as the level and duration of exposure, the characteristics of
the chemical and the service life of a respirator.
 Workers should be medically evaluated for their ability to wear a respirator safely
before they are required to do so.
Hearing Protection
 When effective engineering controls are not feasible or while they are being
implemented or evaluated, hearing protection should be used to protect the health
of workers.
 Hearing loss of speech frequencies may occur with elevated long-term exposure to
noise. The use of hearing protectors gives the best results to users who are well
informed of the risks and trained in their use. If earplugs are used, special attention
should be paid to the proper fitting technique.

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 Hearing protectors should be comfortable, and the users should be trained to use
them properly. Special attention should be paid to possible increased risk of
accidents due to the use of hearing protectors. Earmuffs reduce the capacity to
locate sound sources and prevent warning signals from being heard. This is
especially true for workers with considerable hearing loss.
 No model is suitable for all persons. Those wearing hearing protectors should be
able to choose from alternative products that meet the attenuation criteria.
Earplugs should not be the only solution as not all people can wear them.
 Hearing protectors should be made available at the entrance to the noisy area and
they should be put on before entering the noisy area. Noisy areas should be
indicated by appropriate signs.
 The attenuation of hearing protector’s works well only if they are well maintained.
Good maintenance consists of cleaning, changing replaceable parts such as
cushions, and overall monitoring of the state of the hearing protector.
 Hearing protectors should be evaluated through an audiometric test programme for
exposed workers.
Protection from fall
 When other measures do not eliminate the risk of falling, workers should be
provided with and trained in the use of appropriate fall protection equipment, such
as harnesses and lifelines. Workplaces and traffic lanes in which there are fall
hazards or which border on a danger zone should be equipped with devices which
prevent workers from falling into or entering the danger zone.
 Devices should be provided to prevent workers from falling through floors and
openings.
 Safety harnesses should be worn where required and the lifeline should be
attached to an adequate anchor point.
 Harnesses should be chosen that are safely used with other PPE that may be worn
simultaneously.
 Appropriate and timely rescue should be provided when using fall-arrest equipment
to prevent suspension trauma.
Protection while handling Ammonia
 Adequate number of SCABA apparatus to be provided while handling ammonia
manually or during repairs to ammonia handling equipment.
 Fully covered body suit should be worn while handling ammonia.
 Adequate number of PPE is to be made available in the plant premises.
7.17. Disaster Management Plan

Disaster/ Emergency Management Plan is essential for a chemical plant as the processes
adopted for manufacturing are classified under Factory Act as Hazardous due to handling
and storage of toxic, flammable and explosive hazardous materials. Over the years, the
chemical process plant has created adequate infrastructure and adopted risk mitigation
measures to tackle any emergency that may arise during the manufacturing process. The
important aspect in emergency planning is to control an emergency by technical and

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organizational means, minimize accidents and consequent losses. Emergency planning

also brings to light deficiencies, such as, lack of resources necessary for effective
emergency response. It also demonstrates the organization's commitment to safety of
employees and physical property as well as increases the awareness among management
and employees.
Disaster Management Plan for the plant is necessarily a combination of various actions
which are to be taken in a very short time but in a pre-set sequence to deal effectively and
efficiently with any disaster, emergency or major accident with an aim to keep the loss of
men, material, plant/machinery etc. to the minimum.
A major emergency in a hazardous chemical plant is one, which has the potential to cause
serious injury or loss of life. It may cause extensive damage to property and serious
disruption of both inside and outside the plant. Sometimes, it would require the assistance
of outside emergency services to handle it effectively. Although the emergency at the plant
may be caused by a number of different factors, e.g. leakage of toxic and flammable
materials from piping/tanks, total/partial power failure, earthquake or sabotage, it will
normally manifest itself in fire/toxic release.
Primarily, DMP is prepared to furnish details which may require at the time of the
emergency, to delegate responsibility, to estimate the consequences in advance and to
prepare ourselves to control any type of emergency. The plan explains basic requirements
as follows:
 Definition,
 Objectives,
 Organization set up,
 Communication System,
 Action on site,
 Link with Off-site Emergency Plan,
 Training rehearsal and record aspect.
7.17.1. Definitions
Various definitions on different analogy used on On-site & Off-site Emergency Plan are as
follows:
 Accident: An accident may be defined as “an undesirable and unplanned event
with or without or major damage consequence of life and /or property.
 Major Accident: It is a sudden, unexpected, unplanned event resulting from
uncontrolled developments during an industrial activity, which causes or has the
potential to cause, death or hospitalization to a number of people, damage to
environment, evacuation of local population or any combination of above effects.
 Emergency: This can be defined as any situation, which presents a threat to safety
of person's or/and property. It may require outside help also.
 Major Emergency: Occurring at a work is one that may affect several departments
within and/or may cause serious injuries, loss of life, extensive damage to properly

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or serious disruption outside the works. It will require the use of outside resources
to handle it effectively.
 Disaster: Disaster is a sudden calamitous event, bringing great damage, loss or
destruction.
 Hazards: Hazard may be defined as “the potential of an accident”. Hazard exists in
man and the system of materials and machines.
 Chemical Hazards: It is a hazard due to chemical(s) (including its storage, process,
handling, etc.) and it is realized by fire, explosion, toxicity, corrosively, radiation, etc.
 Risk: Risk may be defined as the combination of consequence and probability or
likelihood of an accident being caused in a given man-material – machine system.
 On-Site Emergency plan: It deals with measures to prevent and control
emergencies within the factory and not affecting outside public or environment.
 Off-Site Emergency plan: It deals with measures to prevent and control
emergencies affecting public and the environment outside the premises.
7.17.2. Objective of the Disaster Management Plan
The primary purpose of this Disaster Management Plan is to equip the Plant with required
resources and information for prompt implementation of the set of actions to be undertaken
in the event of an accident posing hazards to the people and community after
commissioning of the plant.
The objective of Disaster Management Plan (DMP), for the plant is to be in a state of
perceptual readiness through training, development and mock drills, to immediately control
and arrest any emergency situation so as to avert a full fledge disaster and the
consequence of human and property damage and in the event of a disaster still occurring,
to manage the same to that the risk of the damage consequences to life and property are
minimized and thereafter, proper rehabilitation, review and revisions of the DMP to
overcome the shortcomings noticed are undertaken.
The DMP document is prepared keeping in view and to conform the requirements of the
provisions of The Factories Act 1948 under section 41 B (4), Guidelines issued by the
Ministry of Environment and Forests, Govt. of India and Manufacture, Import and Storage
of Hazardous Chemicals Rules, 1989 amended in 2000, Schedule 11 under Environmental
Protection Act 1986.
Following are the main objectives of the plan to:
 Defined and assess emergencies, including hazards and risk
 Control and contain incidents.
 Safeguard employees and people in vicinity.
 Minimize damage to property and/or the environment.
 Minimization of risk and impact of event accident.
 Preparation of action plan to handle disasters and to contain damage.

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 Inform employees, the general public and the authority about the hazards/risk
assessed and to provide safeguard, and the role to be played by them in the event
of emergency.
 Be ready for 'mutual aid' if need arises to help neighboring unit.
 Inform authorities and mutual aid centers to come for help.
 Effect rescue and treatment of casualties.
 Effective rehabilitation of the affected persons and prevention of damage to the
property.
 Identify and list any fatalities.
 Inform and help relatives.
 Secure the safe rehabilitation of affected areas and to restore normalcy.
 Provide authoritative information to the news media.
7.18. Emergency Organization

Roles and Responsibilities
Chief Emergency Coordinator

 Declares emergency if the Shift-in-Charge has not done earlier.
 Ensures proper coordination between Operation & Service wings of the Emergency
management team.
 Takes care of all communications with the higher management.
 Informs adjacent factories.
 Instructs the Emergency Operations Coordinator regarding the control of hazard
situation.
 Informs the Off-Site Emergency Coordinator if the emergency is going to be Off-Site.
 Instructs the Emergency Services Coordinator regarding rescue operations.
 Instructs communication officer to obtain Mutual Aid, inform District Authorities.
 Ensures that the Police, Pollution Control Board and Director of Factories have been
informed.
 Gets in touch with all nearby Fire Brigades, through communications officer.
 Takes care of all activities regarding handling of emergency situation.
 Gives All Clear signal when the emergency has been controlled
Emergency Operations Coordinator
 Instructs operation personnel to stop or trip the plant.
 Instructs Maintenance personnel to attend to the job which needs emergency
maintenance, such as replacement of materials or arresting the leaks etc.
 Makes safety equipment available to the Operation/Maintenance personnel.
 Mobilises the rescue team.
 Informs Safety Officer and the Safety and Fire personnel to assist the emergency
handling.
 Makes sure that the handling of emergency situation is going safely and gets in touch
with Chief Emergency Coordinator for the progress.
 Apprises Chief Emergency Coordinator on actions leading to emergency control.
 Arranges head count at the spot.

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Emergency Services Coordinator
 Gets in touch with Emergency Operations Coordinator to assess the magnitude of

emergency.
 Gets in touch with all possible nearby hospitals.
 Instructs the security for safe evacuation of employees and also for accounting of
employees.
 Instructs the factory Medical Officer regarding treatment, medical help from outside
and also arrangement of hospitals.
 Instructs the Welfare Officer to coordinate with Medical Officer for arranging hospitals,
medical treatment etc.
 Instructs the DGM (PR & Admn.) to mobilise transport from outside agencies to meet
the requirements of emergencies.
 Gets in touch with the Chief Emergency Coordinator for the progress.
7.18.1. Other Key Personnel
The key personnel required for taking decision about further action for shutting down the
plant, evacuate the personnel, and carry out emergency engineering works in consultation
with Chief Emergency Coordinator in light of the information received.
HOD’s /Senior Managers/ Section Heads will be responsible for safety, security, fire, gas
and pollution control, spillage control, communication system including telephone, wireless
etc. Also medical services, transport, engineering, production, technical services, will form
part of advising team.
Emergency Response Team
The role of Emergency Response Team members is to actually combat the emergency at
the site and control the emergency situation and carry out rescue operations.
All team members will be thoroughly trained to deal with fires, explosions, chemical spills
and atmospheric releases, first aid. As per priority list during emergency, the activities will
be carried out as per emergency control plan.
Emergency Personnel’s responsibilities Outside Normal Working Hours of the Factory.
The duties of Shift In-charge & team members have been brought out in emergency
control plan. All team members after evacuating the area shall report to ECC/ Incident
Place. The non-essential workers shall be evacuated from the plants if need arises and this
will be determined with the forcible rate with which incident may escalate. Non-essential
workers shall assemble at the earmarked/specified point of assembly.
Assembly Points
At the proposed plan, at least 2 assembly points will be identified and marked properly.
7.18.2. Emergency Control Centre
For effective control of any emergency situation, it is necessary that the control is done from one
particular spot only. This spot should be away from the likely areas of hazards, should be easily
accessible to personnel under Off-site Emergency Co-ordination and Police and also there

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should be easy access from the factory to this Emergency Control Room. Keeping this in mind,
we have located two Emergency Control Rooms. The First Emergency Control Room (ECR-1)
is near the Security Gate. The second one (ECR-2) is the Mini Conference Room in
Administrative Building. Both these rooms are sufficiently spacious and the size of the rooms
are given below:
1) ECR-1 7.6 M long and 5.8 M wide.
2) ECR-2 (alternate) 6.7 M long and 4.7 M wide.
3) Incident Control Room 9.7 M long and 7.3 M wide
Both the above ECRs comply with the prescribed size given by the Task Force set up by
Karnataka State Government. During general shift hours there will always be vehicles at both
these rooms which can be utilised in emergency. Moreover, the Safety Section and Security
Gate are nearer to the Emergency Control Room-I. The other facilities that are being provided at
both the Control Rooms are given below:
1. Emergency lights
2. Public Address System
3. Hotline between plants
4. Hotline to MRPL & OMPL Fire Station
5. Direct phones for external communication
6. Internal telephones
7. Walkie Talkie
8. Mobile phones
In addition to the above facilities, the following documents connected with the Emergency Plan
are kept in almirahs in both these Control Rooms.
1. Copies of On-site and Off-site Emergency Plans.
2. Factory layout.
3. Emergency telephone numbers.
4. Directory of Internal Telephones.
5. Directory of External (P & T) Telephones.
6. Data on the number of people working in different plants/sections.
7. Data on population around the factory.
The Emergency Control Rooms are suitably located so that there will be least traffic
congestion and approach to the rooms by Emergency Coordinators will be easy.
7.18.3. Fire & Toxicity Control Arrangements
The plant will be well equipped with suitable numbers of firefighting and personnel
protective equipment. The staff will be trained regularly to handle the various emergency
situations.
7.18.4. Medical Arrangements
Availability of first aid facilities in sufficient quantity will be always ensured. In case of
emergency arrangements will be made to avail outside medical help immediately.
Emergency transport facility will be available.

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7.18.5. Transport & Evacuation, Mutual Aid Arrangements:

Transport & Evacuation and Mutual Aid arrangements will be available in the factory.
7.19. Communication System

7.19.1. Declaring the Emergency
Noticing a possible Hazard
The worker or supervisor who works in the spot or nearby will be the first man to notice the
hazardous condition which may turn out to be a Major Hazard. This worker/supervisor will
inform the situation to the Shift-in-Charge (SIC) who is responsible for all the activities in
the shift. The SIC will inform the hazardous condition to the Chief Emergency Coordinator
(CEC) personally or by Walkie Talkie or by telephone or by a messenger. The CEC will
study the situation and declare the Emergency as it may be an 'OFF-SITE' or 'ON-SITE'. If
the Shift-in-Charge feels the situation is On-Site, he will declare so by sounding the siren.
Declaration of Emergency and functions of Chief Emergency Coordinator
After getting information form Shift-in-charge, the Chief Emergency Coordinator will rush to
the factory and assesses the situation. If he finds the situation could result in an 'On-Site' or
'Off-Site' emergency, he would immediately declare the emergency by a coded siren. All
the employees who are working inside the factory will thus know that an emergency
situation has occurred. The plant production personnel will shut down the plants as per
their Supervisor's instructions. Other non plant personnel are required to vacate the
workspots as early as possible and move into predesignated safe places like G-Rooms or
Assembly points. In case the emergency is 'Off Site', the declarer will use his discretionary
powers and decide about the nature of Emergency. In case of ‘Off Site' emergency, the
declarer will contact or get in touch with predecided authority who will be the 'Off Site'
Emergency Coordinator who will take over the management of emergency situation. The
management of emergency will be conducted from an Emergency Control Room or its
alternate. The State Govt. has constituted the District Crisis Group Committee. In our case
the Deputy Commissioner (D.K.) has been designated as the Chief Emergency
Coordinator.
The Chief Emergency Coordinator has many roles to play once he arrives at the work spot
and takes charge of emergency coordination. He will coordinate the action of two groups
viz., Emergency Operations Group and Emergency Services Group which will be headed
by Emergency Operations Coordinator (EOC) and Emergency Services Coordinator (ESC).
The Emergency Operations group will coordinate the activities required for emergency shut
down of the plants and for effective containment of the hazardous situation. They will also
evacuate the injured personnel to Occupational Health Center. For effective coordination of
safety squads/ fire tenders etc., the group will also coordinate with safety section and
ensures that all the personnel trapped in the affected area are brought to safe places.

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The Emergency Services group will co-ordinate the activities such as immediate treatment
to the injured personnel which includes First Aid, transfer of injured personnel to the
designated hospitals, nursing homes, coordination of procuring external medical aid if
necessary, coordinating with local service organisations for assistance in these actions,
evacuation of people from affected areas to safe places, transport arrangement and traffic
control inside the factory area.
Both the above groups will have all the protective equipment that will be readily available in
the Incident control room and other designated places ear-marked for this purpose. The
groups connected with the above said operations and services would have already been
properly trained. This is possible because the nature of various possible hazards and
accidents have been identified by the HAZOP studies and risk analysis studies done
earlier.
7.19.2. Types of Sirens
Emergency Siren has been installed at two places to alert employees inside the Factory
and the general public in case of an emergency involving fire or toxic gas release. The
siren for emergency alarm is different from the siren meant for time indication and is
located at a distinctly different place. Following is the emergency siren code for different
emergencies like Fire or Toxic gas release.
The emergency/ fire siren is tested at 12 noon on every Friday
7.19.3. Internal Communication

It shall be responsibility of ECC to communicate to all employees in the plant. They may
take help of designated communication officer or shift incharge for such communication.
Internal communication is done with public address system, walkie-talkie sets, hot-lines and
internal telephones.

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7.19.3.1 Availability of Key Personnel outside Normal Working Hours

The details of key personnel availability after working hours will be made available with shift
incharge. Shift incharge will call required key personnel from their residence in case
emergency occurs outside normal working hours. Availability of emergency vehicle will be
ensured to fetch the key personnel residing outside.
7.19.3.2 To the Outside Emergency Services
Decision to call outside help to deal with emergency like fire brigade, ambulance, police,
etc., shall be taken by Chief Emergency Coordinator. However, in absence of Chief
Emergency Coordinator, if the shift incharge realizes the situation going out of control, he
may ask for immediate help from outside. ECC will be responsible for calling help from
outside. A list of emergency services available in the area with their telephone numbers will
be provided at ECC, at Security gate and with shift incharge.
7.19.4. Communication to the Authorities
The emergency will be immediately communicated to the government officers and other
authorities such as KSPCB, police, district emergency authority, Factory Inspectorate,
hospital etc. by Emergency Control Centre.
7.19.4.1 To Neighbouring Firms & the General Public
In case of emergency having its outside impact, public will be cautioned regarding the
same. Co-ordination of police will be sought for speedy action. This is to be ensured by
ECC.
7.20. Pre-emergency activities

Internal Safety survey with regard to identification of hazards, availability of protective
equipment’s, checking for proper installation of safety devices will be carried out
periodically.
 Periodic pressure testing of equipment
 Periodic pressure testing of lines.
 Periodic safety/relief valve testing
 Periodic fire hydrant system testing.
 Mock drill to check up level of confidence, extent of preparedness of personnel to
face emergency is being contemplated.
 Regular training is being imparted to all personnel to create awareness.
 Adequate safety equipment will be made available.
 Periodic check-up of emergency lights.
 Safer assembly points will be identified.
 Storage of adequate first aid treatment facilities.
 Statutory information is imparted to workers.
 Post emergency activities:

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Following post emergency actions will be carried out to study in detail and preventive
measures to be taken.
 Collection of records.
 Inquiries
 Insurance claims
 Preparation of reports comprising suggestion and modification.
 Rehabilitation of affected personnel.
 Normalization of plant.
7.20.1. Evacuation and Transportation
In case of emergency, evacuation and transportation of non-essential workers will be
carried out immediately. The affected personnel will be transported for medical aid.
7.20.2. Safe Close Down
During emergency plant shut down will be carried out if situation warrants. This will be as
per the instruction of site main controller under guidance of incident controller.
7.20.3. Use of Mutual Aid
Mutual aid agreement with nearby industries will be ensures to provide help to each other
in the emergency,
7.20.4. Use of External Authorities
As and when necessary, statutory authorities, police, pollution control personnel, medical
aid/ center, ambulance etc. will be contacted.
7.20.5. Medical Treatment
The affected personnel will be brought to safer place immediately to give them first aid.
Immediate medical attention will be sought.
7.20.6. Accounting for Personnel
Proper accounting for personnel will be laid down in all the shifts. The number of persons
present inside the plant premises, their duty etc. will be available with the Security, HR &
Admin. This record will be regularly updated and will be made available.
7.20.7. Access to Records
 The relatives of affected personnel will be informed. The details regarding all
employees will be made available to Administration building.
7.20.8. Public Relations
 In case of emergency, GM- HR will be available for official release of information
pertaining to the incident.
7.20.9. Rehabilitation
 The affected area will be cleared from emergency activities only after positive
ascertaining of the system in all respects. The entry to affected area will have to be

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restricted until statutory authorities visit and inspect the spot of incident. Nothing
should be disturbed from the area till their clearance. The site main controller will
be in charge of the activities to be undertaken.
 The plan will cover emergencies, which can be brought under control by the works
with the help of emergency team/fire services. The DISASTER CONTROL PLAN
for gas leak and fire will be prepared for entire factory.
7.21. Causes of Emergency:

7.21.1. Risk
Nature
In the plant, the nature of dangerous events could be of the following:
 FIRE : Chemical/Electrical
 TOXIC RELEASE : From chemicals & Ammoinia.
 LEAKAGES : Equipment, pipe lines, valves, etc.
 Improper handling of products (raw materials/finished products)
 Large spillage to ground floors resulting in pollution & fire.
 Failures of Equipment / Instruments.
 Release of safety valves or ruptures of vessels due to excessive pressures.
Various Emergency Actions
a. Onsite
 Safe shut down of the plant and utilities.
 Emergency control measures.
 To attempt with the help of trained crew in firefighting to contain the fire spread
up/gas emission and limit within limited space.
 To cut off source of oxygen by use of firefighting appliances/to cut off source of gas
emission.
 Cut off fall sources of ignition like electrical gadgets.
 To protect fire prone area from the fire.
 To remove material which can catch fire to the extent possible from fire prone area.
 Evacuation of non-essential persons.
b. Medical Facilities/Treatment
 The Plant will have a Health centre which is manned with trained male nurse
on continuous basis who can render medical first aid. Depending on
seriousness the injured person shall be shifted to any other hospital.
 Vehicle will be available round the clock for transportation. Ambulance will be
also made available in the campus on regular basis.
c. In the event of Fatal Accidents
The information shall be given to following authorities:
 Inspector of Police
 Inspector of Factories

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 Corporate Office
 Regd. Office
 Insurance the plant
 Regional Officer, KSPCB
d. Seeking Help From Neighbouring Industries / Sources For Fire Engine
e. Advise for evacuation of other areas
Since the effect of fire/gas emission shall be contained within the area of the plant advice of
evacuvation of other areas is not necessary.
Response Time-Minutes
Hazard Fire Fighting Police Medical Services
Fire & Immediate with whatever facilities 10 10 minutes
Explosion available with the plant minutes
External Help within 15 minutes
7.22. Off-Site Emergency Plan

7.22.1. Need of the Site Emergency Plan
Depending upon the wind direction and velocity of the effects of accident in factory may
spread to outside its premises. To avert major disaster it is essential to seek
guidance/assistance of statutory authorities, police and health department. The movement
of traffic may have to be restricted.
Required information will be given to the authority and consultation will be sought for
remedial measures.
A purpose of the off-site emergency plan is:
 To provide the local/district authorities, police, fire, brigade, doctors, surrounding
industries and public the basic information of risk and environmental impact
assessment and appraise them of the consequences and the protection/prevention
measures and to seek their help to communicate with public in case of major
emergency.
 To assist district authorities for preparing the off-site emergency plan for district or
particular area and to organize rehearsals from time to time and initiate corrective
actions on experience.
7.22.2. Structure of the Off-Site Emergency Plan
 Available with concerned authorities.
7.22.3. Role of the Factory Management
The site main controller will provide a copy of action plan to the statutory authorities in
order to facilitate preparedness of district/area off-site emergency plan.
7.22.4. Role of Emergency Co-ordination Office (ECO):
He will be a senior police or fire officer co-ordination with site main controller. He will utilize
emergency control center.

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7.22.5. Role of Local Authority

Preparation of Off Site Plan lies with local authorities. An emergency-planning officer
(EPO) works to obtain relevant information for preparing basis for the plan and ensures that
all those organization involved in offsite emergency and to know their role and
responsibilities.
7.22.6. Role of Fire Authorities:
The fire authorities will take over the site responsibility from incident controller after arrival.
They will be familiarized with site of flammable materials, water and foam applies points,
firefighting equipment.
7.22.7. Role of the Police and Evacuation Authorities:
Senior Police Officer designed, as emergency co-ordination officer shall take over all
control of an emergency. The duties include protection of life, property and control of traffic
movement.
Their functions include controlling standards, evacuating public and identifying dead and
dealing with casualties and informing relatives of dead or injured.
There may be separate authorities/agencies to carry out evacuation and transportation
work.
Evacuation depends upon the nature of accident, in case of fire only neighboring localities
shall be alerted. Whole areas have to be evacuated in case of toxic release.
7.22.8. Role of Health Authorities
After assessing the extent of effect caused to a person the health authorities will treat them.
7.22.9. Role of Mutual Aid Agencies
Various types of mutual aid available from the surrounding factories and other agencies will
be utilized.
7.22.10. Role of Factory Inspectorate
In the event of an accident, the Factory Inspector will assist the District Emergency
Authority for information and helping in getting Neighboring Industries/mutual aid from
surrounding factories.
In the aftermath, Factory Inspector may wish to ensure that the affected areas are
rehabilitated safely.
7.23. Mock Drills and Records

7.23.1. Need of Rehearsal & Training
Regular training and rehearsal program of emergency procedures shall be conducted with
elaborate discussions and testing of action plan with mock drill. If necessary, the co-
operation/guidance of outside agencies will be sought.

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7.23.2. Some Check Points

 The extent of realistic nature of incidents.
 Adequate assessment of consequences of various incidents.
 Availability of sufficient resources such as water, firefighting aids, personnel.
 The assessment of time scales.
 Logical sequences of actions.
 The involvement of key personnel in the preparation of plan.
 At least 24 hour’s covers to take account of absences due to sickness and holiday,
minimum shift manning.
 Satisfactory co-operation with local emergency services and district or regional
emergency planning offices.
 Adequacy of Site.
7.23.3. Records and Updating the Plan
All records of various on-site and off-site emergency plans of the factory will be useful
alone with those of the factors by which statutory authorities draw a detailed plan for the
whole area/district. The records of the activity will be updated regularly.

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CHAPTER 8. ENVIRONMENTAL MANAGEMENT PLAN
This chapter provides mitigation and control measures to attenuate and/or eliminate
environmental impacts, which are likely to be caused by the proposed project. An
Environmental Management Plan (EMP) has been developed to mitigate the potential
adverse impacts and to strengthen the beneficial impacts during the construction and
operation phase.
8.1. General
Environmental Management Plan (EMP) is the key to ensure a safe and clean
environment. A project may have taken proper pollution control measures, but without a
proper management plan, the desired results may not be obtained.
EMP is a tool for planning and implementation of various pollution abatement measures
for any proposed project. It is required to ensure environmentally and ecologically
sustainable developmental activities in the study area. The EMP brings transparency
related to environmental degradation between the project proponent and pollution control
regulatory agency at State & Central level. It has been evaluated that the environment
and the eco-system of the study area will not be affected adversely due to the proposed
project. Mitigation measures at the source level and an overall EMP are elicited so as to
improve the sustaining capacity of the area in concern and also to preserve the
assimilative capacity of the receiving bodies.
The EMP Action Plan aims at controlling pollution at the source level to the possible
extent with the best techno-economically feasible & available methodology before the
pollutants are discharged into atmosphere.
While implementing the project MCF will follow guidelines specified by KSPCB/MoEF
under the Corporate Responsibility for Environmental Protection (CREP) for related
plants. The following environmental management plan has been suggested during
construction and operation phase.
8.2. Environmental Management Plan (EMP) comprises of

Formation of Environmental management system
 Development of Environmental Policy for the Industry relevant to the operations and
support it
 Implementation of Pollution mitigation measures
 Monitoring of pollution control equipment for the effectiveness and documentation of
observations for formulating improvements in the systems.
 Making institutional arrangements like installing Environment Cell & review committee
 Making budget provisions for Environmental Management Activities
 Budgetary allocation for Environmental Activities

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 Compliance of CREP Guidelines

8.2.1. Environmental Management System
The environmental management system shall be formed to enable it to maximize its
beneficial effects and minimize its adverse effects - with emphasis on prevention. Its
functions are to
 Identify and evaluate the environmental effects arising from the industry's proposed
activities, products and services
 Identify and evaluate the environmental effects arising from incidents, accidents and
potential emergency situations;
 Identify the relevant legislative and regulatory requirements;
 enable priorities to be identified and pertinent environmental objectives and targets to
be set;
 facilitate planning, control, monitoring, auditing and review activities to ensure that the
policy is complied with; and
 Allow periodic evaluation to suit changing circumstances so that it remains relevant
8.2.2. Environmental Policy
The proponent shall formulate its policy with the following aspects
 To achieve excellence in the area of environment management;

 To keep in the view the various environmental requirements in all business decisions;
 To continuously adopt ways and means for environmental protection and
environmental improvement around its business units; and
 To adopt sound Environmental Management Practices.
8.3. Management Plan during Construction Phase
Pollution expected during construction phase of proposed project is considerably
insignificant. The impact of the pollutants during construction phase on the environment
would be basically of transient nature and are expected to wear out gradually on
completion of the construction phase.
However, once the construction job related to the proposed project is completed and
operation of proposed units started, the operation stage impacts would overlap the
impacts due to the construction activities. Following factors shall require due
consideration during construction phase:
8.3.1. Site Preparation

The proposed project will be installed within the plant premises of existing fertilizer plant.
Before site preparation, the wild shrubs & herbs shall be required to be removed and
shall be composted for use as manure in green belt area. It is envisaged that minor
leveling of land shall be required for site preparation.

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Stock piling of earthen material would be required during foundation works of the
proposed project. The earth work will generate dust which will be controlled by periodical
sprinkling of water during day time working period.
The management plan with respect to site preparation is summarized as under:
 Cleaning of site
 Removal of abandoned installations and buildings
 Installation of drainage improvement and storm water drainage
 Excavation of built area
 Installation of environmental protection facilities
 Preparation of access roads to each plant
 Constructing support facilities
 Installation of utilities (water, sewage etc.)
8.3.2. Construction Equipment & Waste
Care shall be taken to prevent accidental spillage of any oil from construction equipment.
Combustible waste and other wastes shall be disposed-off by adopting environmentally
compatible methodology. The earthy materials will be generated during erection of walls,
pilings etc. The generated waste shall be used in dressing / leveling of low lying areas,
etc.
During construction of plants and laying of pipes, some solid waste materials will be
generated. These materials will be sold through CPCB / SPCB registered scrap dealers.
The gas cylinders used for welding shall be returned back to the supplier. Cement bags,
coal tar drums and other containers used during construction and discarded as wastes,
shall be auctioned through registered vendors as per standard practices. Similarly, the
damaged tools shall also be disposed in the above manner.
8.3.3. Storage of Hazardous Materials

The hazardous material such as, lubricating oils, compressed gases (for welding), paints,
varnishes, etc. shall be stored at the site during construction phase. Since, these
materials are hazardous; they will be stored as per the prescribed / accepted safety
norms.
8.3.4. Disposal of Solid / Hazardous Waste

The hazardous materials used during the construction may include diesel, welding gas
and paints. These materials would be stored and handled according to the guidelines
specified under Hazardous & other waste (management & trans-boundary) Rules-2016 of
MoEF. Some of the precautions for storage and handling of the hazardous materials
includes the following:
 Enclosures would be provided wherever necessary for storage of hazardous

materials.
 Diesel and other fuels would be stored in separate dyke enclosures.

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 On-site recycling of all waste solvents / thinners & oils and off-site recycling of paint
thinner solvent wastes & waste oil.
 Separate storage for waste paints and thinners, contaminated rags and brushes to
facilitate recycling and reuse. Rags could be laundered for reuse.
 Vehicle maintenance area shall be selected properly to prevent contamination of soil
and ground water by accidental spillage of oil and other wastes.
Wastes generated from construction and demolition activities shall be handled as per
guidelines / notification issued by MoEF&CC in Construction & Demolition Waste
Management Rules, 2016. The waste generated shall be segregated as construction and
demolition wastes and deposited at designated collection centers and handed over to
authorized processing facilities.
8.4. Management Plan during Operation Phase
8.4.1. Air Environment
Ammonia Plant
There will not be any increase in pollution load due to increase in production. This is
achieved by the energy improvement schemes which will be implemented in the plant.
The total firing in the primary reformer will be lower resulting in reduction of fuel
consumption. Also there will be reduction in steam and power requirement for the plant.
Urea Plant
There will not be any significant increase in pollution load after the implementation of
energy improvement project. Capacity of Urea plant will be increased from 4,29,000 t/y
to 5,69,400 t/y after the availability of NG in Mangalore.
The existing modified design prill bucket known as the “Tuttle prill” bucket will be replaced
with “vibropriller” bucket which has special features in the spray hole orientation which
gives prills of very uniform size of improved crushing strength and thereby helps in
reducing the dust formation inside the prilling tower. Also the configuration of louvers with
well-maintained induced draft fans has ensured adequate flow and temperature control.
Prill Tower having internal diameter of 17 m and free fall height of 49.14 M has been
provided for prilling. The highest point of the structure is 72 M from the ground level.
The emission of Particulate matter from the urea prill tower will be about 110 mg/Nm³
which is well within standard of 150 mg/Nm³.
DAP/NPK Plant
The proposed project will not have any significant adverse impact on the existing
environment as sufficient pollution control measures are incorporated in the process
technology and plant design. The technology also incorporates special scrubbing
equipment like Dual Mole Scrubbing System and also Dedusting system. In DAP / NPK
plant Air pollution control equipment viz. Cyclone, Scrubber, Mist eliminator etc. shall be
installed during the commissioning of the plant itself.

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The flow of gaseous emission from the stack (3 No. 45 m each) is expected to be
maximum 720000 Nm³/hr., particulate Matter 50 Mg/Nm³, fluorine 20mg/Nm³ and
Ammonia 150mg/Nm³.
There will not be any gaseous emissions from the proposed PCE plant.
Air Pollution control Systems with Stack Details
There will be no emission from the proposed PCE Plant.
The major gaseous emissions which will generate inside the plant are usually from
Production of Ammonia, Urea, and DAP/NPK plant and DG set.
The impact on air quality due to the operation of the proposed project will be mainly due
to the following sources:
 Emission of particulate matter from the Urea and DAP/NPK Plant.
 Fugitive emissions
Table 8.1 Air Pollution (Control & Treatment)
Plant Emission Pollution Controlling Equipment

Ammonia, Urea and SPM, Urea Dust, Nox, Venturi Gas scrubbers, cyclonic Mist Eliminators,
DAP/NPK Plant NH3, SO2 Bag filter, cyclone, Flayer Stack etc.
PCE Plant No Emission
8.4.2. Water Environment
The water is supplied by Mangalore City Corporation. No additional water drawl due to
the proposed plants. The marginal increase in the water requirement after the
commissioning of the plants will be met by effluent water recovery unit installed.
Ammonia Plant
There is no additional liquid effluent generation from the plant. The plant will remain zero
liquid effluent discharge plant. It is proposed to replace the present low pressure stripper
with medium pressure (MP) stripper which will ensure removal of Ammonia from process
condensate. The gases from the MP stripper will be carried by the steam going to
primary reformer. The effluent generated in the plant shall be treated in the existing
effluent treatment facility and recycled back to the system.
Urea Plant
There will not be any additional effluent generation after the implementation of the new
project. Efflent generation will reduce because of the implementation of various energy
improvement schemes. MCF has installed and commissioned urea hydrolyser stripper
and operated for the treatment of effluent streams from ammonia plant process, urea
stripper system consists of hydrolyser, which is operated at high temperature' and high
pressure, where urea gets hydrolyzed to ammonia and carbon dioxide. Ammonia thus

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produced is separated in the second desorption column. The liquid outlet of second
desorption column contains less than 10 ppm of ammonia and urea. The ammonia
vapours from the second desorption column is fed to the first desorber. The desorber
overhead vapours are condensed in a condenser and reused in Urea plant. The treated
effluent from urea hydrolyser stripper is reused as cooling tower makeup water.
NPK Plant
No trade effluent generation from the proposed DAP/NPK plant. No solid waste will be
generated. Any spillage will be recycled and reused in the proposed plant. There will not
be any additional water drawl from the Mangalore City Corporation for the proposed
project. The marginal increase in the water requirement after the commissioning of
DAP/NPK plant will be met by effluent water recovery unit installed.
Since no liquid effluent and solid waste will be discharged from the plant there will not be
any significant adverse impact on the aquatic ecosystem. The vegetation and aquatic
systems of the area will be protected by adopting the above environmental protection
measures.
floor will be collected in and recycled back to soil conditioners section.
8.4.3. ETP Facility
In Mangalore Chemicals & Fertilizers Ltd., (MCF), the Liquid Effluent streams generated
are only from Ammonia, Urea and Water Treatment Plants. The Ammonium Bi-
carbonate and Di-Ammonium Phosphate Plants are designed to have zero effluent
discharge. In Di-Ammonium Phosphate (DAP) Plant a part of ammonia and urea bearing
effluent from Urea/Ammonia plant is used as process condensate.
8.4.4. STP Facility
With the aim of reusing the treated sewage effluent, sewage effluent treatment system
has been upgraded by adapting Membrane Bio Reactor (MBR) Technology during
2010.The treated sewage effluent is reused in the cooling tower as make up water.
8.4.5. Rainwater Harvesting & Management
The rain water collected from the roof of the permanent buildings shall be harvested for
ground water recharge as a compensation for meeting the requirement due to loss of
permeable area promoting ground water recharging, maintenance of existing hydro-
dynamic pattern of the area and to conserve the salinity of ground water of the area.
Implemented the schemes for harvesting roof water at township and recharge the bore
wells. Total roof area covered is about 3500 m2.
The excess rainwater shall be sent to the trap through storm water drain and attempts
shall be made not to mix any process waste with the storm water. The trap shall have
two compartments one consisting of sized boulders and the other sized hard coke. The

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excess water from sized hard coke shall be collected in another tank before discharge in
to natural drainage system. The drainage system of project area shall be aligned as per
the existing natural drainage pattern of the area.
8.4.6. Water Conservation Measures
MP Condensate stripper:
A medium pressure condensate stripper will be installed in place of LP condensate
stripper. Existing LP stripper consumes 6.5t /h of steam. The proposed MP condensate
stripper recovers heating steam and overhead vapors are generated at higher pressure
and it is consumed in reformer. Hence no venting of steam.
Lower steam demand:
Steam demand from Auxiliary boiler will reduce to 7.5 t/h from present 20 t/h due to
higher heat recovery in the proposed revamp. This will reduce Furnace oil consumption
in auxiliary boiler by about 1.1 t/h which in turn will reduce 3.5 t/h of CO2 emission.
Replacement of Syn Gas Compressor:
Existing Motor and steam Turbine driven Syn Gas compressor will be replaced with
steam turbine driven, higher efficiency compressor. This replacement will reduce
compressor energy consumption by about 2.9 MW even after an increase in the plant
load by 25%. Optimization of steam- electrical energy consumption due to converting
motor and back pressure turbine drive to backpressure and condensing turbine drive will
reduce overall electrical power consumption by 8 MW. This reduction will reduce NG/FO
consumption in Captive power plant. (1.8 t/h of FO or 1.5 t/h of NG)
Addition of Heat NG Feed Preheat Coil and Mixed Feed Coil in Reformer Convection
Section:
Addition of heaters in reformer convection section recovers additional heat from reformer
flue gas. This will reduce flue gas temperature from present 175°C to 126°C.
8.5. Hazardous / Solid Waste Management
8.5.1. Generation of Solid / Hazardous Wastes
As per Hazardous & other waste (management & trans-boundary) rules-2016 of MoEF,
the following items under “Schedule-I [See Rule 3(I), “List of Processes Generating
Hazardous Waste” following items have been declared hazardous waste as per serial
number 18 of the above list:
S. No. Processes Hazardous Waste

18.1 Spent Catalyst
Production of nitrogenous and 18.2 Spent Carbon
(18)
complex fertilizers 18.3 Sludge/ residue containing As
18.4 *Chromium sludge from cooling tower

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* In place of Chromate based cooling water formulation, new generation cooling water formulation
based on polymers (bi/ter polymers) non-oxidising biocides and Chlorine dioxide in place of
chlorine shall be used
8.5.2. Hazardous Waste
As per the Rules, hazardous waste is defined as any waste which by reasons of its
physical, chemical, reactive, toxic, flammable, explosive or corrosive characteristics
causes danger to health or environment, whether alone or when in contact with other
waste or substances.
According to above criteria, the following wastes are considered to be hazardous from
proposed project:
Table 8.2 Quantification of Waste Generation (Existing/Proposed)
Description of Existing After the

Method of collection & storage
waste/ waste Generation proposed
Mode of disposal
category (2016-17) project
Used oil/oil emulsions originating from
compressors, pumps and other
machinery are collected in oil pits and
sent to oil separator. From the oil
separator oil emulsions are collected in
drums. Similarly oil emulsions are
generated in the DG sets of our
Captive Power Plant. This is also
collected in drums. After filling in the
Used Oil/Waste barrels they are temporarily stored in a
yard provided with pavement, curb
Oil (Sl.No. 282 KL 370 KL
walls and water oil separator. Waste oil
No.5.1/5.2/3.3) generated in the DG sets of our
Captive Power Plant is collected and
stored in a tank.
These waste oil/Used oil emulsion are
then sold to outside agencies having
adequate facility for refining and
disposal of hazardous waste. The
agency should possess certification of
registration from Central Pollution
Control Board.
Catalysts are used in different sections
of Ammonia plant. Its life is usually 2-
Spent Catalysts
10 years and is different for each
from Ammonia and Catalyst
As and catalyst. When the catalysts lose their
urea Plants (Sl. quantity will
when activity, they are discharged during
No.18.1). remain
generated. shut downs. After discharging spent
. same.
catalysts are filled in drums and stored
in a shed in secured manner protected
from sun and rain.

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Spent catalysts are sold to outside

agencies for reprocessing and
recovery of metals. The agency should
possess certification of registration
from Central Pollution Control Board. If
reprocessors are not available it will be
disposed as per the directive of
KSPCB
Spent Activated Carbon is generated
from the Demineralisation Plant. After
Spent Carbon (Sl. As and Quantity
discharging, spent activated carbon are
No. 18.2). when will remain
filled in drums and stored in a shed.
generated. same.
Disposed as per the directive of
KSPCB
Sulphur cake Sulphur Cake collected from filter is
(Sl.No. No.17.1) 11 MT 11 MT used in the existing DAP plant as
filler material.
During Annual Shut down of Sulphuric
Acid Plant the catalyst from the
converter is screened to remove
powdered material from the pellets.
The pellets which are in good condition
are charged back to the converter with
the required top up. The left out
Spent Catalyst
As and Quantity material after screening is considered
from Sulphuric Acid
when will remain as ‘spent catalyst’. This is collected in
Plant
generated. same. barrels. Spent catalyst is sold to
(Sl. No.17.2).
outside agencies for reprocessing and
recovery of metals. The agency should
possess certification of registration
from Central Pollution Control Board. If
reprocessors are not available it will be
disposed as per the directive of
KSPCB.
Discarded
Stored in a shed.
Containers (Sl. No. 600 Nos. 660 Nos.
Sold to KSPCB Authorised Handlers.
33.3)
Hence, Due to proposed project, there is only the marginal increment in the quantity in
Used Oil/Waste Oil (Sl.No. No.5.1/5.2/3.3) from 280 KL to 370 KL and Discarded
container by600 Nos to 660 Nos and rest will remain same.
No catalysts are used in the manufacturing process of urea plant. As such no solid
waste shall be generation in the process. The only hazardous waste is the oil recovered
in the oil separator.
8.5.3. Disposal of Hazardous Wastes
Proper precautionary measures shall be taken during storage, transportation and
disposal of hazardous spent catalyst. MCF would keep a record of the type, quantities

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and characteristics of the hazardous wastes. Since, the spent catalysts contain precious
metals and have market value; they will be packed in sealed containers and sold to
CPCB approved recyclers. In case it is not possible to sell the hazardous wastes, it shall
be stored in inert and leak proof containers.
8.6. Green Belt Development
Trees and plants are an essential component of healthy environment. In addition to
maintaining the oxygen-carbon dioxide balance in the atmosphere through
photosynthesis, trees and plants control air and noise pollution, control soil erosion,
provide food and shelter to domestic and wild animals including birds and insects, and
improve the aesthetic value of the environment. The utility of the green belt
predominantly lies in its capacity to attenuate the fugitive emissions and spillage. Thus,
the objectives of the proposed green belt program are as follows:
 To control air pollution due to fugitive emissions and spillage.
 To attenuate noise generated by various machines.
 To attenuate the effect of accidental release of toxic gases.
 To reduce the effect of fire and explosion.
 To improve the general appearance and aesthetics of the area.
 To provide food and habitat for wildlife.
 To control soil erosion.
 To obscure the proposed facilities from general view.
8.6.1. Areas to be Afforested
MCF plant established in about 192 Acres inclusive of 64 Acres of green belt, which is
33% of existing plant area.
There exists a thick green belt around the existing fertilizer plant. While proposing the
layout plan (upcoming facility) for locating the different facilities, extreme care has been
exercised to preserve the existing plantation to the extent possible. Trees, lawns and
gardens developed within the premises to cover all the vacant areas. Extreme care shall
be taken to utilize all available areas for afforestation.
8.6.2. Species for Afforestation
The general approach for selection of species for green belt development is their
potential for attenuation of fugitive emissions and noise, diversity of vegetation,
introduction of species attracting birds and animals, and to create a natural habitat. It is
proposed to develop trees of different heights so as to provide cover from ground level
up to the canopy of tall tree species. Further, trees with big foliage and those known to
prosper well in the area will be developed. Preference will be given to fruit bearing trees
so as to provide food and shelter to birds and insects.
Efforts would be made by M/s MCF in collaboration with Forest Department to explore
mutual areas of interest in the area of identifying trees/ plants to maintain/ enhance the
current biodiversity index.

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Figure 8.1 Existing Green Belt area

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Figure 8.2 Photograph Green Belt area

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8.7. Noise and Vibration

The on-site workers employed by the contractors as well as the employees of the project
shall be the target of enhanced noise level. Following mitigation measures shall be
adopted.
 Project employees as well as contractor workers shall be provided with noise
protection devices like ear-plugs etc.
 Provision for insulating caps and pads at the exit of noise source on the machinery
 Inlet and outlet mufflers shall be provided which are easy to design
 Noise prone activities shall be restricted to the extent possible during night time in
order to have minimum impact on the workers and employees.
Adequate measures shall be incorporated in the proposed plants for control of noise and
vibration from the different equipments. The control of noise within the plants is through
the provision of silencers, hoods, and acoustic walls to the noise generating equipment.
Suppliers of DG Sets, Pumps, compressors, fans, etc shall ensure that the noise levels
from these equipment do not exceed desirable noise level of 90 dB(A). For mitigation of
noise, greenbelt area covering an area of 64 acres has already been developed, which
would further attenuate noise to bring its level down within acceptable levels. In addition,
around 2000 saplings are planted every year.
The control rooms shall be provided with acoustic enclosures to protect the operational
staff from higher noise level. As the operational staff remains within the control rooms/
gas tight rooms for most of the time, they will be exposed to the higher noise levels for
very short duration. During the visits to the areas of higher noise levels, the operational
and maintenance personnel will use earplugs as a safety measure.
Control of vibration shall be achieved by providing proper foundation and alignment to
the vibration generating heavy equipment. Moving parts of equipment and earthmovers
shall be properly maintained and lubricated to minimize the generation of noise.
A sound level meter and noise exposure meter shall be used for regular monitoring.
8.8. Rain Water Harvesting System
A rain water harvesting / aquifer recharging system have been proposed as water
conservation measure. The systems shall be installed at such location of the project
area close to the Administrative building so as to facilitate collection of most of the rain
water from the roofs of the building of the project area within the project site.
The bores shall be provided within 3 m deep enclosures, which will comprise layers of
boulders, gravel and coarse sand so as to separate suspended matter from the water.
Three nos. of ground water recharging system have been proposed to develop in the

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township area and three nos. in the factory area. Rainwater harvesting system will
consist of the following units:
 Rainwater Collection System
 Rainwater Filtration System
 Rainwater Recharging Pond including an active well of depth 20m and dia 100-
150mm
The scheme of rain water harvesting and aquifer recharging is presented below:
Figure 8.3 Rain Water Harvesting System

8.9. Traffic Management Plan
At the starting of the plant most of the material transported through Trucks only.
Gradually MCF reduced the load on the Trucks by using the Railway siding (Wagon) for
the transportation of material (Raw/Product). The site is well connected through the
National Highway-66. No traffic congestion will be there; as well planned network of
internal roads is envisaged in plan.
8.10. Action Plans

8.10.1. Land Environment (Rehabilitation & Resettlement (R&R) Policy)
The proposed expansion of fertilizer plant shall be established within existing unit of
MCF. Hence, an action plan related to Rehabilitation & Resettlement (R & R) policy of
the State Govt. is not at all required for this project.
Action Plan for Disposal of Solid Waste Generated Due To Construction &
Demolition Activities
The proposed expansion of fertilizer plant shall be installed in the free, unencumbered,
vacant land of MCF. However, some old facilities shall be utilized after necessary
refurbishment.
Due to revamping and modification in existing plant, the scrap generated shall be
handled by hiring the agencies as per Govt. practices & norms. The Construction &
Demolition (C & D) waste rules 2016 shall be strictly followed for disposal of the waste
generated.

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Prior to the initiation of excavation activities, work area perimeters will be secured to
restrict or prohibit public access as required. Work zones, decontamination corridors,
and staging areas will be established and posted as required in cooperation with the
selected excavation contractor. All necessary permits and erosion control measures
shall be kept in place prior to disturbing the site. Trees and bushes may be chipped and
disposed of onsite or offsite.
All work at the site is proposed to be conducted in accordance with the provisions of Site
Safety and Health Plan (SSHP) to be developed and submitted to the local body prior to
the initiation of field activities. Excavated materials will be segregated for any deemed
reuse onsite or for offsite disposal at an appropriate facility specific to the characteristics
of the material. It is anticipated that only crushed concrete and stone, and geo-
technically suitable soils that are not contaminated will be reused in the project. If other
materials are to be reused, appropriate reuse scenarios will be developed on a case by
case basis in consultation with the local body.
A storage area for reusable soil and recycled concrete product close to its presumptive
area of end use will be provided. It is anticipated that any unusable debris (wood, tires,
appliances, scrap metal, concrete with rebar, etc.) that may be present at the site will be
handled according to the guidelines specified under Hazardous & other waste
(management & trans-boundary) rules-2016 of MoEF and Construction & Demolition (C
& D) waste rules 2016.
8.10.2. Action Plan To Follow NAAQS
Environmental monitoring plays an important part in environmental management. In
some instances, it is in the interest of the project and environment as well, to perform
continuous monitoring. This can lead to rapid detection and recognition of irregular
conditions and give the operating staff the possibility to correct and restore the optimum
standard operating condition as quickly as possible. Environmental monitoring by regular
spot checking (by manual methods) will suffice to know the status and performance of
equipment and record the emission levels, if any. In general, the frequency of regular
monitoring depends on process technology, type of process equipment, stability of the
process, and reliability of the analytical methods.
A monitoring schedule, prepared in consultation with Karnataka State Pollution Control
Board (KSPCB), shall be maintained for the following environmental parameters:
 Ambient air quality: Adequate number of monitoring stations shall be established
for monitoring of ambient level of PM10, SO2, NOx & NH3. The measurements shall
be performed regularly with the frequency of twice per week to evaluate 24-hourly
concentration.
 Stack Emissions: Stack emissions from Ammonia- Urea plants, DG Sets shall be
monitored by NABL accredited laboratory.

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 Effluent Streams: Monitoring of effluent streams covering all the parameters

specified by KSPCB, with special emphasis on pH, Suspended solids, TKN, Total
Nitrogen, Total Ammonia, Free Ammonia and Oil & Grease.
 Ground water quality: Ground water samples shall be collected and characterized
for all the parameters specified under IS: 10500 at a frequency of once pre-
monsoon and post-monsoon season.
 Noise level: Noise generated from different sources, its level within work zone &
near boundary walls shall be measured once per season.
8.10.3. Action Plan For Solid/ Hazardous Waste
Solid / Hazardous Waste Disposal (Construction Phase)
 The hazardous materials used during the construction may include welding gas
and paints. These materials shall be stored and handled according to the
guidelines specified under Hazardous & other waste (management & trans-
boundary) rules-2016 of MoEF. Some of the precautions for storage and handling
of the hazardous materials includes the following:
 Proper enclosures shall be provided wherever necessary for storage of hazardous
materials.
 Diesel and other fuels shall be stored in separate dyke enclosures.
 On-site recycling of all waste solvents / thinners & oils and off-site recycling of
paint thinner solvent wastes & waste oil.
 Separate storage for waste paints and thinners, contaminated rags and brushes to
facilitate recycling and reuse. Rags shall be laundered for reuse.
 Vehicle maintenance area shall be selected properly to prevent contamination of
soil and ground water by accidental spillage of oil and other wastes.
Solid / Hazardous Waste Disposal (Operation Phase)
The main solid & hazardous wastes are used oil, waste oil, spent catalysts and
discarded containers from proposed project. The E-waste & electronic waste shall be
disposed off through approved vendors following the E-waste (Management) Rules,
2016.
The used and dead battery waste shall be disposed off as per the existing Batteries
(Management and Handling) Rules, 2001 / 2010 and subsequent amendment.
8.11. Socioeconomic Environment
The project will result in social benefits in terms of jobs for the local communities;
induced secondary development in the area; increased cash flow and stimulation of local
economy within the host community and localized economic benefits from materials
supplies by local contractors. With respect to the socio-economic this project will result
into employment for local workers. Due to enhancement in infrastructure facilities and
utilities in living condition will also improve. It will result into the improvement in the
economy of the local vendors.

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8.12. Occupational Safety and Fire Fighting

8.12.1. Organization & Functions
Suitable Safety and Fire-fighting Departments with very good infrastructural facilities is
available in MCF Fertilizer Plant for taking suitable measures for implementation and
observation of safe procedures for prevention and control of accidents and disasters.
Main functions of the department shall be as follows:
 Inspection of different sections of the plant and imparting advice to authorities
regarding unsafe practices
 Procurement and maintenance of PPEs
 Organizing safety motivation programs through competitions on safety and
housekeeping and through posters, cartoons, boards and pamphlets
 Organizing safety training programs to cover all employees and contract labourers
 Implementation of Safety Work Permit system
 Organizing safety auditing through third parties
 Investigation of causes of accidents and recommending reventive/remedial
measures
 Maintaining safety statistics
 Actions for compliance with statutory safety requirements like testing of pressure
vessels, lifting tackles, safety valves, etc.
 Conducting work zone environmental surveys.
All types of PPEs shall be made available to the employees, as and when required.
Explosive meters with alarms will be provided at vulnerable locations. Equipment for
monitoring of working environment shall be maintained in good working condition and
operated.
8.12.2. Occupational Safety and Health
The hazards associated with the proposed project are as follows:
 Exposure to or contact with hazardous materials
 Exposure to thermal radiation resulting from fire
 Exposure to blast overpressure resulting from explosion
The probability of occurrence of fire and explosion in the proposed facilities is too low to
cause occupational safety and health problems.
Occupational Health Centre at MCF
 Well equipped Occupational Health Centre with a full time doctor and qualified /
experienced nurses.
 OHC is totally air conditioned and there are 6 beds which are connected with
centralised oxygen supply system.
 Showers and Eye wash fountains are provided at OHC for decontamination.

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 Treatment Room for examination of patients and conducting minor procedures.

 Emergency medicines are available.
 Small laboratory and autoclave are provided.
 Showers, eye wash fountains and first-aid boxes are provided in all the
departments.
 OHC is provided with following equipments
 Pulse Oxymeter
 ECG Machine
 Suction Apparatus
 Ambu Bag /Oxy pack
 Spirometer
 Defibrillator
 Glucometer
 Cervical collar / splints
 MCF has a well maintained in good condition and suitably equipped Ambulance
Van.
8.12.3. Safety Measures proposed to be adopted in Plants
The following safety measures will be adopted in MCF, Mangalore:
 Plant Safety Committee comprising of senior officers and workmen will meet
regularly to discuss about the safety of the plant and working procedures.
 Safe start-up and shut-down procedures will be followed as prescribed in the
operating manual.
 Interlocks and trips provided for safety of equipment will be checked at regular
intervals.
 All jobs will be carried out as per safe working procedure and with proper safety
permit, which is valid for a particular period.
 Regular safety inspection, checking and safety audits will be carried out and follow-
up action will be taken for implementation of recommendations.
 Any accident occurring will be investigated and remedial measures will be taken to
avoid occurrence of similar type of incidents. Record of accidents will be
maintained and reported.
 Safety valves shall be regularly checked during annual shut-down and a record will
be maintained.
 Before entry into any closed vessel for maintenance/ inspection, the equipment is
isolated and purged with air and checked thoroughly by Safety Department and
permit will be issued. Persons entering will be provided with safety implements
including gas masks, if necessary.
 Periodic lectures shall be conducted to make the plant personnel aware of the
safety rules and codes and their importance. Officers, operators, technicians,
helpers, mazdoors and contract workmen shall be covered in this safety training

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8.12.4. Safety Appliances.
Table 8.3 List of Equipment Required
Each employee working in the factory shall be given the following items:
Safety Helmet Safety Goggles Cotton Hand gloves Ear Plug
Following items are proposed to be kept ready in each plant control room to take care of day to day work
as well as emergencies:
Breathing Set Rescue stretchers Canister Type Gas Mask Extra Canisters
(NH3,, Acid gases and
Organic vapour)
PVC Suit Gum Boots PVC Hand Gloves Hand Gloves
Hood Airline Breathing Set
Safety appliances to be available in the Fire and Safety dept are as under:
Powered Respirators Rescue Sets Breathing Apparatus PVC Suit
Asbestos Suit Hand Gloves Canister Type Gas Mask Line Sets
(NH3, Acid gases and
Organic vapour)
Cartridge Type Gas Dust Respirators
Mask
In addition, Safety equipments shall be available in Stores Department in adequate
quantity. Most of the safety equipments will be codified and a minimum fixed number of
quantities will be maintained in Stores Department. Safety Board and Safety Posters
mentioning hazardous, explosive, toxic and flammable gases, corrosive liquids, NO
SMOKING OR NAKED FLAME and other precautions shall be displayed in vulnerable
areas.
Gas Detectors and smoke detectors shall be provided in vulnerable areas of the plants.
Safety showers and eye wash fountains shall be provided in relevant sections of the
plants.

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Figure 8.4 Medical Facility Inside the MCF Plant

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8.12.5. Fire Fighting System

Fire fighting operations at MCF shall be managed by a well organized team of qualified and
experienced personnel under the leadership of Chief Manager (Safety). The fire service shall be
maintained round the clock. One shift group leader and three fire & safety technicians are
available in each shift.
8.12.6. Fire Protection System
The fire protection system of MCF shall be certified by Insurance Company and also by
Statutory Authorities. The system consists of the followings:
 Fire Water Pumps: The reservoir shall be connected with the Motor Driven, Diesel
Driven and Motor Driven Jockey Pumps
The pressure in the fire hydrant system shall maintain by jockey pump and when the
hydrants are opened, the pressure in the hydrant system decreases.
 Fire Hydrants: Fire water network shall be laid out as per Fire Protection Manual to
cover all plants and buildings (including all floors). The water main shall be
connected with pumps mentioned earlier. Fire hydrants and monitors shall be
provided in the plants to cover all vulnerable areas and other areas:
The fire hydrants and monitors shall be laid out to cover all sections of plants and office
buildings:
 Water spray system in Ammonia Road Tanker loading station, Import Ammonia
Terminal and Urea Plant
 Fire Detection System: Urea and Ammonia Sub-stations and Control Rooms shall
be provided with fixed gas detection system.
 Automatic DCP Extinguishers: Automatic Dry Chemical Power Extinguishers
(capacity- 10 Kg) shall be provided in all the transformers in the plant.
 Alarm System: Urea, Ammonia plants shall be provided with fixed fire alarm
system.
 Fire Fighting Appliances (Main): MCF equipped with one foam tender. A trailer
pump is also available.
8.12.7. Preventive Maintenance
During an annual shutdown of the plant, preventive and predictive maintenance of all the
sections of the plants shall be undertaken. Non-destructive testing of pressure vessels,
pipelines and the storage tanks shall be carried out periodically as part of safety audit of
the equipment.
8.12.8. Disaster Planning
A Disaster Management Centre shall be established for meeting any emergency
situation arising due to fire and explosion and discharge of toxic gases. Fire-fighting

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equipment and other safety appliances shall be kept ready, for use during disaster and
emergency situations. The disaster management plan has been included in Chapter-8.
8.13. Environmental Policy of MCF
The Company’s policy shall integrate the conservation and protection of the environment
and safety of the workmen. The main points in the policy shall be:
 Always striving for the safety of the workmen, public around and betterment of the
Environment.
 Regular and continuous monitoring of ambient air, stacks, work place, etc.
 Healthy Operating Practices.
 Compliance with all National and State Environmental and Safety regulations.
 Responsibility for Environment and Safety compliance as a line function.
 Survey and monitoring of the employees’ health at regular intervals.
 Training at all levels inclusive of contract employees.
 Technical audits to cover environmental aspects, safety, health and energy.
 Environment and Safety policy covering the interests of employees, customers,
community.
 Quantitative Risk Assessment, Disaster Management Plan, Emergency
Preparedness Plan, Accident Investigation, Analysis and Reporting System, Safety
Inspection.
 Environmental Impact Assessment.
 Providing personal protective equipments and their periodic review for
effectiveness and up-gradation.
 Active participation in mutual aid committee. Health survey and monitoring.
8.14. Measures for Protection of Environment
8.14.1. Energy Saving Measures
A well equipped Energy Management Cell with qualified auditors with great deal of
expertise in Energy management and Power conservation shall be set-up in MCF.
Detailed schemes shall be planned by all plants and service groups to arrive at
practicable minimum energy and Power consumption. This will result in significant
improvement in plant performance with added zeal for resource conservation and
environment for upkeep Energy conservation. Few important proposed measures are
presented below:
a) In Waste Heat Recovery Boiler (WHRB), waste/ flue gases shall be used for pre-
heating BFW and power generation.
b) Corro-coating: Corro-coating shall be done in various major energy consuming
sources like cooling tower pumps in main plants and utility plant, fire water pump leading
to substantial amount of power savings.

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c) Evaporating cooling for Process Air Compressor (PAC): Through-put in PAC shall
increase due to evaporating cooling resulting in more ammonia production contributing
to less energy consumption.
d) Use of Automated Control System (ACS) in Ammonia plant: ACS leads to
accurate control of load optimization, steam carbon ratio, CO2 maximization leading to
production maximization which amounts to 0.05 MKcal/ton of energy in ammonia
manufacturing.
e) Use of VFDs: Variable Frequency Drives shall be installed in Ammonia, Steam
generation, Urea plant etc to operate the equipment during various plant requirements at
low RPM to reduce energy consumption to the tune of 25-30%.
f) Use of solar water heaters: Solar heaters shall be installed at strategic locations like
Canteen, Guesthouse etc. to reduce energy consumption.
g) Solar Lighting: Energy saving shall be achieved with lower wattage alternatives
using solar power panels for street lighting, plant lighting, lighting at offices with LED
lamps.
8.14.2. Miscellaneous Energy Saving Programs
MCF shall pay proper attention for implementation of following energy saving programs.
The programs are as under:
Green Light Program
It involves installation of energy efficient lighting system which reduces indirectly
generation of oxides of Carbon, Nitrogen and Sulphur. However, there shall not be any
comprise with required illumination at working places.
Energy Star Program
Use of energy efficient electrical appliances including computers shall be practiced.
8.14.3. Fund allocation for EMP
A fund of about 2.5 % of total project cost has been earmarked against the
environmental management and related expenses. MCF shall also pay proper attention
to improve the working environment by adopting the principle of Ergonomics in the
following line of action:
“In order to maximize the working and skill capability of the work-men, the Environmental
Management Plan considers the strategy and goal of Ergonomics. The application of
ergonomics will reduce the Muscular Skeletal Disorder (MSD)”.
The capital cost for environmental measures related to proposed project is worked out
for implementation of environmental management plan and is given in Tables 8.5 The
total capital cost for EMP is calculated as approximately 56 crores and the recurring cost
is aprox 3 crores.

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Table 8.4 Total estimated budget for implementation of EMP
Capital cost in Rs. (Crores) Annual Recurring

Cost (maintenance
Sr. Ammonia DAP/
Particulars PCE and electrical cost
No. and Urea NPK
Plant and manpower cost)
Plant Plant
in Rs. (Crores)
Water pollution Control,
1 Sewage and Effluent
Treatment plant
2 Air Pollution Equipment
Rain water storage tanks & 30.0 25.0 1.0 3.0
3
green belt development
Solid and Hazardous waste
4
Management
5 Noise Pollution Control
Total 56.0 3.0
“Attempts shall be made to make the Working Environment to fit the Workmen
instead of forcing a workman to adopt the Working Environment.”
8.14.4. Environment Cell
An Environmental Management Group consisting of competent workforce headed by
JGM level was established by the proponent to deal with various environmental aspects
including follow-up with Karnataka SPCB, Regional MoEF&CC and CPCB and to interact
with inter-disciplinary groups responsible for maintenance and operation of pollution
control equipment. The group reports to head of the station. The same group will continue
as nodal department for the proposed project also when in operation, with following
functions.
 Obtaining Consent Order from SPCBs;
 Environmental monitoring;
 Analysis of environment data, reports preparation and transmission of report to
statutory authorities and Corporate Centre etc.;
 Compliance with guidelines and statutory requirements;
 Coordination with statutory bodies, functional groups of the station, Corporate level
etc.;
 Interaction for evolving and implementation of modification programs to improve the
availability / efficiency of pollution control devices / systems;
 Environmental Appraisal (Internal) and Environmental Audit;
The cell will carry out number of activities related to effluent treatment and monitoring of
treated effluent, ambient air quality, noise generation, greenbelt development and stack
emissions. Compliance report w.r.t. environmental clearance conditions will be submitted
to Regional Office, MoEF in every six months.

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8.15. Corporate Responsibility on Environmental Protection (CREP)

Implementation of the recommendations made for the fertilizer plants in the Corporate
Responsibility on Environmental Protection guidelines are prepared and followed as
tabulated below in Annexure VI.
8.16. The Fertilizer Association of India (FAI) Environmental Protection Award
MCF has won the prestigious FAI Environmental Protection Award in the NP/NPK
fertilizer plants excluding captive acids category for the six consecutive years i.e., 2014-
15, 2013-14, 2012-13, 2011-12, 2010-11 and 2009 -10.
Mr. K. Prabhakar Rao, Director- Works receiving the

Mr. K. Prabhakar Rao, Director- Works
FAI Award – 2015 from Mr. Anath Kumar, Hon'ble
receiving the FAI Award – 2014 during FAI
Minister of Chemicals and Fertilizers, Govt. of India
Annual Seminar-2014
during FAI Annual Seminar-2015
Mr. Deepak Anand, Managing Director

Mr. Deepak Anand, Managing Director receiving the
receiving the award from Mr. Srikant Jena,
FAI Award – 2013 from Mr. Sharad Pawar, Hon'ble
Hon'ble State Minister for Chemicals &
Minister for Agriculture, Govt. of India during FAI
Fertilizers, Govt. of India during FAI Annual
Annual Seminar-2013
Seminar-2012

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Mr. Deepak Anand, MD, MCF receiving

Mr. Deepak Anand, Managing Director receiving the
award from Mr. M.K Alagiri, Honorable
award from Shri Srikant Kumar Jena, Hon’ble
Union Minister of Chemicals & Fertilisers,
Minister of State for Chemicals & Fertilizers, Govt.
Govt. of India during FAI annual seminar -
of India during FAI annual Seminar-2011.
2010.
8.17. CSR Activity
 Construction of toilets to the Govt. Schools in the rural areas under the Corporate
Social Responsibility initiative.
 ‘Mangala Akshara Mitra’ a new CSR initiative of MCF was conceptualized during
early part of 2011 with an aim to support Government Rural Primary Education
System. The focus of the initiative is to promote education, to make schooling a
pleasant experience to the rural children by providing required infrastructure like
uniform, school bags, desks, cupboards, table & chair, computers, slotted angle
racks, stainless steel water tumblers & lunch plates for midday meals etc. to
selected schools in remote villages. This programme is also extended to serve for
tribal children and physically/mentally challenged children.
 MCF initiated a programme “Project Eye Care” as a part of CSR activity. The
purpose of this initiative is to prevent blindness especially in rural areas. Free eye
camp facility was conducted in remote villages viz. Kushalnagara, Kashipatna,
Aladangadi and Vogga. During this programme around 1558 patients were
examined. Free spectacles distribution and surgery was arranged by MCF. Free
health and eye checkup camps were also conducted for MCF Contract labourers.
170 patients were examined and treated in the camp.
 Mangala Rytha Suraksha Vima Yojana: The scheme “Mangala Rytha Suraksha
Vima Yojana”, for insurance coverage of Rs.25,000/- for farmers in the event of
their death or disablement has been implemented by MCF. About 1,60,000 farmers
are covered under this scheme.
 Integrated Nutrient Management for the benefit of farmers of Karnataka - Activities
under this project is Technical Advisory Service to farmers addressing issues
relating to soil management, plant nutrient management, pest management and

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water management through crop seminars, demonstrations, product trials, training

programmes & field visits.
 Providing training to students of various Universities and other educational
institutions in Management, Engineering, Environment, Science, Commerce,
Social Work and other disciplines.
 Development/maintenance of new ecological and environmental initiatives like
“Aquatic Park” in Pilikula Nisargadhama.
 Annual maintenance charges for adoption of “Sambar Deer” in Pilikula Zoological
Park.
 Development of golf course at Pilikula.
 Planting of saplings in green belt area.
 Regularly conducting public awareness programmes in the neighbourhood for
educating public in environmental and safety aspects.
 Imparting Internet education, health camps for the benefit of neighbouring public,
uniforms to school children of Thokur and Kulur schools.
 Providing computers to Kannada Medium Higher Primary Schools, sanitation
facility in schools of nearby villages, play grounds to school children and
renovation of school building at Thokur.
 Community development programme, patronizing cultural activities in DK District,
Sponsoring rural sports, sponsoring seminars, workshops at neighbouring
universities and educational institutions and imparting training to students.

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CHAPTER 9. SUMMARY AND CONCLUSION
This chapter concludes on the findings that emerged from the environmental assessment
study and summarizes the key points to be addressed to ensure the environmental
sustainability of the project during the construction and operation phases.
9.1. Summary and Conclusion
The status of the environment at the project site and within the study area of 10 km radius
is delineated with respect to air, noise, water, land, biological and socioeconomic
environment. The different project activities during the construction and operation phases
are identified. To identify the impacts, the interaction between the project activities and
different components of environment are classified phase wise. A summary of the
identified impacts are given in the following paragraphs.
During the constructional phase, the transportation of construction material may have an
impact, especially on air, noise, vibration, and soil. At the time of construction and
operation stage, there will be minor impact on environment.
The additional strength of labourers could temporarily increase the pressure on the
resources of the area. During the operational phase, there could be minor change in air
quality .Transportation of raw material, storage and handling of hazardous material and
the production process could cause a temporary disturbance to environment variables
which will be prevented with the proposed mitigation measures proposed in Chapter 4.
With respect to occupational health, minimal impacts are anticipated on the health of the
employees during operation phase.
In general, expansion of project shall help in enhancement of productivity in the region as
well as generate direct and indirect employment in the area.
9.2. Regulatory Compliance
The project is yet at its technical investigation stage. Prior to its implementation, it will be
necessary to acquire all the necessary clearance from the Government of India, as per
the applicable national regulations. Key clearances include obtaining No Objection
Certificate from the Karnataka State Pollution Control Board (KSPCB) under The Water
(Prevention and Control of Pollution) Act, 1974 and Rules, 1975; The Air (Prevention and
Control of Pollution) Act, 1981 and Rules, 1982. In addition to that Manufacture, Storage
and Import of Hazardous Chemicals (MSIHC) Rules, 1989 and amendments thereafter,
Hazardous and Other Wastes (Management and Trans-boundary Movement) Rules,
2016, Bio Medical Waste (Management & Handling) Rules, 2016 and Municipal Solid
Waste (Management & Handling) Rules, 2016 will also be applicable to the industry.

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9.3. Baseline Conditions
The monitoring of the existing environmental conditions of the proposed project site and
of its close vicinity have been established with respect to physical, biological and human
environment.
The air quality of the area meets the prescribed National Ambient Air Quality Standards
applicable for the Industrial, Residential & Rural Areas. The background noise levels
were also found well within the standards.
The ground water quality prevails in the study area were in good agreement with IS:
10500 permissible limit. Overall the surface water quality of canal, pond and minor is
meeting the Class ‘C’ , Class ‘D’ of BDU Criteria of CPCB for its suitability for wild life and
fisheries.
Ambient noise level of the study area is within the prescribed National Ambient Noise
Quality Standard for respective residential, commercial and industrial category at all the
monitored locations.
9.4. Environmental Impacts and Mitigation Measures
The project entails various impacts on the study area, lots of positive and some negative.
There is going to no adverse impact on water quality or water demand due to proposed
project. There will be no additional water drawl from the Mangalore City Corporation as
the water requirement for the proposed projects will be met by reusing the treated
wastewater.
The impact (incremental GLC) due to the new stacks were computed and all pollutants
post project GLC will be well within NAAQ norms
There will be no adverse impact on land or noise level due to proposed project.
MCFL has taken adequate measures for EHS aspects for the proposed project. In
addition recommendations have been made to further strengthen the EHS measures,
energy conservation and other EMP aspects.
9.5. Recommendations
Based on the environmental impact assessment conducted, the following

recommendations are made:
 Since regulations are fast changing in India, the project proponent must keep
himself or herself updated with respect to applicable laws and take appropriate
actions in case the provisions in some regulations undergo change.
 The impacts envisaged due to construction activities will be for short limited
period. Impact due to operational activities, systems of periodic auditing and

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reporting shall be adopted during the operation period to ensure that the system
adheres to the EMP.
 The project proponent and its team of consultants and contractors are urged to
develop a strategy for effective communication with local people. The construction
team/ developer should effectively follow the suggestions made in the EMP and/
or any other environmental measures so as not to damage the environment of the
project area.
 CSR activities should be taken up in association with district authorities.

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CHAPTER 10. : DISCLOSURE OF CONSULTANTS

Declaration by Experts Contributing to the EIA/EMP REPORT for the Energy improvement
project of Ammonia and Urea plant, 1 million t/y DAP/NPK project and 18,000 MTPA Poly
Carboxy Ether project at Mangalore, Karnataka. I, hereby, certify that I was a part of the EIA
team in the following capacity that developed the above EIA.
EIA Coordinator:
Name: Mr.Yashwant Bordia
Period of involvement January 2017 to finalization of report
Contact Information: 011-30003200
Functional Area Experts

Name of the Involvement (Period and Task**)
Functional Areas
Expert Jan 2017 to finalization of report
 Micro Meteorology and air pollution monitoring
Air Pollution
planning also quality check.
Monitoring & Control S K Jain
 Impact assessment, mitigation & environmental
(AP)****
management plan preparation.
 Analysis of collected baseline data
Air Quality Modeling  Processing of micrometeorological data for using
Sanjeev
and Prediction in model.
Sharma
(AQ)****  Analysis of predicted impact due to the modelling
result.
 Water Quality monitoring network designing.
 Sampling of water samples (surface and ground
water).
 Monitoring of water quality.
Water Pollution (WP) S K Jain
 Water Balance
 Identification & assessment of quantum of water
pollution and its Mitigation measures.
 ETP Suggestion.
 Analysis of collected baseline data
Sanjeev  Processing of data for modelling purposed.
Noise and Vibration*
Sharma  Analysis of predicted impact due to the modelling
result.
 Conducted Ecological survey & preparation of
status report.
 Application of taxonomy in resource inventory
Ecology and Bio-
(Flora & Fauna)
diversity Ratnesh Kotiyal
Conservation (EB)**  List of species animals and plants report.
 Identification & assessment of ecological impact
due to proposed project and its Mitigation
measures.
Solid and Hazardous S K Jain  Identification of hazardous and non-hazardous

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Name of the Involvement (Period and Task**)

Functional Areas
Expert Jan 2017 to finalization of report
Waste Management wastes.
(SHW)  Reuse and recycling of solid wastes.
 Handling and disposal of Non- Hazardous solid
waste & Hazardous waste.
 Baseline socio economic survey(Interviews,
Questionnaires, focused group discussion)
Socio-Economics
T G Ekande  Evaluation of Socio economic development
(SE)***
status of the area.
 Enterprise social commitment provisions.
 Identification of hazards due to proposed project.
 Identification of hazardous substances in the
Risk and Hazards
SK Jain proposed project.
(RH)
 Preparation of risk assessment report and onsite
emergency plan.
Hydrology, Ground Mr. Yamesh
 Site visit, contribution to Baseline environment
Water & Water Sharma
and contribution to EIA documentation
Conservation (HG)
Land Use Mr. Anil Kumar 
Site visit, contribution to Baseline environment
and contribution to EIA documentation
* Shweta has contributed for Noise and Vibration (NV) with concerned FAE.
** Dr. Alok Singh has contributed for Ecology and Bio-diversity Conservation (EB) with
concerned FAE.
*** Anil Kumar has contributed for Socio-Economics (SE) with concerned FAE.
**** Om Prakash has contributed for AP & AQ respectively with concerned FAE.
Declaration by the Head of the Accredited Consultant Organization/authorized person

I, S.K.Jain, hereby confirm that the above-mentioned experts the EIA/EMP REPORT for
Energy improvement project of Ammonia and Urea plant, 1 million t/y DAP/NPK project
and 18,000 MTPA Poly Carboxy Ether project at Mangalore, Karnataka. I also confirm
that the consultant organization shall be fully accountable for any mis-leading information
mentioned in this statement.
Name: S.K.Jain
Designation: Director, Technical
Name of the EIA Consultant organization EQMS India Pvt. Ltd.

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Annexure I: NABET Certificate
EQMS INDIA PVT LTD

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Annexure II: Land Document
EQMS INDIA PVT LTD

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Annexure III: ToR Letter
EQMS INDIA PVT LTD

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Annexure IV: Compliance of Earlier EC Letter
EQMS INDIA PVT LTD

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Annexure V: Agreement with GAIL for Gas Supply
EQMS INDIA PVT LTD

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Annexure VI: Compliance of CREP Guideline
EQMS INDIA PVT LTD

PREFEASIBILITY PROJECT REPORT
(PPR)
ON
1. ENERGY IMPROVEMENT PROJECT OF AMMONIA & UREA

PLANTS BY MODERNISATION AND CAPACITY ENHANCEMENT
OF AMMONIA FROM 2,47,500 t/y TO 3,28,500 t/y AND UREA
FROM 4,29,000 t/y TO 5,69,400 t/y.
2. 1 MILLION t/y DAP / NPK PROJECT
3. POLY CARBOXYL ETHER (PCE) PROJECT OF 18,000 t/y
OCTOBER 2017
MANGALORE CHEMICALS & FERTILIZERS LIMITED

PANAMBUR, MANGALORE – 575 010.
Page 1 of 31
1. PREAMBLE
Mangalore Chemicals & Fertilizers Ltd (MCF) is an 'Adventz' Group Company, a large and
diversified business house. The main products of MCF are Urea, Di-Ammonium Phosphate (DAP),
NP 20:20:00:13, Ammonium Bi-Carbonate (ABC) - Food grade, Sulphuric Acid, Specialty Mixtures
of Plant Nutrients consisting of Water Soluble Fertilizers, Micronutrients & Soil Conditioners and
an Industrial Product called Sulphonated Naphthalene Formaldehyde (SNF) used in construction
industry.
MCF is the only manufacturer of chemical fertilizers in the state of Karnataka. The factory is
strategically located at Panambur, 9 km north of Mangalore City, on the banks of the Gurpur River,
along the National Highway 66, opposite to the New Mangalore Port Trust. MCF is an ISO 14001,
OHSAS 18001 and ISO 22000 certified Company.
The main products are Urea, Di-Ammonium Phosphate (DAP), NP 20:20:00:13, Ammonium Bi-
Carbonate (ABC) - Food grade, Sulphuric Acid, Speciality mixtures of plant Nutrients consisting of
Water Soluble Fertilizers, Micronutrients & Soil Conditioners and an Industrial Product called
Sulphonated Naphthalene Formaldehyde (SNF) used in construction industry.
While fertilizers and Plant nutrient products are marketed in all the Southern States and
Peninsular India, the food grade ABC, which is used mainly in Confectionery Industries is marketed
in domestic as well as international market. The requirement of power for the production facility
(process plants) is met by a Captive Power Plant. Ammonia & Phosphoric Acid, the raw materials
required for DAP & NP production are imported.
Page 2 of 31
The consented capacity for the intermediates and products manufactured are as below:
Sl. No. Product t/y
1 Ammonia 2,40,900
2 Urea 4,19,750
3 DAP & NP (16:20 & 20:20) 4,01,500
4 Ammonium Bicarbonate (ABC) 24,750
5 Sulphuric Acid 1,46,000
6 Sulphonated Naphthalene Formaldehyde 85,000
7 Speciality mixtures of plant nutrients 2,21,000
8 Handling of imported fertilizers 4,00,000
Construction of Ammonia and Urea plants commenced in 1972 and commercial production
started in 1976. Di-ammonium Phosphate (DAP) production commenced during 1986.
Commercial production of Ammonium Bicarbonate started in 1982. Sulphuric Acid Plant was
commissioned during March 2006. Captive Power Plant commissioned during 1986.
A new construction chemical product Sulphonated Naphthalene Formaldehyde facility was

installed in 2010 as part diversification. MCF also has installed a Speciality fertilizer plant to make
Water Soluble Fertilizers & Micronutrients in 2011.
MCF Intends to modernize the existing facilities & expand by putting up the following plants in
existing location at Mangalore.
1. Energy Improvement Project of Ammonia & Urea Plants by modernization and capacity
enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y
to 5,69,400 t/y.
2. 1 million t/y DAP / NPK Project.
3. Poly Carboxyl Ether (PCE) Project of 18,000 t/y.
Page 3 of 31
2. NEED FOR THE PROPOSED PROJECTS
2.1) Energy improvement Project of Ammonia & Urea plants by modernization and capacity
enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to
5,69,400 t/y. : MCF intends to do energy improvement revamp of existing Ammonia / Urea
plants. The revamp is necessitated due to recently announced new urea GOI policy No.
12012/1/2015-FPP dated 25-05-2015. All Ammonia/Urea manufacturers are mandated to
improve their energy norms to particular levels by 2018-19 to keep themselves in black. The
norms prescribed for MCF vintage is 6.5 Gcal/t of urea. As the operation profitability depends
only on energy and payment of all subsidy costs are energy dependent, it becomes necessary
for manufacturers like MCF to bring down energy norms to best achievable industry levels to
continue operation.
The existing Ammonia and Urea plants are running efficiently and scope for energy
improvement is seen due to vintage of plants.
Also, Urea is an important fertilizer segment. The supply/demand gap is huge and more than
8 million tons of urea imports are done as of now. The estimated total demand supply gap
in 2015-2016 was 8.2 Million MT of urea alone. Government of India is bound to support this
industry through conducive policies/subsidies. All southern states of India namely Karnataka,
Tamilnadu, Kerala and Andhra Pradesh have enough demand for Urea. The capacity
enhancement proposed by MCF will help towards filling the supply/demand gap.
2.2) 1 Million t/y DAP/NPK Plant. : DAP/NPK Fertilizer Complex is an important area of fertilizer
segment. India is the third largest producer and second largest user of DAP/NPK and has one
of the largest areas under Irrigation. Complex Fertilizers includes DAP (Di Ammonium
Phosphate) and NPK Fertilizers. There is huge demand for Phosphatic fertilizers in the
country. India has produced, 10.5 million tonnes of DAP/NPK during 2013-14 and imported
6.7 million tonnes of DAP/NPK. In India, DAP is the major product contributing 63% of the
total phosphate consumption. The estimated total demand supply gap by 2017-18 would be
11 Million MT of DAP alone. DAP & NPK fertilizers are in great demand and there is huge gap
between availability and supply. India is a net importer of DAP & NPK fertilizers. DAP/NPK is
an important fertilizer and Government of India is bound to support this industry through
Page 4 of 31
conducive policies/subsidies. All southern states of India namely Karnataka, Tamilnadu,
Kerala and Andhra Pradesh have enough demand for DAP/NPK fertilizers.
MCF intends to put a unit of DAP/NPK along with associated facilities. Bagging plant, bulk
silo, raw material storages, offsite and utilities etc. are part of associated facilities.
This is an expansion project. Accordingly, required site infrastructure and utilities are
available. MCF has vacant land of about 50 acres in the existing fertilizer complex and layout
is developed. The present fertilizer complex is located in Baikampady Industrial Estate
notified by Karnataka Industrial Area Development Board, (KIADB) Karnataka. The site is well
connected and has advantage of good infrastructure facilities like roads, water, power,
effluent treatment facilities and good green belt.
The site selected for the project is currently available at the premises of MCF, which makes
integration of utilities like power and steam generation with existing fertilizer plant very cost
effective. The geographical proximity of the plant with the New Mangalore Port offers
excellent logistic advantage for import of raw material with cost advantage.
Existing infrastructure will be most optimally used resulting in increase of productivity of

existing operations as well as reduction of overall cost of new project. Further the impact on
environment will be minimal compared to the project being set up on a new green field site.
2.3) Poly Carboxyl Ether (PCE) Project of 18,000 t/y. : At present we are manufacturing and
supplying Sulphonated Naphthalene Formaldehyde (SNF) which is mostly used in
Construction Chemical Industry to manufacture water reducing Admixtures also known as
super plasticizers. In India now due to recent developments in construction technology high
strength concrete started coming in to play. SNF was workable till the concrete of M45
grade. But the concrete which is more than M45 grade requires different type of admixtures
known as hyper plasticizers. To formulate hyper plasticizer the basic raw material required
is Poly Carboxylate Ether (PCE).
Page 5 of 31
ADVANTAGES OF PCE:
a. Produces concrete with high levels of workability without segregation.
b. Provides significantly higher strengths and normal setting time.
c. High early strength and 28 day’s strength increase obviously, especially for high dosage fly
ash concrete.
d. Has excellent concrete rheology and handling properties.
e. Provides improved finish ability and surface finishes.
f. Has superior air entrainment control.
g. Provides standard water reduction at normal addition rates and significant water reduction
at higher addition rates.
h. Has no chloride ions and non-corrosion to steel bar.
i. Improves the frost resistance and carbonation resistance of the concrete. Lower drying
shrinkage of the concrete by 20% or more compared to Naphthalene-based admixture.
j. Green product, this product don’t generate pollution in the production process, and meets
the requirements of ISO 14000.
To summarize, Poly carboxylates are sophisticated high end super plasticizers component for
concrete application, are considered superior to any other super plasticizers component.
As a part of growth/diversification strategy, various projects were studied based on MCF’s core
competency and available infrastructure. However it is identified that there is an excellent growth
potential for Poly Carboxylate Ether (PCE) also known as next generation water reducer which is
next to Sulphonated Naphthalene Formaldehyde (SNF).
Page 6 of 31
3. PROCESS DESCRIPTION
Energy improvement Project of Ammonia & Urea plants by modernization and capacity
enhancement of Ammonia from 2,47,500 t/y to 3,28,500 t/y and Urea from 4,29,000 t/y to
5,69,400 t/y.
3.1 Process Description – Ammonia Plant.

Brief Description of the Process. Ammonia plant has the following sections:
a) Naphtha Pretreatment
b) Reforming
c) Shift Conversion
d) Co2 Removal
e) Methanation
f) Compression
g) Synthesis
h) Purge Gas Recovery
a. Naphtha Pretreatment Section:

In this section the feed naphtha is purified of sulfur from say 200 ppm to 1 ppm. The naphtha is
heated to 380C and reacted with hydrogen to convert all the sulfur into hydrogen sulfide in the
reactor filled with CoMox Catalyst of volume.
b. Reforming section:
Reforming of the feed naphtha is carried out in primary and secondary reformer. In the primary
reforming process naphtha is reacted with the steam in the reformer tubes where the
hydrocarbon is converted to hydrogen, methane, carbon dioxide, carbon monoxide in the
presence of the nickel catalyst. The overall reaction is endothermic and heat is supplied by means
of burners on the top of the reformer. There are four rows of 56 tubes each and 5 rows of burners
with 12 burners in each row. In the secondary reforming the process gas from the primary
reformer is made to react with the preheated air. Here the methane content is reduced to say
0.30% and the nitrogen which is required for the ammonia synthesis is added to the process.
Page 7 of 31
c. Shift Conversion:
The process after giving the heat for steam generation in the waste heat boilers enters the high
temperature and the low temperature shift conversion vessels where Carbon monoxide in the
process gas is converted to carbon dioxide in two steps. The catalyst used is copper promoted
iron oxide. At the end of the shift conversion, the CO in the process gas is reduced below 0.20%.
d. CO2 Removal Section:

In this section, Benfield process is adopted. The gas coming out of the shift converter contains
hydrogen, nitrogen, carbon dioxide, carbon monoxide, methane, argon and excess of the steam
added in the reformer. Only hydrogen and the nitrogen are desirable for the production of the
ammonia. CO2 which is the raw material for the production of the urea is separator in this section
and sent to the urea plant.
e. Methanation:
In this process the residual Carbon monoxide from the shift conversion process and the carbon
dioxide from the C02 removal process is converted to methane in the nickel catalyst bed as these
are poisons for the synthesis catalyst.
f. Compressors:
Synthesis gas compressor increases the pressure of the make-up gas to the synthesis pressure as
well as it is used to recirculate the recycle gas. The synthesis section operates at pressure of 200
kg/cm2 as the ammonia reaction is favored by high pressure. Air compressor is used to compress
the air and supply it to the secondary reformer. A refrigeration compressor is used to cool the
synthesis convertor outlet gases to condense and separate the product ammonia.
g. Synthesis:
Synthesis converters are Haldor-Topsoe design S200 configuration. Here the process gas
containing hydrogen and nitrogen in the ratio of 3.0 is passed over the iron catalyst in the two
beds arranged in series with intercoolers and quenches to control the reaction temperatures. The
conversion to ammonia is only partial and hence the requirement of the recirculation.
Page 8 of 31
h. Purge gas recovery:
Purge gas recovery is a cryogenic process, where in the hydrogen from the purge gas is recovered
and recycled to the compressor suction. This helps to increase the production and the process
efficiency. Purge is generally given to maintain the inert in the circulating gas to the converter.
Flow diagram for the existing plant.
Page 9 of 31
3.2. Revamp Process: Ammonia Plant.
The plant is currently operating with naphtha as feed and fuel and operates with an energy
consumption of around 9.6 GCal/t. The plant is already converted in year 2014 to operate on
Natural gas as feed and fuel. In the revamped process, production of the ammonia plant will be
increased with a decrease in the energy consumption to around 8.0 Gcal/t when operated on
natural gas. However, the plant can be operated on Naphtha also and in naphtha based operation,
plant capacity will remain at present level, but energy consumption will reduce to 8.5 Gcal/t. The
revamping process will include the following modifications.
Revamp details.
a) Reformer section:
In the reformer section in the convection side two coils will be added. One is for preheating the
feed NG before it enters the fired heater and the other is to heat the NG and the steam mixture
before it enters the primary reformer. This will increase the inlet temperature to the primary
reformer by heat recovered from flue gases thereby bringing down firing and the heat flux in the
tubes. This calls for the replacement of the cross over line and the inlet pig tails. It also calls for
replacement of some of the coils in the super heater section and replacement of the tubular
combustion air heater with a plate heat exchanger. The temperature to stack will be brought
down to 136°C versus the current value of 170°C.
b) CO2 removal section:

The current CO₂ removal section with UOP Benfield process consists of a single stage regeneration
consumes around 1100 Kcal energy per Nm³ of CO₂ separated. Whereas going forward using the
GV low heat two stage regeneration the regeneration energy can be brought down to around 700
Kcal/Nm³ of CO₂ separated. It calls for an additional regenerator operating at very low pressure
(1.05 kg/cm² a) and the current one will operate at close to 2.0 Kg/cm²a. In addition to this a
blower will be required to boost the CO₂ from the low pressure regenerator. The CO₂ will be
available to the urea plant at 1.40 kg/cm2a compared to the current value of 1.25 Kg/cm²a.
c) Compression section:
a. Synthesis gas compressor
A completely new set of compressor and drive turbine will replace existing Motor + turbine
driven compressor.
Page 10 of 31
b. Air compressor
The new compressor purchased for the gas conversion project along with the existing
compressor will be adequate for the revamped requirements.
c. Refrigeration compressor
To optimize the load on the refrigeration compressor, additional high pressure ammonia
chiller, an interstage cooler and a parallel flash drum will be added.
d) Synthesis section:
An Additional synthesis converter will be added in series (downstream) with the existing S200
converter. The synthesis loop will operate at 186 kg/cm2a. The additional converter will be of a
single bed with a feed-effluent cooler and will have catalyst volume of 45m³. This additional
converter will increase the per pass conversion. This converter will be a cold walled. Additional
BFW heater is provided for heat balance.
e) PGRU
The current PGRU though may not be able to take the additional load and hence will be left
untouched. The additional purge will be used as fuel in the primary reformer.
f) Naphtha Pre-treatment:
The whole revamp is considered with the NG as feed and fuel, hence the pretreatment of Naphtha
section is not considered for any change.
g) MP stripper:
Process condensate from the plant will be stripped using a medium pressure stripper. The treated
condensate produced from this stripper can be used as a make up to the de-aerator thereby
bringing down the fresh DM water requirement for Boiler feed water.
For increasing the capacity of the urea plant to 1560 MTPD, recovery of CO2 from the stack will
also be considered to meet additional CO2 requirement.
Page 11 of 31
4. Process Description – UREA Plant
4.1) Existing Plant
Urea is produced by reacting liquid ammonia and gaseous carbon dioxide at about 180-
185o C and 140-150 kg/cm2 abs. according the following reactions:
2 NH3 + CO2 <====> NH2COONH4 + heat (1)
NH2COONH4 <====> NH2CONH2 + H2O (2)
In the first reaction carbon dioxide and ammonia are converted into ammonium carbamate. This
reaction is fast and exothermic. In the second reaction, which is slow and endothermic, the
ammonium carbamate dehydrates to produce urea and water.
Urea Plant is designed based on CO2 striping process licensed by Stamicarbon. Vs. Netherlands.
Ammonia (NH3) and Carbon Dioxide (CO2) are the main raw materials for Urea production.
Initially, NH3 and CO2 are passed through a High Pressure Condenser where Ammonium Carbonate
is formed. This is sent to autoclave where a portion of it is converted to Urea. The unconverted
Ammonium Carbonate is stripped into NH3 and CO2 gases in a High Pressure Stripper using fresh
CO2 and recycled back to the HP condenser along with fresh Ammonia and dilute Ammonium
Carbonate to again form concentrated solution of Ammonium Carbonate. This cycle thus
continues.
The Urea solution thus coming from the Stripper is separated and concentrated in low pressure
section consisting of a rectification column, a flash vessel, Pre-evaporator and two stages of
evaporation. The molten Urea solution coming from the final evaporator is sent to a revolving
prill bucket at the top of the Prill Tower. The Urea solution is sprayed in the form of fine droplets
by rotation of the prill bucket. The droplets solidified into prills before reaching the bottom of
the Prill Tower as they come in contact with an upward flow of air. The prills are collected and
sent for bagging or storage in silo.
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BLOCK DIAGRAM UREA PROCESS
HP-Carbamate Compressed
Condensation
NH3
to Atmosphere
Urea Scrubbing Absorption

Reaction
Compressed Stripping
CO2
LP Carbamate
Rectification
Condensation
Evaporation Condensation Desorption

Hydrolysation
n
Prilling Purified process

Condensate
Liquid
Storage
Gas
Page 13 of 31
4.2) Revamp of Urea Plant.
Stamicarbon being the process licensor has come up with a new concept called EVOLVE for
revamp and same shall be adopted. Main objectives of the revamp are:- a) Reduce HP steam
consumption in HP stripper - using Stamicarbon low energy concept to achieve 550 - 600 kg/t (38
bara & 400°C). b) Capacity expansion from 4,19,750 t/y to 5,69,400 t/y. c) To improve the quality
of the prilled Urea product.
Process retrofit concepts to fulfil the revamp objectives
Urea is produced by reacting liquid ammonia and gaseous carbon dioxide at about 170 - 185 C
and 135 - 145 bar according to the following reactions:
2 NH3 + CO2 <=====> NH2COONH4 (1)
NH2COONH4 <=====> NH2CONH2 + H2O (2)
In the first reaction, carbon dioxide and ammonia are converted into ammonium carbamate. This
reaction is fast and exothermic. In the second reaction, which is slow and endothermic, the
ammonium carbamate dehydrates to produce urea and water.
Ammonia and Carbon dioxide compression
Liquid ammonia is supplied from battery limits to the high pressure ammonia pump and
compressed to about 165 bar. It is then sent to the pool condenser via the high pressure ammonia
ejector. Additional ammonia is supplied to the MP section. Carbon dioxide from battery limits is
supplied, together with a small amount of air, to the carbon dioxide compressor before it is
compressed to synthesis pressure. The dehydrogenated carbon dioxide is introduced into the
bottom part of the high pressure stripper. Additional carbon dioxide is supplied to the LP section
via the newly installed LP CO2 compressor. Additional air is supplied to this compressor and a
hydrogen converter is placed in the discharge. The two feedstocks, ammonia and carbon dioxide,
are fed to the synthesis section at a molar ratio of 2 : 1.
Synthesis
The dehydration of ammonium carbamate into urea and water takes place in the new
poolcondenser and subsequently in the reactor. The reactor effluent is partially distributed over
the tubes of the high pressure stripper, which is a falling film type shell and tube heat exchanger.
Here, the reactor effluent is contacted counter-currently with carbon dioxide, causing the partial
ammonia pressure to decrease and the carbamate to decompose. The heat is supplied by
saturated high pressure steam.
The urea solution from the high pressure stripper, flows to the low pressure recirculation section
whilst the high pressure stripper off gases are sent to the poolcondenser which is special design
U-tube type heat exchanger. In the pool condenser, condensation of stripped gasses takes place
through the principle of poolcondensation, i.e. the gases are dispersed into a pool of liquid, where
the heat of condensation is being dissipated by submerged heat exchanger tubes. This heat of
condensation is used for two purposes: 1: to dissociate carbamate from the urea solution in the
Page 14 of 31
MP stage (in the lower bundle). 2: to generate low pressure steam of 4.5 bar (in the upper bundle).
This steam is used for heating and desorption as well as for the vacuum.
The pool of liquid in the poolcondenser allows for a considerable amount of urea formation to
take place here. The formed urea, non-converted carbamate, excess ammonia and some non-
condensed ammonia and carbon dioxide are subsequently introduced into the bottom of the
reactor where further conversion of carbamate into urea takes place. The heat, required for the
conversion and for heating the solution in the reactor, is supplied by additional condensation of
ammonia and carbon dioxide.
The reactor discharge goes through the downcomer to the high pressure stripper. The inert,
introduced with the carbon dioxide and part of the unreacted ammonia and carbon dioxide, go
overhead to the high pressure scrubber which contains a shell and tube heat exchanger in the
lower part and a packed bed in the upper part. In the lower part of the high pressure scrubber the
bulk of the ammonia and carbon dioxide are condensed, the heat of condensation being
dissipated into tempered cooling water. This heat is recovered in the pre-evaporator. In the upper
part of the scrubber the gases, leaving the bottom section, are contacted counter currently with
the carbamate solution coming from the medium pressure recirculation section. The gases,
substantially consisting of nitrogen and oxygen and containing only small amounts of ammonia
and carbon dioxide, are vented to the atmosphere via a LP absorber.
The carbamate solution from the high pressure scrubber flows to the high pressure ammonia
ejector.
Medium pressure recirculation section
Liquid leaving the stripper is flashed to MP conditions. The liquid from this flash is led through the
bottom bundle of the pool condenser where the supplied heat enables the dissociation of
carbamate into ammonia and carbon dioxide. The gas from this dissociation is combined with the
off gas from the flash and is led to the first stage evaporation heater, which acts as a MP
carbamate condenser. The heat of condensation of the carbamate is used to evaporate water
from the urea solution. The formed carbamate is sent to the HP scrubber. Small amounts of non-
condensed ammonia and carbon dioxide as well as inerts are sent to the existing LP absorber.
Liquid, leaving the dissociation heater is counter-currently contacted with the off gas from the MP
flash and then discharged to the existing LP section.
Low pressure recirculation section
In this section essentially all of the small amounts of non-converted ammonia and carbon dioxide
are recovered from the urea/ carbamate solution, leaving the MP section. This solution is
expanded to about 4 bar. As a result a portion of the carbamate, left in the solution, decomposes
and evaporates. The remaining liquid is divided onto a bed of Pall rings in the rectifying column.
The urea/ carbamate solution is sent from the bottom of the rectifying column to a new heater
where its temperature is raised to about 135 C in order to decompose the remaining carbamate.
The heat required is supplied by low pressure steam. In the separator (i.e. the bottom part of the
rectifying column) the gas phase is separated from the liquid phase. The gases are sent to the
rectifying column where they are cooled by the colder urea/ carbamate solution. This causes a
Page 15 of 31
portion of the water vapour contained in the gases to condense. The gases leaving the rectifying
column are introduced into the bottom part of the low pressure carbamate condenser where they
are condensed almost completely. The heat of condensation is dissipated into tempered cooling
water. From the level tank of the low pressure carbamate condenser, the carbamate solution
flows to the medium pressure carbamate pump where its pressure is raised and from where the
carbamate solution is carried to the MP section. The urea solution, leaving the bottom of the
rectifying column, flows to the atmospheric flash separator. Due to the adiabatic flash to about
atmospheric pressure, a portion of the water evaporates and some ammonia, carbon dioxide and
inert are liberated. These vapours are partly condensed in the flash separator condenser and the
remaining vapours are sent to the condensers of the evaporation section. Condensate from the
flash separator condenser is recycled to the LP carbamate condenser.
Pre-evaporation and evaporation
The solution from the atmospheric flash separator is sent to the flash separator heater. A portion
of the water in the solution is evaporated so as to increase the urea concentration. Finally, the
urea solution is sent to the urea solution tank from where, the urea solution is pumped to the
evaporators, where it is concentrated to about 99.5 % by weight and is called urea melt.
The urea melt is pumped to the prilling tower. The condensate, leaving the evaporator condenser
is sent to the ammonia water tank via a barometric leg.
Process condensate treatment
Process condensate from the evaporator condenser, containing ammonia, carbon dioxide and
urea, is collected in the ammonia water tank and used as absorbent in the LP absorber and the
atmospheric absorber. Next, the process condensate is pumped from the ammonia water tank to
the first desorber via a desorber heat exchanger. In the first desorber, the bulk of the ammonia
and carbon dioxide is stripped off by means of the overhead vapours of the second desorber and
hydrolyser. The bottom effluent of this first desorber is pumped via a hydrolyser heat exchanger,
where this condensate is heated, to the top of the hydrolyser column. In the hydrolyser, the urea
is decomposed into ammonia and carbon dioxide while being heated by means of live high
pressure steam. To obtain very small urea concentrations in the hydrolyser effluent, the process
condensate is countercurrently contacted with the live steam. On leaving the hydrolyser the
process condensate, containing traces of urea, goes via the hydrolyser heat exchanger to the
second desorber. The overhead vapours of the hydrolyser being sent to the first desorber. After
cooling the hydrolyser effluent in the hydrolyser heat exchanger, this condensate is fed to the top
of the second desorber. Here, the remaining ammonia and carbon dioxide is stripped off by means
of live low pressure steam. The process condensate, leaving the second desorber, is cooled in the
desorber heat exchanger and subsequently in the waste water cooler. It contains very small
amounts of urea and ammonia and can be used for several purposes i.e. for boiler feed water or
cooling water make up. The overhead gases from the first desorber are first partially condensed
in a pre-reflux condenser and after that in the reflux condenser and are transferred as a carbamate
solution to the low pressure carbamate condenser. The non-condensed vapours are sent to the
atmospheric absorber.
Page 16 of 31
4.3) SAILENT FEATURES OF ENERGY IMPROVEMENT PROJECT OF AMMONIA AND UREA
PLANTS.
1. Product Ammonia & Urea
2. Annual Production - Ammonia/Urea (t/y) 328500 / 569400
3. Project Time Schedule 24 months

4. Energy After revamp- Gcal/t Ammonia/Urea 8.5 / 5.75
5. Total Project Capital Cost (Rs. Crores) 540
6. Cost towards pollution control equipment (Rs. Crores) 30
Page 17 of 31
5. DAP/NPK PLANT
NH3 + H3PO4 --------------> NH4H2PO4 + Q2A
(Ammonia) (Phosphoric Acid) (Mono-ammonium Phosphate)
NH4H2PO4 + NH3 --------------> (NH4)2HPO4 + Q2B

(Di-ammonium Phosphate) (Ammonia) (Di-ammonium Phosphate)
a) Dry Section
With reference to the simplified process flow diagram for the Dry Section of the Slurry Process, a
detailed description is furnished as follows:
Page 18 of 31
Phosphoric acid, gaseous Ammonia, and scrubber liquor enter into the Preneutralizer where it is
controlled at a specific gravity of 1.53 and a mole ratio of 1.5, which corresponds to moisture
content in the slurry of 18%. The Preneutralizer is maintained at a mole ratio of 1.5 to ensure
maximum solubility of the slurry. The Ammonium Phosphate slurry is pumped from the
Preneutralizer to the Pipe Reactor where it is combined with strong phosphoric acid, and gaseous
Ammonia and sprayed onto the bed of the Rotary Granulator at a mole ratio of 1.5 and moisture
of 10%. Underneath the bed in the Granulator is the Ammonia sparger that supplies liquid
Ammonia to raise the mole ratio of the fertilizer up to the desired value. The material leaves the
Granulator and enters into the Rotary Dryer where the DAP is dried, using hot gases leaving the
Combustion Chamber, to a moisture of 1.0-1.5% or even lower if needed. After exiting the Dryer
the material enters into the Primary Elevator to be distributed over the Oversize Screens. The
Oversize Screens are double deck screens where the oversize is sent to the chain mills, the
undersize falls onto the Recycle Belt along with the crushed material, and the product size
material is sent to the Product Screen Elevator for distribution on the Product Screens. The
purpose of the Product Screens is to remove the remaining fines that were not removed by the
Oversize Screens. The fines fall onto the Recycle Belt and the on spec material enters into the
Fluidized Bed Cooler or is recycled for control of the recycle ratio. The air entering into the
Fluidized Bed Cooler can be chilled using the Ammonia Air Chiller which will be discussed later.
Once leaving the Fluidized Bed Cooler the material enters into the Product Elevator and is
distributed onto the Polishing Screens. The on spec material then enters into the Coating Drum
and is then conveyed to the storage building. The gases leaving the Dryer, Product Cooler, and
Dedusting system are each sent through a separate set of cyclones. After the dedusting system
offgas exits the cyclones it is sent through a baghouse to be sent to the Combustion Chamber. If
this method of recycling dedusting offgases is not in place then the gases are sent to the RG
Scrubber. The gases leaving the Dryer Cyclones go to the Dryer Scrubber and the gases leaving
the Cooler Cyclones go the Tail Gas Scrubber.
Page 19 of 31
b) Wet Section
With reference to the simplified process flow diagram for the Wet Section of the Slurry Process,
a detailed description is furnished as follows:
Ammonia laden gases exiting the Preneutralizer and Granulator first enter into the Prescrubber
where they are scrubbed with liquor at a mole ratio of 1.4 where 60-70% of the Ammonia is
absorbed. Once exiting the Prescrubber the gases enter into the Reactor Granulator Scrubber
(RG Scrubber) where the gases are scrubbed with liquor at a mole ratio of 0.7. The gases exiting
the Dryer go through a cluster of cyclones and enter into the Dryer Scrubber where the gases are
Page 20 of 31
scrubbed with the same liquor that is used in the RG Scrubber. The liquor that is used in the RG
Scrubber and the Dryer Scrubber is circulated from the Scrubber Tank. Gases from the RG
Scrubber and Dryer Scrubber along with the gases that exit the Cooler Cyclones enter into the Tail
Gas Scrubber and then exit into the atmosphere. The circulating liquor in the Tail Gas Scrubber
is sent through a kettle type heat exchanger to vaporize Ammonia.
c) Pipe Reactor used in conjunction with Preneutralizer

The purpose of the Pipe Reactor is to supply Ammonium Phosphate slurry at a low moisture
content thereby reducing fuel requirements in the drying step. The Pipe Reactor mixes high
strength Phosphoric acid, gaseous anhydrous Ammonia, and reactor slurry from the
Preneutralizer and sprays it onto the bed of the Granulator. The reason the Pipe Reactor can
operate at such a low moisture is because of the high temperature and pressure which keeps the
slurry fluid. Under atmosphere pressure the slurry reaches a minimum moisture content of 18%
and in the Pipe Reactor it can be as low as 10%. The moisture content in the Pipe Reactor is
reduced by vaporizing water from the high heat of reaction of Phosphoric acid and Ammonia.
Another reason why the Pipe Reactor is economical is because it reduces Citrate Insoluble P2O5.
Citrate Insoluble P2O5 increases with increased retention time and since the retention time of a
Pipe Reactor is very low there is virtually no Citrate Insoluble P2O5 produced in the Pipe Reactor.
The average Citrate Insoluble P2O5 can be reduced by 0.2% when a Pipe Reactor is used. The
Preneutralizer mixes Phosphoric acid, Ammonia, and Scrubber liquor to be sent to the Pipe
Reactor or directly to the Granulator. The Phosphoric acid and Scrubber liquor are fed through
the top of the reactor while the gaseous anhydrous Ammonia is fed through spargers located at
the bottom.
The process uses the reduced retention time Preneutralizer where the diameter at the bottom of
the tank is smaller than the top. The advantage of this design is that the Citrate Insoluble losses
are decreased while still maintaining the liquid level necessary to absorb Ammonia and not to
entrain liquid in the exiting gas. The Citrate Insoluble losses increase with increased retention
time so it is necessary to minimize the liquid volume in the Preneutralizer. The Preneutralizer is
much simpler to operate than the Pipe Reactor and when used in conjunction with the Pipe
Reactor it gives the plant a stable baseline and increased controllability.
Page 21 of 31
Using a Preneutralizer reduces the amount of water that is vaporized in the Granulator by the
Pipe Reactor. If less water is vaporized in the Granulator then less air is needed to keep the gas
leaving the Granulator below the saturation point. For a 120 MT/hr. plant, the required airflow in
the Granulator when a Pipe Reactor and Preneutralizer are installed is 44,000 ACFM and when
there is only a Pipe Reactor present is 88,000 ACFM. This reduced airflow reduces the size of the
Granulator, Prescrubber, RG Scrubber, RG Fan, Scrubber Pump and the Tail Gas Scrubber and
Pump.
d) Dual Mole Scrubbing

Dual Mole Scrubbing is a two stage process where gases from the Preneutralizer and Granulator
are scrubbed with a high N/P mole ratio liquor followed by scrubbing at a low mole ratio. The
gases first enter the Prescrubber, which operates at a mole ratio of 1.4, where about 60-70% of
the Ammonia is removed. Next the gases enter into the Reactor Granulator (RG) Scrubber where
the rest of Ammonia as well as the fluorine are removed and this scrubber operates at a mole
ratio of 0.7.
Page 22 of 31
e) Recycling Dedusting System Offgas to the Combustion Chamber
Recycling Dedusting system offgas to the Combustion Chamber takes the heat given off by the
DAP throughout the plant and reuses it in the Dryer. There are various dedusting pickup points
within a DAP plant which mainly come from the belt conveyors, screens, and elevators.
5.1) SAILENT FEATURES OF PROPOSED PROJECT.

MCF is proposing to manufacture DAP and NPK grades (e.g. 10:26:26, 14:35:14:17:17:17) in the
proposed new facility of I million metric tons of DAP/NPK fertilizer plant.
Di Ammonium Phosphate (DAP) /

Product Manufactured NPK Multi-grades
Annual Production 1 Million t/y.
Technology Latest PN / PR technology
Project cost Rs. 987 crores.
Cost towards pollution control equipment Rs. 25 crores
Project Time Schedule 30 Months
Page 23 of 31
Annual Requirement of Raw Materials and Utilities
Ammonia 231700 MT
Phosphoric acid (100% P2O5) 468000 MT
Muriate of Potash (MOP) 280000 MT
Sulphuric acid 130000 MT
Furnace Oil 6500 MT
No trade effluent generation from the proposed DAP/NPK plant. No solid waste will be generated.
Any spillage will be recycled and reused in the proposed plant. There will not be any additional
water drawl from the Mangalore City Corporation due to requirement of proposed project. The
marginal increase in the water requirement after the commissioning of DAP/NPK plant will be met
6. POLY CARBOXYLATES PRODUCTION PROCESS

6.1) PROCESS OVERVIEW
Manufacture of Poly carboxylates is essentially a batch operation and comprises of two main
steps, i.e.
a) Esterification
b) Polymerization
The basic raw materials for Poly carboxylate production are Methoxy Poly Ethylene Glycol
(MPEG / PEGM 2000) and Meth acrylic Acid. The overall chemical reactions involved in the above
mentioned (a) & (b) process steps are schematically shown in Figure 7A and 7B below
Methoxy Poly Ethylene Glycol

Meth acrylic Acid
(MPEG / PEGM 2000)
Catalyst Reactor Polymerisation Retarder
MPEG-MAA
Figure 7A : ESTERIFICATION REACTIONS
Page 24 of 31
MPEG-MAA
Evocating
Chain transfer agent
Agent Reactor
Polycarboxylate
superplasticizer
Finished Product
Figure 7B : COPOLYMERIZATION AND NEUTRALIZATION REACTIONS
PROCESS BLOCK DIAGRAM is placed at Figure 8 below:
Methoxy Poly Ethylene Glycol

Condenser Water (MPEG / PEGM 2000)
Meth acrylic Acid.

Nitrogen
Vacuum
Machine
Steam
Product
Condensate Tank
Page 25 of 31
6.2) Salient Features Poly Carboxyl Ether Project
Product Manufactured Poly Carboxyl Ether
Annual Production 18000 MTPA
Technology Batch process
Project cost Rs. 20 crores.
Project Time Schedule 12 Months
Annual Requirement of Raw Materials
Methoxy polyethylene glycol 19365 MTPA.
Methacrylic Acid 830 MTPA.
No liquid effluent and solid waste generation is envisaged
Page 26 of 31
7. ENVIRONMENTAL MANAGEMENT
7.1) Modernization of Ammonia & Urea Plants

7.1.1) Ammonia Plant
There will not be any increase in pollution load due to increase in production as the basic intention
of this project is to reduce feed and fuel consumption in the ammonia production. The total firing
in the primary reformer will be lower and there will be reduction in steam and power requirement
for the plant. As a result, emissions will reduce.
There is no additional liquid effluent generation from the plant. The plant will remain zero liquid
effluent discharge plant.
It is proposed to replace the present low pressure stripper with medium pressure (MP) stripper
which will ensure removal of Ammonia from process condensate. The gases from the MP stripper
will be carried by the steam going to primary reformer and hence not let out.
The quantity of effluent generated in the plant shall reduce due to lower steam to carbon ratio in
the plant. This effluent shall be treated in the existing effluent treatment facility and recycled back
to the system as cooling tower make up.
7.1.2) Urea Plant
There will not be any significant increase in pollution load after expansion of Urea plant capacity.
The emission of Particulate matter from the urea prill tower will be about 110 mg/Nm3 which is
well within standard of 150 mg/Nm³.
Net quantity of treated water generated from urea hydrolyser will reduce even there is a increase
in production. This will be achieved due to lower effluent generation in Ammonia plant. The
treated water will continued to be used as make up water in cooling tower.
Description of urea hydrolyser stripper:

MCF has installed and commissioned urea hydrolyser stripper at the cost of Rs. 8.5 crores in 1990
and same is being operated for the treatment of effluent streams from ammonia plant process,
urea plant process and condensates from urea plant compressors. The urea hydrolyser stripper
system consists of hydrolyser, which is operated at high temperature' and high pressure, where
Page 27 of 31
urea gets hydrolyzed to ammonia and carbon dioxide. Ammonia thus produced is separated in
the second desorption column. The liquid outlet of second desorption column contains less than
10 ppm of ammonia and urea. The ammonia vapours from the second desorption column is fed
to the first desorber. The desorber overhead vapours are condensed in a condenser and reused
in Urea plant. The treated effluent from urea hydrolyser stripper is reused as cooling tower
makeup water.
In total, reduction in feed-fuel consumption in ammonia plant, reduces emissions in ammonia

plant. Lower steam consumption, reduces process condensate effluents. Hence, the proposed
project will not have any adverse impact on the existing environment in total.
Additional CO2 required for Urea production will be recovered from reformer flue gas by Carbon
dioxide Recovery (CDR) unit which inturn reduces the emission of CO2, a greenhouse gas.
Waste Water Recovery Plant:

As corporate social responsibility, with the aim of reusing the entire treated effluent and to
achieve the target of zero effluent discharge MCF has installed Waste Water Recovery Units
during 2009-2010 by investing about Rs. 7.0 crores for treating the effluent streams consisting of
the following:
1. Sand filter back wash water from water treatment plant and cooling tower
2. Water treatment plant resin regeneration effluent - acidic and alkaline
3. Cooling tower blow down.
4. Domestic effluent
Based on the characteristics of the effluent streams, trade effluents are categorized and is
treated as given below:
1. Sand filter back wash water from water treatment plant and cooling tower containing high
suspended solids effluent is treated by using. Lamella Clarifier technology.
Static mixer, Lamella clarifier, centrifuge and sand filter are major equipment for treating the high
suspended solids effluent streams. Back wash water of sand filter and activated carbon filter
from water treatment plant and cooling 'tower side stream filter are treated in this unit. The
treated water is reused in cooling tower as makeup. The slurry containing solids is pumped to a
centrifuge for separating liquid which is recycled to static mixer. The thickened slurry is used in
DAP plant.
Page 28 of 31
2. Water treatment plant resin regeneration and cooling tower blow down effluents
The high dissolved solids effluent stream containing water treatment plant resin regeneration
effluent and cooling 'tower blow down is passed through clarifier, pressure sand filter and Ultra
Filtration (UF) units to remove suspended solids and colloidal particles. Then it is treated in
Reverse Osmosis (RO) units to remove dissolved solids. Treated water is reused in cooling tower
as makeup.
The high dissolved solids effluent streams are collected in an equalization tank. This stream after
dosing with NaOCI, Coagulant, Lime, Dolomite & Polymer is pumped to High Rate Solids Contact
Clarifier (HRSCC). The clarified water from HRSCC is passed through Multi Grade' filter for
reduction of suspended solids.
Then the filtered water is fed into the Ultra filtration unit (UF) to remove colloidal silica and related
colloids of iron and aluminum in water causing fouling, scaling and poor performance of the plane
the stream which is free from suspended and colloidal particles will be passed through Reverse
Osmosis unit (RO). The Dissolved solids are removed in 2 stages of RO unit. In the first stage R01
about 75 % of desired quality water will be recovered and reject is fed to second stage R02 wherein
further 10% is recovered. The R02 reject containing high dissolved solids is used in DAP plant.
The recovered water is used in cooling tower as makeup. The sludge collected in the HRSCC is
pumped to centrifuge to remove water. The separated liquid is recycled to equalizing tank and
thickened slurry is used in DAP plant.
7.2) DAP/NPK Plant

The proposed project will not have any significant adverse impact on the existing environment as
sufficient pollution control measures are incorporated in the process technology and plant
design. The technology also incorporates special scrubbing equipment like Dual Mole Scrubbing
System and also Dedusting system. In DAP / NPK plant, Air pollution control equipment viz.
Cyclone, Scrubber, Mist eliminator etc. are incorporated right from conceptualization.
Page 29 of 31
There will be no liquid waste and solid waste generation from the plant. All liquid spillages shall
be collected and recycled back to the process.
The flow of gaseous emission from the stack (3 no. 45 m each) is expected to be maximum of
720000 Nm³/hr., particulate Matter 50 mg/Nm³, fluorine 20 mg/Nm³ and Ammonia 150 mg/Nm³.
Since no liquid effluent and solid waste will be discharged from the plant there will not be any
significant adverse impact on the aquatic ecosystem. The vegetation and aquatic systems of the
area will be protected by adopting the above environmental protection measures.
7.3) PCE project

There will not be any gaseous emission from the proposed plant.
There will be no liquid effluent generated in the plant. The spillages if any from the plant floor will
be collected in and recycled back to soil conditioners section.
There is no solid waste from the plant. The spillages if any from various points in the plant are
effectively collected and recycled back to the system.
8. Sewage Treatment Plant:

The domestic effluent generated due to new 1 million ton DAP/NPK & PCE complex also shall be
collected and treated at existing sewage treatment plant (STP). The details of the existing STP is
given below:
MCF has put up a centralized sewage treatment unit. The combined sewage from the factory is
collected in the sump tanks and pumped to the bar screen chamber and oil trap to remove
floating solids and oil traces respectively. After this preliminary treatment the effluent is fed to
equalization tank.
Effluent from the equalization tank is fed to the Membrane Bio-Reactor (MBR) tank at constant
flow rate. The high amount of bacteria gives better and complete removal of organic matter from
the raw effluent in relatively small area. Aeration is done both to the equalization and MBR tanks
Page 30 of 31
through diffuser membranes by using blowers.
The suction pumps directly sucks permeate and the filtration is carried out by the membrane.
The suspended solids, turbidity, bacteria and viruses in permeate water are removed to the levels
required for reusing treated water. The treated water is reused in cooling tower as makeup.
By installation of the above wastewater treatment plants with latest technologies, MCF has
achieved the aim of reusing the entire treated wastewater and the target of zero wastewater
discharge.
9. Green Belt
MCF has already developed and maintained a green belt covering an area of about 64 acres.
The green belt contains around 63,000 trees of different species viz. Mangium, Casurina,
Subabul, Acacia, Gulmohar, Jack, Cashew, Mango, Banyan, Peepal, etc.
-------------------- x ---------------------
Page 31 of 31

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Environmental Impact Assessment

EQMS INDIA PVT. LTD. INDIA

EQMS INDIA PVT LTD

5.1. Potential Location ........................................................................................................... 159

EQMS INDIA PVT LTD

9.1. Summary and Conclusion ............................................................................................... 234

EQMS INDIA PVT LTD

Table 3.28 : Composition of Non-Workers ................................................................... 126

EQMS INDIA PVT LTD

Figure 3.14 : Concentration of PM2.5 in the study area ...................................................... 91

EQMS INDIA PVT LTD

1.2. History of Existing Plant

1.3. Justification for Proposed Projects

Energy improvement Project of Ammonia & Urea plants by modernization and

EQMS INDIA PVT LTD

New DAP/ NPK plant

New PCE Plant

1.4. Need of the Study

This Environmental Impact Assessment (EIA) study undertaken is mainly focused on

1.5. Project Location

EQMS INDIA PVT LTD

DAP Plant PCE Plant

Ammonia Plant Urea Plant

EQMS INDIA PVT LTD

Figure 1.2 : Location of the Project Area

EQMS INDIA PVT LTD

1.6. Scope of Study

EQMS INDIA PVT LTD

Table 1.1 Terms of Reference Compliance

EQMS INDIA PVT LTD

under the provisions of the EIA Notification 1994

EQMS INDIA PVT LTD

XII. Status of acquisition of land. If acquisition is not

EQMS INDIA PVT LTD

provided as an annexure to the EIA Report .

EQMS INDIA PVT LTD

operations, extent recycled and reused for different chapter 4.

i. Plan and fund allocation to ensure the occupational

EQMS INDIA PVT LTD

are the exposure levels of hazards and whether they are

EQMS INDIA PVT LTD

will be implemented in the plant.

EQMS INDIA PVT LTD

EQMS INDIA PVT LTD

Chapter-1: Introduction: This chapter provides background information of the

EQMS INDIA PVT LTD

CHAPTER 2. PROJECT DESCRIPTION

2.1. Brief Overview of Existing Plant and Proposed Expansion

Table 2.1 : Salient Features (Existing & Proposed)

EQMS INDIA PVT LTD

plant. Proposed project

Table 2.2 : Co-ordinates (lat-long) of all four corners of the site

Location Latitude Longitude

EQMS INDIA PVT LTD

Figure 2.1 : Location on Topo Map

EQMS INDIA PVT LTD

Figure 2.2 : Location on Google Map

EQMS INDIA PVT LTD

Figure 2.3 : Coordinates of Project boundary

EQMS INDIA PVT LTD

Figure 2.4 : Plant Layout (All the Facility)

EQMS INDIA PVT LTD, DELHI

Figure 2.5 : Plant Layout (Revamp of Urea & Ammonia Facility)