REVAMPING OF UREA- I & II PLANTS AT GSFC COMPLEX

EQMS India Pvt. Ltd. 1 | P a g e

ADDENDUM TO ENVIRONMENTAL IMPACT ASSESSMENT REPORT

for

REVAMPING OF UREA- I & II PLANTS

AT GSFC COMPLEX

located at

P.O. Fertilizernagar, Tal. and District- Vadodara, Gujarat-391750

Type of Project Modernization under Para 7(ii) as per EIA Notification,2006 and its

subsequent amendments.

Category as per EIA notification

2006 and its amendments:

Activity 5(a) , Chemical Fertilizers

Category A

Production Capacity Total Production Capacity (After Revamping) Urea: 3,67,200 MTPA

Total Cost of Project ₹ 306 Crores

Baseline Monitoring Period December,2020 to February,2021 (Winter Season)

NABET Acc. No. NABET/EIA/1922/RA0197 valid till 23.11.2022

PROJECT PROPONENT

GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED

P. O. Fertilizernagar-391750, Dist. Vadodara, Gujarat, India.

Email: [email protected]; Phone no.: +91-265-2242451, 2242651, 2242751

UID No.: EQMS/PFR/GSFC/5(a)A/PR-659/23112021

Report Release Date: 23/01/2021 Revision No: 01

ENVIRONMENT CONSULTANT

(Approved Consultant)

EQMS INDIA PVT LTD.

QCI/NABET Accredited Consultant

304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower, Community Centre, Karkardooma, Delhi – 110092

Phone: 011-42270087, 43062757; Website: www.eqmsindia.com ; E-mail: [email protected]

Disclaimer: This document has been prepared with all reasonable skills, knowledge, care, and diligence by M/s. EQMS India Pvt. Ltd.,

Karkardooma, Delhi, the NABET accredited and national level leading Environmental Consultancy Organization within the terms of the

contract with the client (Project Proponent), incorporating their General Terms and Conditions of Business and taking account of the

resources devoted to it by Business Agreement. The report was discussed with the project proponent in details before releasing. This report

has been prepared using information received from Client, collecting primary data and compilation of secondary data from available

resources. We are not responsible for the origin and authenticity of the information, drawings or design details provided by the Client.

mailto:[email protected]

http://www.eqmsindia.com/


Addendum to Environmental Impact Assessment Report

Revamping of Urea-I & II Plants at GSFC Complex at Fertilizernagar, Vadodara, Gujarat

By M/s Gujarat State Fertilizers & Chemicals Limited


DECLARATION FROM PROJECT PROPONENT





REPORT RELEASE

GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED (GSFC)

Addendum to EIA Report of Revamping of Urea-I&II Plants at GSFC Complex at P.O.

Fertilizernagar, Tal. and District- Vadodara, Gujarat-391750

© EQMS India Pvt Ltd (‘EQMS’), November,2021

This report is released for the use of Gujarat State Fertilizers & Chemicals Limited (GSFC),

Regulators and relevant stakeholders solely as part of the subject project’s Environmental

Clearance process. Information provided (unless attributed to referenced third parties) is

otherwise copyrighted and shall not be used for any other purpose without the written

consent of EQMS.

PROJECT DETAILS

Name of

Publication

Addendum to EIA Report of Revamping of Urea-I&II Plants at GSFC

Complex at P.O. Fertilizernagar, Tal. and District- Vadodara, Gujarat-

391750 by M/s Gujarat State Fertilizers & Chemicals Limited (GSFC)

Project Number PR-659 Report

No. 1 Version 1 Released

November,

2021

Managed by Manager EIA Released By EIA Co-ordinator

CONTACT DETAILS

Head Quarter: Delhi / NCR

EQMS India Pvt. Ltd.

304 & 305, 3rd Floor, Rishabh Towers,

Plot No. 16, Community Centre, Karkardooma, Delhi - 110092. (India)

Email: [email protected]; T: + 91-11-30003200/219; F: +91-11-22374775

DISCLAIMER

EQMS India Pvt Ltd has taken all possible precautions in the preparation of this report as

per its auditable quality plan. EQMS also believes that the facts presented in the report

are accurate as on the date it was written. However, it is impossible to dismiss absolutely,

the possibility of errors or omissions. EQMS therefore specifically disclaims any liability

resulting from the use or application of the information contained in this report. The

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





DISCLOSURE OF CONSULTANT

Declaration by Experts Contributing to the EIA EMP REPORT for Addendum to EIA Report of

Revamping of Urea-I&II Plants at GSFC Complex at P.O. Fertilizernagar, Tal. and District-

Vadodara, Gujarat-391750 by M/s Gujarat State Fertilizers & Chemicals Limited (GSFC).

I, hereby, certify that I was a part of the EIA team in the following capacity that developed

the above EIA report

EIA Coordinator

Signature

Name Mr. PK Srivastava

Period of involvement December,2020 to Finalization of report

Contact Information 8890836012

Team Member/Associated EIA Co-ordinator: Mrs. Sweta Shah

Functional Area Experts

Functional

Areas

Name of the

Expert

Team

Member

Involvement

Period and Task

June 2021 to finalization of

report

Signature

Air Pollution

Monitoring &

Control AP

Mrs. Sweta

Shah

Mr. Kapil

Singh

• Identification of

appropriate pollution

control devices and

mitigation measures for

the impact identified for

the proposed project

Air Quality

Modeling and

Prediction

AQ

Mrs Sweta

Shah

Mr. Kapil

Singh

• Identification and

Assessment of impact of

proposed project

activity on ambient air

Noise Mrs. Sweta

Shah

Mrs.

Sweta

Shah

• Assessment of noise level

and vibration potential

due to proposed project

and its mitigation

measures

Water Pollution

WP

Mr.SK Jain

Mr. Kapil

Singh

• Water Balance

• Identification &

assessment of quantum

of water pollution and its

Mitigation measures





Functional

Areas

Name of the

Expert

Team

Member

Involvement

Period and Task


report

Signature

Ecology and

Bio diversity

Conservation

EB

Mr. Ratnesh

Kotiyal

Ms.

Khushboo

Thakur

• Identification &

assessment of

ecological impact due

to proposed project and

its Mitigation measures

Solid and

Hazardous

Waste

Management

SHW

Mrs. Sweta

Shah

- • Identification of

hazardous and non

hazardous wastes

• Reuse and recycling of

solid wastes

• Handling and disposal of

non-Hazardous solid

waste & Hazardous

waste

Risk and

Hazards RH

Mr.PK

Srivastava

Ms. Kirti

Patni

• Identification of hazards

due to proposed

project

• Identification of

hazardous substances in

the proposed project

• Preparation of risk

assessment report and

onsite emergency plan

Land Use (LU) Mr. Anil

Kumar

Mr.

Kaleem

Ahmad

• Assessment of impact of

proposed project on

landuse of the site and

surrounding

Socioeconomi

cs (SE)

Mr. Anil

Kumar

- • Assessment of impact of

proposed project on

social environment of

the surrounding

Geology Mr. Hardik

Patel

- • Recommendations and

preparation of reports

on geology.

Hydrogeology Mr. Yamesh

Sharma

- • Estimation of run-off

generation from site &

post project

development

• Formulation of rainwater

harvesting plan

• Formulation of water

conservation plan





Functional

Areas

Name of the

Expert

Team

Member

Involvement

Period and Task


report

Signature

Soil

Conservation

Mr. Yamesh

Sharma

- • Impact assessment of

project on soil quality

and development of

management plan

DECLARATION BY THE HEAD OF THE ACCREDITED CONSULTANT ORGANIZATION

I, S K Jain, hereby confirm that the above mentioned experts prepared the EIA/EMP REPORT

for Addendum to EIA Report of Revamping of Urea-I&II Plants at GSFC Complex at P.O.

Fertilizernagar, Tal. and District- Vadodara, Gujarat-391750 by M/s Gujarat State Fertilizers &

Chemicals Limited (GSFC). I also confirm that EIA Co-ordinator has gone through the report,

and the consultant organization shall be fully accountable for any mis-leading information

mentioned in this statement.

It is certified that no unethical practices including plagiarism have been carried out and

external data/ text has not been used without proper acknowledgement, while preparing

this EIA report.

Signature:

Name Mr. S K Jain

Designation Director, Technical

Name of the EIA Consultant organization EQMS India Pvt Ltd

NABET Certificate No and date NABET/EIA/1922/RA0197 dated 15.03.2021

valid till 23.11.2022





CERTIFICATE OF PLAGLARISM CHECK

Title of EIA Report Addendum to EIA Report of Revamping of Urea-I&II

Plants at GSFC Complex at P.O. Fertilizernagar, Tal. and

District- Vadodara, Gujarat-391750 by M/s Gujarat State

Fertilizers & Chemicals Limited (GSFC)

Name of Accredited

Organization

M/s EQMS India Pvt. Ltd.

Unique Identification

Number

EQMS/PFR/GSFC/5(a)A/PR-659/29072021

Name of EIA Co-ordinator

(EC):

Mr. P.K. Srivastava

Name of the Software Plagiarism Checker X

Date of check: 01.12.2021

Time of check: 16:00

DECLARATION BY THE HEAD OF THE ACCREDITED CONSULTANT ORGANIZATION/

AUTHORIZED PERSON

I hereby certify that this EIA Report has been evaluated using online/In-house software

viz., Plagiarism Checker X. The report produced has been analysed by the system based

on it, I certify that the EIA report produced in accordance with good scientific practice.

Date and Sign of EIA Coordinator

Name: Mr. P K Srivastava

Signature:

Designation: EIA Co-ordinator

Date and Sign of Head of Accredited Organization

Name: Mr. Sanjay Kumar Jain

Signature:

Designation: Director, Technical

Name of the EIA Consultant Organization: M/s EQMS India Pvt. Ltd.

NABET Certificate No. & Issue Date: NABET/EIA/1922/RA0197; Issue date: 15.03.2021,

Validity date: 23.11.2022





TABLE OF CONTENTS

Chapter 1. INTRODUCTION ........................................................................................................ 18 1.1. Preamble ......................................................................................................................... 18 1.2. Brief About Project & Project Proponent ...................................................................... 19 1.3. Need for the project and its importance to the country ........................................... 33 1.4. Project Site ....................................................................................................................... 35 1.5. Chronology of Project and Need of the EIA Study ..................................................... 40 1.6. TOR Compliance............................................................................................................. 41 1.7. Structure of the Report ................................................................................................... 71

Chapter 2. PROJECT DESCRIPTION ........................................................................................... 74 2.1. Details of Project ............................................................................................................. 74 2.2. Site Location and Surrounding ...................................................................................... 74 2.3. Land Requirement .......................................................................................................... 79 2.4. Products with capacities for the proposed project .................................................... 84 2.5. Manufacturing Process & Mass Balance of Products ................................................. 84 2.6. Raw Material ................................................................................................................... 96 2.7. Onsite/Offsite Facilities & Machineries ......................................................................... 97

2.7.1. Offsite/Onsite Facilities ............................................................................................... 97 2.7.2. Machineries and Equipments .................................................................................. 101

2.8. Resource Requirements ............................................................................................... 109 2.8.1. Infrastructure .............................................................................................................. 109 2.8.2. Power & Fuel requirement ....................................................................................... 109 2.8.3. Water .......................................................................................................................... 110 2.8.4. Employment .............................................................................................................. 116 2.8.5. Parking Area .............................................................................................................. 116

2.9. Environmental Aspects ................................................................................................. 116 2.9.1. Water Pollution .......................................................................................................... 116 2.9.2. Air Pollution ................................................................................................................ 120 2.9.3. Noise Pollution ........................................................................................................... 123 2.9.4. Solid & Hazardous Waste Generation .................................................................... 124

2.10. Green Belt development Plan..................................................................................... 125 2.11. Project Cost and Schedule .......................................................................................... 126

Chapter 3. DESCRIPTION OF THE ENVIRONMENT ................................................................... 127 3.1. Introduction ................................................................................................................... 127 3.2. Background and Salient Environmental Features of the Study Area ..................... 127 3.3. Components of Methodology of Baseline Survey .................................................... 133 3.4. Topography and Physiography ................................................................................... 135 3.5. Geology & Hydrogeology ........................................................................................... 140 3.6. Drainage ........................................................................................................................ 143 3.7. Land use- Land Cover Classification .......................................................................... 146 3.8. Soil Environment ............................................................................................................ 152 3.9. Water Environment ....................................................................................................... 162 3.10. Air Environment ............................................................................................................. 181 3.11. Ambient Air Quality ...................................................................................................... 190 3.12. Noise Environment ........................................................................................................ 203 3.13. Ecology and Biodiversity .............................................................................................. 206

3.14. Socio Economic Environment .................................................................................... 222 3.15. Traffic Study ................................................................................................................... 236

Chapter 4. Anticipated Environmental Impacts and MITIGATION MEASURES .................. 239





4.1. Introduction ................................................................................................................... 239 4.2. Impact Assessment Criteria ......................................................................................... 239 4.3. Summary of Baseline of Project Area ......................................................................... 241 4.4. Identification Linkage between Project Activities and Associated Impact .......... 243 4.5. Impact Assessment and Evaluation ............................................................................ 245 4.6. Impacts during Construction & Operation Phase ..................................................... 245

4.6.1. Impact on Air Environment ...................................................................................... 245 4.6.2. Impact on Noise Environment ................................................................................. 247 4.6.3. Impact on Water Quality ......................................................................................... 249 4.6.4. Impact due to Waste ............................................................................................... 251 4.6.5. Impact on Land Environment .................................................................................. 252 4.6.6. Impact on Soil Quality .............................................................................................. 253 4.6.7. Impact on Ecology and Biodiversity ....................................................................... 254 4.6.8. Socio-economic environment ................................................................................. 256 4.6.9. Traffic Impacts ........................................................................................................... 258

4.7. Conclusion ..................................................................................................................... 258 Chapter 5. ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITES) ......................................... 261

5.1. Analysis of Alternative Site ........................................................................................... 261 5.2. Alternative Technology ................................................................................................ 262

5.2.1. Advantages of Revamping ..................................................................................... 262 5.2.2. Concept of Ammonia Stripping Technology ........................................................ 262 5.2.3. Technological Differences between Total Recycle Process and Ammonia

Stripping Process ....................................................................................................... 263 5.2.4. Benefits due to Proposed Revamping .................................................................... 265 5.2.5. Proposed Existing Plant Configurations and Modifications .................................. 266 5.2.6. New Installations for Proposed Revamping ........................................................... 267 5.2.7. Anticipated Water Conservation due to Revamping .......................................... 268 5.2.8. Anticipated Energy Conservation due to Revamping ......................................... 268 5.2.9. Energy Conservation Measures already adopted within the plant .................... 268 5.2.10. Implementation of Additional Energy Conservation/Resource Optimization

Measures .................................................................................................................... 268 5.2.11. Green Initiatives Implemented by GSFC ................................................................ 269

Chapter 6. ENVIRONMENT MONITORING PROGRAMME ...................................................... 271 6.1. Objective ....................................................................................................................... 271 6.2. Performance Indicators ............................................................................................... 271

6.2.1. Ambient Air Quality Monitoring System (AAQMS) and Online Continuous Emission

Monitoring System (OCEMS) .................................................................................... 272 6.2.2. Weather Station ........................................................................................................ 272 6.2.3. Water Quality Monitoring and Online Continuous Effluent Monitoring System

(OCEMS) ..................................................................................................................... 273 6.2.4. Noise Level Monitoring ............................................................................................. 274 6.2.5. Soil Quality ................................................................................................................. 274 6.2.6. Green Area Development ....................................................................................... 274 6.2.7. Workplace Monitoring .............................................................................................. 274 6.2.8. Occupational Health & Safety ................................................................................ 275 6.2.9. Energy Audit .............................................................................................................. 275

6.3. Environmental Monitoring Laboratory ........................................................................ 275 6.4. Environment Monitoring Plan ....................................................................................... 277 6.5. Submission of Compliance & Audit Report ................................................................ 279





Chapter 7. ADDITIONAL STUDIES ............................................................................................. 280 7.1. Introduction ................................................................................................................... 280 7.2. Scope of Work ............................................................................................................... 280 7.3. Objectives ...................................................................................................................... 281 7.4. Methodology of HIRA ................................................................................................... 281 7.5. Hazardous Material at GSFC Plant .............................................................................. 282 7.6. Detailed QRA Approach: Rule Sets and Assumptions .............................................. 285 7.7. Effect and Consequence Analysis .............................................................................. 289 7.8. Hazardous Incidents Impact........................................................................................ 290 7.9. Consequence Analysis ................................................................................................. 292 7.10. Hazardous Scenario Chemicals .................................................................................. 292 7.11. Conclusions and Recommendations ......................................................................... 294 7.12. Safety Measures ............................................................................................................ 294 7.13. Occupational Health and Safety ............................................................................... 296 7.14. Disaster Management Plan ......................................................................................... 297 7.15. Emergency Action Plan/Onsite Emergency Plan ..................................................... 298 7.16. Offsite Emergency Plan ................................................................................................ 300

Chapter 8. PROJECT BENEFITS ................................................................................................. 302 8.1. Environmental Benefits ................................................................................................. 302

Social Developmental Activities ................................................................................. 302 8.3. Corporate Social Responsibility (CSR)/Enterprise Social Commitment (ESC) ........ 305

Chapter 9. ENVIRONMENT COST BENEFIT ANALYSIS .............................................................. 311 Chapter 10. ENVIRONMENT MANAGEMENT PLAN .................................................................. 312

10.1. Introduction ................................................................................................................... 312 10.2. Objectives of EMP ......................................................................................................... 312 10.3. Environment Management System and Policy ......................................................... 312 10.4. Environment Management Plan ................................................................................. 313 10.5. Occupational Health & Safety System at GSFC ....................................................... 329 10.6. Green Belt Development ............................................................................................. 344

10.7. Resource Conservation Waste Minimization ........................................................... 350 10.7.1. Anticipated Water Conservation due to Revamping .......................................... 350 10.7.2. Anticipated Energy Conservation due to Revamping ......................................... 350 10.7.3. Energy Conservation Measures already adopted within the plant .................... 350

10.8. Facilities for Employees ................................................................................................ 350 10.9. Rehabilitation and Resettlement Plan ........................................................................ 351 10.10. Compliance of CREP Guidelines................................................................................. 351 10.11. Institutional Framework for implementation of EMP.................................................. 356

10.11.2. Hierarchical of Environmental Management Cell (EMC) ................................ 357 10.11.3. Intergated Management Policy of GSFC .......................................................... 359 10.11.4. Grievance Redress Mechanism .......................................................................... 361 10.11.5. Reporting ............................................................................................................... 361

10.12. Budget for Environmental Management Plan .......................................................... 362 Chapter 11. SUMMARY AND CONCLUSION ............................................................................. 363

11.1. Project Description ........................................................................................................ 363 11.2. Description of the Environment ................................................................................... 367 11.3. Anticipated Environmental Impacts and Mitigation Measures ............................... 370 11.4. Environmental Monitoring Programme ...................................................................... 375 11.5. Additional Studies ......................................................................................................... 375 11.6. Project Benefits .............................................................................................................. 376





11.7. Environment Management Plan ................................................................................. 376 Chapter 12. Disclosure of Consultant ....................................................................................... 377

LIST OF TABLES

Table 1.1 : Consolidated Details of Project (Post Revamping Urea Plant) .............................. 21 Table 1.2 : Changes in Environmental Parameters .................................................................... 23 Table 1.3 : Products and Services by GSFC ................................................................................ 24 Table 1.4 : Contact Details of Authorized Signatory, GSFC ...................................................... 26 Table 1.5 : List of Awards and Achievements of GSFC .............................................................. 26 Table 1.6 : Details of GSFC Ventures and Projects ..................................................................... 32 Table 1.7 : Details of Permits and Clearance Applicable and its Status ................................. 40

Table 1.8 TOR Compliance ........................................................................................................ 42 Table 2.1 : Salient Features of the Project Site ............................................................................ 75 Table 2.2 : List of Nearby Industries .............................................................................................. 79 Table 2.3 : Land Breakup of Project Site ...................................................................................... 79 Table 2.4 : Product specifications (Urea by Total Recycle Process) ........................................ 84 Table 2.5 : Ammonia emissions through vent stack and distribution ....................................... 87 Table 2.6 : Mass Balance (Post Revamping) .............................................................................. 95 Table 2.7 : Details of Raw Materials for Proposed Revamping ................................................. 96 Table 2.8 : Storage Facilities at GSFC, Vadodara ...................................................................... 98 Table 2.9 : Details of Fire Water Pumps ....................................................................................... 99 Table 2.10 : Details of Mobile Fire fighting appliances .............................................................. 99 Table 2.11 : Details of Stationary Fire fighting appliances ....................................................... 100 Table 2.12 : Details of Portable Fire Fighting Extinguishers ....................................................... 100 Table 2.13 : Details of Chemicals in Fire fighting System ......................................................... 100 Table 2.14 : List of Equipments & Machineries in Urea-I Plant ................................................. 101 Table 2.15 : List of Equipments & Machineries in Urea-II Plant ................................................ 103 Table 2.16 : List of Proposed Modifications/New Installations under Revamping ................ 107 Table 2.17 : Details of Total Water Requirement (Existing & After Revamping) .................... 112 Table 2.18 : Details of Existing Process Gas Stacks (Urea-I & II Plants) .................................... 123 Table 2.19 : Details of Proposed Flue Gas Stacks ..................................................................... 123 Table 2.20 : Management of Hazardous & Non-Hazardous Waste ....................................... 124

Table 3.1 Environmental Sensitivity of Proposed Site and Study Area ................................ 129

Table 3.2 Summary of Methodology for Primary Secondary Baseline Data Collection .. 134

Table 3.3 Physiography & Topography of Vadodara District ............................................... 137



Table 3.6 Land use of the Study Area ..................................................................................... 150 Table 3.7 : Soil Sampling Locations ............................................................................................ 153 Table 3.8 : Method for Analysis of Soil Properties ..................................................................... 155 Table 3.9 : Physicochemical Characteristics of Soil {Winter Season (2020-2021)} ................ 157 Table 3.10 : Soil Reaction Classes .............................................................................................. 159 Table 3.11 : Soil Reaction Classes .............................................................................................. 161 Table 3.12 : Water Quality Sampling Stations ........................................................................... 163 Table 3.13 : Test Method used for the analysis ......................................................................... 167 Table 3.14 : Surface Water Standards as per IS: 2296-1982 ..................................................... 168 Table 3.15 : Surface Water Quality Criteria as per CPCB ........................................................ 169 Table 3.16 : Surface Water Quality Results ................................................................................ 171 Table 3.17 : Interpretation of Surface Water Quality ............................................................... 173





Table 3.18 : Ground Water Quality Results ................................................................................ 174 Table 3.19 : Modified weights for computations for WQI based on DO, FC, pH, and BOD 179 Table 3.20 : Sub-index equation used to calculate NSF WQI for DO, FC, pH, and BOD ..... 180 Table 3.21 : Water Quality Classification and Best Designated Use ...................................... 180 Table 3.22 : Surface Water Quality Index (Results) ................................................................... 181 Table 3.23 : Water Quality Classification based on WQI Value for Ground Water .............. 181 Table 3.24 : Ground Water Quality Index .................................................................................. 181 Table 3.25 : Climate Data of IMD Vadodara (1981-2010) ....................................................... 182 Table 3.26 : Meteorological Data of 2020-2021 (Vadodara) ................................................. 184 Table 3.27 : Summary of Site-Specific Meteorological Data .................................................. 187 Table 3.28 : List of nearby industries ........................................................................................... 191 Table 3.29 : Location of Air Monitoring Stations ....................................................................... 192 Table 3.30 : Sampling Methodology .......................................................................................... 194 Table 3.31 : Summary of Ambient Air Quality (I) ....................................................................... 196 Table 3.32 : Summary of Ambient Air Quality (I) ....................................................................... 196 Table 3.33 : AQI Category for Monitoring Station .................................................................... 199 Table 3.34 : Ambient Noise Quality Monitoring Locations ...................................................... 204 Table 3.35 : Ambient Noise Leq at Monitoring Location ......................................................... 206 Table 3.36 : Sensitive Environment Features within study area ............................................... 208 Table 3.37 : Tree Species recorded in the Study Area ............................................................. 209 Table 3.38 : Medicinal Plants recorded in Study Area ............................................................. 214 Table 3.39 : Major crops in the study area ................................................................................ 215 Table 3.40 : List of mammalian species recorded (direct or indirect evidence) from study

area ....................................................................................................................................... 216 Table 3.41 : Reptiles observed in Study Area ............................................................................ 217 Table 3.42 : List of Avifauna recorded during the study .......................................................... 217 Table 3.43 : List of Surface water bodies in study area ........................................................... 220 Table 3.44 : List of fish species in study area (Mahi River) ........................................................ 220 Table 3.45 : List of Schedule-I species in study area ................................................................ 221 Table 3.46 : Caste-Wise Population Distribution of 2.0 km Radial Zone ................................. 224 Table 3.47 : Details of Sex Ratio in Study Area .......................................................................... 227 Table 3.48 : Details of ST & ST Population in Study Area .......................................................... 228 Table 3.49 : Details of Sex Ratio in Study Area .......................................................................... 229 Table 3.50 : Distribution of Work Participation Rate ................................................................. 230

Table 3.51 : Composition of Non Workers ................................................................................ 232 Table 3.52 : Village Wise Basic Amenities Availability .............................................................. 233 Table 3.53 : Traffic Load Conditions at NH-8 ............................................................................. 237 Table 4.1 : Impact Assessment Criteria ...................................................................................... 240 Table 4.2 : Impact Assessment Criteria ...................................................................................... 240 Table 4.3 : Summary Baseline Scenario of Project Area and Likely extent of Impact ......... 241 Table 4.4 : Impact Identification Matrix .................................................................................... 244 Table 4.5 : Analysis of Significance of with & without Mitigation Measures .......................... 259 Table 5.1 : Measures for Energy Conservation in GSFC Plant ................................................. 268 Table 6.1 : Instruments for Gaseous Emission Monitoring available at GSFC ........................ 272 Table 6.2 : Instruments for Water Monitoring available at GSFC ............................................ 273 Table 6.3 : List of Instruments available in laboratory .............................................................. 276 Table 6.4 : Environmental Monitoring Program ........................................................................ 277 Table 7.1 : Bulk Storages of Hazardous Chemicals involved in Proposed Revamping Project

................................................................................................................................................ 282





Table 7.2 : Hazard Analysis of Products ..................................................................................... 283 Table 7.3 : Hazard Analysis of Bulk Storage Raw Materials ..................................................... 283 Table 7.4 : Risk Classification ....................................................................................................... 286 Table 7.5 : Effects due to Incident Radiation Intensity ............................................................ 287 Table 7.6 : Thermal Radiation Impact to Human ..................................................................... 287 Table 7.7 : Tolerable Intensities for various objects .................................................................. 287 Table 7.8 : Damage due to Overpressure ................................................................................ 288 Table 7.9 : Different Failure Scenarios ........................................................................................ 290 Table 7.10 : Hazard Scenario Impact ........................................................................................ 290 Table 7.11 : Details of Hazardous Scenario Chemicals ........................................................... 293 Table 8.1 : Contributions in Socio-development activities by GSFC ...................................... 305 Table 8.2 : Funds utilized under Corporate Social Responsibility (from 2014- 2021) ............. 309 Table 8.3 : Proposed CSR Fund (2021-2022) .............................................................................. 310 Table 10.1 : Environment Management Plan during Construction Phase ............................ 314 Table 10.2 : Environment Management Plan during Operational Phase ............................. 317 Table 10.3 : Details of Personal Protective Appliances for Emergency Handling ................ 334 Table 10.4 : Details of Safety Training (2020-2021) ................................................................... 336 Table 10.5 : Zone-wise Alarm & Detection Points ..................................................................... 340 Table 10.6 : Plant-wise Alarm & Detection Points ..................................................................... 340 Table 10.7 : Fire Tender Details ................................................................................................... 340 Table 10.8 : Details of Facilities at OHC ..................................................................................... 343 Table 10.9 : Details of Examination under Periodical Medical Check-up ............................. 343 Table 10.10 : Details of Examination under Periodical Medical Check-up ........................... 344 Table 10.11 : No. of trees planted in GSFC Complex .............................................................. 345 Table 10.12 : Types and Species of Trees in GSFC .................................................................... 347 Table 10.13 : Measures for Energy Conservation in Urea Plants at GSFC .............................. 350 Table 10.14 : Compliance of CREP Guidelines ......................................................................... 351 Table 10.15 : Members of Environment Management Cell, GSFC ......................................... 356

Table 10.16 Budget for Environmental Management Plan .................................................. 362

Table 10.17 Budget for Environmental Management Plan .................................................. 362 Table 11.1 : Consolidated Details of Project (Post Revamping Urea Unit) ............................ 364 Table 11.2 : Changes in Environmental Parameters ................................................................ 366

LIST OF FIGURES

Figure 1.1 : Precepts of GSFC ....................................................................................................... 25 Figure 1.2 : Project Boundary Map .............................................................................................. 36

Figure 1.3 Project Location Map ............................................................................................... 37

Figure 1.4 Connectivity Map of the Project Site ...................................................................... 38

Figure 1.5 Toposheet Map showing the project site ............................................................... 39

Figure 2.1 Location Map of Study Area .................................................................................... 77 Figure 2.2 : Site Photographs ........................................................................................................ 78 Figure 2.3 : Land-use Breakup of GSFC Complex ...................................................................... 80 Figure 2.4 : Layout Plan of Urea-I Plant including Revamped Urea Plant ............................... 81 Figure 2.5 : Layout Plan of Urea-II Plant including Revamped Urea Plant .............................. 82 Figure 2.6 : Plant Layout (showing location of Proposed Revamping Project on GSFC

Complex) ................................................................................................................................ 83 Figure 2.7 : Chemical Reaction of Urea Manufacturing (Total Recycle Process) .................. 84 Figure 2.8 : Process Description of Urea Manufacturing (Existing Technology) ...................... 88





Figure 2.9 : Process Description of Urea Manufacturing (Proposed Technology- Ammonia

Sripping)................................................................................................................................... 94 Figure 2.10 : Existing Water Balance (Urea-I Plant) .................................................................. 113 Figure 2.11 : Existing Water Balance (Urea-II Plant) .................................................................. 114 Figure 2.12 : Water Balance (Total after Revamping) ............................................................. 115 Figure 2.13 : Process Flow Diagram of Wastewater Treatment Section ................................ 119 Figure 3.1 : Study Area Map ....................................................................................................... 128 Figure 3.2 : Topo Map showing Site & Surrounding Environmental Features within 10 km Area

................................................................................................................................................ 132 Figure 3.3 : Topographic Map of Vadodara District ................................................................ 136 Figure 3.4 : Physiographic Map of Vadodara District .............................................................. 138 Figure 3.5 : Digital Elevation Map of Study Area ...................................................................... 139 Figure 3.6 : Seismic Zones Map ................................................................................................... 141 Figure 3.7 : Seismic Zones Map of Gujarat ................................................................................ 141 Figure 3.8 : Hydrogeological Map of Vadodara District ......................................................... 142 Figure 3.9 : Drainage Map of Vadodara District ...................................................................... 143 Figure 3.10 : Drainage Map of Project Site ............................................................................... 145 Figure 3.11 : Graph Showing Land Use of the Study Area (10 km Radius) ............................ 150

Figure 3.12 : Land Use Map of the Study Area 10 km Radial Zone ..................................... 151 Figure 3.13 : Soil Map of Vadodara District ............................................................................... 152 Figure 3.14 : Location of Soil Sampling Stations ........................................................................ 154 Figure 3.15 : Photographs of Soil Sampling ............................................................................... 156 Figure 3.16 : Photographs of Water Sampling .......................................................................... 164 Figure 3.17 : Location of Water Quality Sampling Stations (Groundwater & Surface Water)

................................................................................................................................................ 165 Figure 3.18 : Climatological Trend of IMD Vadodara (1981-2010) ......................................... 183 Figure 3.19 : Comparison of Trend between IMD (1989-2010) & 2020 {Temperature} ......... 185 Figure 3.20 : Comparison of Trend between IMD (1989-2010) & 2020 {Humidity} ................ 185 Figure 3.21 : Comparison of Trend between IMD (1989-2010) & 2020 {Rainfall & Rainy Days}

................................................................................................................................................ 186 Figure 3.22 : Comparison of Trend between IMD (1989-2010) & 2020 {Wind Speed} .......... 186 Figure 3.23 : Site-specific Windrose Diagram ............................................................................ 188 Figure 3.24 : Wind-Class Frequency Distribution Diagram ....................................................... 188 Figure 3.25 : Comparative Trend Analysis of site specific data with secondary MET Data

(Temperature) ....................................................................................................................... 189 Figure 3.26 : Comparative Trend Analysis of site specific data with secondary MET Data

(Relative Humidity) ............................................................................................................... 189 Figure 3.27 : Comparative Trend Analysis of site specific data with secondary MET Data (Wind

Speed) ................................................................................................................................... 190 Figure 3.28 : Location of the Ambient Air Monitoring Stations ................................................ 193 Figure 3.29 : Photographs of Air Quality Sampling ................................................................... 195 Figure 3.30 : Graphical Representation of Ambient Air Quality (Average) .......................... 198 Figure 3.31 : Baseline Comparative Chart ................................................................................ 202 Figure 3.32 : Map of Soil Monitoring Locations Maps .............................................................. 205

Figure 3.33 : Male Female wise Population Distribution in the study area ........................... 227 Figure 3.34 : Scheduled Caste Population in the Study Area ................................................. 228 Figure 3.35 : Scheduled Tribes Population in the study area .................................................. 228

Figure 3.36 : Male Female wise Distribution of Literates & Illiterates ..................................... 229 Figure 3.37 : Workers Scenario of Study Area ........................................................................... 230





Figure 3.38 : Composition of Main Workers ............................................................................... 231 Figure 3.39 : Composition of Marginal Workers ........................................................................ 232

Figure 3.40 : Composition of Non Workers ............................................................................... 232 Figure 3.41 : Photographs of Traffic Study and Counting ....................................................... 236 Figure 3.42 : Graphical Representation of Traffic Load at NH-8 ............................................. 238 Figure 5.1 : Difference of Process Flow Diagram (Total Recycle & Ammonia Stripping) ..... 264 Figure 6.1 : Water Quality Monitoring Equipment .................................................................... 274 Figure 8.1 : Social Development Activities ................................................................................ 303 Figure 8.2 : Existing CSR Activities carried out by GSFC ........................................................... 308 Figure 10.1 : ISO 45001:2018 OH&S Management System Certificate ................................... 329 Figure 10.2 : ISO 9001:2015 Quality Management System Certificate .................................. 330 Figure 10.3 : ISO 14001:2015 Environment Management System Certificate ...................... 331 Figure 10.4 : ISO 50001:2018 Energy Management System Certificate ................................ 332 Figure 10.5 : Fire Prevention Methods practiced at GSFC ..................................................... 339 Figure 10.6 : Existing Green Belt at GSFC ................................................................................. 349 Figure 10.7 : Organogram of Environment Management Cell, GSFC .................................. 358 Figure 10.8 : Integrated Management System Policy of GSFC .............................................. 360

LIST OF ABBREVIATIONS

GSFC Gujarat State Fertilizers & Chemicals Limited

ToR Terms of Reference

EIA Environment Impact Assessment

AAQ Ambient Air Quality

APHA American Public Health Association

BDL Below Detection Level

BIS Bureau of Indian Standards

CPCB Central Pollution Control Board

MoEF&CC Ministry of Environment, Forests & Climate Change

SAP Sulphuric Acid Plant

DMS Di-Methyl Sulphate

HCL Hydrochloric Acid

TPD Tons per Day

SO3 Sulphur Tri Oxide

CAGR Compound Annual Growth Rate

IRR Internal rate of return

CTE Consent to Establish

CTO Consent to operate

MT Metric Tones

NOC No Objection Certificate

EAC Expert Appraisal Committee

B Boron

Zn Zinc

KLD Kilo Litre per Day

N North

S South

E East

W West

NE Northeast

SW Southwest





NH National Highway

km Kilometer

M2 Square meter

Kg Kilogram

SA / H2SO4 Sulphuric Acid

KCl Potassium Chloride

HDPE High Density Polyethylene

PP Polypropylene

EOT Electric overhead traveling

PM Particulate Matter

ETP Effluent Treatment Plant

MS Mild steel

RCC Reinforced Cement Concrete

kVA/ KW Kilo Volt ampere/ Kilo watt

DG Diesel Generator

F Floride

SO2 Sulphur Dioxide

NO2 Nitrogen Dioxide

HC Hydrocarbon

NH3 Ammonia

Cl Chlorine

STP Sewage Treatment Plant

GLC Ground level Concentration

CFM Cubic Feet per Minute

Mg/ Nm3 Milligram per Normal meter cube

DDS Dedusting System

SPCB State Pollution Control Board

dBA Decibel (A)

RO Reverse Osmosis

CER Corporate Environment Responsibility

QA/QC Quality Assurance/ Quality Control

SRTM Shuttle Radar Topography Mission

GIS Geographic Information System

CGWB Central Ground Water Board

FCC False Color Composite

MSS multispectral

µg m3 Microgram per metercube

PCU Passenger Car Unit

IRC Indian Road Congress

BDU Best Designated Use

GW Ground water

CaCO3 Calcium Carbonate

Mbgl Meter below ground level

IUCN International Union for Conservation of Nature’s

CO Carbon Monoxide

APCM Air Pollution Controlling Measures

PUC Pollution Under Control

ILO International Labour Organization

PPEs Personal protective equipment

VOC Volatile Organic Carbon

USEPA United State Environmental Protection Agency





AERMOD American Meteorological Society/Environmental Protection Agency

Regulatory Model.

UTM Universal Transverse Meter

TSDF Treatment, Storage, And Disposal Facility

ZLD Zero Liquid Discharge

RET Rare, Endangered and Threatened

FPS Fine Particulate Matter Sampler

DGMS Directorate General of Mines Safety,

EMP Environment Management Plan

DMP Disaster Management Plan

RSPM Respirable suspended particulate matter

GPCB Gujarat Pollution Control Board

EHS Environment Health & Safety

EMC Environment Management Cell

ERPG Emergency Response Planning Guidelines

IDLH Immediately Dangerous to Life Or Health

LDO Light Diesel Oil

HSD High Speed Diesel

LEL Lower Explosive Limit

UEL Upper Explosive Limit

ACGIH The American Conference of Governmental Industrial Hygienists

STEL Short-Term Exposure Limit

TLV Threshold Limit Value

IT Inhalation Toxicity

AEGL Acute Exposure Guideline Levels

HAZOP Hazard and Operability Study

EPP Emergency Preparedness Plan

LED Light Emitting Diode

NAAQS National Ambient Air Quality Standards

MSRL Mild Steel Rubber Lined

ALARP As Low as Reasonably Practicable

CCPS Centre for chemical process safety

CR Catastrophic Rupture

FBR Full Bore Rupture

IRPA Individual Risk Per Annum

LFL Lower Flammable Limit

LOC Loss of Containment

LSIR Location Specific Individual Risk

MCLS Maximum Credible Loss Scenarios

MIQA Maintenance Integrity and Quality Assurance

NA Not Applicable

NH No Hazard

NR Not Reached

IOGP International Association of Oil & Gas Producers

PLL Potential Loss of Life

QRA Quantitative Risk Assessment

RRM Risk Reduction Measures

UFL Upper Flammable Limit

UK HSE UK Health and Safety Executive





CHAPTER 1. INTRODUCTION

1.1. Preamble

Gujarat State Fertilizers & Chemicals Ltd (GSFC) is a renowned industry in the fertilizer

sectors and a leading manufacturer of Nitrogenous and Phosphatic Fertilizers. Along with

production of fertilizer the organization is also involved in Petrochemical and Industrial

products. GSFC is a star performer of Gujarat state industrial horizon and a model for

long term value creation unit. Developing solutions for sustainable agriculture & industrial

growth, through environmentally safe manufacturing processes is focus area of GSFC.

The organization has multi-location industrial plants within Gujarat state. GSFC has wide

and well-established marketing networks in almost all the major cities of India for fertilizer

as well as industrial product. GSFC has its two fertilizer manufacturing units at Vadodara

and Jamnagar, Gujarat. One of the plants located at P.O. Fertilizernagar, Dist.-

Vadodara, Gujarat-391750 possess the following plants within the area of total 328 Ha.:

A. FERTILIZER COMPLEXES

1. Ammonia III & IV Plants

2. Urea-I & II Plants

3. Ammonium Sulphate Plants

4. DAP/NPK/MAP/ASP Plant

5. Ammonium Sulphate Phosphate Plant

6. Urea Phosphate Plant

B. INORGANIC PLANTS

1. Sulphuric Acid Plants

2. Phosphoric Acid Plant

C. PETROCHEMICAL COMPLEX & SYNTHETIC ORGANIC MANUFACTURING PLANTS

1. Caprolactam Plants

2. Nylon-6 Plants

3. MEKO Plant

4. Melamine Plants

5. Methanol

6. HAS Crystal

The complex possesses 2 no. of Urea Plants i.e., Urea-I & Urea-II based on Toyo

Technology (Total Recycle Process). Urea-I and Urea-II plants were established in year

1967 & 1969 respectively i.e., before the purview of EIA Notification,1994 and its

This chapter provides background information of the project, need of the project,

need of the EIA study, scope and EIA methodology adopted and structure of the

report.





subsequent amendments thereof. Thereafter, no changes were carried out in both the

plants.

As per New Urea Policy 2015 and Revision of Energry Norms under NUP-2015 vide Letter

No. 12012/1/2015-FPP, all gas-based urea manufacturing units (Group-II) have been

directed to achieve target energy norms of 6.2 GCal/MT of Urea. The target energy

norms will be continued upto 31st March,2025.

To achieve the targeted energy norms and improve the reliability of old existing plants

i.e., Urea-I & Urea-II, GSFC as planned for revamping of its existing Urea plants by

replacing existing “Total Recycle Process” to latest “Ammonia Stripping Process.” The

combined capacity of revamped urea plants will remain the same i.e., 3,67,200 MTPA.

From proposed revamping, the unit will be able to attain energy upto 5.773 GCal/MT of

Urea which is even better than targeted energy consumption goal.

Due to no increment in overall production capacity of plant, there will no increase in

pollution load. Additionally, under proposed revamping project, new wastewater

treatment (WWT) section will be installed to treat the process condensate generated

from vacuum evaporation package. Treated water will be used as a raw water makeup

in cooling tower. Therefore, it will eventually reduce net raw water requirement of the

plant. The revamped process scheme is targeted to achieve a specific energy saving

of atleast 0.6 GCal/MT Urea. Energy is reduced also on account of reduction in specific

consumption of Ammonia and Power in addition to Steam. Since the proposed project

involves refurbishing of 2 Urea Plants with efficient and conservational technology to

produce combined capacity of 3,67,200 MTPA, the project does not pose increment in

pollution load. Additionally, the project will reduce use of natural resources like

freshwater and natural gas consumption.

Hence, GSFC requests MoEF&CC (Industry-III) to consider the merits of the proposal and

appraise the same under para 7(ii) of EIA Notification,2006 and its subsequent

amendments. It is hence requested to exempt the project from scoping stage and

appraise for grant of Environmental Clearance.

1.2. Brief About Project & Project Proponent

GSFC has proposed for “Revamping of existing Urea Plants (Urea-I & II) by replacing

existing total recycle process to latest ammonia stripping process”. The combined

capacity of revamped project will be 3,67,200 MTPA. The details of the project after

revamping have been provided below in Table 1.1.

Since both the plants were established before the 1994, they did not come into the

purview of EIA Notification, 1994 and its subsequent amendments. The proposed

revamping project falls under Activity 5(a); Category A as per EIA Notification,2006 and

its subsequent amendments. Due to legitimate advantages of the proposed project and

no increase in pollution load, GSFC requests for consideration of the proposal under

Clause 7(ii) & thereby exempt it from scoping stage and appraise directly for the grant

of Environmental Clearance.





GSFC Complex being a Notified Area by Industries, Mines and Energy Department vide

Notification No. GU-87-46-GID-1086(I) 2338 dated 21.08.1987. (Notification annexed as

Enclosure-I), the project has been exempted from Public Hearing as per clause 7 (i) (III)

of EIA notification 2006 & OM J-11011/321/2016-IA. II(I) dated 27.04.2018.





Table 1.1 : Consolidated Details of Project (Post Revamping Urea Plant)

S.No. Particulars Unit Details Impact /Remarks

Existing Proposed Post Revamping

1. Production

Capacity

MTPA Urea-I

Unit 103200

0

(Revamping) Post

Revamping

Urea Unit

367200

No Change

Urea-II

Unit 264000

2. Technology - M/s Toyo Engineering

Corporation, Japan,

using MTC (Mitsui Toastu

Corporation) Total

Recycle

“C” process.

Ammonia

Stripping

Ammonia

Stripping Process

Ammonia Stripping

Process is more

conservational and

efficient technology.

3. Total Plot Area Ha. 328 No Change

4. Green Area Ha. 123.2 (37.56% of total plot area) No Change

5. Cost of Project Rs.

(in Crores)

- 306 306 -

6. Employment No. 124 -60 64 Decrease

7. Total Water

Requirement

KLD 6046.1 -2144.2 3901.9 Decrease

m3/hr 251.92 -89.34 162.6

8. Freshwater

Requirement

KLD 5035.7 -2128.1 2907.6 Decrease

m3/hr 209.82 -88.67 121.15

9. Wastewater

Generation

KLD 1060.08 -302.4 757.68 Decrease

m3/hr 44.17 -12.6 31.57







10. Wastewater

Treatment

Scheme

- Nil WWT Section Wastewater Treatment

Section

(Hydrolyser, Desorber,

Hydrolyser Pre-heater,

Treated Water Final

Cooler, Hydrolyser Feed

pump, Treated

Condensate Pump).

To Recover NH3, CO2

and Urea contained in

the process water and

to produce clean

process condensate

that can be used in

Cooling Tower

Makeup.

11. Treated Water

Recycle

KLD 0 691.2 691.2 Increase

m3/hr 0 28.8 28.8

12. Process Effluent

going to PA

Plant

KLD 144 0 144 No Change

m3/hr 6 0 6

13. Steam

Condensate

Export Credit-

Recycle as

Water

KLD 1010.4 -707.3 303.12 Decrease

m3/hr 42.1 -29.47

12.63

14. Power

Consumption

kWh/MT 205 -22 183 Decrease

15. Power Backup kVA - 500 500 Increase





Details of changes in Environmental paramaters due to proposed revamping have been provided below:

Table 1.2 : Changes in Environmental Parameters

S.No. Particulars Unit Existing Proposed Post Revamping Impact/

Remarks

1. Prill Tower PM

(kg/MT of Urea)

2 0 2 No Change

NH3

(mg/Nm3 of Urea)

175 0 175

2. Total Water

Consumption

m3/MT of Urea 5.38 -1.88 3.50 Decrease

3. Freshwater

Consumption


4. Liquid Effluent/

Wastewater

Generation


5. Energy Consumption GCal/MT of Urea 6.523 -0.750 5.773 Decrease





Project Proponent

Gujarat State Fertilizers and Chemicals Limited (GSFC) was incorporated in 1962 and its

plants went into the production of fertilizers in 1967. In its very first decade of existence,

GSFC became known for its path breaking achievements. To name a few, it was the first

industrial complex in the country to set up in the joint sector, the first company to set up

fertilizer plants. GSFC has set up the first DAP fertilizer complex in India at Sikka, Jamnagar

on the west coast of Gujarat. Its technical edge as well as engineering resources

acquired during its very first decade have been catalysts in providing impetus to the

expansion and diversification strategies spread over the next four decades. GSFC

Adding to its credit, also set up India's first Melamine plant. The expansion and

diversification of GSFC's product portfolio unfolded new growth vistas to the nation by

providing much needed fertilizers for agricultural growth and chemicals for industrial

growth.

GSFC is involved in various arrays of fields and departments. The following are details of

products and services provided in GSFC:

Table 1.3 : Products and Services by GSFC

S.No. Products & Services

1. Fertilizers

Urea, Ammonium Sulphate, Di-Ammonium Phosphate, APS, NPK- 12:32:16,

NPK-10:26:26, Ammonium Phosphate, Mono Ammonium Phosphate (MAP),

Urea Phosphate, Water Soluble Fertilizers (WSF)- NPK- 19:19:19, Mono

Potassium Phosphate (MKP), Potassium Nitrate (KNO3), Potassium Sulpate

(SOP).

2. Industrial Products- Major

Ammonia, Phosphoric Acid, Caprolactam, Melamine, Nylon-6, Methyl Ethyl

Ketoxime, Methanol, Hydroxylamine Sulphate, Sulphuric Acid, Technical

Grade Urea, Oleum, HAS Crystal

3. Micronutrient Mixture

4. Plant Growth Promoters

Sardar Amin Granules (SAG), Sardar Amin Liquid, cryogenically grinded

seed/spice through grinding

5. Soil Conditioners

Nutri+ Granules, City Compost, Phospho Gypsum (Dry Basis).

6. Co-generation

Co-generation Plants

VISION OF GSFC

“Our vision is to efficiently produce an array of valuable, superior and reliable products

that enrich lives of millions in farms, industries and homes. The Company envisions

operating in synergy with its environment and seeks to be recognized as an enterprise

that is for total customer satisfaction and creates credible long-term value for its





stakeholders. Integrity and transparency remain the corner-stones of Company's

governance.”

MISSION OF GSFC

The Company seeks to enrich lives.

• of customers by providing goods and services that add value to farm enterprises,

industries, and homes.

• of stakeholders by continuously adding value by managing responsibly, sensibly

and maintaining ethical standards of highest quality.

• of neighborhood community by working in synergy with its environment and

enriching the biodiversity.

• of employees by providing them a work environment that fosters growth,

learning, achievement, teamwork, and a perfect work-life balance.

SIX PRECEPTS OF GSFC

Figure 1.1 : Precepts of GSFC





GSFC Vadodara Unit is certified for Integrated Management System (ISO 9001, ISO

14001, ISO 45001, ISO 50001 from TUV CERT Certification Body & Responsible Care logo

from ICC). Contact Details of Authorized Signatory have been provided below in Table

1.4:

Table 1.4 : Contact Details of Authorized Signatory, GSFC

Project Proponent : M/s Gujarat State Fertilizers & Chemicals Limited

Registered Address : P. O. Fertilizernagar-391750, Dist. Vadodara, Gujarat, India

Authorized Signatory : Mr. K.S. Badlani

Designation : Vice President (I & MB, U&EC & FU)

Email Id : [email protected]

Contact No. : (0265) 309 2831, Mob: +91-9909965842

LATEST AWARDS AND ACHIEVEMENTS TO GSFC:

GSFC, Vadodara has won several awards and accolades. Following is the list of honors

awarded to GSFC (Table 1.5)

Table 1.5 : List of Awards and Achievements of GSFC

Sr.No. Awards Details

2003-2004

1. National Safety

Award 2003

Production, Promotion & Marketing of Bio-fertilizers.

2. Excellent

Performance

Award

Improvement in Overall Performance

3. Safety Award National Safety Award 2003

4. Safety Award Certificate of Merit and Runners up Trophy -2003 from

Gujarat Safety Council & Directorate of Industrial safety

& Health, Gujarat State

5. Safety Award International Safety Award 2004

6. Safety Award Five Star Rating in Health & Safety Audit 2004

7. Safety Award Sword of Honour 2004 awarded for maintaining highest

level of health & safety standard.

2005-2006

8. Excellence in Cost

Management

Award

ICWAI National Award (Third Best) for Excellence in

Cost Management, 2006

9. Award for Bio-

Fertilizer’s

producers

NPC 2005-06 (Second Best) Award for Bio-Fertilizers

Producers

10. Best Employers for

Disabled Persons

National Award 2006 for one of the Best Employers for

disabled persons.

11. Video Film Award

for Increase in

Fertilizer Use

Video Film Award for Increase in Fertilizer use efficiency

through Micro Irrigation System







12. Production,

Promotion &

Marketing

Award for Production, Promotion & Marketing of Bio-

fertilizers.

13. Best Production

Performance

Award

Award for Best Production Performance- Complex

(P2O5) Fertilizer Plant

14. Safety Award Certificate of Honour

15. Safety Award International Safety Award 2005

16. Excellence in Cost

Management

Award

ICWAI National Award (Second Best) for Excellence in

Cost Management, 2005

2007-2008

17. Excellence in

Management of

Health, Safety &

Environment Award

Excellence in Management of Health, Safety &

Environment under Category-I

18. Scope Meritorious

Award

Environment

Excellence & Sustainable Development in recognition

of long-term commitment and dedication to

environment protection measures.

19. Best overall

performance for

P205 in Complex

Fertilizers for Sikka

Unit

Best overall performance of an operating fertilizer unit

for P2O5 in complex fertilizers for Sikka Unit for the year

2007-08.

20. International Safety

Award

International Safety Award - 2007

21. Safety Award

Continuous two million accident-free working man-

hours for the year 2006.

22. Greentech Gold

Award

Outstanding achievement in Environment

Management.

2008-2009


Award

Environment

Excellence &

Sustainable

Development in recognition of long-term commitment

and dedication to environment protection measures &

GOLD TROPHY.

24. National Energy

Conservation

Awards

First prize in Fertilizer Sector in National Energy

Conservation Awards-2009

25. ICC ADITYA BIRLA

AWARD

Best Responsible Care Committed Company for the

year 2008

26. International Safety

Award

International Safety Award - 2008

27. SRISHTI's G-CUBE

AWARD

Award for Good Green Governance

2009-2010







Award

Environment

Excellence &

Sustainable

Development in recognition of long-term commitment

and dedication to environment protection measures &

GOLD TROPHY.

29. National Energy

Conservation

Awards

First prize in Fertilizer Sector in National Energy

Conservation Awards-2009

2010-2011

30. National Energy

Conservation

Award-2011

Certificate of Merit for National Energy Conservation

Award-2011 for GSFC's vital contribution in the field of

energy conservation.

2011-2012

31. Award for

Environmental

Protection in the

NP/NPK Fertilizer

Plants excluding

captive acids

category.

Environmental

Protection in the NP/NPK Fertilizer Plants excluding

captive acids category for the year 2011-12 for Sikka

Unit.

32. Award for Best

Overall

Performance of an

operating Fertilizer

Unit for Complex

Fertilizers

Best Overall Performance of an operating fertilizer unit

for Complex Fertilizers for the year 2011-12 for

Vadodara Unit.

2012-2013

33. FAI Award for the

Best Production

Performance of

Nitrogenous Plant

for the year 2012-

13.

Runner up for FAI Award for the Best Production

Performance of Nitrogenous Plant for the year 2012-13.

34. FAI Environmental

Protection Award in

the NP/NPK fertilizer

plants for the year

2012-13.

FAI Environmental Protection Award in the NP/NPK

fertilizer plants for the year 2012-13.


Best Production

Performance of an

Operating

Phosphoric Acid

Plant for the year

2012-13

Best overall performance of an operating Phosphoric

Acid plant for the year 2012-13






36. Prestigious SAP-ACE

AWARD -2013 for

Best Run Public

Sector Undertaking

Prestigious SAP-ACE AWARD -2013 for Best Run Public

Sector Undertaking

37. BPC Award for

Good House

keeping

GSFC adjudged as a winner of BPC's Good

Housekeeping Award for the year 2012-13.

38. British Safety

Council (BSC)

Award

The Occupational Health & Safety audit was

conducted by BSC during Nov-Dec 2012 for GSFC's 4

Units viz. Vadodara, Sikka, Polymers &Fibre. Awarded 5

Star with 92.6% rating.

2014

39. Golden Peacock

Award

National Winner of 'Golden Peacock Award for

Corporate Social Responsibility' for the year 2014.

40. FAI Environmental

Protection Award in

the NP/NPK fertilizer

plants-Sikka Unit for

the year 2013-14.

FAI Environmental Protection Award in the NP/NPK

fertilizer plants-Sikka Unit for the year 2013-14

41. Mahadhan Award

2013-14

Mahadhan Award for excellence in Crop

Improvement & Productivity from FAI-Western Region

42. ICC Award 2013

ICC Award for Excellence in Chemical Plant Design

and Engineering of Hydroxyl Amine Sulphate (HAS)

Crystal Plant for the year 2013

2015

43. Adam Smith Award

–Asia - 2015.

Award for Best Risk Management Solution by Treasury

Today Asia 2015.

44. India’s Most Trusted

Brand

'Sardar' brand voted as India’s Most Trusted Brand. The

award is instituted by IBC InfoMedia Pvt. Ltd.

(International Brand Consultants) which is a division of

IBC InfoMedia Corporation, New Jersey, USA.


Best Production

Performance

The Fertilizer Association of India (FAI), a premier

Fertilizer Manufacturers Consortium has honoured

Gujarat State Fertilizers & Chemicals (GSFC) with the FAI

Award for the Best Production Performance of an

operating fertilizer unit for complex fertilizers for the year

2014-15.

46. SKOCH’s ‘SMART

TECHNOLOGY’

Awards for 2015

GSFC’s e-parivartan project got the SKOCH Order-of-

Merit Award and Smart Technology Award for the year

by The SKOCH Foundation at New Delhi.

47. Gold Medal to

GSFC

Gold Medal for organizational excellence by The

Institute of Economic Studies, New Delhi.

48. International

Excellence Award

to Dr. S.K. Nanda,

IAS, CMD-GSFC

International Excellence Award to Dr. S.K. Nanda, IAS,

CMD-GSFC by The Institute of Economic Studies, New

Delhi






49. Environment

Excellence Awards

2015

Vadodara News Magazine's (VNM) ‘Environment

Excellence Award 2015’ under the category Green

Manufacturing Unit, large scale.

50. National Award for

Manufacturing

Competitiveness

National Award for Manufacturing Competitiveness

(NAMC) 2014-15, in the Fertilizer and Agro Chemicals

Sector.

51. Mahadhan Award

Mahadhan Award for excellence in Crop

Improvement & Productivity from FAI-Western Region.

52. Global Visionary

Award

Indian Society.

The Vision World Academy, Ahmedabad, conferred its

Global Visionary Award on Dr. S K Nanda, IAS,

Chairman and Managing Director of GSFC, for his

invaluable contributions to the

53. India's No.1 Brand-

2014

GSFC was chosen as India's No.1 Brand for the year

2014 by the New Jersey based No.1 Brand Awards

Council, and IBC InfoMedia, the International Brand

Consultants.

54. FGI award for

excellence - 2013

FGI award for excellence in the field of Industrial

Relations.

55. The Global Award

for Perfection,

Quality & Ideal

Performance.

Perfection, Quality & Ideal Performance. Award to

GSFC by Association Otherways Management &

Consulting, Paris-France.

56. Udyog Rattan

Award to Dr. S.K.

Nanda, IAS, CMD,

GSFC and

Excellence Award

to GSFC

Udyog Rattan Award to Dr. S.K. Nanda, IAS, CMD, GSFC

and Excellence Award to GSFC by Institute of

Economic Studies, New Delhi.

57. Leadership Award

to Dr. S.K. Nanda,

IAS - CMD, GSFC

Leadership Award for excellence in Corporate Social

welfare.

58. INDIA CEO

Awards'15 to Dr. S K

Nanda, IAS, CMD,

GSFC

INDIA CEO Awards'15. is awarded to the top 100 CEOs

across India.

2018

59. GSFC has been

recognized as “Top

50 Organizations

with Innovative HR

Practices (PSUs)”

Gujarat State Fertilizers & Chemicals Ltd. (GSFC) has

been recognized as “Top 50 Organizations with

Innovative HR Practices (PSUs)” and was felicitated at

17th Edition of the Asia Pacific HRM Congress,

presented by Times Ascent, at Bengaluru on 4th

September 2018.

Shri Sandeep Purohit, Head (HR) accepted the award

from Shri Roshan Kaluarachchi, CEO, SLT Human

Capital Solutions Pvt. Ltd., Sri Lanka on behalf of GSFC.

The award has been endorsed by CHRO Asia and the






Certificate is provided by World Federation of HR

Professionals.

This award is presented to the Organizations who have

embraced innovation as a part of its own ‘cult’ and

built that into the fabric Strategy of the business. This

award has been presented to GSFC based on its

continuous demonstration of effective, creative and

proactive HR and people management practices

cultivated over the years based on the support,

nurturing and direction provided by its Managing

Directors, HR Leaders, HR Teams and each and every

employee of GSFC.

GSFC family is proud of this achievement.

60. GSFC RECEIVES

AWARD OF MODEL

EMPLOYER

(EXEMPTED

CATEGORY)

Gujarat State Fertilizers & Chemicals Limited (GSFC)

was conferred with ‘Model Employer’ award in the

Exempted category by the Ministry of Labour and

Employment, Government of India on 1st May 2018 in

New Delhi. The award was presented by Hon. Minister

for Road Transport & Highways, Shipping and Water

Resources, River Development & Ganga Rejuvenation,

Shri Nitin Gadkari and Minister of State (Independent

Charge), Labour and Employment, Govt. of India, Shri

Santosh Kumar Gangwar to Mr. V D Nanavaty,

Executive Director (Finance) & CFO of the company.

Speaking on the occasion, Mr. V D Nanavaty,

Executive Director (Finance) & CFO, GSFC Ltd. Said

“This award is a prestigious honour for GSFC & we are

grateful to the Ministry for their extended appreciation

as a Model Employer from amongst 1300 exempted

establishments. We constantly thrive to adopt and

execute best practices in employee relations”.

GSFC has been complying with various Rules &

Regulations related to PF from its establishment and

hence this prestigious Award is an honour of consistent

efforts made by the Company.

61. GSFC, Sikka has

won the FAI

Environmental

Protection Award

for the year 2017-

18.

Gujarat State Fertilizers & Chemicals Ltd., Sikka Unit has

won the FAI Environmental Protection Award in the

NP/NPK fertilizers plants without captive acids category

for the year 2017-18.

The Award was presented by the Chief Guest at the

inaugural function of the FAI Annual Seminar 2018 in

New Delhi on Wednesday, the 5th of December 2018.

2019

62. GSFC has been

recognized as “Best

in class for Training

& Development

(PSUs)”

Gujarat State Fertilizers & Chemicals Ltd. (GSFC) has

been recognized as “Best in class for Training &

Development (PSUs)” and was felicitated at 18th

Edition of the Asia Pacific HRM Congress at Bengaluru

on 17th September, 2019






2020

63. GSFC receives

“SKOCH Order of

Merit” Award

GSFC competed for the said Award by presenting its

project “Managing Emotions, Enhancing Motivation in

times of Covid-19 - The GSFC Way”, where GSFC shared

its Challenges during Emergency Lockdown, when

Company was shut, and when it reopened. The

proactive and responsive Strategies taken up for its

employees, dependents, community and Country to

fight COVID in an essential service set up. Based on its

work, GSFC qualified for Beacon of Hope merit list

which has culminated into receiving SKOCH Order of

Merit on 28th November 2020.

2021

64. AAOYM Awards - 65. National Award for

Excellence in Cost

Management

Gujarat State Fertilizers & Chemicals Ltd has won the

2nd Position in the 17th National Award for Excellence

in Cost Management, 2019. GSFC won the award

under the category of Manufacturing-Public-Large.

GSFC VENTURES

Table 1.6 : Details of GSFC Ventures and Projects





S.No. Ventures Objectives

1 GSFC Agrotech Limited

(GATL)-100% subsidiary

company

The objectives of GATL shall be to carry on the

Business in Agriculture Sector which includes

Liquid Biofertilizers, Cereal Protein Hydrolysate

based Biotech Products, Tissue Culture, Seeds

etc. initially.

2 Gujarat Green Revolution

Company Limited (GGRC)

GGRC provides professional services on Micro

Irrigation System, coupled with required

equipments to the farmers of Gujarat, either

outsourced or self produced. It aims to bring

about the Second Green Revolution, with the

aim of saving water and energy, besides

providing multiple benefits to improve

agricultural productivity and farmer's prosperity

at large. The company is promoted by GSFC,

GNFC and GAIC.

3 Tunisian Indian Fertilizers

S.A. (TIFERT)

The TIFERT plant in Tunisia is a strategic JV that

aims to ensure a consistent supply of Phosphoric

Acid to GSFC's Sikka Unit. Currently, there is

limited avaibility of Phosphoric Acid in the

international market. The supply of Phosphoric

Acid from the TIFERT plant will help optimize

production of GSFC's DAP plant.

4. Vadodara Effluent

Channel Project Limited

(VECL)

VECL was commissioned in 1983 to handle the

effluent discharge of chemical and other units in

the Vadodara area. During 1999-2000 the

Effluent Channel Project was converted to a

Company with a major stake of four Major units,

including GSFC.

5. GSFC University

GSFC University is recognized under the Gujarat

Private University (Second Amendment) Act,

2014 and is established by the GSFC Education

Society - an initiative of Gujarat State Fertilizers

and Chemicals Ltd, a Six-decade old industrial

giant to continue the tradition of serving the

community in multiple ways.

1.3. Need for the project and its importance to the country

The proposed project is refurbishing of old urea plants into more energy efficient and

sustainable production plant with state-of the art technology. GSFC wishes to revamp its

existing Urea plants i.e., Urea – I & II by replacing manufacturing technology from total

recycle process to latest ammonia stripping process. The total production capacity of

the revamped plant will not exceed combined capacity of the plants i.e., 3,67,200

MTPA. The project will prove an exemplary industry from the viewpoint of sustainable

agriculture. Major highlights of the project have been covered in Table 1.1 above:





UREA POLICY,2015

Based on The Cabinet Committee on Economic Affairs (CCEA) decision, Department of

Fertilizers notified “New Urea Policy-2015 (NUP-2015)” with the objectives of maximizing

indigenous urea production, promoting energy efficiency in urea production and

rationalizing subsidy burden on the government. Under NUP-2015, the compensation for

other variable cost e.g., the cost of gas, water charges & electricity and fixed cost is

determined in accordance with existing provisions of New Pricing Scheme (NPS)-III &

Modified New Pricing Scheme (NPS)-III.

As per NUP – 2015, the preset energy norms for the 25 gas based urea units fixed during

earlier policies have been mopped up and they are eligible to get the concession rate

on the basis of revised energy norms fixed for each group from 1st June, 2015 to 31st

March, 2018 which is the simple average of pre-set energy norms of NPS-III and average

actual energy consumption achieved during the years 2011-12, 2012-13 and 2013-14 or

the pre-set set energy norms of NPS-III, whichever is lower.

The urea units were given target energy consumption norms to be achieved in the year

2018-19. For Group-I, target energy norms for the year 2018-19 is 5.5 G Cal/MT (except

Tata Chemicals Limited-Babrala for which existing pre-set energy consumption norm of

NPS-III i.e., 5.417 G Cal/MT will continue). For Group-II and Group-III, the target energy

consumption norms for the year 2018-19 have been 6.2 GCal/MT and 6.5 GCal/MT

respectively.

Department of fertilizers vide notification 28th March,2018 has approved the following

decisions with regard to Target Energy Norms given to all urea manufacturing units:

(i) For 11 Urea manufacturing units viz. YFIL, NFL-Vijaipur, GIL, CFCL- Gadepan-I &

II, IFFCO- Aonla-II, IFFCO Kalol-I, IFFCO Phulpur-I & II, the target energy

consumption norms as mentioned in Para 3.2. of NUP-2015, wil come into force

w.e.f. 1st April,2018.

(ii) The existing norms under New Urea Policy-2015 for remaining 14 urea

manufacturing units viz., NFL-Vajiapur-I, KRIBHCO-Hazira, KFL-Shahjahanpur,

NFCL- Kakinda-I, NFCL-Kakinada-II, GNFC-Bharuch, GSFC-Vadodara, NFL-

Bhatinda, NFL-Nangal, NFL-Panipat, SFC-Kota, KFCL-Kanpur, RCF Trombay-V,

ZACL-Goa are hereby extended for further periods of 2 years i.e., till 31st

March,2020.

(iii) The aforesaid target energy norms may be continued upto 31st March,2025.

Meanwhile, an expert body under NITI Aayog would be engaged to

recommend the energy norms to be achieved from 1st April,2025.

NUP-2015 has resulted in additional production of 20 LMT during the year 2015-16, without

adding any capacity. The production of urea during the year 2015-16 was 244.75 LMT,

i.e., the highest ever urea production in the country. The total production of urea during

2016-17, 2017-18 and 2018-19 was 242.01 LMT, 240.23 LMT & 240 LMT respectively, which

is significantly higher than 2014-15.





Therefore, proposed revamping project has been planned. However, the industry has

proposed for reduction in energy consumption to even more reduced level of 5.773

GCal/MT of Urea.

BENEFITS OF PROPOSED REVAMPING

• Reduction in energy consumption in turn reduction in Natural gas consumption.

• Operation of high-pressure section @ 165 kg/Cm2g instead of current pressure of

205 kg/Cm2g. Lower operating pressure will have a positive effect on the

expected lifecycle of existing high-pressure equipment and related piping.

• Addition of Vacuum package & Wastewater Treatment section to recover the

Process Condensate suitable to be used as cooling tower raw water make up /

export to grid.

• Provision of safety blow down systems in High pressure section for discharge of

vents to safe locations.

• Reduction in dust emission, solid handling, and maintenance by eliminating

crystallizer, Centrifuge, Dryer, and other solid handling equipment with installation

of new vacuum evaporation section.

1.4. Project Site

The GSFC Complex is located at P.O. Fertilizernagar, Tal. and District- Vadodara, Gujarat-

391750. GSFC was incorporated in 1962 and the plants went to production of fertilizers in

1967. The land had been in possession of GSFC since 1962. The proposal is for revamping

of Urea-I & Urea-II plants to develop revamped Urea plant. The co-ordinates of center

of proposed revamped site are Latitude: 22°22'17.54"N; Longitude : 73° 9'16.24"E. The

project is well-connected to National Highway-8 (East direction of Project Site). The

location maps of the project site are given below in Figure 1.2, 1.3 & 1.4





Figure 1.2 : Project Boundary Map





Figure 1.3 Project Location Map





Figure 1.4 Connectivity Map of the Project Site





Figure 1.5 Toposheet Map showing the project site





1.5. Chronology of Project and Need of the EIA Study

• GSFC was incorporated in 1962 and its plants went into production of fertilizers in

1967.

• In Phase-1 (1967), Urea-I along with several plants like Ammonia-I, DI-ammonium

Phosphate, Sulphuric Acid, Ammonium Sulphate and Phosphoric Acid Plants were

established.

• In Phase-II (1969), further expansion was done in the unit. Ammonia-II & Urea-II was

established.

• Urea-I & Urea-II are operational in accordance with CCA granted from Gujarat

Pollution Control Board vide Consent No. AWH-78404 dated 07.06.2016 (valid upto

31.12.2021).

• Now, to achieve target energy norms as prescribed in NUP-2015 and its amendments

i.e., 6.2 GCal/MT of Urea, GSFC has planned for “Revamping of existing Urea Plants

(Urea-I & II) by replacing existing total recycle process to latest ammonia stripping

process”. The combined capacity of the project will be 3,67,200 MTPA. The energy

levels target will get even reduced to even better extent i.e., 5.773 GCal/MT of Urea

from proposed revamping.

As per the Government of India (Ministry of Environment, Forests & Climate Change

(MoEF&CC) EIA Notification,2006 and further amendments, the proposed project will be

covered under Activity 5(a); Category A and hence requires environmental clearance

from MoEF&CC, New Delhi. Due to legitimate advantages of the proposed project and




The environmental study for proposed revamping within the existing unit is aimed to

integrate and optimize existing line of operations related to fertilizer production, latest

technology, existing environmental conditions of the Study area (around proposed

project site), predicting environmental impacts associated with the proposed project

and suggesting mitigation measures to either eliminate or minimize the environmental

impacts The study also aims to assess feedback of different stakeholders addressing

their concerns in mitigation plans

1.5.1. Regulatory Framework

Details of permits and clearance applicable to this project along with status are as under

in Table 1.7:

Table 1.7 : Details of Permits and Clearance Applicable and its Status





S

No

Permit

Clearance Standards

For Proposed

Project

Status

1 No Objection Certificate to

Establish from Gujarat State

Pollution Control Board

PCB for the project

Mandatory To be applied to GPCB for

proposed project.

2 Factory License Mandatory Already obtained for the

existing plant

3 Water withdrawal

Permission/ MOU

Required Available for existing and

proposed water demand

from Vadodara Irrigation

Division vide Order No.

VID/PB-

1/IND/REQ.2021022/GSFC/725

dated 17.03.2021 (Annexed

as Enclosure-IV)

4 Consent to Operate from

Gujarat State Pollution

Control Board PCB for

the project under Water

Prevention and Control of

Pollution Act, 1974 and Air

(Prevention and Control of

Pollution Act, 1981

Mandatory Already have Consolidated

Consent and Authorization

(CC&A) for existing plant from

GPCB vide order no Consent

Order No. -AWH-78404 with

further amendments (valid till

31.12.2021) (Annexed in

Enclosure-II)

For the revamping, to be

applied after CTE.

5 The Hazardous & Other

Waste (Management and

Transboundary Movement)

Amendment Rules, 2016

Authorization

required for

storage,

transportation,

and disposal of

the hazardous

waste

Obtained with Consolidated

Consent and Authorization

(CC&A) (Annexed in

Enclosure-II)

6 Clearance for Boiler

Operation

From Inspector of Boilers,

Gujarat

Mandatory Obtained for all boilers.

7 License to store hazardous

fuels/explosive substances

from Director of Explosives,

Vadodara

Mandatory Obtained

1.6. TOR Compliance

Since the project is being applied under “Para 7(ii)” of EIA Notification,2006 & its

subsequent amendments thereof, Addendum of Environment Impact Assessment

Report has been prepared in reference to Standard Terms of Reference by MoEF&CC.





The EIA study is conducted in line with the Standard TOR and taking into consideration

the structure of the report given in the Appendix III of EIA Notification 2006 The

compliance to the approved TOR is presented in Table 1 8:

Table 1.8 TOR Compliance

S.No. TOR Terms Compliance

1 Executive summary GFSC has proposed for “Revamping of existing

Urea Plants (Urea-I & II) by replacing existing

total recycle process to latest ammonia

stripping process in GSFC Complex” located

at P.O. Fertilizernagar, Dist.-Vadodara,

Gujarat-391750. The combined capacity of

revamped project will be 3,67,200 MTPA.

Since both the plants were established before

the 1994, they did not come into the purview

of EIA Notification, 1994 and its subsequent

amendments. The proposed revamping

project falls under Activity 5(a); Category A as

per EIA Notification,2006 and its subsequent

amendments. Due to legitimate advantages

of the proposed project and no increase in

pollution load, GSFC requests for consideration

of the proposal under Clause 7(ii) & thereby

exempt it from scoping stage and appraise

directly for the grant of Environmental

Clearance.

Baseline studies for the project were done for

Winter Season (December,2020 to

February,2021). The topography of proposed

site is almost plain The site elevation ranges

between 35 to 60 amsl

Temperature Mean minimum temperature (at

8:30 hr) varies from 13.20C (Jan) to 27.50C

(June) while mean maximum temperature (at

17:30 hr) varies from 29.70C (Dec) to 39.90C

(May).

Relative Humidity Relative Humidity at 8:30 hr

varies from 53% (March) to 88% (Aug) while at

17:30 hr it ranges from 23% (April) to 75% in






(Aug). During the monsoon season relative

humidity generally varies between 75% to 83%

in the morning and 51% to 75% in the

afternoon. The driest part of the year is the

summer season when in the afternoon’s

relative humidity becomes as low as 23%

Rainfall Total annual mean rainfall was

observed to be 846 mm. Around 95% of total

rainfall occur in the months of June to Sep.

There are about 36.3 rainy days in a year.

Wind Speed Mean wind speed was observed

from 7 kmph (December) to 15.1 kmph (June).

Wind Direction- The wind pattern of the region

shows that the predominant wind direction is

SW for October to February and NE for March

to September. However, the annual

predominant wind direction is SW.

Seismicity

As per Seismic map of India the study area falls

in Zone II Moderate Risk Zone

SOIL

The soil sampling was done at seven locations

in the study area. Based on Nutrient Index

Value for N, P and K, the soils of study area fall

into medium fertility status.

LAND USE

Land use of project site is Industrial use. Most of

the land within the 10 km area of the project

Site is Agricultural land. As per the land use

based on satellite image, about 49% of the

land is under Agricultural Land. 16 % of land is

under vegetation, 23 % of the land is under

settlement, 10 % land is under open scrub land,

2 % Water body and rest of the land is under

other uses.






WATER

Ground water was monitored at eight

locations in the study area. All physical and

general parameters were observed within the

permissible limit as per IS10500:2012 (Second

Revision). Thus, it is recommended that water

be filtered and disinfected prior to be given for

drinking water requirements.

Surface water was monitored at seven

locations in the study area. Comparing the

values as per classification for designated best

use water quality criteria by CPCB, all surface

water locations were classified under “Class C-

Drinking water source after conventional

treatment and disinfection” except SW-4 i.e.,

Parevi River which has been categorized

under “Class B- Outdoor Bathing (Organized)”.

AMBIENT AIR QUALITY

Air quality was monitored at nine locations

within 10km study area. The monitoring results

of ambient air quality were compared with the

National Ambient Air Quality Standards

(NAAQS) prescribed by MoEF; GoI Notification

dated 16.11.2009. The maximum

concentration of PM10, PM2.5, SO2, NOX, NH3

& CO was 96 µg/m3, 49 µg/m3, 12.8 µg/m3, 20.6

µg/m3, 27.7 µg/m3, 1.22 µg/m3 respectively.

AMBIENT NOISE QUALITY

Noise monitoring was done at seven locations

within the study area. The noise levels

observed in the project site and study are

within prescribed limits except at N-6 i.e.,

Sumant Park located 4.85 km in SW direction of

the project.

TRAFFIC STUDY

The site is approachable via NH-8 which is

located adjacent to the unit. Traffic count

study was undertaken at NH-8 as it is the main






road for transportation of raw materials and

finished products. As per baseline survey, the

capacity of approach road is 10286 PCU/hr

while the existing traffic of the road is 825

PCU/hr.

ECOLOGY AND BIODIVERSITY

There is no protected and reserved forest is

present in the study area (10 km area around

proposed site. Among record, Crocodylus

palustris (Crocodile) and Lissemys punctata

(Flap shell Indian Turtle) & Pavo cristatus

(Indian Peafowl) have been categorized

under Schedule-I Category. As per present

study, 33 avifauna species have been

recorded in the study area, of which peafowl

is the only Schedule-I species while the rest

belong to Schedule-IV & V. Mahisagar is one

of the important perennial rivers of central

Gujarat, flowing westward to terminate into

Gulf of Cambay. This river sustains good level

of fresh water as well as estuarine fishery as

capture fishery and contributes to economy of

Gujarat state.

SOCIO-ECONOMIC ENVIRONMENT

As per provisional reports of Census India,

population of Vadodara in 2011 is 1,670,806; of

which male and female are 869,647 and

801,159 respectively. Although Vadodara city

has population of 1,670,806; its urban /

metropolitan population is 1,822,221 of which

949,998 are males and 872,223 are females.

ANTICIPATED IMPACT & MITIGATION MEASURES

The proposed revamping will not have major

impact w.r.t air during construction and

operation phase. There will be demolition of

few parts in units with refurbishing of existing

machineries for proposed revamping.

Construction activities will be done keeping in






consideration with the environmental

parameters in and around the project site.

GSFC Vadodara being a reputed industry

already complies to all norms and

responsibilities for environment protection and

management. Since, there is no increase in

production capacity, there will be no increase

in air emissions. After revamping, there will be

decrease in freshwater requirement and

increase in treated water reuse that will

positively affect water environment. Socio-

economic environment will be impacted

positively through employment generation

during construction phase.

RISK ASSESSMENT AND HAZARD

IDENTIFICATION

The risk assessment studies were done for

storage facilities within the site. It was

recommended to

• The existing ammonia storage facilities

will be used.

• The safety measures and emergency

actions being taken for risk and

associated hazards are adequate and

are being followed properly.

• On-site and off-site emergency action

plan should be regularly followed and

complied.

• Regular mock-drills should be done,

and the assessment should be done via

audits.

• Provision of ammonia detectors/sensors

at strategic locations in the common

corridors should be maintained.

Total cost for proposed project is Rs 306 Crores.

Executive summary is given in Chapter 11.

2 Introduction






i. Details of the EIA Consultant

including NABET accreditation

M/s EQMS India Pvt. Ltd. an NABET Accredited

A category consultant for sector 5(a) is an EIA

consultant for the proposed project. Brief

Details of EQMS India Pvt ltd along with NABET

accreditation certificate is enclosed in

Chapter 12.

ii. Information about the project

proponent Gujarat State Fertilizers and Chemicals Limited

(GSFC) was incorporated in 1962 and its plants

went into the production of fertilizers in 1967. In

its very first decade of existence, GSFC

became known for its path breaking

achievements. GSFC Adding to its credit, also

set up India's first Melamine plant. The

expansion and diversification of GSFC's

product portfolio unfolded new growth vistas

to the nation by providing much needed

fertilizers for agricultural growth and chemicals

for industrial growth.

Details about project and project proponent

are given Section 1.2 of Chapter 1.

iii. Importance and benefits of the

project

The proposed revamping project will lead to

reduction in ammonia, power & energy

consumption, decrease in freshwater

consumption and emissions. The project has

been planned to achieve targeted energy

consumption of 5.773 GCal/MT of Urea which

is even reduced against target of 6.2 GCAL/mt

of Urea as instructed by GOI via Urea

Policy,2015.

Further Details about importance and project

benefits are given Section 1.3 of Chapter 1 and

Chapter 8.

3 Project Description

i. Cost of project and time of

completion. Total cost for proposed project is Rs 306 Crores.

The total timeline for the project is 30 months

from basic engineering to plant operation set-

up. The anticipated month for completion of

project is June,2023.

ii. Products with capacities for the Total production capacity of Urea after






proposed project. revamping will remain the same as combined

capacity of Urea-I & Urea-II plants i.e., 367200

MTPA.

iii. If expansion project, details of

existing products with capacities

and whether adequate land is

available for expansion,

reference of earlier EC if any.

Existing Production Capacity Details:

Urea-I: 103200 MTPA

Urea-II: 264000 MTPA

Revamping has been proposed in the existing

facilities of GSFC Complex i.e., Urea-I & Urea-II.




amendments.

Details of land requirement is given in Section

2.4 of Chapter 2.

iv. List of raw materials required and

their source along with mode of

transportation.

List of raw material, consumption, sources and

transportation method are given in Section 2.6

of Chapter 2.

v. Other chemicals and materials

required with quantities and

storage capacities

List of other raw chemical and materials

required with quantities and storage is given in

Section 2.6 of Chapter 2.

vi. Details of Emission, effluents,

hazardous waste generation and

their management.

Air Emissions: The main sources of existing air

emissions are Suspended Particulate Matter &

Ammonia (NH3). To control measures, APCM

like Water Scrubbers and H2SO4 Scrubbers

have been installed, online monitoring system

has been installed, green belt development

has been done. As per the guidelines, the

emissions from the existing plant stacks are well

within the statutory limits prescribed by Gujarat

Pollution Control Board. Under proposed

revamping, since there is no increment in total

production capacity after revamping, there

will be no increase in air emissions. Existing

stacks will be used after proposed revamping.

Infact, due to proposed revamping, there will

be reduction in dust emission by elimination of

crystallizer, centrifuge, dryer, and other

handling equipments with installation of new






vacuum evaporation section. Hence, it will

also lead to decrease in fugitive emissions too.

Liquid Effluent: Under existing phase, The total

wastewater generation from Urea-I & Urea-II

plants is 1060.08 KLD (44.17 m3/hr). Out of total,

144 KLD (6 m3/hr) is being sent to Phosphoric

Acid Chalk Pond/Urea lagoon that is sent to

PA Plant for reuse. Rest of wastewater i.e.,

916.08 KLD (38.17 m3/hr) to sea via VECL

Common Effluent Channel. There is no

treatment scheme for wastewater generated

from the units as most of the wastewater is

being disposed to the effluent disposal pond.

Under proposed revamping, the total

wastewater generation will be 757.68 KLD

(31.57 m3/hr). Process condensate generated

from plant i.e., mainly vacuum evaporator

section will be treated in Wastewater Section

and treated water i.e., 691 KLD (28.8 m3/hr) will

get directly reused in cooling tower makeup.

144 KLD (6 m3/hr) will be sent to Phosphoric

Acid Plant for recycle. Rest of wastewater i.e.,

613.68 KLD (25.57 m3/hr) CT blowdown will be

directed to effluent disposal pond as per

existing practices. Additionally, steam

condensate 303.12 KLD (12.63 m3/hr) will also

be directly reused as raw water make up.

Hazardous Wastes: Industrial hazardous

wastes such as spent oil, discarded containers

etc. are being sent to TSDF site/registered

recycler. Authorization under Hazardous

Waste Management Rules has been obtained

from GPCB vide CCA Order No. AWH-78404

valid till 31.12.2021. Wastes are dried, packed

and stored in separate designated hazardous

waste storage facility before its disposal. GSFC

strictly complies with the rules and regulations

with regards to handling and disposal of

hazardous waste in accordance with

Hazardous & Other Waste (Management and






Transboundary Movement) Amendment

Rules, 2021. Hazardous waste is disposed at

approved TSDF sites of M/s Nandesari

Environment Control Limited (NECL).

Further details about air emission, effluent and

hazardous waste and their management are

given in Section 2.9 of Chapter-2.

vii. Requirement of water, power,

with source of supply, status of

approval, water balance

diagram, man-power

requirement (regular and

contract)

Water Requirement: The total water

requirement of revamped Urea plant will be

3901.9 KLD (162.6 m3/hr) out of which

freshwater requirement will be 2907.6 KLD

(121.15 m3/hr) supplied from existing

freshwater source i.e., 4 no. of French wells by

Mahi River located at Parthampura (2 no.) and

IOCL Refinery (2 no.) respectively. Water

Balance has been provided in Section 2.8.3;

Chapter-2.

Power Requirement & Back-up: For existing

Urea Plants, specific power consumption is 205

kWh/MT Urea. After revamping, specific power

consumption will get reduced to 183 kWh/MT

Urea. For power backup, 1 DG set of capacity

500 kVA will be installed in the plant. Details of

power requirement have been provided in

Section 2.8.2; Chapter-2.

Manpower Requirement: The existing

manpower of the plant is 124 no. for both Urea-

I & II plants. After revamping, there will be

reduction in manpower as only one Urea Plant

i.e., revamped urea plant will be operational.

Manpower will get reduced to 64 no.

Details of water, power, boiler, fuel, manpower

and other details are given in Section 2.8 of

Chapter 2.

viii. Process description along with

major equipment’s and

machineries, process flow sheet

(quantities) from raw material to

Process flow diagram and other

manufacturing details are given in Section 2.5

of Chapter-2.

List of major equipment’s and machineries to






products to be provided be installed in proposed project and already

installed machinery is given in Section 2.7.2 of

Chapter 2

ix. Hazard identification and details

of proposed safety systems.

Hazard identification and risk assessment

studies have been done. The following are

recommendations:

• The existing ammonia storage facilities

will be used.

• The safety measures and emergency

actions being taken for risk and

associated hazards are adequate and

are being followed properly.

• On-site and off-site emergency action

plan should be regularly followed and

complied.

• Regular mock-drills should be done,

and the assessment should be done via

audits.

• Provision of ammonia detectors/sensors

at strategic locations in the common


Further details are given in 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 existing

environmental clearances




amendments. Thereafter, no changes were

carried out in both the plants.

However, GSFC has various production units

with several EC’s as mentioned below:

1. Environmental Clearances granted

from SEIAA; Gujarat vide Letter No.

SEIAA/GUJ/EC/5(E)/684/2020 dated

09.06.2020.

2. Environmental Clearance granted from

MoEF&CC vide letter No. J-

11011/901/2007-IA. II(I) dated

06.03.2019 and amendment on

08.05.2020.






including Amendments shall

be provided. In addition,

status of compliance of

Consent to Operate for the

ongoing I existing operation of

the project from SPCB shall be

attached with the EIA-EMP

report.


SEIAA; Gujarat vide Letter No.

SEIAAGUJ/EC/5(f)/228/2016 dated

31.03.2016

4. Environmental Clearances granted

from SEIAA; Gujarat vide Letter No.

SEIAA/GUJ/EC/5(E)/131/2013 dated

05.07.2013.


MoEF&CC vide letter No. J-

11011/901/2007-IA(II) dated 31.07.2008.

Certified Compliance of earlier EC’s of GSFC

Complex has been annexed as Enclosure-III.

b. In case the existing project

has not obtained

environmental clearance,

reasons for not taking EC

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.

The plant has Consolidated Consent and

Authorization (CC&A) for existing plant from

GPCB vide order no Consent Order No. -AWH-

78404 with further amendments (valid till

31.12.2021). (Annexed as Enclosure-II).

4 Site Details






i. Location of the project site

covering village, Taluka/ Tehsil,

District and State, Justification for

selecting the site, whether other

sites were considered.

GSFC (Vadodara Unit) is located at P.O.

Fertilizernagar, Dist.-Vadodara, Gujarat-

391750. Details of Project location is given in


No alternative site has been examined as the

proposed project is revamping of existing Urea

units to develop revamped Urea plant with

latest technology.

Justification for site selection and merits is

given in Section 5.1 of Chapter 5.

ii. A toposheet of the study area of

radius of 10km and site location

on 1:50,000/ 1:25,000 scale on an

A3/A2 sheet. (Including all eco-

sensitive areas and

environmentally sensitive places)

Toposheet Map is given in Figure 1.5 of

Chapter 1 and enclosed as Enclosure-XVI.

iii. Details w.r.t. option analysis for

selection of site

Details are given in Section 5.1 of Chapter 5.

iv. Co-ordinates (lat-long) of all four

corners of the site.

Project location with Co-ordinates of all four

corners of the complex is given below:

Position Latitude Longitude

A 22°23’15.59” N 73°8’37.76” E

B 22°22’49.97” N 73°8’11.38” E

C 22°22’25.01” N 73°8’19.54” E

D 22°21’51.48” N 73°9’30.91” E

E 22°22’2.48” N 73°9’42.67” E

Urea

Plants

22°22'17.54"N 73° 9'16.24"E

v. Google map-Earth downloaded

of the project site.

Google earth map is given in Figure 1.2 & 1.3

of Chapter 1.

vi. Layout maps indicating existing

unit as well as proposed unit

indicating storage area, plant

area, greenbelt area, utilities etc.

If located within an Industrial

area/Estate/Complex, layout of

Industrial Area indicating

location of unit within the

Industrial area/Estate.

Layout map of GSFC Complex showing

proposed Urea revamping has been given in

Figure 2.4 to 2.6 of Chapter 2.

Engineering Layout plan of proposed

revamping has been attached as Figure 2.5 of

Chapter-2. The same have been annexed as

Enclosure-XV.

GSFC Complex is a Notified estate notified by

Industries, Mines and Energy Department vide

Notification No. GU-87-46-GID-1086(I) 2338






dated 21.08.1987. The same has been

enclosed as Enclosure-I.

vii. Photographs of the proposed

and existing (if applicable) plant

site. If existing, show photographs

of plantation/greenbelt.

Site photograph showing process area is given

in Section 2.2.2 & Figure 2.2 of Chapter 2.

Photograph showing greenbelt area is given in


viii. Land use break-up of total land

of the project site (identified and

acquired), government/private -

agricultural, forest, wasteland,

water bodies, settlements, etc

shall be included. (Not required

for industrial area)

Plant Area (Processing): 1747000 m2 (53.26%)

Township Area: 301000 m2 (9.18%)

Green Area (including plant and township):

1232000 m2 (37.56%)

Break-up of total land of the project site given

in Section 2.3 of Chapter 2.

ix. A list of major industries with

name and type within study area

(10km radius) shall be

incorporated. Land use details of

the study area

The project site is in vicinity of GIDC Ranoli,

Nandesar Industries Association (NIA), GIDC

Savli & Petrochemical Complex INA. A list of

major industries with name and type within

study area (10 km radius) given in Section 2.2.3

of Chapter 2.

Land use of project site is Industrial Use. Most of

the land within the 10 km area of the project

Site is Agricultural land. As per the land use

based on satellite image, about 49% of the

land is under Agricultural Land. 16 % of land is

under vegetation, 23 % of the land is under

settlement, 10 % land is under open scrub land,

2 % Water body and rest of the land is under

other uses. Land use details of the study area is


x. Geological features and Geo-

hydrological status of the study

area shall be included.

In major part of the district, in north and almost

in eastern half of the district, the hard rocks,

such as phyllite, schist, granite, gneiss, basalt

and other sediments such as sandstone,

limestone etc., form aquifers, whereas

multilayered alluvium deposits form aquifer

system in remaining central, south-central, and

western half of the district. In Vadodara,

groundwater occurs both as unconfined and

confined conditions. The depth to water is

greater in upland areas whereas in valley






portion and shallow grounds, the levels are

close to surface. In hilly terrain of eastern,

northeast and south-east part of the district,

spring zones are seen in stream river section;

also, along the section of the Mahi, the

Narmada and the Orsang rivers. GSFC

Vadodara is located the Alluvium section of

Vadodara district. GSFC Vadodara lies in

Taluka- Vadodara of Vadodara district with

semi-critical groundwater development status.


xi. Details of Drainage of the project

upto 5km radius of study area. If

the site is within 1 km radius of any

major river, peak and lean

season river discharge as well as

flood occurrence frequency

based on peak 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)

In study area (10 km) of industry, following rivers

are flowing:

• Galiath River,4.58 km (NE)

• Vishwamitri River,5.71 km(E)

• Meni River,7.00 km(W)

• Parevi River,7.08 km(N)

• Surya River,8.04 km(E)

• Mahi River,9.35 km(W)

However, Galiath River, Parevi River & Surya

River are dried riverbeds. Drainage details

have been provided in Section 3.6 of Chapter-

3.

xii. Status of acquisition of land. If

acquisition is not complete,

stage of the acquisition process

and expected time of complete

possession of the land.

Site has already been acquired.

xiii. R&R details in respect of land in

line with state Government policy

No R&R is applicable.

5 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)

Not Applicable

ii. Land use map based on High Not Applicable






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.

Not Applicable

iv. The projects to be located within

10 km of the 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

Not Applicable

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

Among record of reptiles, Crocodylus palustris

(Crocodile) and Lissemys punctata (Flap shell

Indian Turtle) and among avifauna, Pavo

cristatus (Peafowl) have been categorized

under Schedule-I Category.

Conservation Plan of the above-mentioned

species has been submitted to Chief Wildlife

Warden of the State Government & the same

has been approved. Approved Conservation

Plan has been annexed as Enclosure-XIII.

vi. Copy of application submitted

for clearance under the Wildlife

(Protection) Act, 1972, to the

Standing Committee of the

National Board for Wildlife

Not Applicable

6 Environmental Status

i. Determination of atmospheric

inversion level at the project site

and site specific micro-

Temperature Mean minimum temperature (at

8:30 hr) varies from 13.20C (Jan) to 27.50C

(June) while mean maximum temperature (at






meteorological data using

temperature, relative humidity,

hourly wind speed and direction

and rainfall.

17:30 hr) varies from 29.70C (Dec) to 39.90C

(May).

Relative Humidity Relative Humidity at 8:30 hr

varies from 53% (March) to 88% (Aug) while at

17:30 hr it ranges from 23% (April) to 75% in

(Aug).

Rainfall Total annual mean rainfall was

observed to be 846 mm. Around 95% of total


Wind Speed Mean wind speed was observed

from 7 kmph (December) to 15.1 kmph (June).

Wind Direction The wind pattern of the region

shows that the predominant wind direction is

SW for October to February and NE for March

to September. However, the annual

predominant wind direction is SW.

Details of site specific micro-meteorological

data is given in Section 3.10.2 of Chapter 3.

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 monitoring

stations shall be based CPCB

guidelines and take into account

the pre-dominant wind direction,

population zone and sensitive

receptors including reserved

forests.








& CO was 96 µg/m3, 49 µg/m3, 12.8 µg/m3, 20.6


Further details are given in Section 3.11 of

Chapter 3.

iii. Raw data of all AAQ

measurement for 12 weeks of all

stations as per frequency given in

the NAAQM Notification of Nov.

2009 along with – min., max.,

average and 98% values for

each of the AAQ parameters

from data of all AAQ stations

Raw data of all AAQ measurement for 12

weeks of all stations as per frequency given in

the NAAQM Notification of Nov. 2009 along

with – min., max., average and 98% values for

each of the AAQ parameters from data of all

AAQ stations are attached as Enclosure-XII.






should be provided as an

annexure to the EIA Report.

iv. Surface water quality of nearby

River (100m upstream and

downstream of discharge point)

and other surface drains at eight

locations as per CPCB/

MoEF&CC guidelines.


locations in the study area. The pH values of all

analyzed samples ranged between 7.12 –

7.86. TDS levels were observed to be in range

from 206 to 482 mg/l. Total hardness levels

were observed to be in the range of 118 to 220

mg/l. Dissolved Oxygen values ranged

between 4.9 to 6.9 mg/l. The chlorides level

was observed to be in range of 29.35 to 125

mg/l. Sulphate level were found to be ranging

from 18.05 to 48 mg/l. Nitrate levels were found

to be observed within the range of 1.34 to

12.36 mg/l. Total Coliform levels were found to

be in the range of 0.94*103 to 1.7*103 MPN/100

ml. Biochemical Oxygen Demand (BOD) was

observed to be in range of 2.6 to 12 mg/l.

Comparing the values as per classification for

designated best use water quality criteria by

CPCB, all surface water locations were

classified under “Class C- Drinking water

source after conventional treatment and

disinfection” except SW-4 i.e., Parevi River

which has been categorized under “Class B-

Outdoor Bathing (Organized)”.

Further Details are given in Section 3.9 of

Chapter 3.

v. Whether the site falls near to

polluted stretch of river identified

by the CPCB/MoEF&CC, if yes

give details.

Not applicable.

vi. Ground water monitoring at

minimum at 8 locations shall be

included.

Groundwater was analysed at eight locations

across the study area. The analysis results

indicate that the pH ranged between 7.09 to

7.62 which are well within the specified

standard of 6.5 to 8.5 limit. Total hardness levels

were recorded in the range between 56.11 to

561 mg/l that is within permissible limits of 600

mg/l. Total dissolved solids were recorded in






the range of 312 to 1140 mg/l that falls within

permissible limits of 2000 mg/l. Chloride levels

were recorded between 31.3 to 166.32 mg/l

that falls within the range of permissible limit

i.e., 1000 mg/l. Sulphate levels were observed

in the range of 36.81 to 82.19 mg/l and were

within the acceptable limit i.e., 400 mg/l.

Bacteriological studies reveal that no coliform

bacterial are present in the samples. The

heavy metal contents were observed to be in

below detectable limits. Parameters for toxic

substances were recorded within the

permissible limits. All physical and general

parameters were observed within the




drinking water requirements


Chapter 3.

vii. Noise levels monitoring at 8

locations within the study area.

Noise monitoring was done at seven locations

within the study area. The noise levels

observed in the project site and study are

within prescribed limits except at N-6 i.e.,

Sumant Park located 4.85 km in SW direction of

the project.


Chapter 3.

viii. Soil Characteristic as per CPCB

guidelines. The soil sampling was done at seven locations

in the study area. As per the grain size

distribution the percentage of Sand in all

sampled soil was found varied from 54.9% to

62.52%, Silt varied from 17.17% to 22.1% and

Clay from 16.32% to 24.6% during study season.

Thus, the soil texture is Sandy Clay loam. The

soil pH ranges were observed from 7.1 to 8.01

during study season, thereby indicating the soil

is “Slightly alkaline” in nature. The Organic

Carbon content of sampled soil during study






seasons varied from 0.048% to 1.48%, thereby

implying that soils are low with organic carbon

content except at S-4 where Organic Carbon

content is 1.48%. Available nitrogen content in

the surface soils ranges between 242 kg/ha to

378 kg/ha thereby indicating that soils are

medium to high in available nitrogen content.

Available phosphorus content ranges

between 19.6 kg/ha to 22.4 kg/ha thereby

indicating that soils are medium in available

phosphorus content. Available potassium

content in these soils ranges between 158

kg/ha to 218 kg/ha thereby indicating that the

soils are medium in potassium content.

Based on Nutrient Index Value for N, P and K,

the soils of study area fall into Medium Fertility

Status.

Further details of soil are given in Section 3.8 of

Chapter 3.

ix. Traffic study of the area, type of

vehicles, frequency of vehicles

for transportation of materials,

additional traffic due to

proposed project, parking

arrangement etc.

Project is in industrial area and well connected

with National Highway-8. No major traffic and

congestion are present at the approach road.

Traffic count of the area is represented in


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

species. If Schedule-I fauna are

found within the study area, a

Wildlife Conservation Plan shall

be prepared and furnished.

GSFC has already developed approx. 123.2

Ha. of green area in the complex. The

company has developed green belt along the

periphery of the plant site and in common

premises available outside the company

premises, township after consultation with

horticulture expert. Total 179001 no. of trees

have been planted till now in the complex.

Most of the land is under industrial use,

settlement, agriculture, and water bodies. No

reserved and protected forest patches are

present in the study area. Degraded and scrub

vegetation is the prime feature of the flora.

Under the schedule of Indian Wildlife






Protection Act 1972, list of reptiles has also

been listed in various categories to raise

concern over varying degree of protection.

Among record of fauna, Crocodylus palustris

(Crocodile) and Lissemys punctata (Flap shell

Indian Turtle) & Pavo cristatus (Indian Peafowl)

have been categorized under Schedule-I

Category. As per present study, 33 avifauna

species have been recorded in the study area,

of which peafowl is the only Schedule-I species

while the rest belong to Schedule-IV & V.

Mahisagar is one of the important perennial

rivers of central Gujarat, flowing westward to

terminate into Gulf of Cambay. This river

sustains good level of fresh water as well as

estuarine fishery as capture fishery and

contributes to economy of Gujarat state.


xi. Socio-economic status of the

study area.

Vadodara city is governed by Municipal

Corporation which comes under Vadodara

Metropolitan Region. The Vadodara city is in

Gujarat state of India. As per provisional

reports of Census India, population of

Vadodara in 2011 is 1,670,806; of which male

and female are 869,647 and 801,159

respectively. Although Vadodara city has

population of 1,670,806; its urban /

metropolitan population is 1,822,221 of which

949,998 are males and 872,223 are females.


Chapter 3.

7 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 Modelling

shall be done using inputs of the

specific terrain characteristics for

There shall be no increase in Air pollution.

Hence due to propose revamping there shall

be no incremental ground level

concentrations.






determining the potential

impacts of the project on the

AAQ. Cumulative impact of all

sources of emissions (including

transportation) on the AAQ of the

area shall 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 showing the

location of project site,

habitation nearby, sensitive

receptors, if any.

ii. Water Quality modelling – in case

of discharge in water body

Not Applicable

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

transport of raw materials and

finished products and wastes

(large quantities) by rail or rail-

cum road transport or conveyor-

cum-rail transport shall be

examined.

Air quality will not get impacted to a larger

extent as total raw materials will be

transported into the plant via pipeline and

most of finished product is being transported

via rails. Same will be done after revamping.

Hence, there will be minimal increment of

vehicular movement due to proposed

revamping.

Impact of the transport is given in Section 4.7.9

of Chapter 4.

iv. A note on treatment of

wastewater from different plant

operations, extent recycled and

reused for different 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.

Under proposed revamping, Wastewater

Treatment Section will be installed. It will be

installed to recover NH3, CO2 and Urea

contained in the process water and, at the

same time, to produce clean process

condensate, which can be used as Cooling

Tower Makeup.

Details are given in Section 2.9.1 of Chapter 2.

v. Details of stack emission and

action plan for control of

emissions to meet standards.

The main sources of existing air emissions are

Suspended Particulate Matter & Ammonia

(NH3). To control measures, APCM like Water

Scrubbers and H2SO4 Scrubbers have been






installed, online monitoring system as been

installed, green belt development has been

done. As per the guidelines, the emissions from

the existing plant stacks are well within the

statutory limits prescribed by Gujarat Pollution

Control Board. Under proposed revamping,

since there is no increment in total production

capacity after revamping, there will be no

increase in air emissions. Existing stacks will be

used after proposed revamping.

Details of emission and air pollution control

measures are given in Section 2.9.2 of Chapter

2.

vi. Measures for fugitive emission

control Under proposed revamping, there will be

reduction in dust emission by elimination of

crystallizer, centrifuge, dryer, and other

handling equipments with installation of new

vacuum evaporation section. Hence, it will

also lead to decrease in fugitive emissions too.

Various control measures for fugitive emissions

have been done. Few of them are following:

• Off-gases streams from various emission

points of the plant are scrubbed in the

washing tower and then emitted to the

atmosphere.

• All vessels used in the manufacturing

process are closed to reduce fugitive

emissions.

• Adequate ventilation system has been

provided in work areas.

• Fugitive emissions from process vessels

are treated in Off Gas Treatment Unit

and discharge emission is being

monitored. Offgas Treatment Unit is

operated efficiently and effectively.

Details are given in Section of 2.9.2 of Chapter

2.






vii. Details of hazardous waste

generation and their storage,

utilization and management.

Copies of MOU regarding

utilization of solid and hazardous

waste in cement plant shall also

be included. EMP shall include

the concept of waste-

minimization,

recycle/reuse/recover

techniques, Energy conservation,

and natural resource

conservation.

Hazardous Waste: Industrial hazardous wastes

such as spent oil, discarded containers etc. are

being sent to TSDF site/registered recycler.

Authorization under Hazardous Waste

Management Rules has been obtained from

GPCB vide CCA Order No. AWH-78404 valid till

31.12.2021. Wastes are dried, packed and

stored in separate designated hazardous

waste storage facility before its disposal. GSFC

strictly complies with the rules and regulations

with regards to handling and disposal of

hazardous waste in accordance with

Hazardous & Other Waste (Management and


Rules, 2021. Hazardous waste is disposed at

approved TSDF sites of M/s Nandesari

Environment Control Limited (NECL).

Details of Hazardous waste generation and

their storage, utilization and management is

given in Section 2.9.4 of Chapter 2.

Measures adopted by plant for Waste

Minimization, recycle/reuse/recover

techniques are described in Section 10.7 of

Chapter 10.

Measures adopted for energy conservation,

and natural resource conservation is given in


viii. Proper utilization of fly ash shall

be ensured as per Fly Ash

Notification, 2009. A detailed

plan of action shall be provided.

No generation of ash in the plant.

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

around the project boundary

Approx. 123.2 ha. of green area i.e., 37.56% of

total plot area has been developed. Out of

total, 32.8 ha of green area has been

developed within the plant premises while 90.4

ha. green area has been developed in GSFC

township part of GSFC complex plot. Total






and a scheme for greening of the

roads used for the project shall

also be incorporated.

179001 no. of trees & plantations have been

developed within the premises.

Details of green belt development is given in


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 water and also to use

for the various activities at the

project site to conserve fresh

water and reduce the water

requirement from other sources.

There is rainwater harvesting system present at

the following locations:

• Guest House

• Science Foundation Building

• Township Residential Areas

GSFC has constructed 16 no. of rainwater

harvesting structures (Recharge well and

Furrat System) across the complex. The

filtration rate is in the rate of 65-70 m3/hr each

well. Four ponds have also been dug out to

store the rainwater runoff and percolate the

same.

Details of rainwater harvesting system in plant

is given in Section 2.9.1.2 of Chapter 2.

xi. Total capital cost and recurring

cost/annum for environmental

pollution control measures shall

be included.

GSFC has provided adequate funds to

implement the conditions stipulated by

MoEF&CC and it is integral part of the project.

The fund earmarked to implement the

conditions has been utilized for intended

purpose only.

Till 2020-21, GSFC has spent Rs. 521649.49 Lakhs

on Environment Management Plan. Details are


xii. Action plan for post-project

environmental monitoring shall

be submitted.

Action Plan for post-project environmental

monitoring is given in Chapter 6.

xiii. Onsite and Offsite Disaster

(natural and Man-made)

Preparedness and Emergency

Management Plan including Risk

Assessment and damage

control. Disaster management

plan should be linked with District

Disaster Management Plan.

Details of Risk assessment associated with

project is given in Chapter 7.

Onsite Emergency plan prepared and

implemented by GSFC in plant is annexed as

Enclosure-IX.

Off-site Emergency Plan has been annexed as

Enclosure-X.






8 Occupational health

i. Plan and fund allocation to

ensure the occupational health

& safety of all contract and

casual workers

Arrangement made in plant for Occupational

Health & safety of workers is given in Section

10.5 of Chapter 10.

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, Vision

testing (Far & Near vision, colour

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-

mentioned parameters as per

age, sex, duration of exposure

and department wise.

Details of exposure specific health status

evaluation of workers is given in Chapter 7.

iii. Details of existing Occupational

& Safety Hazards. What 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,

Details are given in Chapter 7.

iv. Annual report of heath status of

workers with special reference to

Occupational Health and Safety

Sample health records as per Form 32

enclosed as Enclosure -XI.

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.

GSFC has a well laid down environmental

policy approved by Managing Director.

Details of policy is given in Section 10.11.3. of

Chapter 10.






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.

A separate EMP cell, Fire & Safety cell and

Occupational Health Centre is provided in the

plant for compliance of Environmental

management plan and OHSAS guideline

Company.

Environmental policy suggests adhering to

compliance of all applicable legislative and

other statutory requirements. Company has

also maintained many SOPs for compliance of

norms.

Institutional Framework with responsibility for

implementation of EMP is given in Section

10.11 of Chapter 10.

iii. What is the hierarchical system or

administrative order 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.

Details of hierarchical system is given in Section

10.11.2 of Chapter 10.

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

All non-compliances / violations of

environmental norms are reported by Env.

Management Cell (EMC) to VP/Sr. VP/ED.

10. Details regarding infrastructure

facilities such as sanitation, fuel,

restroom etc. to be provided to

the labour force during

construction as well as to the

casual workers including truck

drivers during operation phase.

Details are given in the Section 10.8 of Chapter

10.

11 Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of

the project cost) shall be

earmarked towards the

Enterprise Social Commitment

As the site is a notified industrial estate, hence

public hearing/public consultation is

exempted for the proposal.






based on Public Hearing issues

and item-wise details along with

time bound action plan shall be

included. Socio-economic

development activities need to

be elaborated upon.

12 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 unit received

any notice under the Section 5 of

Environment (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.

None

13 A tabular chart with index for

points-wise compliance of

above TORs

Complied

A Specific TOR

1 Details on requirement of energy

and water along with its source

and authorization from the

concerned department.

Water Requirement: The total water

requirement of revamped Urea plant will be

3901.9 KLD (162.6 m3/hr). Out of which,

freshwater requirement will be 2907.6 KLD

(121.15 m3/hr) supplied from existing

freshwater source i.e., 4 no. of French wells by

Mahi River located at Parthampura (2 no.) and

IOCL Refinery (2 no.) respectively. Water

Balance has been provided in Section 2.8.3;

Chapter-2.

Power Requirement & Back-up: For existing

Urea Plants, specific power consumption is 205

kWh/MT Urea. After revamping, specific power

consumption will get reduced to 183 kWh/MT

Urea. For power backup, 1 DG set of capacity

500 kVA will be installed in the plant. Details of






power requirement have been provided in

Section 2.8.2; Chapter-2.

2 Energy conservation in ammonia

synthesis for urea production and

comparison with best

technology

Details of energy conservation in ammonia

synthesis for urea production is given in Section

5.2.9 of Chapter 5.

3 Details of ammonia storage and

risk assessment thereof

Details are given in Chapter 7.

4 Measures for control of urea dust

emissions from prilling tower

Measures for control of urea dust emission are

given in Section 2.9.2 of Chapter 2.

5 Measures for reduction of

freshwater requirement


6 Details of proposed source

specific pollution control

schemes and equipment s to

meet the national standards for

fertilizer

All national standards for fertilizer are

maintained in the plant. Details are given in

Section 2.9.2 of Chapter 2.

7 Details of fluorine recovery

system in case of phosphoric

acid plants and SSP to recover

fluorine as hydrofluorosilicicacid

H2SiF6 and its uses

Not applicable.

8 Management plan for

solid hazardous waste including

storage, utilization and disposal

of bye products viz , chalk, spent

catalyst, hydro fluoro silicic acid

and phosphor gypsum, sulphur

muck, etc

Hazardous Wastes: Industrial hazardous wastes

such as spent oil, discarded containers etc. are

being sent to TSDF site/registered recycler.

Authorization under Hazardous Waste

Management Rules has been obtained.

Wastes are dried, packed and stored in

separate designated hazardous waste

storage facility before its disposal. GSFC strictly

complies with the rules and regulations with

regards to handling and disposal of hazardous

waste in accordance with Hazardous & Other

Waste (Management and Transboundary

Movement) Amendment Rules, 2021.

Hazardous waste is disposed at approved TSDF

sites of M/s Nandesari Environment Control

Limited (NECL).







9 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 emissions and evaluation

of the adequacy of the

proposed pollution control

devices to meet standards for

point sources and to meet AAQ

standards as applicable








& CO was 96 µg/m3, 49 µg/m3, 12.8 µg/m3, 20.6


Details are provided in Section 3.11 of Chapter

3.

10 Details on water quality

parameters in and around study

area such as pH, Total Kjeldhal

Nitrogen, Free Ammoniacal

Nitrogen, free ammonia,

Cyanide, Vanadium, Arsenic,

Suspended Solids, Oil and

Grease, Cr as Cr 6, Total

Chromium, Fluoride, etc

Observations on Ground Water Quality:

Groundwater was analysed at 8 locations

within 10 km study area. The analysis results

indicate that the pH ranged between 7.09 to

7.62 which are well within the specified

standard of 6.5 to 8.5 limit. Total hardness levels

were recorded in the range between 56.11 to

561 mg/l that is within permissible limits of 600

mg/l. Total dissolved solids were recorded in

the range of 312 to 1140 mg/l that falls within

permissible limits of 2000 mg/l. Chloride levels

were recorded between 31.3 to 166.32 mg/l

that falls within the range of permissible limit

i.e., 1000 mg/l. Sulphate levels were observed

in the range of 36.81 to 82.19 mg/l and were

within the acceptable limit i.e., 400 mg/l.

Bacteriological studies reveal that no coliform

bacterial are present in the samples. The

heavy metal contents were observed to be in

below detectable limits. Parameters for toxic

substances were recorded within the

permissible limits. All physical and general

parameters were observed within the








1.7. Structure of the Report

This EIA report has been prepared based on available on site primary data survey

monitoring and secondary literature data The EIA report contains project features,

baseline environmental setup, assessment of environmental impacts, and formulation of

mitigation measures, environmental management, and monitoring plan with risk &

disaster management plan The report would include 12 Chapters and the structure of

the EIA Report with necessary tables, drawings and annexure is as follows

Chapter 1: Introduction

This chapter provides background information on need of project, need of EIA study

and brief of the project. The scope and EIA methodology adopted in preparation of EIA


drinking water requirements.

Observations on Surface water Quality:


locations in the study area. The pH values of

all analyzed samples ranged between 7.12 –

7.86. TDS levels were observed to be in range

from 206 to 482 mg/l. Total hardness levels

were observed to be in the range of 118 to 220

mg/l. Dissolved Oxygen values ranged

between 4.9 to 6.9 mg/l. The chlorides level

was observed to be in range of 29.35 to 125

mg/l. Sulphate level were found to be ranging

from 18.05 to 48 mg/l. Nitrate levels were found

to be observed within the range of 1.34 to

12.36 mg/l. Total Coliform levels were found to

be in the range of 0.94*103 to 1.7*103 MPN/100

ml. Biochemical Oxygen Demand (BOD) was


Comparing the values as per classification for

designated best use water quality criteria by

CPCB, all surface water locations were

classified under “Class C- Drinking water

source after conventional treatment and

disinfection” except SW-4 i.e., Parevi River

which has been categorized under “Class B-

Outdoor Bathing (Organized)”.

Details on water quality parameter is provided

in Section 3.9 of Chapter 3.





report have also been described in this Chapter. It also covers the identification of

project & project proponent, brief description of nature, size, location of the project and

its importance to the country and the region. Scope of the study details about the

regulatory scoping carried out as per the generic structure given in the EIA Notification,

2006.

Chapter 2: Project Description

This chapter deals with the project details of the existing unit and the proposed

revamping of Fertilizer project, with type of details in project, need for the revamping at

the project site, location, size & magnitude of operation including associated activities

required by and for the revamping project, proposed schedule for approval and

implementation, including technical details of raw material, quality and quantity etc.

Chapter 3 Description of the Environment

This chapter presents the existing environmental status of the study area around the

existing unit including topography, drainage pattern, water environment, geological,

climate, transport system, land use, flora & fauna, socio economic aspects, basic

amenities etc Environmental assessment of the proposed project site considering the

already established existing unit regarding its capability to receive the proposed new

development is also discussed in this Chapter

Chapter 4 Anticipated Environmental Impacts and Mitigation Measures

This chapter describes the overall impacts of the existing and proposed revamping

project activities and underscores the areas of concern, which need mitigation

measures and describing the already implemented mitigation measures at the existing

unit for respective environment concerns It predicts the overall impact of both existing

and the proposed project on different components of the environment viz air, water,

land, noise, biological, and socio economic

Chapter 5 Analysis of Alternatives (Technology & Sites)

This chapter indicates the justification for selection of revamping of project site instead

of any other alternate site within existing unit and alternate technology used for

sustainability.

Chapter-6: Environment Monitoring Programme

Technical aspects of monitoring the effectiveness of mitigation measures which are

already set for the existing unit and updated as per the need of revamping proposed

at the site (incl. Measurement methodologies, frequency, location, data analysis,

reporting schedules, emergency procedures, detailed budget & procurement

schedules).

Chapter 7: Additional Studies





This chapter deals with the potential risk assessment carried out for the proposed

revamping at fertilizer project during construction and operation due to bulk storages of

Hazardous materials and sample disaster management plan

Chapter 8: Project Benefits

This chapter presents the details of direct and indirect benefits due to proposed project.

Chapter 9: Environment Cost Benefit Analysis

This chapter defines the benefits on Environment due to the proposed project.

Chapter 10: Environmental Management Plan

This chapter details the inferences drawn from the environmental impact assessment

exercise and the EMP already developed for the existing unit to strengthen the

mitigation measures of project. It describes the overall impacts of the proposed activities

during construction and operation phases and underscores the areas of concern, which

need mitigation measures. It also provides mitigation and control measures for

environmental management plan (EMP) for minimizing the negative environmental

impacts and to strengthening the positive environmental impacts of the proposed

project.

Chapter 11: Summary & Conclusion

This chapter provides the summary and conclusions of the EIA study of the proposed

project with overall justification for implementation of the project and explanation of

how, adverse effects will be mitigated.

Chapter 12: Disclosure of Consultants Engaged

This chapter provides the brief resume of the consultants engaged and the team

engaged to carry out the EIA study.





Chapter 2. PROJECT DESCRIPTION

2.1. Details of Project

GSFC has proposed “Revamping of existing Urea Plants (Urea-I & II) by replacing existing

total recycle process to latest ammonia stripping process” in its existing complex located

at P.O. Fertilizernagar, Dist.-Vadodara, Gujarat-391750. The unit is operational in

accordance Latest Consolidated Consent and Authorization (CC&A) granted from

GPCB vide Consent No. AWH-78404 valid till 31.12.2021 with further amendments. Other

then Urea, the complex is involved in production of Ammonia, Urea, Melamine,

Phosphoric Acid, ASP, DAP/SAP/MAP/NPK, Sulphuric Acid, Cogeneration Plant,

Caprolactam, Nylon-6, MEK Oxime, Urea Phosphate, Methanol, HAS Crystal, Sardar Amin

Granules (SAG), Sardar Amin Liquid (SAL) & cryogenically grinded seed/spice plant,

Water Soluble Fertilizers (WSF) & Micronutrient Mixture (MM) Plant, Ammonium Sulphate.

To achieve the targeted energy norms of 5.773 GCal/MT Urea stipulated by GOI and

improve the reliability of old existing plants i.e., Urea-I & Urea-II, GSFC has planned for

the proposed project. The total capacity of revamped urea plant will not exceed the

combined capacity of plants i.e., 3,67,200 MTPA. Due to no increase in production

capacity of the project, there will be no increment in pollution load due to proposed

revamping project. Under the proposal, new wastewater treatment (WWT) section will

also be installed to treat the process condensate generated from vacuum evaporation

package that will be reused in cooling tower or exported to GSFC grid. This will lead to

reduction in raw water requirement of plant. Energy is reduced also on account of

reduction in specific consumption of Ammonia and Power in addition to Steam.

In contemplation with the circumstantial advantages of proposed project, it is requested

MoEF&CC (Industry-III Committee) to consider the revamping project under para 7(ii) of

EIA Notification,2006 and its subsequent amendments and exempt the project from

scoping stage and appraise for the grant of Environmental Clearance.

The consolidated details of the project with total production capacity after revamping

are provided in Table 1.1 in Chapter-1.

2.2. Site Location and Surrounding

2.2.1. Site Location

Salient features of the project site are given below in Table 2.2 and Location map of the

study area is given in Figure 2.1

This chapter deals with the project details of the existing & proposed manufacturing

plant, project location, size & magnitude of operation including associated

activities required by and for the project, proposed schedule for approval and

implementation, including technical details of raw material, quality and quantity

etc.





Table 2.1 : Salient Features of the Project Site

S No Particular Details

1. Plot/Survey/Khasra No P.O. Fertilizernagar

2. Village Fertilizernagar

3. Tehsil Vadodara

4. District Vadodara

5. State Gujarat-391750

6. Latitude 22°22'17.54"N

7. Longitude 73° 9'16.24"E

8. Land Area 328 ha.

9. Defense Installations None

10. Ecological Sensitive

Areas Protected Areas

as per Wildlife Protection

Act 1972 National Parks

Wildlife sanctuaries bio

sphere reserves tiger

reserves

None

11. Reserved Protected

Forest

None

12. Water Bodies Galiath River,4.58 km (NE)

Mahi River,9.35 km(W)

Meni River,7.00 km(W)

Parevi River,7.08 km(N)

Vishwamitri River,5.71 km(E)

Surya River,8.04 km(E)

However, distributaries of rivers located

nearby project are dry riverbeds.

13. Nearest National

Highway/ Other Road

National Highway-8(0.64km, E)

Bajwa Channi Road (0.72 km, S)

Ahmedabad-Vadodara Expressway (2.76

km, NE)

State Highway-158 (4.08 km, SE)

State Highway-11 (8.88 km, SE)

14. Nearest Railway Station Bajuwa Railway Station (0.99 km, SW)

Chhayapuri Railway Station (1.33 km, SE)

Ranoli Railway Station (5.21 km, NW)

Vadodara Railway Station (7.69 km, S)

15. Nearest Airport Vadodara Airport (8.80 km, SE)

16. Nearest Residential Area GSFC Township (1.28 km, NW) Adjacent to

the complex





S No Particular Details

Dashrath (0.89 km, NE)

Vadodara (8.09 km, SE)

17. Nearest Educational

Institute

Fertilizernagar School (1.43 kM, NW)

Yagnik Vidyalaya (1.64 km, SE)

Global Public School (3.45 km, SE)

Podar World School (4.02 km, SE)

18. Nearest Hospital Satyam Hospital (2.36 km, SE)

Om Multi-specialty Hospital (5.55 km, SW)

Shukan Multi-specialty Hospital

(7.67 km, SE)

19. Nearest Temple Shri Vishwakarma Mandir Channi (1.52 km,

SE) Ram Mandir (1.78 km, SE)

Tapovan Mandir (2.82 km, SW)

Shri Swaminaryan Mandir (7.82 km, SE)

Shri Kamnath Mahadev- Navnath (7.35 km,

SE)





Figure 2.1 Location Map of Study Area





Figure 2.2 : Site Photographs





2.2.2. Major Industries in 10 km radius

The project site is in vicinity of GIDC Ranoli, Nandesari Industries Association (NIA), GIDC

Savli & Petrochemical Complex. There are small and medium industries within 10 m

radius. The same have been mentioned below in Table 2.2.

Table 2.2 : List of Nearby Industries

S.No. Name of Industry Type of Industry Distance

1. Spectrochem Private

Limited

Chemical Manufacturing

Industry

0.21 km, E

2. Shiv Tapes Packaging Industry 0.26 km, E

3. Petrochemical Complex INA Petrochemical Complex 2.45 km, W

4. SICGIL Indsutrial Gases

Limited

Dry Ice Manufacturer &

Supplier

1.94 km, N

5. Agarwal Petrochem Limited Chemical Manufacturing

Industry

3.57 km, NW

6. Micron Engineers Industrial Equipment

Manufacturer

3.20 km, N

2.3. Land Requirement

The land has been under possession of GSFC since 1962. The complex has been classified

under Notified Area by Industries, Mines and Energy Department vide Notification No.

GU-87-46-GID-1086(I) 2338 dated 21.08.1987 (Documents have been provided as

Enclosure-I). The total land area is 3280000 m2 (328 Hectares). Revamping will be done

by demolition of few parts of existing Urea -I & II plants and modifications in existing

machinery and installation of several new machineries for construction of revamped

plant. There will be installation of machineries and equipment for proposed revamping.

G+1 story electrical substation will be built for installation of new PMCC electrical panels

& VFDs. Mechanical maintenance workshop also shall be developed. Detailed break-

up of land has been provided in Table 2.4 below and the layout plan of the project is

depicted in Figure 2.3. Layout Plans of location of Urea-I, Urea-II and revamping of Urea

Plants and detailed plot of revamping have been provided in Figure 2.4 to Figure 2.6,

respectively.

Table 2.3 : Land Breakup of Project Site

S.No. Particulars Unit Details %Age Distribution

1 Plant Area (Processing) m2 1747000 (174.7 Ha.) 53.26

2 Township Area m2 301000 (30.1 Ha) 9.18

3 Green Area (including

plant and township)

m2 1232000 (123.2 Ha.) 37.56

Total Plot Area m2 3280000 (328 Ha.) 100





Figure 2.3 : Land-use Breakup of GSFC Complex





Figure 2.4 : Layout Plan of Urea-I Plant including Revamped Urea Plant





Figure 2.5 : Layout Plan of Urea-II Plant including Revamped Urea Plant





Figure 2.6 : Plant Layout (showing location of Proposed Revamping Project on GSFC Complex)





2.4. Products with capacities for the proposed project

List of products have been provided in Table 1.1 of Section 1.2; Chapter-1 above.

Storage and Transportation

The finished product i.e., prilled product of Urea are being stored in Bagging Unit for

bagging and transported through rails and roads all over the country.

2.5. Manufacturing Process & Mass Balance of Products

2.5.1. Process Description of Urea (Earlier Technology-Total Recyle Process)

MISTSUI TOATSU TOYA KOATSU JAPAN; TOTAL RECYCLE “C” PROCESS DETAILED

ENGG. BY: LOYO ENGINEERING CORPORATION, JAPAN

Table 2.4 : Product specifications (Urea by Total Recycle Process)

Nitrogen By wt. (min) 46.20% 46.20%

Moisture By wt. (max) 00.5% 00.4%

Biuret By wt. at 90% 00.75% 00.36%

Load (max)

By wt. at 50% 1.00% 1.00%

pH of 10% solution 7-9 7-9

Screen Analysis min 95% 95%

(8-24 US MESH))

Figure 2.7 : Chemical Reaction of Urea Manufacturing (Total Recycle Process)





1. Synthesis Section

2. Decomposition Section

3. Concentration/Filtration

4. Finishing Section- Crystallization/Centrifuge

5. Drying, Melting and Prilling

6. Recovery Control

7. Emission Control

Synthesis Section: Both the reactants Ammonia and Carbon dioxide are pressurized to

210 kg/cm2 with the help of liquid Ammonia high pressure reciprocating pumps and

reciprocating CO2 compressors, respectively, and are fed to the reactor. The reactor is

vertical, multi-layered carbon steel and Titanium lined. The reaction between Ammonia

and Carbon dioxide is carried out on the reactor at temp. of 193°C and at a pressure of

210 kg/cm2 as follows: -

Carbamate formation: 2NH3 + CO2 -----→ NH2 COO NH4 + 38500 CAL

Dehydration of: NH2COONH4 -----→ NH2CONH2 + H2O – 7700 CAL

The first reaction of formation of Ammonia Carbamate is exothermic and is complete at

reaction condition. But the second reaction of dehydration of Carbamate to form urea

is endothermic and does

not go to completion under all practical conditions. Excess liquid NH3 is fed in the ratio of

4.1 to control the reaction condition and to increase the conversion. The maximum

conversion of CO2 to Urea can be achieved is 67% only in this process.

Decomposition Section: The liquid effluent from the reactor contains 29% of urea only and

rest is water, Ammonia, unreacted Carbamate and Biuret. To recover urea from the

solution, the excess Ammonia from the reactor products. The decomposition of

Ammonium Carbamate takes place in two stages at a pressure of 16 kg/cm2 in high

pressure decomposer and 1.5 kg/cm2 in low pressure decomposer.

Concentration/Filtration: The urea solution from low pressure decomposer flow to the

concentrator upper part operating at a pressure of 0.3 kg/cm2g where last traces of

Ammonia and Carbon dioxide are removed and then flows down to the lower part. In

the lower part of the concentrator air is blown to remove moisture and oxidised metallic

impurities. The separated gas from the top of the concentrator upper goes to gas

condenser. The urea solution rom the concentrator is passed through pressure left filter

coated with diatomaceous earth to remove oil and metallic impurities.

Finishing Section- Crystallization/Centrifuge: The urea solution coming from filter enters

the upper part of the crystalliser. The crystalliser is divided into two parts:





• The upper part is a vacuum evaporator with vacuum generator. The vacuum

evaporator operates at 90 mm HG absolute pressure and 60°C temp.

• The lower part of crystalliser is where urea crystals are suspended in urea slurry.

Almost entire water in the supplied urea solution is vapourised. At this condition urea slurry

(super saturated urea solution) comes down from evaporator through barometric leg to

crystalliser, which is operated at atmospheric pressure and 60°C temp, and crystal growth

takes place. Crystals formed are seperated from the mother liquid by pusher type

centrifuges. A part of the circulation urea slurry is sent to the cooler of high-pressure

absorber for heat recovery and this cooler again comes back to evaporator.

Drying, Melting and Prilling

The urea crystals from centrifuges are conveyed and fed to the bottom of a fluidized bed

dryer-cum pneumatically conveyed (with the help of induced drafition) to the top of

pilling tower where air and urea crystals are separated in cyclones. The cyclone outer air

is washed and let into atmosphere. The dry urea crystals are melted in steam heated

(melting point of urea 133°C) at temp. of 137°C. The molten urea from the meted is

sprayed inside the prilling tower with the help of prilling nozzles which have numbers of

holes of 0.6 mm dia. to from prills. The prills are cooled down after traveling downward.

Distance of 45°C is achieved at fluidised bed cooler (CFI). The prilled product is sent to

bagging plant for bagging.

Recovery Section: In the recovery section, the gases from gas separator, upper part of

Ammonia recovery column and Ammonia feed pump are absorbed by mother liquor,

dust chamber solution, dissolving tank solution, Ammonia carbonate (KT) solution and

D.M. water (or condensate) in gas condenser. The liquor from gas condenser is utilised to

absorber.

The liquor from the low-pressure absorber is utilised to absorb gases coming from the high-

pressure absorber cooler (HAC) by spraying it over the lower packed section of the gases

CO2 and water vapours are absorbed in liquid Ammonia and Aqua Ammonia. The

vapour from the top of high-pressure absorber is essentially pure Ammonia and Aqua

Ammonia. The vapour from the top of high-pressure absorber is essentially pure Ammonia

and goes cooler for high pressure absorber where it absorbs the incoming gases from the

high-pressure decomposer. The heat of absorption in gas condenser and low-pressure

absorber is removed by cooling water and in case of high-pressure absorber cooler is the

heat of absorption is removed by circulation of urea solution from crystalliser and cooling

water. The solution from high pressure absorber cooler is pumped to carbonate recycle

pump and then it is pumped to reactor.

Recovery of Ammonia from vent stacks of Urea Plant (ECS): In urea process, passivity air

is introduced in urea reactor and high-pressure decomposer to control corrosion in the





process. This air is ultimately vented to atmosphere from gas condensers. This air contains

residual Ammonia which gets lost to atmosphere. In oxidation column, air is introduced

at the bottom of the oxidizer to oxidize Ferric ions (FE3+) to Ferric ions (FE3+) in 70% urea

solution to enable iron removal in filters and subsequent stripping of Ammonia and water

evaporation. The exit air from oxidation column contains Ammonia and water vapour

and it is vented to atmosphere. These two streams from plant emit Ammonia through

vent stacks to atmosphere and its distribution as per design values is as under.

Table 2.5 : Ammonia emissions through vent stack and distribution

Name Unit Urea-I Urea-II

Oxidising Column MT/D 0.7 2.12

Gas Condensor MT/D 0.4 0.82

Total MT/D 1.1 2.94

Process Description: Vent gases from oxidation column and gas condensers from both

urea plants are joined together and are passed through the knockout drum to separate

the Ammonical condensate is transferred to vapor liquor separator by gravity with liquid

seal to prevent back flow of gas. The vent gases of pressure of 0.1 kg/cm2 and 100°C

temperature enter shell side of all gas condenser in which part water vapor is condensed

with cooling water in tube side.

The outlet gas temperature is maintained at 65-70°C temperature to prevent choking

due to urea entrainment from the proceed. The cooling water of vent gases in off gas

condenser results in reduced load in downstream equipment E.G., blower, scrubber. The

vent gases from off gas condenser enter the vapour liquor separator where Ammonical

condensate in process for emergency disposal. The scrubber has two zones. Bottom zone

is packed with polypropylene rings to a weight of 3 mts and top zone is having bubble

caps fro final scrubbing with DM water. The scrubber solution from bottom of scrubber is

neutralized with 98% H2SO4 in an acid mixing tee and then pumped through circulation

pump to scrubber liquor circulation cooler. The cooled solution at temperature 40°C is

recycled in scrubber at the top of the packing. A part of scrubber liquor is exported to

A.S. plant through auto level controller or scrubber pH of circulating liquor is maintained

in acidic range (3.5-4.5) to have best scrubbing of Ammonia. The concentration of A.S.

solution is maintained through density controller by addition of DM water at scrubber top.





Figure 2.8 : Process Description of Urea Manufacturing (Existing Technology)





2.5.2. Process Description and Mass Balance of Urea (Ammonia Stripping

Technology)

The urea manufacturing process is described under the following sections:

1. Ammonia Pumping and Carbon Dioxide Compression

2. High Pressure Urea Synthesis


4. Urea Concentration and Vacuum Condensation

5. Recovery Section

6. Prilling Section

7. Wastewater Treatment Section

8. Emission Control Scheme


Liquid Ammonia coming from battery limit will be sent to new Ammonia recovery tower

(XU-V550) to recover the vapour ammonia generated from existing Ammonia condenser

(XU-E504A/B/C/D/E) and then it will be stored in existing Ammonia reservoir (XU-V503).

Then, Liquid ammonia is pumped to the suction of liquid ammonia high pressure

reciprocating pumps (XU-P101A/B/C) by means of existing liquid ammonia booster pump

(XU-P502 A/B). Then liquid Ammonia is pressurized to approx. 220 kg/cm2g by liquid

ammonia high pressure reciprocating pumps and sent to new Ammonia Pre-heater (XU-

E252) and XU-E101 for heating to 95 °C.

Carbon dioxide coming from battery limit at a pressure of 0.35 kg/cm2g is fed to the

carbon dioxide compressors XU-K101A/B and UK-101A. The carbon dioxide is compressed

to a pressure of about 165 kg/cm2g in the existing carbon dioxide compressors.

Compressors are four stage reciprocating driven by electric motor. Interstage coolers are

provided to cool down the CO2 gas. Existing two compressors of Urea-II Plant (XUK-

101A/B) and one compressor of Urea-I Plant (UK-101A) will be refurbished to operate at

lower discharged pressure after revamping i.e. at 165 kg/cm2g.


Compressed CO2 gas is fed to the bottom of existing modified Reactor XU-R102. The

reaction between NH3 and CO2 is carried out in the reactors at temp of 190°C and at a

pressure of 159 kg/cm2gas follows.

2 NH3 + CO2 ↔ NH2-CO-ONH4 (ammonium Carbamate) --------- (1)

NH2-CO-ONH4 ↔ NH2-CO-NH2 (Urea) + H2O--------------------------- (2)

Reaction (1) involving formation of ammonium Carbamate is rapid and exothermic.





Reaction (2) involving decomposition of Carbamate into urea and water is slow

andslightly endothermic

The synthesis reaction conditions are: -

Pressure: - 159 kg/cm2g

Temperature: - 190 °C

NH3/CO2: - 3.1 – 3.2

H2O/CO2: - 0.57 – 0.62

CO2 Conversion: - 60%

One new reactor (XUR-101N) will be installed to accommodate the volume on account

of increase in capacity / plant load of Urea-II plant. The two reactors will be connected

in series. Existing XU-R102 acts as a first reactor and XU-R101N provided with CASALE high

efficiency tray (HET) actsas a second reactor. Reactor has sufficient volume to

accommodate the residence time of the relatively slow endothermic reaction (2)

involving Carbamate conversion in urea. The function of the HET trays is to improve the

heat and mass transfer phenomena, which occur inside the reactor and in this way to

increase the CO2 conversion.

The Urea solution exit from the top of 1st reactor and injected in the 2nd reactor XU-R101N

bottom to maximize the urea conversion. At the top of the reactor XU-R101N, the mixture

is separated in the two phases. The fluid reaction mixture leaves the reactor via an

internal overflow pipewith entrance at the top of the reactor and ultimately flows

downward into the HP Stripper (XU-E151) (by gravity) top channel, whereas the vapor

phase, which contains the oxygen used for reactor passivation, is routed towards the

stripper bottom channel.

New HP Stripper will be provided to decompose the unreacted solution from the reactor,

reducing the load of the downstream section. Stripper works at a pressure slightly lower

than the reactor to improve thedecomposition of Carbamate. The urea solution fed to

the top channel is distributed to create a falling film inside the tubes. To passivate the

internal material, injection of the inert gases from XU-R101N reactor top into the Stripper

bottom is provided. 22 kg/cm2g saturated steam is used as a heating media in the HP

Stripper shell side for Carbamate decomposition. A dedicated steam saturator shall be

installed (XU-V154). In the HP Stripper, almost complete dissociation of most of the

Carbamate into its components takes place together with the desorption and

evaporation of CO2 and NH3 formed from this dissociation as well as the evaporation of

excess NH3 and some H2O from solution. The liquid urea solution containing un-

dissociated Carbamate leaves the bottom of HP Stripper. Vapours comingfrom the HP





Stripper mixed with a stream of Carbamate solution coming from the pump XU-P102

A/B/C and enter Carbamate condenser. Two new HP Carbamate Condensers is

proposed for recovering the gaseous stream from the HP Stripper and controlling the heat

balance of the section. The condensation occurs in two horizontal HP Carbamate

condensers, where the heat is recovered by producing steam at about 5.5 kg/cm2g in

the 1st HPCC (XU-E152) and 3.8 kg/cm2g in the 2nd HPCC (XU-E153). The stream of

Carbamate solution is added to aid the vapour condensation and toreduce the

crystallization temperature of the Carbamate solution. The Carbamate solution is

collected in the Carbamate separator XU-V151 and injected intoUrea Reactor (XU-R102)

by means of the HP ejector (XU-J151), wherein HP ammonia discharged from HP pumps

will act as a motive fluid.

3. Decomposition

Urea solution from the bottom of the HP Stripper, containing about42.69% by weight urea,

25.25% by weight water plus any not dissociated Carbamate, isexpanded to about 17

kg/cm2g, which causes part of the residual Carbamate todissociate and evaporate. The

vapour fraction is separated in the top part of existing HP Decomposer (XU-V201), while

the liquid content is sent to existing LP Decomposer operated at 1.5 kg/cm2g.

HP Decomposer reboiler (XU-E201A/B) is attached with HP Decomposer. It consists of one

vertical shell-and-tube heat exchangers divided into two parts, where Urea solution flows

upward on tube side. Lower part ofreboiler uses 5.5 kg/cm2g steam as heating medium,

while upper partuses HP steam condensate as heating medium to recover the heatof

the steam condensate coming from the HP Stripper.

Urea solution with un-decomposed Carbamate (60.35% urea, 31.68% water by weight)

exitsthe HP Decomposer at 161°C and enters the existing LP Decomposer (XU-V202

operated at about 2 kg/cm2g. The decomposer is a vertical type of shell-and-tube

exchanger. Here, decomposition of Carbamate takes place at lower pressure by use of

LPD reboiler (XU-E202). Steam generated from Carbamate condenser is used as a

heating medium in reboiler. Vapours released from top of decomposer condense in the

existing Low-Pressure absorber (XU-E502). Urea solutions exist the LP decomposer at 133

°C (66.58% urea, 31.63% water by weight)

The urea solution from low pressure decomposer flows to the existing Gas Separator

upper part operating at 0.3 kg/cm2g where the last trace of ammonia and carbon

dioxide are removed and then flows to the concentrator. The separated gas from the

top of the gas separator upper part goes to existing Gas condenser XU-E503.





4. Urea Concentration & Vacuum Condensation

Urea solution at approximately 68 %wt from Gas Separator top section is supplied by

Filter Pumps XU-P201A/B to the new Evaporation section. The evaporation section is

having 2 vacuum stages. The 1st stage comprises two bundles directly coupled. The first

bundle, Vacuum Pre-Concentrator XU-E551A, exploits the condensation of vapors from

HP Decomposer XU-V201to concentrate the urea solution up to approximately 85 %wt.

In the second bundle, XU-E551B, Urea solution is concentrated up to about 95 % wt using

3.8 kg/cm2g steamproduced by 2nd HP Carbamate Condenser. The generated vapours

are then separatedfrom the liquid phase in 1st Stage Evaporator XU-V551. From the 1st

evaporator separatorurea at 95 %wt flows to the 2nd evaporator XU-E552 where 99.7 %wt

concentration isobtained at abt. 138°C and 0.03 kg/cm2a. In the 2nd evaporator 3.8

kg/cm2g steam fromthe 2nd HP Carbamate Condenser is also used. The vapours are

separated by the 2ndevaporator separator XU-V552 from the urea melt which is pumped

via the new urea meltpumps XU-P552A/B and split between the existing prilling towers. A

new vacuum system XU-X551, including indirect CW condensers and steam ejectors

(using 3.8 kg/cm2g LP steam as motive fluid), will be installed to condense the

processvapours from the 1st and 2nd stage of evaporation. The process condensate from

thenew vacuum system is collected in a new buffer tank XU-V556 and transferred to the

newWaste Water Treatment section via new Process Condensate pump XU-P556 A/B.

Aminor stream of process condensate will be recycling to Off-gas Condenser XU-E602 to

aid ammonia absorption.

5. Prilling Section

Molten urea is sprayed inside the existing prilling tower with the help of prilling nozzles

which gave number of hole of 0.6 mm / 0.66 mmdiameter to form prills. Urea-I and Urea-

II prilling tower will be used for prilling. The prills are cooled down after travelling

downward through prilling tower with the help of ascending air. The final cooling

temperature of 45 °C is achieved at fluidized bed cooler (CFD). The prilled product is

entering to bagging plant for bagging.


The process condensate from the new Buffer Tank XU-V556 is fed, via the new pumps XU-

P556A/B to the new Desorber XU-C851. The upper part of the new column XU-V851

removes most part of NH3 and CO2. The water from chimney tray ofthe Desorber XU-

V851 will feed the Hydrolyzer XU-R851, after being pumped by newHydrolyzer Feed pump

and preheated in the Hydrolyzer Pre-Heater Exchanger from thewater coming out from

the Hydrolyzer itself. The Hydrolyzer will reduce the urea content inthe treated water





down to 5 ppm. The hydrolyzed water, after having been cooled downby XU-R851 inlet

stream, will come back to Desorber XU-V851, where the NH3 content will be reduced at

around 5 ppm by means of 3.8 kg/cm2g steam. The vapours from both Desorber column

XU-V851 and Hydrolyzer XU-R851 arecondensed in the existing LP Section jointly with the

vapours from the LP Decomposer. This willallow maximizing the energy saving in the new

NH3 preheater XU-E252. The reflux to Desorber XU-V851 is provided by HP Absorber Pump

XU-P504 A/B.

The treated process condensate leaving the Desorber will warm up the feed into the XU-

E852 and being sent to the battery limits through the new pumps XU-P853 A/B. A

minorportion of the treated water will be used as make-up for the scrubbers of the prilling

tower. Final Cooler XU-E853 will lower the temperature of the treated water down to 45°C.

The treated water will be used as make up water to Cooling Towers or else it will be

exported to GSFC grid as condensate make up.

7. Recovery Section

In the existing recovery section, the gases from Gas Separator, LP Decomposer are

absorbed by dust chamber solution, dissolving tank solution, ammonium Carbamate (KT)

solution and D. M water in Gas Condenser XU-E503. The liquid from gas condenser is

utilized to absorb the gas from low pressure decomposer in the low-pressure absorber

(XU-E502). The liquor from the low-pressure absorber is utilized to absorb the gases coming

from the high-pressure absorber cooler (HAC) by spraying it over the packed section of

HAC. The top section of high-pressure absorber (XU-V501) is having bubble cap tray and

here the gases CO2 and water vapours are absorbed in liquid ammonia and aqua

ammonia. The vapour from the top of high-pressure absorber is essentially pure ammonia

and goes to ammonia condenser. The heat of absorption in gas condenser and low-

pressure absorber and high-pressure absorber cooler is removed by cooling water. The

solution from high pressure absorber cooler is pumped to Carbamate recycle pump (XU-

P501 A/B/C) and then it is pumped to XU-P102A/B/C.


Vent gases from gas condenser are passed through knockout drum to separate the

ammonical condensate. The condensate is transferred to existing vapour liquid separator

(XU-V601) by gravity with liquid seal to prevent back flow of gas. The vent gases of

pressure of 0.1 kg/cm2 and 100 °C temperature enter shell side of off gas condenser (XU-

E602) in which part of water vapour is condensed with cooling water in tube side. The

outlet gas temperature is maintained at 65-70 °C temperature to prevent chocking due

to urea entrainment from the process. The vent gases from off gas condenser enter





vapour liquid separator (XU-V601) where ammonical condensate having 3-4% ammonia

is separated from vent gases. This ammonical condensate is further recycled in scrubber

circulation. The vent gases from vapour liquid separator are fed to scrubber (XU-T601).

The scrubber solution from bottom of scrubber is neutralized with 98% H2SO4 in acid mixing

tee and then pumped to scrubber liquid circulation cooler. Cooled solution of 40 °C is

recycled in scrubber at the top of the packing. A part of scrubber liquid is exported to AS

Plant. Circulation liquor is maintained in acidic range (3.5 – 4.5) to have best scrubbing

of ammonia.

Figure 2.9 : Process Description of Urea Manufacturing (Proposed Technology- Ammonia

Sripping)





Table 2.6 : Mass Balance (Post Revamping)

Specific Consumption (MT/MT) Output

Name Qty. Name Qty.

Raw Material Side

Ammonia 0.570 Urea 1.000

CO2 0.757 Water 0.327

(Water generated in

manufacturing process,

which will be used for

internal consumers)

Total 1.327 Total 1.327

Steam Side

Steam Import 0.967 Steam Condensate

export

0.257

Steam Export 0.324

Direct Steam

Consumption

0.272

Steam Condensate

for internal

consumers

0.114

Total 0.967 Total 0.967

2.5.3. Energy Balance

Existing Conditions:

1. Specific NH3 Consumption: - 0.585 MT/MT Urea ---- XXX

2. Specific Power Consumption: - 204.943 kWh/MT Urea---- YYY

3. Specific Steam Import Consumption: -1.337 MT/MT Urea ----- ZZZ

4. Specific Steam Export Consumption: - 0 MT/MT Urea ----- WWW

Specific Energy Consumption (Existing): 6.523 GCal/MT Urea

CALCULATIONS:

XXX = specific ammonia consumption [MT_NH3 / MT_Urea]

YYY = specific electrical consumption [kWh / MT_Urea]

ZZZ = specific steam consumption [MT_steam / MT_Urea]

WWW = specific 13 kg/cm2g steam export [MT_steam / MT_Urea]

SPECIFIC ENERGY CONSUMPTION = 7.943 Gcal/MT_NH3 x XXX + (YYY x 0.00286) + (ZZZ x

0.7) – (WWW x 0.649)





CONDITIONS AFTER REVAMPING:

1. Specific NH3 Consumption: - 0.570 MT/MT Urea ---- XXX

2. Specific Power Consumption: - 183 kWh/MT Urea---- YYY

3. Specific Steam Import Consumption: -0.967 MT/MT Urea ----- ZZZ

4. Specific Steam Export Consumption: - 0.324 MT/MT Urea ----- WWW

Specific Energy Consumption (Post Revamping): 5.773 GCal/MT Urea

Reduction in Energy Consumption (Post Revamping) will be ~0.750 Gcal/MT Urea.

Therefore, atleast 0.5773 GCal/MT in energy reduction is anticipated to get achieved

due to proposed revamping project.

2.6. Raw Material

Details of raw materials along with estimated quantity and likely source have been

provided in Table 2.7 below:

Table 2.7 : Details of Raw Materials for Proposed Revamping

S.No. Particulars Unit Details (MT/MT Urea) Impact

Existing Total after

Revamping

1. Condensate

Exp. (By pro.)

MT/MT Urea Steam

Condensate:

- 0.900

Steam

Condensate: -

0.258

Decrease

2. NH3 MT/MT Urea 0.585 0.570 Decrease

3. CO2 MT/MT Urea 0.800 0.757 Decrease

4. Steam MT/MT Urea 1.420 0.967 Decrease

5. Power kWh/MT Urea 205 183 Decrease

6. DM water

makeup

m3/MT Urea 0.015 0.02 Increase

7. Cooling water

makeup

m3/MT Urea 3.53 1.18 Decrease

Transportation

1. Ammonia and Carbon-di-oxide are being transported from Ammonia group of

plants via pipeline.

2. Transportation of Ammonia and other hazardous chemicals are performed

through GPS enabled vehicles.





Storage

1. All the safety precautions are taken for safe handling and storage i.e., Illumination

of piping and storage area, ensuring leak proof system, use of PPR, keeping an

eye on all the process parameters day to day through DCS on round the clock

basis, required trips and alarm system etc. Safety department for necessary

compliance pertaining to Factory Act and Manufacture, Storage, and Import of

Hazardous Chemical Rules.

2.7. Onsite/Offsite Facilities & Machineries

2.7.1. Offsite/Onsite Facilities

GSFC Complex Vadodara possess the following offsite/onsite facilities:

1. Water Supply and Treatment Facilities

2. Power Distribution System (WindMill/Cogeneration Plant/MGVCL)

3. Bulk Storage Facilties

4. Plant and Instrument Air Supply

5. Product Storage and Bagging Plant

6. Railway Platfrom Facility

7. Natural Gas Supply

8. Fire & Safety equipment

9. Pay loaders, Crane, Dumpers

10. Office equipment & Communication equipment

11. Workshop and Laboratory equipment

12. Effluent Treatment Plant

13. Sewage Treatment Plant

14. Wastewater Disposal Facility

15. Emergency Power Generation Sets (DG Sets)

1. Water Supply and Treatment Facilities

Water requirement and its supply is sourced from 4 no. of French wells sourced from Mahi

River. 2 no. of french wells are located at Parthampura and rest 2 no. of french wells are

located at IOCL Refinery. Raw Water received from french wells is passed through

pressure sand filters of Water Treatment Plant through Raw Water Pump to remove

suspended particles and distributed to the consumers (excluding CEP and Ammonia-IV

Plant). Water Permission for withdrawal of water from notified river reservoir has been

provided by Executive Engineer, Vadodara Irrigation Division vide Letter No. VID/PB-

1/IND-REQ.2021-22/GSFC/725 dated 17.03.2021. (Water Permission has been attached as

Enclosure-IV).





At GSFC DM WATER plants having capacity (1) WT – II 130 M3/Hr (2) WT – III 140 M3/Hr and

(3) P.W. 110 M3/Hr (4) DM Water Plant having capacity of 9600 M3/Day at CEP plant. DM

water from DM plants is used as raw water for polished water production. The WT Plants

treat raw water and produce DM Water and Polish water for consumption of GSFC’s

various plants. The DM Water produced from Water Treatment plants are distributed to

various plants of the complex, such as Urea, Caprolactam – I, Steam Generation, Nylon-

6, Melamine, Caprolactam – II and Acid Group of plants, e.g., Sulfuric Acid Plant – III (SA-

III), Sulfuric Acid Plant – IV (SA-IV) and Ammonia –IV. DM Water is also being received as

per availability from Capro Expansion DM Water Plant.

Recently, M/s CASALE has revised the total CW circulation rate from 4653 to 5395 M3/hr

(i.e., increase of 742 m3/hr). To cater the additional requirement, water for original

Ammonia-I Cooling Tower makeup instead of Melamine-I plant will be utilized.

2. Power Distribution

The power requirement for GSFC Complex sourced from WindMill/Cogeneration

Plant/MGVCL. GSFC has installed 152.8 MW Wind Farm in Kucchh& Saurashtra region, the

same is utilized in Baroda & Sikka Unit. Solar Power Plant of 10 MW is recently executed at

Charanka Patan. The operation of Co-Generation Plants at GSFC is dependent on the

steam & power demand (requirement) of the complex, NG availability and GIPCL power

share. There are three numbers of medium pressure process boilers in steam generation

plant and are used as an additional source of steam supply as and when required.

Electricity Permission from MGVCL & GIPCL have been annexed as Enclosure-V.

3. Bulk Storage Facilities

Table 2.8 : Storage Facilities at GSFC, Vadodara

Raw Material Type of Storage Number of Storage Storage Capacity

Urea Storage Tank 1 355 m3

Ammonia Storage Tank 2 10,000 MT

4. Natural Gas Supply

Natural Gas is being supplied to the plant by GAIL. Agreement of supply of gas from GAIL

has been annexed as Enclosure-VI.

5. Fire & Safety Equipment

Adequate fire fighting facilities are available at GSFC and regularly tested & maintained.

Detailed operating manuals have been prepared & effective training has been imparted

to various Depts. / Plants.The details of fire fighting& emergency measures are included





in the Safety Manual & Onsite Emergency Action Plan and kept in various Control rooms

of the premises & on GSFC Intranet.

Industry is regularly providing training to all its workers on work safety & in using personal

Protective Equipments (PPE’s). All the accidents are analyzed investigated and remedial

measures are being taken to avoid reoccurrence of the same. Fire and safety

department is sending the report of accident investigation to concern process group

and service department for implementation of the remedial measures. Constant follow

up is done by the management to rectify the unsafe working conditions & practices etc.

The industry has Hazard identification Group as well as Safety Committee. Both these

groups study accident and unsafe working conditions and provide necessary innovative

suggestions for accident prevention.

Fire Water Storage: The fire water network is divided in six zones in GSFC BU having total

capacity of approx 1,41,000 m3 (Zone-A: 68,000 m3, Zone-B: 1260 m3, Zone-C: 51,860 m3,

Zone-D: 10,000 m3, Zone- E: 4596 m3, Zone-F: 5000 m3)

Fire Water Pumps

Table 2.9 : Details of Fire Water Pumps

S.No

.

Description Jocke

y

Electrica

l

Diesel Submersible Capacity (m3/hr)

Jocke

y

Electrical Diesel Submersible

1 Zone-A 2 1 1 - 12 450 450 -

2 Zone-B 2 1 1 - 40 410 341 -

3 Zone-C 2 1 2 - 40 396 396 &

410

-

4 Zone-D 2 1 2 - 40 410 410 -

5 Zone-E 2 3 1 2 40 273 & 390 273 390

6 Zone-F 2 1 1 - 40 410 410 -

Fire Fighting Appliances

Table 2.10 : Details of Mobile Fire fighting appliances

S.No. Description Quantity (No.)

1 Fire Tenders 09 (07 Foam Tenders & 02 DCP Tenders)

2 Hydraulic Platform 01

3 DCP Trailor 01

4 Trailor Pump 01

5 Flood light mast 01

6 Trailor Monitor 01





Table 2.11 : Details of Stationary Fire fighting appliances

S.No. Description No. Details

1 Hydrants 513 In whole GSFC complex

2 Monitors 80 In whole GSFC complex

3 Risers 79 In whole GSFC complex

4 MCP 333 At various locations in GSFC, BU

5 Fixed Foam Installation 12 At various location in GSFC BU, Capacity is

variable for all installations.

6 Detectors 491 At various locations in GSFC, BU

7 MV Water Spray System 38 At various locations in GSFC, BU

Table 2.12 : Details of Portable Fire Fighting Extinguishers


1 DCP (10 kg) 83 Placed at various locations in plants


3 DCP (22.5/25 kg) 129 Placed at various locations in plants


5 DCP (4.5 kg) 09 Placed at various locations in plants



Table 2.13 : Details of Chemicals in Fire fighting System


1 AR-AFFF FOAM 23500 Litres Used in Hydrocarbons, Alcohol fire etc.

2 FFFP FOAM 14000 Litres Used in other flammable liquid as molten

sulphur etc

Detection & Monitoring System

Fire Alarm Panel: It contains 125 manual call points spread in whole plant on average

distance of 50 feet. Heat detector and smoke detector in instrumentation, Electrical

installation, and other sophisticated equipment. These detectors are attached with main

panel installed in main control room and repeater Panel in fire control room.

CO & Cl2 Online Detectors: Installed at CO and Chlorine handling plants, indicating their

concentration in ppm and give alarms /signals in control room.

6. Effluent Treatment Plant





The complex has 2 no. of Effluent Treatment Plants for treatment of process effluent from

Caprolactam-I & II Plant and Nylon plants. The capacities of ETP-I & II are 1200 KLD and

1920 KLD respectively. Treated water from ETP’s will be disposed to sea through common

effluent channel of M/s. Vadodara Enviro Channel Limited (VECL).

7. Sewage Water Reclamation Plant

GSFC has installed Sewage Water Reclamation Plant having capacity 3175 KLD for the

treatment of sewage emanating from the township.

8. Wastewater Disposal Facility

The final treated effluent conforming to the standards prescribed under the Environment

(Protection) Rules, 1986 is being ultimately discharged to Effluent Conveyance Channel

(ECP) andutlimated conveyed to sea for final disposal. Latest Membership for disposal of

wastewater with VECL has been annexed as Enclosure-VII.

9. Emergency Power Generation Sets (DG Sets)

For Backup purposes, various DG sets have been installed in the complex unit-wise i.e.,

Main s/s: 300 kW; Steam Gen: 500kW; CaproExp.: 800 kW; PA: 560 kW; Nylon-6: 450 kW; SA

- IV: 500 kW; Cogen-III: 500 kW; Amm. -IV: 1000 kW; Data Centre: - 250 kVA; Methanol: 750

kVA; CQP DG :750 kVA; M-III DG: 3000 kVA, N-6-III DG: 1250 kVA.

2.7.2. Machineries and Equipments

The following tables (Table 2.14 and Table 2.15) describes existing list of machineries and

equipments in Urea-I & Urea-II Plant.

Table 2.14 : List of Equipments & Machineries in Urea-I Plant

Sr. Item No. Equipments QTY.

STATIONARY EQUIPMENTS

I. Urea Synthesis Section: 1 UR-101 Urea Reactor 1

2 UE-101 Ammonia Pre-Heater 2

3 CO2 Gas Pre-Cooler 1

4 UV-104 CO2 Snubber 1

5 UV 101 Pulsation Dampener for Liquid Ammonia Feed line 1

6 UV 105 Gland C.W. Tank 1

II. Purification Section: 1 UV-201 High Pressure Decomposer 1

2 UV-202 Low-Pressure Decomposer 1

3 UV-203 Concentrator 1

4 UV-204 Mixing Tank 1

5 UV-205 Steam Condensate Tank 1

6 Flash drum 1







7 UE-201 Re-Boiler for High Pressure Decomposer 1

8 UE-202 Re-Boiler for Low Pressure Decomposer 1

9 US-201 AB Filter 2

10 Cooler for Passivation Air Compressors 1

11 Volume Bottle for Passivation Air Compressors 1

III. Crystal Seperation Section: 1 UV-302 Hot Water Tank 1

2 UV-303 Mother Liquor Tank 1

3 US-301 Vacuum Generator with ejectors& barometric condensers 1

4 CY heater 1

IV. Drying and Prilling Section 1 UV-401 Melted Urea Pump Tank 1

2 UE-401 Air Heater 1

3 US-402 Cyclone 2

4 US-403 Strainer 2

5 US-404 Head Tank 1

6 US-405 A TO F Distributors 6

7 US-406 Fluidizing Cooler 1

8 US-409 Belt Scale for Prilled Urea 1

9 US-411 Prilling Tower 1

V. Recovery Of Unconverted Carbamate 1 UV-501 High Pressure Absorber 1

2 UV-502 Drain Seperator 1

3 UV-503 Recovery Liquid Ammonia Reservoir 1

4 UV-504 Ammonium Carbonate Solution Tank (KT Tank) 1

5 UE-501 Cooler For High Pressure Absorber (HAC) 1

6 UE-502 Low Pressure Absorber (LA) 1

7 UE-503 Gas Condenser (GC) 1

8

UE-504-

ABCDE Ammonia Condensers (5 Nos. of Condensers) 5

9 UE-506 Ammonia Recovery Column (NRA) (3 NOS.) 1

10 Liquid Ammonia Air Releaser 1

ROTARY EQUIPMENTS

I. Urea Synthesis Section

1 UK-101 AB CO2 Compressor 2

2 UK-102 Air Blower for Sub-Station 2

3 UP-101 AB Liquid Ammonia Feed Pump 2

4 UP-102 A Recycle Solution Pump - Reciprocating 1

5 UP-102 B Recycle Solution Pump - Centrifugal 1

6 UP-103 High Pressure Flooding Pump 1

7 UP-104 A Low Pressure Flooding Pump 1





8 UT-101 Over-Head Crane for CO2 Compressor and pump house 1

9 AK-201 CO2 Blower 1

10 UP-105AB Gland Cooling Water Pump 2

11 UP-801 AB Compr. C.W. Return Pump 2

12 UP-107 CO2 precooler effluent export pump 1

II. Purification Section

1 UK-201 Air Blower for oxidizing 1

2 UP-201 AB Filter Pump 2

3 UP-202 AB Steam Condensate Pump 2

4 UK-202 1,2&3 Passivation Air Compressor 3

5 Sorbocel Dozing Tank with Agitator 1

6 Sorbocel Dozing Pump 1

III. Crystal Seperation Section

1 UV-301 Crystallizer (Upper & Lower) with Agitator 1

2 UP-301 AB Urea Solution Circulation Pump 2

3 UP-302 AB Slurry Pump 2

4 UP-303 AB Hot Water Pump 2

5 UP-304 AB Mother Liquor Pump 2

6 US-302 ABC Centrifuge 3

7 UT-301 AB Screw Conveyor 2

8 UP-801 FG Barometric Pit Return Water Pump 2

IV. Drying and Prilling Section

1 UK-401 Induced Fan for Dryer 1

2 UK-402 Air Blower for Fluidizing Cooler 1

3 UP-401 AB Melted Urea Pump 2

4 UP-403 B Circulation Pump for Prilling Tower Dusting 1

5 US-401 Dryer 1

6 US-408 Elevator (Lift) 1

7 UT-401 Screw Conveyor from Dryer 1

8 UT-402 Bucket Elevator 1

9 UT-403 Belt Conveyor for Prilled Urea 1

10 UE-402 Melter with Agitator 1

V. Recovery Of Unconverted Carbamate

1 UP-501 AB Circulation Pump for Cooler 2

2 UP-502 ABC Liquid Ammonia Boost-Up Pump 3

3 UP-503 AB Aqua Ammonia Pump 2

4 UP-504 AB Absorbent Pump for High Pressure Absorber 2

5 UP-505 AB Absorbent Pump for Low Pressure Absorber 2

6 UP-506 AB Water Pump 2

7 UP-507 AB KT Solution Transferring Pump 2

VI. Blue Star A.C. Capacity of 12 MT for control room 1

Table 2.15 : List of Equipments & Machineries in Urea-II Plant







I. Urea Synthesis Section: 1 XUR-101 & 102 Reactors (OLD & NEW) 2

2 XUV-102 Instrument Air Receiver 1

3 XUE-101 Liquid Ammonia Pre-Heater 1

4 XUV 104 Gland C.W Tank 1

5 CO2 Gas precooler 1

II. Purification Section: 1 XUV-201 High Pressure Decomposer 1

2 XUV-202 Low Pressure Decomposer 1

3 XUV-203 Concentrator 1

4 XUV-204 Mixing Tank 1

5 XUV-205 Steam Condensate Tank 1

6 Flash drum 1

7 XUE-201 Re-Boiler for High Pressure Decomposer 1

8 XUE-202 Re-Boiler for Low Pressure Decomposer 1

9 XUE-203 Condensate cooler 1

10 XUS-201 AB Filter 2

III. Crystal Seperation Section 1 XUV-302 Hot Water Tank 1

2 XUV-303 Mother Liquor Tank 1

3 XUS-301

Vacuum Generator with ejectors & barometric

condensers 1

IV. Drying and Prilling Section 1 XUV-401 Dissolving Tank 1

2 XUE-401 Air Heater 1

3 XUE-402 Melter 1

4 XUS-401 Pneumatic Dryer 1

5 XUS-402 Cyclone 1 SET

6 XUS-403 Strainer 1

7 XUS-404 Head Tank 1

8 XUS-405 A TO H Distributors 8

9 XUS-406 Fluidizing Cooler (CFD Bed) 1

10 XUS-409 Belt Scale 1

11 XUS-410 Filter For Dissolving Tank 1

12 XUS-411 Prilling Tower 1

13 XUS- 412 Dust Collector 1

V. Recovery of Unconverted Carbamate 1 XUV-501 High Pressure Absorber (HA) 1

2 XUV-502 Drain Seperator 1






3 XUV-503 Recovery Liquid Ammonia Reservoir 1

4 XUV-504/403 Ammonium Carbonate Solution Tank (Old & New) 2

5 XUE-501 Cooler For High Pressure Absorber (HAC) 1

6 XUE-502 Low Pressure Absorber (LA) 1

7 XUE-503 Gas Condenser (GC) 1

8 XUE-504 A TO E Ammonia Condensers 5

9 XUE-506 Ammonia Recovery Column (NRA)(3 NOS.) 1

VI. EMMISSION CONTROL SCHEME 1 XUE-602 Off-Gas Condenser 1

2 XUE-601 A&B Circulation Cooler 2

3 XUV-601 Vapour Liquid Seperator 1

4 XUT-601 Scrubber 1

VII. COOLING TOWERS 1 CT-2B 2.5 Kg/Cm2g Cooling Tower 1

2 CT-2A 4.5 Kg/Cm2g Cooling Tower 1

3 Sand Filter 1

4 Chlorination Unit / Chlorine Absorber 1

ROTARY EQUIPMENTS

I. Urea Synthesis Section 1 XUK-101 AB CO2 Compressor 2

2 XUK-103 B CO2 Blower 1

3 XUP-101 ABC Liquid Ammonia Feed Pump 3

4 XUP-102 A Recycle Solution Pump - Centrifugal 1

5 XUP-102 BC Recycle Solution Pump - Reciprocating 2

6 XUP-103 AB High Pressure Flooding Pump 2

7 XUP-104 Low Pressure Flooding Pump 1

8 XUP 105 AB Compressor C.W. return Pump 2

9 XUP 106 AB Gland C.W Circulation Pump 2

10 XUP-107 CO2 precooler effluent transfer pump 1

II. Purification Section 1 XUK-201 Air Blower for Oxidizing 1

2 XUP-201 AB Filter Pump 2

3 XUP-202 AB Steam Condensate Pump 2

4 XUP 203 Condensate pump for Desuper-Heater 1

III. Crystal Seperation Section 1 XUV-301 Crystallizer (Upper & Lower) with Agitator 1

2 XUP-301 AB Urea Solution Circulation Pump 2

3 XUP-302 AB Slurry Pump 2

4 XUP-303 AB Hot Water Pump 2

5 XUP-304 AB Mother Liquor Pump 2






6 XUS-302 ABCD Centrifuge with Screw Conveyor 4

7 XUT-301 Belt Conveyor from centrifuge 1

8 XUT-302 Belt Conveyor to dryer 1

IV. Drying and Prilling Section 1 XUK-401 Induced Fan for Dryer (ID Fan) 1

2 XUK-402 Air Blower for Fluidizing Cooler (CFD Blower) 1

3 XUK-403 Forced Fan for Dryer (FD Fan) 1

4 XUP-402 AB Water Pump 2

5 XUP-403 AB Circulation Pump for Prilling Tower Dust Chamber 2

6 XUS-408 Elevator (Lift) 1

7 XUT-401 Screw Conveyor to Melter 1UNIT

8 XUT-402 Belt Conveyor for final product 1

9 MXUP-405 DM Water for Prilling Tower 1

10 MXUP-406 Dissolving Tank Pump 1

11 MXUP-404 KT Solution Transferring Pump 1

12 MXUP-407 KT Solution Transferring Pump 1

V. Recovery of Unconverted Carbamate 1 XUP-501 AC Circulation Pump for Cooler 2

2 XUP-502 AB Liquid Ammonia Pump 2

3 XUP-503 AB Aqua Ammonia Pump 2

4 XUP-504 AB Absorber Pump for High Pressure 2

5 XUP-505 AB Absorber Pump for Low Pressure 2

6 XUP-506 AB Water Pump 2

7 XUP-507 Ammonium Carbonate Solution Pump 1

8 XUP-601-ABC Lagoon Pit Pumps for effluent transfer 3

VI. EMMISSION CONTROL SCHEME 1 XUP-614 AB SA Transfer Pump 2

2 XUP-613 AB Condensate Transfer Pump 2

3 XUP-612 AB Circulation Pump 2

4 XUP-611 AB Solution Transfer Pump 2

VII. COOLING TOWERS: 1 XUTP-303-AB Cold Well Pump for 2.5 K Cooling Tower 2

2 XUTP-304-A&B Hot Well Pump for 2.5 K Cooling Tower 2

3 2.5 Kg C.F.No.1 & 2 Cooling Fan 2

4 XUTP-302-A&B Cold Well Pump for 4.5 K Cooling Tower 2

5 XUK-301 Air Blower for Sand Filter 1

6 4.5 Kg C.F.No.1 & 2 Cooling Fan 2

For proposed refurbishing of units, there will be modifications in the existing Urea plants

along with addition of few machineries and equipments. The following Table 2.16

represents the details of modifications/new installations of the project.





Table 2.16 : List of Proposed Modifications/New Installations under Revamping

S.No. Particulars Details

MODIFICATIONS IN EXISTING MACHINERIES AND EQUIPMENTS

1. Carbon-di-oxide

Compressors

Refurbishing of CO2 Compressors at Urea-II Plant (XU-

K101A/B) and Urea-I Plant (U-K101A) for operation at

lower compressors discharge pressure (~165 kg/cm2g)

2. High-pressure NH3

pumps

Replacement of 1 no. of High-pressure Ammonia Pump

(XU-P101A) with lower capacity with new electric

motor.

3. High-pressure

Recycle

Carbamate Solution

(RC) pumps

Refurbishing of existing turbine driven centrifugal pump

(XU-P102A) for operation at lower speed for lower flow

rate.

Replacement of motor-driven reciprocating pump

(XUP-102C) with new warehouse centrifugal pump with

new electric motor pump.

4. High-pressure Urea

Reactors (XU-R101,

XU-R102 & XU-

R101N)

Modification in top cover and inlet nozzles of XU-R102

will be done.

5.

High Pressure

Decomposer (XU-

V201) and High-

pressure

Decomposer

Reboiler (XU-E201)

Bottom internals of XU-V201 will be changed by

installation of chimney tray to change urea solution

circulation mode from thermosiphon reboiler to single

pass.

To optimizer energy consumption, High-pressure

Decomposer Reboiler (XU-E201) wil be replaced with

new item (XU-E201A/B).

6. Cooler for HP

Absorber (XU-E501)

Due to increased efficiency of synthesis section and

New Vacuum pre-concentrator (XU-E551A), the duty of

XU-E501 will be lowered as compared to existing

conditions. Slurry circulation is replaced by cooling

water. The upper part of XU-E501 will be modified to

have only one tube pass instead of 2 no. to optimize

heat exchanger pressure drop.

7. Crystallation Section Existing Cystallization technology will be replaced by

modern evaporation section to improve steam

balance and achieve required energy saving target.

Crystallization section will be idled. Crystallizer (XU-






V301) will be maintained as additional tank to store

either urea solution or process condensate.

NEW INSTALLATIONS

1. New Reactor (XU-

R101N)

New Reactor will be installed in nearby area of existing

reactor (XU-R102) will be provided with full set of Casale

High Efficiency trays to achieve optimal conversion.

2. New HP Synthesis

Section

Components: HP Stripper (XU-E151), HP Carbamate

Condensers (XU-E152 & XU-E153), HP Ejector (XU-J151),

HP Carbamate Separator (XU-V151) will be installed.

It wil reduce load on downstream sections i.e.

Decomposition Section.

3. Steam Consensate

Separator (XU-V251)

Small steam consendate separator (XU-V251) will be

installed to collect steam condensate from the lower

part of HPD reboiler XU-E2101A and send it to 2nd HP

Carbamate condenser.

4. Evaporation and

Prilling Section

New Evaporation section will be installed with following

equipments:

• Vacuum Pre-Concentrator XU-E551A

• 1st Stage Evaporator XU-E551B

• 1st Stage Separator XU-V551

• 2nd Stage Evaporator XUE552

• 2nd Stage Separator XU-V552

• Vacuum Evaporation package (XU-X551),

which includes indirect CW condensers and

steam ejectors

5. New Wastewater

Treatment Section

Components:

• Hydrolyzer XU-R851

• Desorber XU-V851

• Hydrolyzer Preheater XU-E851

• WWT Feed Preheater XU-E852

• Treated Water Final Cooler XU-E853

• Hydrolyzer Feed Pump XU-P851 A/B

• Treated Condensate pump XU-P853 A/B

It will be installed to recover NH3, CO2 and urea

contained in process water and to produce clean

process condensate which can be used as Cooling

Tower Makeup.






6. New Blowdown and

Close Drain Section

New Blowdown Vessel (XU-V852) will be installed to

collect new HP section and WWT section safety valve

discharge. Liquid collected in nlwo down vessel will be

sent to WWT section for treatment.

New Close Drain Tank will be installed (XU-V855) to

recover all process drains from new HP loop as well as

existing items.

2.8. Resource Requirements

2.8.1. Infrastructure

The site is located at P.O. Fertilizernagar, Tal. and District- Vadodara, Gujarat-391750.

GSFC Complex is well connected to National Highway-8 (East direction of Project Site).

Internal road and other infrastructure have already been developed within the site.

Various facilities like R&D Laboratory, Canteen, Administration Block. Drinking water

facilities, Water Treatment facilities etc. have already been provided within the plant.

A well-developed residential township (GSFC TOWNSHIP) located adjacent to the

complex; NW has been constructed to provide residential accommodation to the staff.

In addition to residential accommodation, other amenities like School, Guest House,

Swimming Pool, Gymnasium, Open Air Theatre, Officers Club, Ladies Club etc.

Fertilizernagar township is equipped with shopping centre to fulfil basic needs of residents

of the township & surrounding areas. The township has various (category-wise) quarters

with adequate facilities like water, light, housekeeping & security arrangements.

2.8.2. Power & Fuel requirement

Construction Phase: Existing power supply within GSFC Complex i.e.,

Windmill/Cogeneration Plant/MGVCL shall be used for construction purposes.

Operation Phase: The power requirement for GSFC Complex sourced from WindMill

/Cogeneration Plant/MGVCL/GPCL.GSFC has installed 152.8 MW Wind Farm in Kucchh

& Saurashtra region, the same is utilized in Baroda & Sikka Unit. Solar Power Plant of 10

MW is recently executed at Charanka, Patan. The operation of Co-Generation Plants at

GSFC is dependent on the steam & power demand (requirement) of the complex, NG

availability and GIPCL power share.

The existing connected load for GSFC Complex is 157 MW. For existing Urea Plants,

specific power consumption is 205 kWh/MT Urea. After revamping, specific power

consumption will get reduced to 183 kWh/MT Urea. For power backup, 1 No. of DG set of





capacity 500 kVA will be installed in revamped urea plant that will be used during

emergency only.

2.8.3. Water

Construction Phase: Approx. 10 KLD water will be required during construction phase of

proposed revamping project. 4 KLD freshwater will be used in domestic purposes for

labours that will be supplied by existing source of GSFC Complex i.e., 4 no. of French wells

of Mahi River. Domestic sewage will be disposed in septic tanks with soak pits.

Operational Phase:

Existing Phase:

Industrial Water Requirement

Urea-I Plant: The total water requirement of the Urea-I plant is 2286.5 KLD (95.27 m3/hr)

that is being consumed for manufacturing process and cooling tower make-up. Raw-

water requirement of plant is 1996.08 KLD (83.17 m3/hr) being supplied from 4 no. of

French wells of Mahi River. 290.4 KLD (12.10 m3/hr) of steam condensate is re-directed

into the plant for raw water makeup of Cooling Tower. The total wastewater generation

from the project is 429.36 KLD (17.89 m3/hr). Out of which, 41.28 KLD (1.72 m3/hr) of process

effluent is being discharged to PA Chalk Pond/Urea Lagoon for recycle in Phosphoric

Acid Plant. Rest of wastewater i.e., 388.08 KLD (16.17 m3/hr) blowdown from Cooling

Tower is being diverted to effluent disposal pond for discharge to sea via VECL Common

Effluent Channel.

Urea-II Plant: The total water requirement of Urea-II plant is 3759.6 KLD (156.65 m3/hr). Raw-

water requirement is 3039.6 KLD (126.66 m3/hr). 720 KLD (30 m3/hr) is re-directed into the

plant for raw water makeup in cooling tower. The total wastewater generation of unit is

630.72 KLD (26.28 m3/hr) from which, 102.72 KLD (4.28 m3/hr) is being sent to Phosphoric

Acid Plant & 528 KLD (22 m3/hr) is being is being diverted to effluent disposal pond.

Domestic Water Requirement: Total freshwater requirement for domestic purposes is 6

KLD being supplied from existing freshwater source.

Total after Revamping:

Industrial Water Requirement: The total water requirement of revamped Urea plant will

be 3901.9 KLD (162.6 m3/hr). Out of which, freshwater requirement will be 2907.6 KLD

(121.15 m3/hr) supplied from existing freshwater source. 303.12 KLD (12.63 m3/hr) steam

condensate will be directed into the plant for raw water makeup in cooling tower. The

total wastewater generation will be 757.68 KLD (31.57 m3/hr). Process condensate

generated from plant i.e., mainly vacuum evaporator section will be treated in

Wastewater Section and treated water i.e., 691 KLD (28.8 m3/hr) will get directly reused in





cooling tower makeup. 144 KLD (6 m3/hr) will be sent to Phosphoric Acid Plant for recycle.

Rest of wastewater i.e., 613.68 KLD (25.57 m3/hr) CT blowdown will be directed to effluent

disposal pond as per existing practices.

Domestic Water Requirement: Freshwater requirement will be reduced to 3 KLD due to

decrease in manpower. Sewage will be disposed into soak pits as per existing practices.

Details of total water requirement and wastewater generation are shown below in Table

2.17.





Table 2.17 : Details of Total Water Requirement (Existing & After Revamping)

Particulars

Existing Proposed

Total after

Revamping UREA-1 UREA-II Total

m3/hr KLD m3/hr KLD m3/hr KLD m3/hr KLD m3/hr KLD

Total Water Consumption

(A)=(B+D+E) 95.27 2286.5 156.65 3759.6 251.92 6046.1 -89.34 -2144 162.6 3901.9

Freshwater Requirement

(B) 83.17 1996.1 126.65 3039.6 209.82 5035.7 -88.67 -2128 121.15 2907.6

Wastewater Generation

(CT Blowdown diverted to

eff. disposal pond) (C)

16.17 388.08 22 528 38.17 916.08 -12.6 -302.4 25.57 613.68

Treated Water Recycle -

WWT Section (D) 0 0 0 0 0 0 28.8 691.2 28.8 691.2

Steam Condensate Export

Credit- Recycle as water

(E)

12.1 290.4 30 720 42.1 1010.4 -29.47 -707.3 12.63 303.12

Process effluent going to

PA Plant (F) 1.72 41.28 4.28 102.72 6 144 0 0 6 144

MP Steam export (G) 0 0 0 0 0 0

15.85 380.4

15.85 380.4

Water Balances for existing urea plants and revamped Urea plants have been depicted in Figure 2.9 to 2.11:





Figure 2.10 : Existing Water Balance (Urea-I Plant)





Figure 2.11 : Existing Water Balance (Urea-II Plant)





Figure 2.12 : Water Balance (Total after Revamping)





2.8.4. Employment

Construction Phase: Local labours will be hired by contractors for the construction works.

Existing facilities like washroom and drinking water facilities shall be used by labours.

Operational Phase: There will be reduction in manpower due to running of only one urea

plant at a time. Existing manpower of the plant will be utilized. Approx. 64 nos. of people

will be allocated for operation and maintenance of the plant.

2.8.5. Parking Area

Separate Truck Loading Parking facility has been appropriately provided in the plant for

easy movement of vehicles. Existing facilities in parking areas will be used for proposed

development in project. The traffic movement will be well defined and will have

sufficient turning radius for trucks.

2.9. Environmental Aspects

The environmental aspects of the fertilizer plant are described with the following

environmental attributes

• Water Pollution

• Air Pollution

• Noise Pollution

• Solid Hazardous Waste Generation

2.9.1. Water Pollution

Construction Phase: Approx. 3 KLD domestic sewage will be disposed in septic tanks with

soak pits.

Operational Phase

Existing Phase

Industrial Effluent: The total wastewater generation from Urea-I & Urea-II plants is 1060.08

KLD (44.17 m3/hr). Out of total, 144 KLD (6 m3/hr) is being sent to Phosphoric Acid Chalk

Pond/Urea lagoon that is sent to PA Plant for reuse. Rest of wastewater i.e., 916.08 KLD

(38.17 m3/hr) to sea via VECL Common Effluent Channel. There is no treatment scheme

for wastewater generated from the units as most of the wastewater is being disposed to

the effluent disposal pond.

Domestic Sewage: 5 KLD domestic sewage is being disposed off to soak pits located

within the plants.

Total after Revamping

Industrial Effluent: The total wastewater generation will be 757.68 KLD (31.57 m3/hr).

Process condensate generated from plant i.e., mainly vacuum evaporator section will

be treated in Wastewater Section and treated water i.e., 691 KLD (28.8 m3/hr) will get





directly reused in cooling tower makeup. 144 KLD (6 m3/hr) will be sent to Phosphoric

Acid Plant for recycle. Rest of wastewater i.e., 613.68 KLD (25.57 m3/hr) CT blowdown will

be directed to effluent disposal pond as per existing practices.

Domestic Effluent: 3 KLD domestic sewage will be disposed as per existing practices.

2.9.1.1 Process Description of Wastewater Treatment Section

Under proposed revamping, new Wastewater Treatment Section will be installed for

treatment of process generated from vacuum system under which treated process

condensate will be used as raw water makeup in cooling tower. It will be installed to

recover NH3, CO2 and Urea contained in the process water and, at the same time, to

produce clean process condensate, which can be used as Cooling Tower Makeup.

Following equipment and machinery will be installed in new section.








The process condensate from the new Buffer Tank XU-V556 is fed, via the new pumps

XU-P556A/B to the new Desorber XU-C851. The upper part of the new column XU-V851

removes most part of NH3 and CO2. The water from chimney tray ofthe Desorber XU-

V851 will feed the Hydrolyzer XU-R851, after being pumped by newHydrolyzer Feed

pump and preheated in the Hydrolyzer Pre-Heater Exchanger from thewater coming

out from the Hydrolyzer itself. The Hydrolyzer will reduce the urea content inthe treated

water down to 5 ppm. The hydrolyzed water, after having been cooled downby XU-

R851 inlet stream, will come back to Desorber XU-V851, where the NH3 content will be

reduced at around 5 ppm by means of 3.8 kg/cm2g steam. The vapours from both

Desorber column XU-V851 and Hydrolyzer XU-R851 arecondensed in the existing LP

Section jointly with the vapours from the LP Decomposer. This willallow maximizing the

energy saving in the new NH3 preheater XU-E252. The reflux to Desorber XU-V851 is

provided by HP Absorber Pump XU-P504 A/B.

The treated process condensate leaving the Desorber will warm up the feed into the XU-

E852and being sent to the battery limits through the new pumps XU-P853 A/B. A

minorportion of the treated water will be used as make-up for the scrubbers of the prilling

tower. Final Cooler XU-E853 will lower the temperature of the treated water down to

45°C. The treated water will be used as make up water to Cooling Towers or else it will

be exported to GSFC grid as condensate make up.





New Blow down Vessel (XU-V852) will be installed to collected new HP Section and WWT

Section Safety Valve discharge. Liquid collected in blow down vessel will be then sent

to WWT section for treatment. New Close Drain Tank will be installed (XU-V855), to

recover all process drains from new HP loop as well as existing items. Process Flow

Diagram of Wastewater Treatment Section has been provided below in Figure 2.12





Figure 2.13 : Process Flow Diagram of Wastewater Treatment Section





2.9.1.2 Rainwater Harvesting System

There is rainwater harvesting system present at the following locations:

• Guest House

• Science Foundation Building

• Township Residential Areas

The system is well equipped with water recharging, roof top rainwater harvesting and

rainwater harvesting ponds. GSFC has constructed 16 no. of rainwater harvesting

structures (Recharge well and Furrat System) across the complex. The filtration rate is in

the rate of 65-70 m3/hr each well. Four ponds have also been dug out to store the

rainwater runoff and percolate the same.

2.9.2. Air Pollution

Construction Phase: The main sources of air emissions will be construction machinery like

drills, cranes etc. and vehicular movement. To control air emissions during construction,

following measures will be implemented: -

• Barricading will be done around the construction site to control dust dispersion

into the surroundings.

• Construction material vehicles will be covered during transportation.

• Dust suppression will be done by regular water sprinkling in and around the

project site.

Operation Phase: The main sources of air emissions from Urea Plants are the following:

• Dust from prilling tower and product handling.

• Ammonia fumes from prilling tower and scrubbers.

• Fugitive emissions due to leaks, improper handling etc.

• Combustion emissions from static sources like DG sets.

As per the guidelines, the emissions from the existing plant stacks are well within the

statutory limits prescribed by Gujarat Pollution Control Board. However, since there is no

increment in total production capacity after revamping, there will be no increase in air

emissions. Existing stacks will be used after proposed revamping.

Infact, due to proposed revamping, there will be reduction in dust emission by

elimination of crystallizer, centrifuge, dryer and other handling equipments with

installation of new vacuum evaporation section. Hence, it will also lead to decrease in

fugitive emissions too.

The plant is maintaining control in air emissions by following various mitigation measures.

The same will be followed after revamping also.





AIR EMISSION MITIGATION MEASURES

• Adequate air pollution control system has been installed to achieve prescribed

norms.

• Approx. 123.2 Ha. of Green Area i.e.,37.56 of total plot area has been provided

in the plant.

• Online Stack Monitoring System has been installed in the plant for online air

parameters measurement and is connected to CPCB/GPCB.

• Urea Plants are operational having forced draft prilling tower. Both these plants

have scrubbers to achieve existing norms of urea dust emission. The emissions are

within the norms specified by GPCB. Moreover, Vibropriller has been installed in

prilling tower for reduction of dust emissions.

• GSFC carries out regular ambient air quality monitoring at the periphery and

nearby villages about SO2, NOX, PM10, PM2.5 and Ammonia as well as SO3,

Flouride and Acid Mist parameters. Monthly average results are online submitted

to GPCB. Moreover, 4 no. of online AAQMS are in operation at the periphery of

premises and connected to GPCB and CPCB server.

• Stack monitoring facilities like portholes, ladder/platform etc. have been

provided to all stacks/vents and chimney.

FUGITIVE EMISSION MITIGATION MEASURES

• Off-gases streams from various emission points of the plant are scrubbed in the

washing tower and then emitted to the atmosphere.

• All vessels used in the manufacturing process are closed to reduce fugitive

emissions.

• Adequate ventilation system has been provided in work areas.

• Fugitive emissions from process vessels are treated in Off Gas Treatment Unit and

discharge emission is being monitored. Offgas Treatment Unit is operated

efficiently and effectively.

• Workplace monitoring is being carried out at 52 different locations in different

plants.

• For existing plants, emissions in the workplace are confirmed to limits imposed by

Directorate of Industrial Safety and Health (DISH) i.e., NH3& NOX<25 ppm, SO2<2

ppm, HF<3 ppm, Benzene<0.5 ppm.

• 4 no. of Online Ambient Air Quality Monitoring Station (AAQMS) have been

installed. Ambient Air parameters are being monitored through NABL approved

laboratory (M.s Ecosystem Resource Management, Surat (NABL) and are well

within standards.

• Internal roads are paved properly to reduce fugitive emissions.

• LDAR System with various gas detectors for Ammonia, Hydrocarbon and Chlorine,

Sulphur Dioxide have been installed in the plants. In case of leakage, same

actuates and alarm appears in the control room. Such leakages are isolated and

repaired.





Prilling Tower: Water scrubbing system for Prilling Tower air: For minimization of dust

emission from Prilling Tower, Dust chamber filled with DM water is provided along the

periphery of Prilling Tower. The dust coming out from Prilling Tower top along with air

changes its direction due to baffle plate arrangement in dust chamber. Dust particles

impact with baffle plate and fall into dust chamber and get dissolved in water and dust

free air flows out into the atmosphere. Cyclone outlet air containing fine dust particles

are scrubbed with water from dust chamber. Part of water is diverted to dust chamber

and excess water is conveyed to dissolving tank from where it is reused in the process.

Emission Control Scheme: The emission control scheme is designed to scrubs ammonia

from vent gases of Urea Plant with Sulphuric Acid (SA). SA scrubbing system is selected

because SA is having strong affinity with Ammonia. Hence, it requires smaller scrubbing

tower and also available facility of processing ammonium sulphate solution. Vent gases

from both plants are connected to common line and knock out drum is provided on the

line to separate out line condensate. The condensate collected at bottom is transferred

to vapour liquid separator. Gases leaving knock out drum enter off gas condensate shall

side and are cooled by cooling water passing in the tubes. Gases are practically

condensed. Off-gas condenser is provided to size down the scrubber tower by reducing

vapour on it. The cooled off gases enter the vapour liquid separator where water

condensate containing 3-4% ammonia is separated out. Gases from the vapour liquid

separator are passed through a blower and fed to the bottom of the scrubber packing

section. From the tower bottom solution 90% of the solution is recirculated to packing

top with circulation pump. Mixing tee is provided for sulphuric acid addition. 10% of the

tower bottom solution is transferred to AS are cooled by cooling water passing in the

tubes. Gases are partially condensed. Off-gas condenser is provided to size down the

scrubber tower by reducing vapour on it. The cooled of gases enter the vapour liquid

separator where water condensate containing 3 to 4% ammonia is separated out.

Gases from the vapour liquid separator is passed through a blower and fed to the

bottom of the scrubber – packing section. From the tower bottom solution 90% of the

solution is transferred to AS plant. AS solution pH controlled by feeding SA at 5.5 in the

mixing tee. This ensures 3% free acid in the circulating AS solution. Ammonia from the

gases is scrubbed with the free acid in the packed section. On the top of the tower

water is fed on the buffle cap tray for final scrubbing of the gases.

Proposed Emission Control Scheme (Reamping)

Vent gases from gas condenser are passed through knockout drum to separate the

ammonical condensate. The condensate is transferred to existing vapour liquid

separator (XU-V601) by gravity with liquid seal to prevent back flow of gas. The vent

gases of pressure of 0.1 kg/cm2 and 100 °C temperature enter shell side of off gas

condenser (XU-E602) in which part of water vapour is condensed with cooling water in

tube side. The outlet gas temperature is maintained at 65-70 °C temperature to prevent

chocking due to urea entrainment from the process. The vent gases from off gas

condenser enter vapour liquid separator (XU-V601) where ammonical condensate





having 3-4% ammonia is separated from vent gases. This ammonical condensate is

further recycled in scrubber circulation. The vent gases from vapour liquid separator are

fed to scrubber (XU-T601). The scrubber solution from bottom of scrubber is neutralized

with 98% H2SO4 in acid mixing tee and then pumped to scrubber liquid circulation cooler.

Cooled solution of 40 °C is recycled in scrubber at the top of the packing. A part of

scrubber liquid is exported to AS Plant. Circulation liquor is maintained in acidic range

(3.5 – 4.5) to have best scrubbing of ammonia.

Details of process gas emissions and flue gas emissions from the project have been

provided below in Table 2.18 and Table 2.19.

Table 2.18 : Details of Existing Process Gas Stacks (Urea-I & II Plants)

Sl.

No Plant

Stack

attached

to

APC

Device

Diameter

(m)

Stack

height

(m)

Avg.

Emission

Rate

(Nm3/hr)

Velocity

(m/sec)

Tempe-

rature

(°C)

Parameters

1 Urea –

I

Prilling

Tower

Water

Scrubber

4 x 1 (3

nos.) 38

155000 4.12 61 SPM: - 2

Kg/T Urea

NH3: - 175

mg/Nm3

2 Urea –

II

Prilling

Tower

Water

Scrubber

1.45 x

4.36 (4

nos.)

70

520000 4.05 60 SPM: - 2

Kg/T Urea

NH3: - 175

mg/Nm3

3

Urea –

Mel

(Urea

ECS)

Condenser

oxidation

column

H2SO4

Scrubber

(Eff.

99.5%)

1.25 38

1200 - - NH3: - 175

mg/Nm3

Table 2.19 : Details of Proposed Flue Gas Stacks

Sl. No Plant Stack attached to Stack Height Parameter

1 Revamped

Urea

Emergency D.G. Set

(500kVA)

30 m As per GSR 771(E)

SPM: - ≤ 0.2 gm/kw-hr

NOX+HC: ≤ 4.0 gm/kw-

hr

2.9.3. Noise Pollution

Construction Phase: -The main sources of noise pollution will be construction machinery,

DG sets and vehicular movement during establishment of the plant.

Mitigation Measures: -

• Acoustic enclosures will be installed for DG sets in accordance with CPCB norms.

• Green Belt will be provided around the project boundary to curb excessive noise

emissions from the construction site.





• Construction machineries will be provided with acoustic pads for noise reduction

during operation.

• PPE will be provided to labours.

• The construction activity will be carried out mostly during daytime.

• Proper maintenance of noise generating transport vehicles.

Operation Phase:

Industry has taken adequate measures for control of noise levels from its own sources

within the premises to maintain ambient air quality standards in respect to noise to less

than 75 dB(A) during daytime and 70 dB(A) during nighttime. Daytime is reckoned in

between 6:00 am to 10:00 pm and nighttime is reckoned between 10:00 pm to 6:00 AM.

Noise measurement is being carried out periodically.

Mitigation Measures:

• Various engineering controls are taken at different plants like on exhaust, acoustic

enclosures, soundproof cabin, preventive maintenance etc.

• Earmuff etc. have been provided to workers exposed to high noise.

• Noise levels at periphery are monitored through NABL approved laboratory.

• Approx. 123.2 Ha. of Green Area i.e., 37.56% of total plot area has been provided.

2.9.4. Solid Hazardous Waste Generation

Construction Phase: Waste generated from the construction activity shall be disposed

as per be C&D waste Management Rules, 2016. Demolition waste and de-

commissioned machineries will be disposed in the nearby C&D waste disposal site.

Recyclable waste shall be sold to recyclers.

Operational Phase: Industrial hazardous wastes such as spent oil, discarded containers

etc. are being sent to TSDF site/registered recycler. Authorization under Hazardous

Waste Management Rules has been obtained from GPCB vide CCA Order No. AWH-

78404 valid till 31.12.2021 (Authorization under HWMH Rules has been annexed as

Enclosure-II). Wastes are dried, packed and stored in separate designated hazardous

waste storage facility before its disposal. GSFC strictly complies with the rules and

regulations with regards to handling and disposal of hazardous waste in accordance

with Hazardous & Other Waste (Management and Transboundary Movement)

Amendment Rules, 2021. Hazardous waste is disposed at approved TSDF sites of M/s

Nandesari Environment Control Limited (NECL). TSDF Membership of GSFC with

Nandesari Environment Control Ltd., Detox India Pvt. Ltd. and Saurashtra Enviro Projects

Pvt. Ltd. has been annexed as Enclosure-VIII. Type, source, mode of storage and

treatment and disposal of hazardous waste is shown in Table 2.20.

Table 2.20 : Management of Hazardous & Non-Hazardous Waste





Sr. No Name of

Waste

Hazardous

Waste

Category

Quantity Method of

Collection/

Storage

Method

of Disposal As per

Authorization

from GPCB

Total after

Revamping

1. Discarded

Containers

Sch-1/33.3 10000 Nos./year

(including 100

Nos/year for

Urea-I & II)

10000 Nos./year

(including 85

Nos/year for

Revamped

Urea)

Storage

Yard

Collection,

storage,

transportation,

and Sale

Vendor

2. Insulation

waste

Sch-1/33.1 75 MT/year

(including 3.0

MT/year for Urea-

I & II)

75 MT/year

(including 3.0

MT/year for

Revamped

Urea)

Stored in

bags at

specified

storage

area.

Disposal

at TSDF

3.

Contaminat

ed cotton

rages &

other

cleaning

materials

Sch-1/33.2

5 MT/year

(including 1.1

MT/year for Urea-

I & II)

5 MT/year

(including 1.1

MT/year for

Revamped

Urea)

Stored in

bags at

specified

storage

area.

Disposal at

CHWIF of M/s

NECL

/SEPPL/DIPL/BEIL

/co-processing

sites.

4. Used Oil

Sch-1/5.1 250 MT/year

(including 90

MT/year for Urea-

I & II)

250 MT/year

(including 90

MT/year

Revamped

Urea)

Drums/Ta

nks in

Room

Collection,

storage,

transportation,

and Sale

register refiner

All the Hazardous wastes are stored on impervious floor having roof, boundary wall.

Discarded containers are thoroughly cleaned / decontaminated before disposal.

SOLID WASTE MANAGEMENT

Construction Phase: Approx. 11 kg/day solid waste generated from labours will be sent

to approved vendors for treatment and disposal.

Operational Phase: Total Solid Waste Generation from the plants is 36 kg/day that is

being segregated into Biodegradable and Non-biodegradable waste which is being

further sent to respective authorized vendors/recyclers. There will be reduction in solid

waste generation to 20 kg/day. Similar practices will be maintained after revamping.

2.10. Green Belt development Plan

Approx. 123.2 ha. of green area i.e., 37.56% of total plot area has been developed. Out

of total, 32.8 ha of green area has been developed within the plant premises while 90.4

ha. green area has been developed in GSFC township part of GSFC complex plot. GSFC

has also made adequate plantation on roadsides and other open areas. The industry

has put serious efforts in terms of selection of tree species within the areas.





2.11. Project Cost and Schedule

Total cost for proposed project is Rs 306 Crores. The total timeline for the project is 30

months from basic engineering to plant operation set-up. Being a revamping project, all

the activities will be carried out without disturbing existing plant operations. Plant shut

down will be taken for hook-up activities. The anticipated month for completion of

project is June,2023.





Chapter 3. DESCRIPTION OF THE ENVIRONMENT

3.1. Introduction

This chapter illustrates the description of the existing environmental status of the study

area with reference to the prominent environmental attributes. As a precursor for the

prediction of various types of environmental impacts likely to arise due to

implementation of this project, it is essential to establish the base line environmental

status.

The existing environmental setting is considered to adjudge the baseline environmental

conditions, which are described with respect to physico-chemical, biological, and

socio-economic parameters in the project area and within the project influence area.

The objective of this section is to define the present environmental status which would

help in assessing the environmental impacts due to the proposed project.

3.2. Background and Salient Environmental Features of the Study Area

GSFC (Vadodara Unit) is located at P.O. Fertilizernagar, Dist.-Vadodara, Gujarat-391750.

The proposed revamping will be done within the existing premises only. The plant is

spread over an area of 328 Ha. The geographical co-ordinates from center of the

project area Latitude: 22° 22.283'N; Longitude : 73° 9.268'E. Study area map comprising

direct impact area which includes area covered under 10 km radius from the project

boundary is shown in Figure 3.1.

This Chapter describes the baseline environmental conditions around the project site

for various environmental attributes, i.e., physical, biologica, 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.





Figure 3.1 : Study Area Map





3.2.1. Study Period

To establish the base line environmental status of the physico-chemical, biological, and

socio-economic parameters in the project area and within the project influence area,

the baseline study and primary data collection has been carried out during 1st

December 2020 to 28th February 2021. Field monitoring for meteorological conditions,

ambient air quality, water quality, noise quality, soil quality etc. has been carried out,

which constitute major portions of the Baseline environmental studies. In addition to

these other major aspects like Geology, Hydrology, ground water and water

conservation, Land use, Socio-economic study, Ecology, and biodiversity etc. have also

been covered. All this information is based on primary and secondary information

sources and surveys and constitute the baseline environmental studies. The entire data

has been collected through actual physical surveys and observations, literature surveys,

interaction with locals, government agencies and departments.

3.2.2. Environmental Setting and Salient Environmental Features of the Project

Area


The proposed revamping will be done within the existing premises only. The plant is

spread over an area of 328 Ha. The site is approachable via NH-8 which is located

adjacent to the unit. It is situated 8.09 km away from Vadodara City in SE direction.

Nearest Railway Station to the project is Bajuwa Railway Station located at 0.99 km, SW

direction. Nearest Airport located to the project is Vadodara Airport located at 8.80 km,

SE.

Galiath River is the nearest river flowing at 4.58 km (NE) from the project site. Mahi River

is flowing at 9.35 km (W) from the site. There are several rivers located in 10 km area of

the project site. There are no environmentally sensitive components within study area.

Location map and topo map showing site and surrounding environment features within

the 10 km area is provided in Figure 3 2 & Figure 3.3, respectively The Environmental

Sensitivity of plant site within 500m, 2 km and 10 km radius are summarized at Table 3.1.

Table 3.1 Environmental Sensitivity of Proposed Site and Study Area

S

No

Environmental

Features

Within 500 m-2

km area around

Project Site

Within 2-5 km

area around

Project Site

Within 5-10 km

area around

Project Site

1. Ecological Environment

A Presence of Wildlife

Sanctuary National

Park Biosphere

Reserves

None None None

B Reserved

Protected Forests

None None None





S

No

Environmental

Features

Within 500 m-2

km area around

Project Site

Within 2-5 km

area around

Project Site

Within 5-10 km

area around

Project Site

C Wetland of state

and national interest

None None None

D Mangroves None None None

E Critically Polluted

Area

Vadodara (CEPI Score: 89.09) as per NGT order. However,

there is a stay on the said NGT order by Supreme Court.

2 Physical Environment

F Road Connectivity National

Highway-8

(0.64 km, E)

Bajwa Channi

Road (0.72 km, S)

Ahmedabad-

Vadodara

Expressway

(2.76km, NE)

State Highway-

158 (4.08 km, SE)

State Highway-11

(8.88 km, SE)

G Rail Connectivity Bajuwa Railway

Station

(0.99 km, SW)

Chhayapuri

Railway Station

(1.33 km, SE)

Ranoli Railway

Station (5.21 km,

NW)

Vadodara Railway

Station

7.69 km, S)

H Defence Installation None None None

I Densely Populated

Area

Dashrath

(0.89 km, NE)

GSFC Township

(1.28 km, NW

Adjacent to the

complex)

None Vadodara

(8.09 km, SE)

J Other village close

to Plant Site

Bajwa, Karachiya

K Topography 35-60amsl 34-60amsl 25-60amsl

L Seismicity Seismic Zone-III (Moderate Risk Zone)

M Surface Water

Resources

Rivers

1. None Galiath

River,4.58 km

(NE)

Vishwamitri

River,5.71 km (E)

Meni River,7.00 km

(W)

Parevi River,7.08 km

(N)

Surya River,8.04 km

(E)

Mahi River,9.35 km

(W)

3 Social Environment

N Physical Setting Industrial Industrial and

Residential

Residential

O Physical Sensitive

Receptors

Schools Schools Hospitals





S

No

Environmental

Features

Within 500 m-2

km area around

Project Site

Within 2-5 km

area around

Project Site

Within 5-10 km

area around

Project Site

• Fertilizernagar

School (1.43

kM, NW-

Adjacent)

• Yagnik

Vidyalaya

(1.64 km, SE)

Temples

• Shri

Vishwakarma

Mandir

Channi (1.52

km, SE)

• Ram Mandir

(1.78 km, SE)

• Global

Public

School (3.45

km, SE)

• Podar World

School (4.02

km, SE)

Hospitals

Satyam Hospital

(2.36 km, SE)

Temples

Tapovan Mandir

(2.82 km, SW)

• Om Multi-

specialty

Hospital (5.55

km, SW)

• Shukan Multi-

specialty

Hospital

(7.67 km, SE)

Temples

• Shri

Swaminaryan

Mandir (7.82

km, SE)

• Shri Kamnath

Mahadev-

Navnath (7.35

km, SE)

P Archaeological

Monuments

None None None

(Source: EQMS)





Figure 3.2 : Topo Map showing Site & Surrounding Environmental Features within 10 km Area





3.3. Components of Methodology of Baseline Survey

3.3.1. Components of Baseline Survey

The guiding factors for the present baseline study are Ministry of Environment, Forests &

Climate Change’s (MoEF&CC) requirements for the Environmental Impact Assessment

(EIA) notification and local regulations and directives. The methodology to conduct

baseline environmental survey has been considered as per the guidelines given in the

Environmental Impact Assessment Guidance Manual. Further, a buffer area extending

up to 10 km radius from the site has been studied. The studies were conducted by

consideration of the following:

The various environmental attributes were divided into primary and secondary studies.

Primary attributes such as air environment, water, soil, noise, flora and fauna, and Socio-

economic were assessed by conducting field studies, on-site monitoring and review of

the past studies conducted.

Baseline data on environmental attributes (Air, Noise, Water and Soil) have been

collected for One season i.e Winter Season (December,2020 to February,2021) in the

study area. The data has been collected by the EIA Consultant by engaging NABL/MoEF

accredited laboratory Noida Testing Laboratories (ISO: 9001:2015 & ISO 45001:2018

Certified Laboratory). Secondary attributes such as land use studies, geology,

physiological characteristics, and socio-economic environment have been assessed by

literature review of previous studies conducted by various government publications.

3.3.2. The Methodology Adopted for the EIA Study

An interdisciplinary team through discussions, criteria questions and professional

judgement formulated the scoping and the extent of data generation. The baseline

studies started with site visits and reconnaissance survey in the study area for fixing the

monitoring locations for the primary data. As a secondary data review, various

government agencies were approached for procuring information and relevant data

of the area.

3.3.2.1 Physical Environment Study

The study related to physical environment shall be conducted through both site visits

and review of the secondary sources like the DPR and other published peer information

in respect of the topographical and physiographical features, regional and the local

geology of the project area, climatology, and seismicity. Soil characteristics shall be

establishing through physio-chemical tests of the soil samples revalidated though the

published literature while land use and land cover, slope of the study area shall be

establishing through remote sensing by using GIS tools.

The field observations and the results of the baseline study have been used-

• To assess the positive and negative impacts due to the proposed project.





• To suggest appropriate mitigation measures for negating the adverse

environmental impacts, if any; and

• To suggest post-project monitoring requirements and suitable mechanism for it.

3.3.2.2 Primary Data Collection: Monitoring Plan and Quality Assurance Procedures

Standard TOR for Fertilizer Project as well as 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 analyses, data coding, statistical analyses, presentation, and

communication of results. The baseline environmental data generation has been

collected for the study period. The Summary of monitoring plan with parameter and

frequency is summarized in Table 3.2

Table 3.2 Summary of Methodology for Primary Secondary Baseline Data Collection

Parameters

No f

sampling

locations

Frequency

season Remark

Ambient Air Quality

PM 10 , PM 2 5 , SO2

, NOx

CO, NH3, HC

(Methane/ Non-

methane)

9

locations

Twice a

Week

For post

monsoon

season

AAQ monitoring was carried out at 8

locations representing upwind,

downwind, and sensitive locations 24

hours sampling at each location was

carried out as per CPCB guidelines

CPCB Gazette notification dated

18 11 2009 on AAQ

Meteorology

Temperature,

Humidity, Wind

speed, Direction,

Rainfall etc

One

location

Hourly for

Post

Monsoon

Met station already established at GFSC

site to record the site specific hourly

met. data

Ground Water Quality

Physical,

chemical, and

biological

parameters as

per IS 10500

8

locations

in study

area

Once in a

season

Ground water Sampling was

conducted at 8 locations Samples

were preserved, transported, and

analyzed for different parameters

based on APHA methods Temp,

conductivity, and pH which were

measured instantly at site itself

Surface Water Quality

Physical,

chemical, and

biological

parameters as

per IS 10500

7

locations

in study

area

Once in a

season

Surface Water Sampling was

conducted at Three locations Samples

were preserved and transported for

analysis for different parameters based

on APHA methods Temp, conductivity,

DO and pH which were measured

instantly at site itself





Parameters

No f

sampling

locations

Frequency

season Remark

Soil

Texture, bulk

density, pH,

conductivity,

cation exchange

capacity,

organic matter,

Total N, P, K, and

Heavy metals etc

7

locations

in study

area

Once in a

season

Soil samples were collected at eight

locations within the study area and

analyzed as per IARI method

Noise

Noise profiling for

24 hrs

7

locations

in study

area

Once in

season

Noise monitoring was conducted within

the 10 km area of project site for noise

profiling for 24 hrs using integrated

sound level meter, as per CPCB

guidelines

Ecology Flora & Fauna

Flora & Fauna Once Primary survey and Secondary sources

Demography & Socioeconomics

Demography &

Socioeconomic Once Primary survey Secondary sources

3.4. Topography and Physiography

Vadodara is situated in the banks of river Vishwamitri. The district is in central part of

mainland Gujarat. The district falls in Survey of India, degree sheet numbered 46B, 46F,

46J & 46G. It is bounded in north & northeast by Anand, Panchmahals & Dahod districts,

in east & in southeast by Madhya Pardesh & Maharashtra State, in southeast by

Narmada district & in south & in west by Bharuch district. Vadodara city, the district

headquarter is about 100 km south of Ahmedabad, is well connected to other parts of

the State & Country by network of highways and railway network.

The topography of Vadodara is divided into two distinct regions i.e., Western Regions

and Eastern Regions. The western region of the city possesses a number of educational

institutions, residential complexes etc. The eastern region contains some of the

landmarks like Nyay Mandir, Mandvi & Laxmi Vilas Palace.





Figure 3.3 : Topographic Map of Vadodara District

PHYSIOGRAPHY

Vadodara district forms a part of the great Gujarat plain. The eastern portion of the

district comprising the Chhota Udepur, the Kavant, the Jambughoda and the Naswadi

taluka is hilly terrain with several ridges, plateaus and isolated relict hills have elevation

in range of 150 to 481 m amsl. The southeastern plateau has the highest peaks of the

district – Amba Dungar & Mandai Dongar 637 m amsl. The rest of the district, the western

& southern part, comprising of Mahi & Narmada Doab, is a level plain with gentle

undulating terrain have elevation in range of 120 to 20 m amsl. The overall elevation

ranges from 610m in east to 20 m amsl in south-west. Most of the western part, comprising

of Mahi – Narmada Doab and northern alluvial plain is more or less level terrain, have

elevation in range from 20 to 80 m amsl. There are some linear tracts, along Mahi,

Viswamitre, Dhadahar and Orsang rivers, have ravine landforms, with typical head ward

erosional featured gully formation in soft alluvium. The banks of the Mahi have high

vertical cliff, 10 to 25 m height, generally on left bank; same way left bank of the

Narmada also has high cliff of 10 to 20 m high on right bank. All such features of Mahi-

Narmada Doab, like ravine features, high cliff along banks and entrenched meandering

courses with dry and wide sandy riverbed of intermediate independent river systems of

the Dhadhar & its tributaries indicate mature river stage and tectonic uplift of Doab

portion in Recent geological past. The central part of the district is low level undulating

plain with low level plateau and few relict hills. The area between the Unch and the

Orsang river have aeolian low level stabilized dune with rolling topography. The hilly

terrains of north - eastern part have residual hill features with more or less flat-topped





plateau. Except few volcanic peaks – Phenai Mata Hills and Amba Dungar, all have

plateau or ridge type features and are few tens of meter height than surrounding rocky

dissected plain. The highest plateaus are in southeastern part of the district, marked with

rift valley of the Narmada River towards south.1

Table 3.3 Physiography & Topography of Vadodara District

S.No. Parts of District Physiography Topography

1 Eastern (Chhota Udepur,

the Kavant, the

Jambughoda and the

Naswadi taluka)

Hilly Terrain with several

ridges, plateaus, and

isolated relict hills

150 to 481 m amsl

2 Western and Southern

(Mahi & Narmada Doab)

Levelled Plain 20 to 120 m amsl

3 Western Part (Mahi –

Narmada Doab)

Level terrain 20 to 80 m amsl

4 Central Part low level undulating plain

with low level plateau and

few relict hills

-

(Source: District Groundwater Brochure- Vadodara)

The project site lies in Mahi and Narmada Doab. Topography around 10 km area of the

proposed site is plain The average elevation in 10 km study area ranges between 25 to

60 metres above mean sea level The topography of proposed site is almost plain The

site elevation ranges between 35 to 60 amsl Digital Elevation Map of the 10 km area

around site is shown in Figure 3.5. The contours in Toposheet have been digitized in the

GIS environment and assigned the respective elevation values in meters with reference

to the mean sea level Using the SRTM Shuttle Radar Topography Mission data, the

elevation values has been verified.

1 District Groundwater Brochure-Vadodara (CGWB)





Figure 3.4 : Physiographic Map of Vadodara District





Figure 3.5 : Digital Elevation Map of Study Area





3.5. Geology & Hydrogeology

3.5.1. Geology


Area Ranges Stratigraphic Outline

Continental sediments – fluvio-marine, fluvial

and aeolian

Quaternary

Marine and fluvio-marine sediments Tertiary

Unconformity

Basalts of the Deccan Trap with associated

differentiates and intrusive bodies

Upper Cretaceous to

lower Eocene

Unconformity

Marine, fluvio-marine and fluvial sediments Cretaceous

Unconformity

Crystalline rocks -Metasediments associated

with granite, gneiss and other mafic rocks

Precambrian (Aravalli)

3.5.1.1 Geomorphology

In major part of the district, in north and almost in eastern half of the district, the hard

rocks, such as phyllite, schist, granite, gneiss, basalt and other sediments such as

sandstone, limestone etc., form aquifers, whereas multilayered alluvium deposits form

aquifer system in remaining central, south-central, and western half of the district. The

weathered basalts, granite, gneiss etc., covered by soil / muram and the valley fill &

piedmont deposits forms potential aquifer in the vicinity of rivers and on vast undulating

plains adjacent to hilly terrain, but their regional continuity and extent are limited due to

heterogeneous nature of deposits with limited thickness and as such rarely exceed a

few square kilometers.

3.5.1.2 Seismicity of 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 II Moderate Risk Zone The seismic zone map of study area is given in

Figure 3.6 & 3.7.





Figure 3.6 : Seismic Zones Map

Figure 3.7 : Seismic Zones Map of Gujarat

PROJECT SITE

Project Site





3.5.2. Hydrogeology

In Vadodara, groundwater occurs both as unconfined and confined conditions. The

depth to water is greater in upland areas whereas in valley portion and shallow grounds,

the levels are close to surface. In hilly terrain of eastern, northeast and south-east part

of the district, spring zones are seen in stream river section; also, along the section of the

Mahi, the Narmada and the Orsang rivers. GSFC Vadodara is located the Alluvium

section of Vadodara district.

Figure 3.8 : Hydrogeological Map of Vadodara District

3.5.2.1 Depth of Water Level

Groundwater in the area is around ~25 m depth below ground level. Vadodara block

falls under Semi-Critical zone as per Groundwater Resource-2011 but Vadodara District

Groundwater Brochure published by CGWA shows it falls in Over-Exploited zone.

3.5.2.2 Groundwater Development

The level of ground water development at year 2007 in all the talukas of the Vadodara

district computed range from 15.94 % to 87.43 %. The average for district is 64.58 %. The

units of assessment (talukas) have been categorized for ground water development in

different categories such as Safe, Semi-critical, Critical and Over Exploited, based on

the stages of ground water development and the long-term trend of pre and post

monsoon ground water levels. GSFC Vadodara lies in Taluka- Vadodara of Vadodara

district. Levels of groundwater development and categorization for the project site have

been provided in Table 3.5 below:






Taluka Available

Ground Water

Recharge in

MCM / Year

Existing Gross

Ground Water Draft

for all uses in MCM

/ Year

Level of Ground

Water Development

( % )

Category

Vadodara 163.22 140.65 86.17 Semi-

critical

However, the district is categorized as “Safe” taking into consideration of water level

rising trend.

3.6. Drainage

The Narmada and the Mahi are the main rivers of the district, flow along the

northwestern and southern boundary respectively while independent small river system

of the Dhadhar with its numerous tributaries flow in south central part of the district.

Broadly, the entire district forms a part of three River basins, namely the Narmada, the

Mahi Basin and the Dhadhar. The Mesari, the Goma and the Karad are the small rivers

flowing northwest part of the district, are tributaries of Mahi River, and are part of the

Mahi Basin. The Jambuva, the Surya, the Viswamitre and the Dhadhar, which flow

through central part of the district and empty into the Gulf of Khambat, are part of the

Dhadhar Basin. The eastern and the southern part of the district, drained by the

Narmada River and its tributaries, like the Unch, the Heran, the Dev, the Orsang, the

Karjan, the Aswan and the Bhukhi, constitutes the Narmada basin.

Figure 3.9 : Drainage Map of Vadodara District





In study area (10 km) of industry, following rivers are flowing:

• Galiath River,4.58 km (NE)

• Vishwamitri River,5.71 km(E)

• Meni River,7.00 km(W)

• Parevi River,7.08 km(N)

• Surya River,8.04 km(E)

• Mahi River,9.35 km(W)

However, distributaries of rivers located nearby project site are dry riverbeds. Drainage

map of study area is given below in Figure 3.10.





Figure 3.10 : Drainage Map of Project Site





3.7. Land use- Land Cover Classification

3.7.1. Introduction

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

imagery.

3.7.2. Land Use Based on Satellite Imagery

Satellite imagery contains detail records of features on the ground at the time of satellite

overpass. An image interpreter systematically examines the images for generating the

information required by him. Other supporting materials such as published maps and

reports from various sources will increase the accuracy of the interpretation. The chain

of process in visual interpretation of the shape and pattern in an image begins with

detection. There are certain fundamental characteristics seen on images which aid in

the visual interpretation of satellite imagery. These are tone / colour, size, shape, texture,

pattern, location, association, resolution, and season. Visual interpretation is subjective

and differs from person to person and upon the season, scale, spectral bands, spatial

resolution, overall image contrast and quality of the data.

3.7.3. Data Source & Analysis

Remote Sensing Technique is used to prepare the present Land use Landover Map. A

remotely sensed image is not considered a photograph. An image is a rendition, or

model, of target features described using spectral reflectance. These reflectance values

are stored in a quantitative, numerical fashion in a manner suitable for input to a

computer. Software and hardware specially designed to analyse these images give us

the ability to see a pictorial rendition of targets. The images that we see on a computer

screen are made up of picture elements called pixels. These images which are

“Discretized” are called as a digital image. Remote Sensing Data and few secondary

data set were used to study and map the present Land Use pattern of the area. These

are, Multi spectral and Multi temporal images are used as the input data. (FCC) Landsat-

TM (MSS) multispectral & PAN imagery has been used as input data. The spatial resolution

of the dataset is 30m & 15m. The bands used as input data for the current study have

these following features

Band 2: 0.52 - 0.59 μm (green): This band corresponds to the green reflectance of

healthy vegetation and is spanning the region between the blue and red chlorophyll

absorption bands.

Band 3: 0.62 - 0.68 μm (red): This red chlorophyll absorption band of healthy green

vegetation is one of the most important bands for vegetation discrimination. In addition,

it is useful for soil-boundary and geological boundary mapping. Band 3 may exhibit more

contrast than bands 1 and 2 because the effect of the atmosphere is reduced. The





0.69m cut-off represents the beginning of a spectral region from 0.68 to 0.75m where

vegetation reflectance crossovers occur that can reduce the accuracy of vegetation

studies.

Band 4: 0.77 - 0.86 μm (near infrared): For reasons discussed above, the lower cut-off for

this band was placed above 0.75 m. This band is especially responsive to the amount of

vegetation biomass present in a scene. It is useful for identification of vegetation types

and emphasizes soil-crop and land-water contrasts

3.7.4. Other Secondary data

The secondary database considered for validation and geo-referencing of the image is

as follows: US Army Sheet (1:250,000).

3.7.5. Digital Image Interpretation

Digital image processing is the use of computer algorithms to perform image processing

on digital images. As a subfield of digital signal processing, digital image processing has

many advantages over analog image processing; it allows a much wider range of

algorithms to be applied to the input data and can avoid problems such as the build-

up of noise and signal distortion during processing. In today's world of advanced

technology where most remote sensing data are recorded in digital format, virtually all

image interpretation and analysis involve some element of digital processing. Digital

image processing may involve numerous procedures including formatting and

correcting of the data, digital enhancement to facilitate better visual interpretation, or

even automated classification of targets and features entirely by computer. To process

remote sensing imagery digitally, the data must be recorded and available in a digital

form suitable for storage on a computer tape or disk. Obviously, the other requirement

for digital image processing is a computer system, sometimes referred to as an image

analysis system, with the appropriate hardware and software to software to process the

data. Several commercially available software systems have been developed

specifically for remote sensing image processing and analysis.

3.7.6. Methodology

Most of the common image processing functions available in image analysis systems

can be categorized into the following four categories:

1. Pre-processing

2. Image Enhancement

3. Image Transformation

4. Image Classification and Analysis

1. Pre-processing Functions involve those operations that are normally required prior to the main data

analysis and extraction of information and are generally grouped as radiometric or

geometric corrections. Radiometric corrections include correcting the data for sensor

irregularities and unwanted sensor or atmospheric noise and converting the data, so





they accurately represent the reflected or emitted radiation measured by the sensor.

Geometric corrections include correcting for geometric distortions due to sensor-Earth

geometry variations, and conversion of the data to real world coordinates (e.g. latitude

and longitude) on the Earth's surface.

2. Image Enhancement

The objective of the second group of image processing functions grouped under the

term of image enhancement is solely to improve the appearance of the imagery to

assist in visual interpretation and analysis. Examples of enhancement functions include

contrast stretching to increase the tonal distinction between various features in a scene,

and spatial filtering to enhance (or suppress) specific spatial patterns in an image.

3. Image transformations

Are operations similar in concept to those for image enhancement. However, unlike

image enhancement operations which are normally applied only to a single channel of

data at a time, image transformations usually involve combined processing of data from

multiple spectral bands. Arithmetic operations (i.e. Subtraction, addition, multiplication,

division) are performed to combine and transform the original bands into "new" images

which better display or highlight certain features in the scene. We will look at some of

these operations including various methods of spectral or band rationing, and a

procedure called principal components analysis which is used to represent the

information more efficiently in multichannel imagery.

4. Image classification and Analysis

Operations are used to digitally identify and classify pixels in the data. Classification is

usually performed on multichannel data sets (A) and this process assigns each pixel in

an image to a class or theme (B) based on statistical characteristics of the pixel

brightness values. There are a variety of approaches taken to perform digital

classification. We will briefly describe the two generic approaches which are used most

often, namely supervised, and unsupervised classification. The intent of the classification

process is to categorize all pixels in a digital image into one of several land covers

classes, or "themes". This categorized data may then be used to produce thematic maps

of the land cover present in an image. Normally, multispectral data are used to perform

the classification and, indeed, the spectral pattern present within the data for each pixel

is used as the numerical basis for categorization (Lillesand and Kiefer, 1994). The

objective of image classification is to identify and portray, as a unique gray level (or

color), the features occurring in an image in terms of the object or type of land cover

these features actually represent on the ground. Image classification is perhaps the most

important part of digital image analysis. It is very nice to have a "pretty picture" or an

image, showing a magnitude of colors illustrating various features of the underlying

terrain, but it is quite useless unless to know what the colors mean. (PCI, 1997). Two main

classification methods are Supervised Classification and Unsupervised Classification.





Supervised Classification: With supervised classification, we identify examples of the

Information classes (i.e., land cover type) of interest in the image. These are called

"training sites". The image processing software system is then used to develop a statistical

characterization of the reflectance for each information class. This stage is often called

"signature analysis "and may involve developing a characterization as simple as the

mean or the rage of reflectance on each band, or as complex as detailed analyses of

the mean, variances and covariance over all bands. Once a statistical characterization

has been achieved for each information class, the image is then classified by examining

the reflectance for each pixel and deciding about which of the signatures it resembles

most. (Eastman, 1995)

Unsupervised Classification: Unsupervised classification is a method which examines

many unknown pixels and divides into a number of classed based on natural groupings

present in the image values. Unlike supervised classification, unsupervised classification

does not require analyst specified training data. The basic premise is that values within

a given cover type should be close together in the measurement space (i.e. have similar

gray levels), whereas data in different classes should be comparatively well separated

(i.e. have very different gray levels) (PCI,1997; Lillesand and Kiefer, 1994; Eastman, 1995

)The classes that result from unsupervised classification are spectral classed which based

on natural groupings of the image values, the identity of the spectral class will not be

initially known, must compare classified data to some form of reference data (such as

larger scale imagery, maps, or site visits) to determine the identity and informational

values of the spectral classes. Thus, in the supervised approach, to define useful

information categories and then examine their spectral separability; in the unsupervised

approach the computer determines spectrally separable class, and then define their

information value. (PCI, 1997; Lillesand and Kiefer, 1994) Unsupervised classification is

becoming increasingly popular in agencies involved in long term GIS database

maintenance. The reason is that there are now systems that use clustering procedures

that are extremely fast and require little in operational parameters. Thus, it is becoming

possible to train GIS analysis with only a general familiarity with remote sensing to

undertake classifications that meet typical map accuracy standards. With suitable

ground truth accuracy assessment procedures, this tool can provide a remarkably rapid

means of producing quality land cover data on a continuing basis

3.7.7. Ground truth study

A detailed ground truth was carried out to check the discrepancy of the interpreted

data. Comprising of data collection of ground features along with the respective

geographical position in terms of latitudes and longitudes.

3.7.8. Land use at 10 km Study area

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 imagery.





Land use of project site is Industrial use. Most of the land within the 10 km area of the

project Site is agricultural land & settlement. As per the land use based on satellite

image, about 49% of the land is under Agricultural Land. 16 % of land is under vegetation,

23 % of the land is under settlement, 10 % land is under open scrub land, 2 % Water body

and rest of the land is under other uses. Refer Figure 3.11 and Table 3.6). Land use map

of the 10 km study area is shown in Figure 3.12.

Table 3.6 Land use of the Study Area

Class Area (Sq km) Area (Hectares) Percentage (%)

Agricultural land 191.06 19106 49

Water body 7.04 704 2

Settlement 89.17 8917 23

Open Scrub Land 37.45 3745 10

Vegetation 63.40 6340 16

Dry Riverbed 1.32 132 0.001

Total 389.44 38944 100

(Source: Satellite Data Analysis by EQMS)

(Source: Satellite Image Analysis by EQMS)

Figure 3.11 : Graph Showing Land Use of the Study Area (10 km Radius)





(Source: Interpretation of Satellite Image)

Figure 3.12 : Land Use Map of the Study Area 10 km Radial Zone





3.8. Soil Environment

Soil is the most important medium for supporting agricultural development. Its properties

influence fertility, water retention capacity, physical support capacity of plant roots,

determination of various other chemical constituent parameters. It is thus a vital

necessity to study the nutrient status of soil regime.

SOIL CHARACTERISTICS OF DISTRICT

The soils of Vadodara district can be broadly classified into three groups. They are black

soils, alluvial soils, and hilly soils.

Figure 3.13 : Soil Map of Vadodara District

As depicted in the map, the soil of the project site is Alluvial Soil. Alluvial soil has coarse

sandy to clayey beds of varied thickness. Sandy loam of sandy clay loam type soils are

fond in the northwestern part of the district. Alluvial soils are classified into two types such

as (i) Goradu or Gorat and (ii) Bhatta soils. The Goradu soils are nothing but alluvial soils

of older origin, while Bhatta soils are of recent origin deposited chiefly along the banks

of river. In some places even a third type soils locally known as Besar is also found. They





are silty loam to clay loam in texture. Soils of this group are deep, well-drained and

reddish brown in colour. These soils are more fertile.

3.8.2. Selection Criteria for Soil Sampling Location

For studying soil quality of the study area and with a view to ascertain the impacts due

to proposed activities on the nearby agriculture, vegetative, urban settlement land,

eight sampling locations, representing various land use conditions, were selected to

assess the existing soil conditions in and around the project area. The location of the soil

samples is presented in Table 3.7 and shown in Figure 3.14

Table 3.7 : Soil Sampling Locations

Location

Code

Sampling

Locations

Latitude /

Longitude

Aerial Distance

(KM)and Direction

from site

Location Remark

S-1 Project Site 22°22'17.54"N

73° 9'16.24"E

- Project Site

S-2 Fertilizer

Nagar

22°22'48.33"N

73° 8'43.16"E

0.69 km, NW Residential

S-3 Dhanora 22°22'47.60"N,

73° 6'8.93"E

3.51 km, WSW Agriculture Field

S-4 Ganpatpura 22°22'55.83"N,

73°11'46.92"E

3.91 km, ENE Agriculture Field

S-5 Pratapgunj 22°19'13.21"N,

73°10'51.92"E

5.36 km, S Agriculture Field

S-6 Khanpur 22°19'7.48"N,

73° 7'8.68"E

5.99 km, SSW Agriculture Field

S-7 Nandesari 22°25'0.04"N,

73° 5'14.33"E

7.06 km, NW Agriculture Field





Figure 3.14 : Location of Soil Sampling Stations





3.8.3. Methodology

3.8.3.1 Sampling Technique

Soils vary from place to place. In view of this, efforts should be made to take the samples

in such a way that it is fully representative of the field. Random five sub-locations were

identified at each location. Scrap away surface liter; obtain a uniformly thick slice of soil

from the surface to the plough depth from each place. A V-Shaped cut is made with a

spade to remove 1 to 2 cm slice of soil. The sample may be collected on the blade of

the spade and put in a clean bucket. In this way collect samples from all the spots

marked for one sampling unit. In case of hard soil, samples are taken with the help of

augur from the plough depth and collected in the bucket. Pour the soil from the bucket

on a piece of clean paper or cloth and mix thoroughly. Spread the soil evenly and divide

it into 4 quarters. Reject two opposite quarters and mix the rest of the soil again. Repeat

the process till left with about half kg of the soil, collect it and put in a clean cloth /

polyethylene bag. Each bag should be properly marked with the name of sampling

location & number to identify the sample.

3.8.3.2 Storage Technique

Collected Samples are immediately transported to the laboratory. They are shade dried

in wooden or enameled trays (except for the analysis of moisture content) and stored.

The dried soils are ground using mortar and pestle (taking care to break only the clods

but not the sand and gravel particles) and sieved through a 2mm mesh sieve.

3.8.3.3 Soil Quality Parameters and Method of Analysis

The analysis of soil properties shall be done as per standard methods as described in the

Methods Manual of Soil Testing in India, Department of Agriculture & Co-operation,

Ministry of Agriculture, Government of India, New Delhi (Table 3.8).

Table 3.8 : Method for Analysis of Soil Properties

S. No. Parameters Methods of Analysis

Physical Parameters

1 Moisture content (%) Gravimetric

2 Water Holding Capacity (%) Gravimetric

3 Bulk Density (%) Gravimetric

4 Texture Hydrometer Method

Chemical Parameters

5 pH Electrometric (pH meter)

6 EC (μS/m) Electrometric

7 Acidity (mg/kg) Titrimetric

8 Alkalinity (mg/kg) Titrimetric

9 Chloride(mg/kg) Titrimetric

10 Calcium (mg/kg) Titrimetric

11 Magnesium (mg/kg) Titrimetric

12 Sodium(mg/kg) Flame Photometer

13 Potassium(mg/kg) Flame Photometer

14 Available Potassium(mg/kg) Flame Photometer

15 Sulphate(mg/kg) Spectrophotometer





S. No. Parameters Methods of Analysis

16 Nitrate(mg/kg) Kjedahl method

17 Phosphate(mg/kg) Bray’s Extractant

18 Available

Phosphorus(mg/kg)

Spectrophotometer

19 Organic Carbon (%) Wet Digestion

3.8.3.4 Protocol for Assessment of Soil Physico-Chemical Properties

Methods of Manual of Soil Testing in India, Department of Agriculture & Cooperation,

Ministry of Agriculture, Government of India, New Delhi, were followed for collection of

soil samples, preparation for testing and analyzing various physico-chemical properties

of soil.

3.8.4. Soil Quality Analysis

The homogenized samples were analyzed for physico-chemical characteristics. The

physical and chemical analysis results of the soil samples collected at site during Winter

Season (December,2020 to February,2021) are presented in Table 3.9.

Figure 3.15 : Photographs of Soil Sampling





Table 3.9 : Physicochemical Characteristics of Soil {Winter Season (2020-2021)}

Sl. No. Parameters Unit Test Method

Project Site

S-1

Fertilizer

Nagar

S-2

Dhanora

S-3

Ganpatpura

S-4

Partapgunj

S-5

Khanpur

S-6

Nandesari

S-7

1 pH - IS:2720(Part-26) 7.1 7.58 8.01 7.46 7.22 7.44 7.7

2

Electrical Conductivity

at 25o C (1:5

suspension.)

μmhos/cm IS:2720(Part-21) 328 462 586 610 409 320 474

3 Sodium (as Na) (mg/kg)

Standard Test

Procedures of

Soil Sampling

Analysis

232 342.5 325.2 186.52 320.5 242 164.22

4 Water holding

capacity (%) by mass 12.22 32.8 28 32.62 28.3 14.32 26.22

5 Potassium (as K) (kg/ha) 158 212 176 218 212 166 204

Texture - Sandy Clay

Loam

Sandy

Loam

Sandy

Clay

Loam

Sandy Clay

Loam

Sandy Clay

Loam

Sandy

Loam

Sandy

Loam

6

Particle

Size

Distribution

Sand (%) by mass) 56.47 57.8 58 58.2 54.9 58.32 62.52

Clay (%) by mass) 26.36 20.1 20.4 24.6 26.1 23.42 16.32

Silt (%) by mass) 17.17 22.1 21.6 17.2 19 18.26 21.16

7 Calcium (as Ca) (mg/kg) 1068 1202 998.8 1622 1205 1152 1482

8 Magnesium (as Mg) (mg/kg) 432 554.6 356.4 419 618 462 210

9 Sodium Absorption

Ration (SAR) - 1.68 2.85 2.3 0.92 3.2 1.82 0.84

10 Cation Exchange

Capacity (CEC) (meq/100gm) 1.25 1.23 2.18 5.16 2.15 1.32 4.85

11 Available Phosphorus

(as P) kg/ha 17.66 22.4 19.6 23.1 22.4 19.7 20.4

12 Organic carbon (%) by mass) 0.79 0.048 0.15 1.48 0.5 0.7 0.58





Sl. No. Parameters Unit Test Method

Project Site

S-1

Fertilizer

Nagar

S-2

Dhanora

S-3

Ganpatpura

S-4

Partapgunj

S-5

Khanpur

S-6

Nandesari

S-7

13 Porosity (% by mass) 27.68 32.5 28 30.76 34.2 34.52 28.45

14 Bulk Density (g/cm3) 1.209 1.286 1.25 1.247 1.256 1.162 1.235

15 Nitrogen Kg/ha 298 378 242 312 278 304 340

16 Silica content (as SiO2) % By mass 36.55 52.5 56.2 68.9 54.8 42.68 60.34

17 Zinc (as Zn) mg/kg 1.98 56.2 61.4 48.32 65.2 2.11 38.44

18 Manganese (as Mn) mg/kg 13.82 18.5 72.96 12.48 21.4 15.48 10.28

19 Chromium (Cr+6) mg/kg <0.1 <0.1 <0.5 <0.1 <0.1 <0.1 <0.1

20 Lead (as Pb) mg/kg 1.28 <0.1 <0.1 6.4 0.42 1.32 5.32

21 Cadmium (as Cd) mg/kg <0.05 <0.05 <0.1 <0.05 <0.05 <0.05 <0.05

22 Copper (as Cu) mg/kg 18.35 21.4 18.23 16.22 25.4 22.32 14.86

23 Mercury (Hg) mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

(Source: Soil sample analysis via Lab)





3.8.5. Soil Reaction Classes and Critical Limits for Macro and Micronutrients in

Soil

According to Soil Survey Manual (IARI, 1970), the soils are grouped under different soil

reaction classes viz. as mentioned below in Table 3.10

Table 3.10 : Soil Reaction Classes

Parameter Range Property of Soil

Soil Reaction

Classes (pH)

pH<4.5 Extremely acidic

pH 4.5-5.0 Very strongly acidic

pH 5.1-5.5 Strongly acidic

pH 5.6-6.0 Moderately acidic

pH 6.1-6.5 Slightly acidic

pH 6.6-7.3 Neutral

pH 7.4-7.8 Slightly alkaline

pH 8.5-9.0 Strongly alkaline

Organic

Carbon (OC)

<0.50% Low

0.50-0.75% Medium

>0.75% High

Available Nutrients (Fertility Status)

Available

Nitrogen

<280 kg/ha Low

280 to 560 kg/ha Medium

>560 kg/ha High

Available

Phosphorous

<10 kg/ha Low


>25 kg/ha High

Available

Potassium

<108 kg/ha Low


>280 kg/ha High

Micronutrient Critical Value

Mn <0.5 mg/kg Deficient

Zn <2.0 mg/kg Deficient

Cu <0.2 mg/kg Deficient

(Singh et. al. 2004, Mehta et. al.1988, Follet & Lindsay 1970 and Berger & Truog,

1940)

3.8.6. Interpretation of Soil Characteristics

Soil Texture: As per the grain size distribution the percentage of Sand in all sampled soil

was found varied from 54.9% to 62.52%, Silt varied from 17.17% to 22.1% and Clay from

16.32% to 24.6% during study season. Thus, the soil texture is Sandy Clay loam.

Soil Reaction: Soil pH is an important soil property, which affects the availability of several

plant nutrients. It is a measure of acidity and alkalinity and reflects the status of base





saturation. The soil pH ranges were observed from 7.1 to 8.01 during study season,

thereby indicating the soil is “Slightly alkaline” in nature.

Organic Carbon: The effect of soil organic matter on soil properties is well recognized.

Soil organic matter plays a vital role in supplying plant nutrients, cation exchange

capacity, improving soil aggregation and hence water retention and soil biological

activity. The Organic Carbon content of sampled soil during study seasons varied from

0.048% to 1.48%, thereby implying that soils are low with organic carbon content except

at S-4 where Organic Carbon content is 1.48%.

Macronutrients: Nutrients like nitrogen (N), phosphorus (P) and potassium (K) are

considered as primary nutrients and sulphur (S) as secondary nutrient. These nutrients

help in proper growth, development and yield differentiation of plants and are generally

required by plants in large quantity.

Available Nitrogen:

Nitrogen is an integral component of many compounds including chlorophyll and

enzyme essential for plant growth. It is an essential constituent for amino acids which is

building blocks for plant tissue, cell nuclei and protoplasm. It encourages aboveground

vegetative growth and deep green colour to leaves. Deficiency of nitrogen decreases

rate and extent of protein synthesis and result into stunted growth and develop chlorosis.

Available nitrogen content in the surface soils ranges between 242 kg/ha to 378 kg/ha

thereby indicating that soils are medium to high in available nitrogen content.

Available Phosphorus:

Phosphorus is important component of adenosine di-phosphate (ADP) and adenosine

triphosphate (ATP), which involves in energy transformation in plant. It is essential

component of deoxyribonucleic acid (DNA), the seat of genetic inheritance in plant

and animal. Phosphorous take part in important functions like photosynthesis, nitrogen

fixation, crop maturation, root development, strengthening straw in cereal crops etc.

The availability of phosphorous is restricted under acidic and alkaline soil reaction mainly

due to P-fixation. In acidic condition it get fixed with aluminium and iron and in alkaline

condition with calcium. Available phosphorus content ranges between 19.6 kg/ha to

22.4 kg/ha thereby indicating that soils are medium in available phosphorus content.

Available Potassium:

Potassium is an activator of various enzymes responsible for plant processes like energy

metabolism, starch synthesis, nitrate reduction and sugar degradation. It is extremely

mobile in plant and help to regulate opening and closing of stomata in the leaves and

uptake of water by root cells. It is important in grain formation and tuber development

and encourages crop resistance for certain fungal and bacterial diseases. Available





potassium content in these soils ranges between 158 kg/ha to 218 kg/ha thereby

indicating that the soils are medium in potassium content.

3.8.7. Interference

Soil nutrient status for N, P and K is better explained by working out Nutrient Index Value

for each.

Parker had classified the nutrient index values

a. less than 1.5 as the indicative of low nutrient status and

b. between 1.5 to 2.5 as medium

c. while higher than 2.5 as high nutrient status.

The following equation is used to calculate Nutrient Index Value

Nutrient Index = {(Nl x 1) + (Nm x 2) + (Nh x 3)} / Nt

Nt = Total number of samples analyzed for a nutrient in any given area.

Nl = Number of samples falling in low category of nutrient status.

Nm = Number of samples falling in medium category of nutrient status.

Nh = Number of samples falling in high category of nutrient status

Nutrient Index Value for, N = {(1X1) +(6X2) +(0X3)}/ 7=1.85 (Medium)

Nutrient Index Value for, P = {(0X1) +(0X2) +(7X3)}/ 7= 2 (Medium

Nutrient Index Value for, K = {(0X1) +(7X2) +(0X3)}/7 = 2 (Medium)

Thus, based on Nutrient Index Value for N, P and K, the soils of study area fall into Medium

Fertility Status.

Table 3.11 : Soil Reaction Classes

Parameter

Interpretation

Core Zone Buffer Zone

Value Category Value Category

Soil Reaction Classes

(pH) 7.1 Neutral 7.22 to 8.01

Neutral to Slightly

alkaline

Organic Carbon (%) 0.79 High 0.048 to 1.48 Low to High

Available Nutrients (Fertility Status)

Available Nitrogen

(kg/ha) 298 Medium 242 to 378 Low to Medium

Available

Phosphorous

(kg/ha)

28.66 Medium 32.87 to 54.2 Medium

Micronutrient

Mn (mg/kg) 13.82 Non-deficient 12.48 to 72.96 Non-deficient

Zn (mg/kg) 1.98 Deficient 2.11 to 65.2 Non-deficient

Cu (mg/kg) 18.35 Non-deficient 14.86 to 25.4 Non-deficient





(Singh et. al. 2004, Mehta et. al.1988, Follet & Lindsay 1970 and Berger & Truog, 1940)

3.9. Water Environment

Water quality is a complex subject, which involves physical, chemical, hydrological, and

biological characteristics of water and their complex and delicate relations. The quality

of water is of vital concern for mankind since it is linked with human welfare. Water

quality characteristics of aquatic environments arise from multitude of physical,

chemical, and biological interactions. The water bodies are continuously subjected to

dynamic state of changes with respect to their geo-chemical characteristics. The

dynamic balance in aquatic ecosystem is upset by human activities.

For assessment of baseline data of water quality status, general reconnaissance survey

of River upstream and downstream of proposed study area will be done. “Protocol for

Water Quality Monitoring” notified by Govt of India in conjunction with CPCB Guidelines

for Water Quality Monitoring, 2007-08, shall be followed.

3.9.1. Reconnaissance Survey

The objectives of water quality monitoring programme are identification of state and

trends in water quality, both in terms of concentrations and effect. It is pertinent to make

a reconnaissance survey of the river during the planning stage, noting all sources of

wastes, all entering tributaries that might contribute a potential pollutant, and all uses

and abstractions of the water. This action will also include a survey of background

information such as geography, topography, climate and weather, hydrology,

hydrogeology, land use, urbanization, industrialization, and agriculture, including

farming in the riverbed. The information required has been collected through primary

surveys and secondary sources. Surface water sources and groundwater sources

covering 10 km radial distance were identified for examining for physico-chemical and

bacteriological parameters. Narmada canal is the main water bodies in the area.

3.9.2. Selection Criteria for Water Sampling Location

The selection of sites for water sampling was done considering the location of different

project components, junction of streams and river course, spots of high-water velocity

and some of the stagnated pools along with the areas having human interference.

Sampling stations should be located upstream and downstream of significant pollution

outfalls like city sewage drains and industrial effluent outfalls. Drinking water intake

points, bathing ghats, irrigation canal off-take points should be considered for

monitoring. Additional downstream stations are necessary to assess the extent of the

influence of an outfall and locate the point of recovery. Stations on both sides

downstream are useful to make an estimate of the extent of the mixing zone. In case of

groundwater sampling only tubewells, dug-well and handpumps which are in use should

be selected.





The sampling site selection is generally linked with water quality monitoring objectives.

For example, if the monitoring is carried out for judging suitability of water for drinking

water source, then the monitoring site should be closer to the intake point whereas for

outdoor bathing it should be near bathing ghats. The usual purpose of a monitoring

exercise is to determine the degree of man induced pollution, and the damage that is

caused to aquatic life. The reference station serves to assess the situation with respect

to background water quality and biological aspects, which may vary locally and

regionally. Seven sampling locations of surface water nearby the project were selected.

Within 10 km study area, several rivers like Vishwamitri River, Mahi River, Meni River etc.,

are located. Out of nearby lakes, the nearest lake i.e., Channi Lake was also selected.

Eight ground water samples have also been collected. The location details of the

surface and ground water monitoring stations is presented in Table 3.12 and shown in

Figure 3.17.

Table 3.12 : Water Quality Sampling Stations

Station

Code

Station Name

Distance (km) and Direction

w.r.t. Site

Coordinates

GROUNDWATER LOCATIONS

GW-1 Borewell near Project

Site

0.05 km, E 22°22'34.93"N

73° 9'27.23"E

GW-2 Saurashtra Society 1.10 km, SW 22°22'2.04"N

73° 8'44.37"E

GW-3 Dashrath 1.28 km, NE 22°23'7.64"N

73° 9'24.78"E

GW-4 Ranoli GIDC 3.36 km, NW 22°23'58.96"N

73° 8'10.37"E

GW-5 Ganesh Nagar Society 2.31 km, SE 22°21'31.05"N

73°10'3.85"E

GW-6 Vadodara 7.75 km, S 22°18'25.08"N

73°10'53.72"E

GW-7 Koyali 4.38 km, SW 22°21'28.38"N

73° 6'51.25" E

GW-8 Sisva 3.68 km, NE 22°23'51.82"N

73°10'46.01"E

SURFACEWATER LOCATIONS

SW-1 Chhani Lake 1.84 km, SE 22°21'58.78"N

73°10'11.97"E

SW-2 Mahi River 8.71 km, W 22°22'57.10"N

73° 3'50.29"E

SW-3 Meni River 6.56 km, N 22°25'40.35"N

73° 7'37.70"E

SW-4 Parevi River 10.42 km, NE 22°28'4.30"N





73° 8'59.89"E

SW-5 Galiath River 7.52 km, NE 22°25'28.14"N

73°12'7.00"E

SW-6 Vishwamitri River 6.55 km, SE 22°21'17.74"N

73°12'49.38"E

SW-7 Surya River 9.20 km, E 22°22'19.73"N

73°14'34.84"E

Figure 3.16 : Photographs of Water Sampling





Figure 3.17 : Location of Water Quality Sampling Stations (Groundwater & Surface Water)





3.9.3. Sampling Frequency

Grab samples of surface and ground water were collected and analyzed once during

study period (Winter).

3.9.4. Sampling Technique

Grab samples were collected from well-mixed section of the river (mainstream) 30 cm

below the water surface. Samples from reservoir sites were collected from the outgoing

canal, power channel or water intake structure. DO was determined in a sample

collected in a DO bottle using a DO sampler. The DO in the sample must be fixed

immediately after collection, using chemical reagents. Weighted sample bottle was

used to collect sample from an open well about 30 cm below the surface of the water.

Samples from the production tube wells were collected after running the well for about

5 minutes. Some parameters like pH, dissolved oxygen, temperature, conductivity, and

turbidity should be analyzed in situ.

3.9.4.1 Sample Preservation and Transport

Samples for BOD and bacteriological analyses should be stored at a temperature below

4oC and in the dark as soon as possible after sampling by placing them in an insulated

cool box together with ice or cold packs. Samples collected for chemical oxygen

demand (COD) should be preserved below pH 2 by addition of concentrated sulphuric

acid. Samples which are to be analyzed for the presence of heavy metals, should be

acidified to below pH 2 with concentrated nitric acid.

Samples should be transported to concerned laboratory as soon as possible, preferably

within 48 hours. Analysis of bacteriological samples should be started and analyzed

within 24 hours of collection. If samples are being brought to the laboratory, they should

be transported in less than 24 hours

3.9.4.2 Parameters considered for Analysis

In general list of parameters to be considered for analysis and frequency of sampling is

provided in the “Protocol for Water Quality Monitoring” notified by Govt of India should

be followed.

3.9.5. Water Quality Analysis

The limnological parameters are recorded mainly following the standard methods

described by Welch (1948), CSIR (1974). Mackereth et.al. (1978) and APHA, AWWA,

WPCF (1995) as following:

Parameters Instrumentation

S.No. Parameter Instrumentation

1. Ambient temperature : Digital thermometer (stainless steel Sensor

probe)

2. Transparency : Seehi dise method (Weleh 1948)

3. Water velocity : EMCON digi current meter





4. Turbidity : Nephelometer

5. Total Dissolved Solids : Titration method

6. pH : Digi pH meter (HANNA)

7. Alkalinity, Acidity,

Chlorides, Silicates, DO,

Free CO2, Zn, Si, Fe and

Nutrients (Phosphorus,

Sulphates)

: Aquamerck / Aquaquant kits

8. Total Ca and Mg Hardness

– EDTA

: Titrametric methods (Natrajan and Jhingran

1988)

9. Inorganic phosphates : Colorimetric Methods

10. BOD : Titration

11. E-Coli and Total Coliform : Macconkey broth

Table 3.13 : Test Method used for the analysis

Parameters Test Method

pH value IS :3025(Pt-11)1983RA2017

Temperature IS: 3025(Pt-9)

Conductivity IS: 3025(Pt-14)

Turbidity IS: 3025(Pt-10)1984RA2017

Total Dissolved Solids IS: 3025(Pt-16)1984 RA 2017

Total Suspended solids IS-3025 (p-17) :1984 RA 2006

Total Hardness (as CaCO3) IS: 3025(Pt-21)2009R2014

Chlorides (as Cl) IS: 3025(Pt-32) 1988R2014

Total Alkalinity as CaCO3 IS: 3025(Pt-23) 1986R2014

Sulphate (as SO4) IS: 3025(Pt-24) 1986R2014

Nitrate (as NO3) IS: 3025(Pt-34) 1988R2014

Fluoride (as F) APHA 23rd Ed, 4500 F (D)

Iron (as Fe) APHA 23rd Ed, 3111

Zinc (as Zn) APHA 23rd Ed, 3111

Calcium (as Ca) IS: 3025(Pt-40) 1991R2014

Magnesium (as Mg2+) APHA 23rd Ed, 3500 Mg B

Sodium (as Na) APHA 23rd Ed, 3500 Na (B)

Potassium (as K) APHA 23rd Ed, 3500 K (B)

Cadmium (as Cd) APHA 23rd Ed, 3111

Total Chromium (as Cr) APHA 23rd Ed, 3111

Copper (as Cu) APHA 23rd Ed, 3111

Nickel (as Ni) APHA 23rd Ed, 3111

Lead (as Pb) APHA 23rd Ed, 3111

Mercury (as Hg) APHA 23rd Ed, 3112

Total arsenic (as As) APHA 23rd Ed, 3114

Phenolic Compounds (as C6H5OH) IS: 3025(Pt-43) 1992R2014

Total Coliforms IS: 1622-2003 RA - 2009





3.9.6. Water Quality

Water sampling and analysis has been carried out through NABL accredited and MoEF

recognized Laboratory to determine the existing baseline water quality around the

project area. Sampling and analysis have been carried out following standard

guidelines for physical, chemical, and bacteriological parameters. The physical,

chemical, and biological analysis results of the water samples are presented in Table

3.14 and Table 3.15

Table 3.14 : Surface Water Standards as per IS: 2296-1982

S.No. Test

Parameters

Unit As per IS:

2296 Class A

(Clause 3.3)

As per IS:

2296 Class

B (Clause

3.3)

As per IS:

2296 Class

C (Clause

3.3)

As per

IS: 2296

Class D

(Clause

3.3)

As per

IS: 2296

Class E

(Clause

3.3)

1 Apparent

Colour

Hazen

units

10 300 300 - -

2 Taste - Agreeable Agreeable Agreeable - -

3 pH Value - 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5

4 Turbidity mg/l - - - - -

5 Electrical

conductivity

- - - 1000 2250

6 Total

Alkalinity

mg/l - - - - -

7 DO mg/l 6 5 4 4 -

8 BOD (27o C

for 3 days)

mg/l 2 3 3 - -

9 COD mg/l - - - - -

10 Total

Dissolved

Solid

mg/l 500 - 1500 - 2100

11 Total

Suspended

Solids

mg/l - - - - -

12 Total

Hardness

(CaCO3)

mg/l 300 - - - -

13 Calcium (as

Ca)

mg/l 200 - - - -

14 Magnesium

(as Mg)

mg/l 100 - - - -

15 Fluorides (F) mg/l 1.5 1.5 1.5 - -

16 Chlorides

(as Cl)

mg/l 250 - 600 - 600

17 Chromium

(Cr+)

mg/l 0.05 1 0.05 - -

18 Cadmium

(Cd)

mg/l 0.01 - 0.01 - -

19 Iron (as Fe) mg/l 0.3 - 50 - -

20 Zinc (Zn) mg/l 15 - 15 - -

21 Copper

as(Cu)

mg/l 1.5 - 1.5 - -





S.No. Test

Parameters

Unit As per IS:

2296 Class A

(Clause 3.3)

As per IS:

2296 Class

B (Clause

3.3)

As per IS:

2296 Class

C (Clause

3.3)

As per

IS: 2296

Class D

(Clause

3.3)

As per

IS: 2296

Class E

(Clause

3.3)

22 Arsenic (As) mg/l 0.05 0.2 0.2 - -

23 Lead (Pb) mg/l 0.1 - 0.1 - -

24 Selenium

(Se)

mg/l 0.01 - 0.05 - -

25 Nitrates (as

NO3)

mg/l 20 - 50 - -

26 Sulphate (as

SO4)

mg/l 400 - 400 - -

27 Phenolic

Compounds

mg/l 0.002 0.005 0.005 - -

28 Pesticides mg/l Absent - Absent - -

29 Oil & Grease mg/l - - 0.1 0.1 -

30 Total Coli

form

MPN/100

ml

50 500 5000 - -

As per IS: 2296-1982, the tolerance limits of parameters are specified as per classified

use of water depending on various uses of water. The following classifications have been

adopted in India.

Table 3.15 : Surface Water Quality Criteria as per CPCB

Designated-Best-Use Class of

Water

Criteria

Drinking Water Source

without conventional

treatment but after

disinfection

A Total Coliforms Organism MPN/100ml shall be

50 or less

pH between 6.5 and 8.5

Dissolved Oxygen 6mg/l or more

Biochemical Oxygen Demand 5 days 20°C

2mg/l or less

Outdoor bathing

(Organized)

B Total Coliforms Organism MPN/100ml shall be

500 or less.

pH between 6.5 and 8.5.



3mg/l or less

Drinking water source

after

conventional treatment

and disinfection

C Total Coliform Organism MPN/100ml shall be

5000 or less.

pH between 6 to 9.



3mg/l or less

Propagation of Wildlife

and Fisheries

D pH between 6.5 to 8.5


Free Ammonia (as N) 1.2 mg/l or less

Irrigation, Industrial

Cooling, Controlled

Waste disposal

E pH between 6.0 to 8.5

Electrical Conductivity at 25°C micro mhos/cm

Max.2250





Sodium absorption Ratio Max. 26

Boron Max. 2mg/l

Below E Not Meeting A, B, C, D & E Criteria





Table 3.16 : Surface Water Quality Results

S.No. Parameter Test Method Units Channi Lake

SW-1

Mahi River

SW-2

Meni River

SW-3

Parevi River

SW-4

Galiath

River

SW-5

Vishwamitri

River

SW-6

Surya

River

SW-7

1 pH IS:3025(Part-11) - 7.86 7.64 7.68 7.56 7.24 7.12 7.4

2 Temperature IS:3025(Part-9) 0C 23 28 26 26 20.2 22.8 18.6

3 Turbidity IS:3025(Part-10) NTU 6.5 2.2 2.5 6.8 15.3 12.2 16

4

Electric

Conductivity

@250C

IS:3025(Part-14) µS/cm 722 414 416 536 420 260 403

5 Sulphate (SO4) IS:3025(Part-24) mg/l 48 21 25 48 18.05 20.2 28.8

6 Nitrate (NO3) IS:3025(Part-34) mg/l 12.36 1.34 1.38 9.8 10.1 6.8 8.8

7 Total Hardness

(As CaCO3) IS:3025(Part-21) mg/l 204 176 184 202 118 172 220

8 Chloride (as Cl) IS:3025(Part-32) mg/l 64.57 29.35 33.26 68.44 90.21 118 125

9 Fluoride (as F) APHA 4500F mg/l 0.68 0.24 0.28 0.61 0.42 0.22 0.21

10 COD (as O2) APHA-5220 B mg/l 25 19.8 22 12 12 30 32

11 Iron (as Fe) IS:3025(Part-53) mg/l 0.81 0.41 0.45 0.85 0.37 0.3 0.35

12 Dissolved Oxygen IS-3025(Part-38) mg/l 5.8 6.9 6.8 5.6 5.5 5 4.9

13 Total Dissolved

Solids IS:3025(Part-16) mg/l 472 206 208 482 242 388 358

14 Total Suspended

Solid IS:3025(Part-17) mg/l 12.2 6.5 6.8 13.2 15 12.6 8.5

15 BOD

(3 days at 270C) IS:3025 (P-44) mg/l 4.5 4.1 4.2 2.6 4 12 10





S.No. Parameter Test Method Units Channi Lake

SW-1

Mahi River

SW-2

Meni River

SW-3

Parevi River

SW-4

Galiath

River

SW-5

Vishwamitri

River

SW-6

Surya

River

SW-7

16 Calcium (as Ca) IS:3025(Part-40) mg/l 44.8 43.28 46.49 48.1 44.45 18.46 25.08

17 Magnesium (as

Mg) IS:3025(Part-46) mg/l 21.3 11.35 12.28 25.2 23.64 11.41 14.3

18 Arsenic (as As) IS:3025(Part-37) mg/l BDL BDL BDL BDL BDL BDL BDL

19 Lead (as Pb) IS:3025(Part-47) mg/l BDL BDL BDL BDL BDL BDL BDL

20 Copper (as Cu) IS:3025(Part-42) mg/l 0.18 0.09 0.012 0.2 BDL BDL 0.38

21 Zinc (as Zn) IS:3025(Part-49) mg/l 0.087 0.076 0.078 0.089 0.52 0.2 0.62

22 Manganese (as

Mn) IS:3025(Part-59) mg/l 0.16 0.14 0.144 0.18 0.15 BDL BDL

23 Total Chromium

(as Cr) IS:3025(Part-52) mg/l 0.076 0.065 0.068 0.079 BDL BDL BDL

24 Sodium (as Na) IS:3025(Part-45) mg/l 52 32 34 54 16.5 10.2 12.8

25 Potassium (as K) IS:3025(Part-45) mg/l 1.4 1.4 1.42 1.6 2 2.4 2.4

26 Total Alkalinity (as

CaCO3) IS:3025(Part-23) mg/l 192 152 160 196 102 155.6 144

27 Phosphate (as P) IS:3025(Part-31) mg/l 0.121 0.118 0.121 0.125 <0.1 0.22 0.15

28 Nitrite (as NO2) IS:3025(Part-34) mg/l 0.085 0.079 0.082 0.088 <0.05 <0.05 <0.05

29 Faecal Coliform IS-1622 MPN/100

ml 1.2*103 1.1*103 1.0*103 0.98*103 1.2*103 0.8*103 0.86*103

30 Total Coliform IS-1622 MPN/

100ml 1.5*103 1.2*103 1.2*103 1.1*103 1.7*103 1.2*103 0.94*103

(Source: Lab Analysis of Surfacewater samples)





3.9.6.1 Interpretation of Surface Water Quality

Table 3.13 shows the physico-chemical characteristics of surface water samples

collected from upstream and downstream of canal, during post monsoon season and

compared with the surface water quality standard (ISI-IS: 2296-1982) reference values.

The pH values of all analyzed samples ranged between 7.12 – 7.86. TDS levels were

observed to be in range from 206 to 482 mg/l. Total hardness levels were observed to

be in the range of 118 to 220 mg/l. Dissolved Oxygen values ranged between 4.9 to 6.9

mg/l. The chlorides level was observed to be in range of 29.35 to 125 mg/l. Sulphate level

were found to be ranging from 18.05 to 48 mg/l. Nitrate levels were found to be

observed within the range of 1.34 to 12.36 mg/l. Total Coliform levels were found to be

in the range of 0.94*103 to 1.7*103 MPN/100 ml. Biochemical Oxygen Demand (BOD) was


Table 3.17 : Interpretation of Surface Water Quality

Surface Water Monitoring

Locations

Class of Surface

Water as per CPCB

Inference

SW-1 (Channi Lake) C Drinking water source after


and disinfection SW-2 (Mahi River) C

SW-3 (Meni River) C

SW-4 (Parevi River) B Outdoor bathing

(Organized)

SW-5 (Galiath River) C Drinking water source after


and disinfection SW-6 (Vishwamitri River) C

SW-7 (Surya River) C

Comparing the values as per classification for designated best use water quality criteria

by CPCB, all surface water locations were classified under “Class C- Drinking water

source after conventional treatment and disinfection” except SW-4 i.e., Parevi River

which has been categorized under “Class B- Outdoor Bathing (Organized)”.





Table 3.18 : Ground Water Quality Results

S.No. Parameter Test Method Unit

Requirement

(Acceptable

Limit)

Permissible

Limit in

absence of

alternate

source

Borewell

nearby

Project

Site

GW-1

Saurashtra

Society

GW-2

Dashrath

GW-3

Ranoli

GIDC

GW-4

Ganesh

Nagar

Society

GW-5

Vadodara

GW-6

Koyali

GW-7

Sisva

GW-8

1 Escherichia

coli IS-1622

Absent/100ml

Absent Absent Absent Absent Absent Absent Absent Absent

2 Coliform

Bacteria IS-1622

Absent/100ml

Absent Absent Absent Absent Absent Absent Absent Absent

ORGANOLEPTIC & PHYSICAL PARAMETERS

1 Colour IS-3025(P-

04)

Hazen

Unit 5 15 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00

2 Odour IS-3025(P-

05) - Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

3 Taste IS-3025(P-07

& 08) - Agreeable - Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

4 Turbidity IS-3025(P-

10) NTU 1 5 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00

5 pH value IS-3025(P-

11) - 6.5 - 8.5 - 7.21 7.62 7.16 7.48 7.2 7.62 7.26 7.09

6 Conductivity IS:3025(Part-

14) µmhos/cm - - 856 624 1192 960 1752 1440 1052 955

7 Total dissolve

solid (TDS)

IS-3025(P-

16) mg/l 500 2000 424 312 735 620 1140 944 682 560

1 Aluminium

(as Al)

IS: 3025 (P-

55) mg/l 0.03 0.2 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

2 Total

Ammonia

IS: 3025 (P-

34) mg/l 0.5

No

Relaxation <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10






Requirement

(Acceptable

Limit)

Permissible

Limit in

absence of

alternate

source

Borewell

nearby

Project

Site

GW-1

Saurashtra

Society

GW-2

Dashrath

GW-3

Ranoli

GIDC

GW-4

Ganesh

Nagar

Society

GW-5

Vadodara

GW-6

Koyali

GW-7

Sisva

GW-8

3

Anionic

Detergents

(As MBAS)

Annex K of

IS-13428 mg/l 0.2 1 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10

4 Barium (as

Ba) IS: 15302 mg/l 0.7

No

Relaxation <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10

5 Boron (as B) IS: 3025 (P-

57) mg/l 0.5 1 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10

6 Calcium (as

Ca)

IS: 3025 (P-

40) mg/l 75 200 91.38 56.11 64 72.14 132 89.77 74 68

7 Chloramines

(as Cl2)

IS: 3025 (P-

26) mg/l 4

No

Relaxation <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00 <1.00

8 Chloride (as

Cl)

IS: 3025 (P-

32) mg/l 250 1000 62.61 31.3 129.5 89.92 166.32 196 125.6 112.6

9 Copper (as

Cu)

IS: 3025 (P-

42) mg/l 0.05 1.5 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

10 Fluoride (as

F)

IS: 3025 (P-

60) mg/l 1 1.5 0.31 0.29 0.66 0.32 0.89 0.8 0.62 0.58

11 Free Residual

Chlorine

IS: 3025 (P-

26) mg/l 0.2 1 BDL BDL BDL BDL BDL BDL BDL BDL

12 Iron (as Fe) IS: 3025(P-

53) mg/l 1

No

Relaxation 0.157 0.204 0.182 0.136 0.234 0.245 0.161 0.176

13 Magnesium

(as mg)

IS: 3025 (P-

46) mg/l 30 100 30.42 19.45 44.6 31.85 56.2 39.58 31.2 28.5

14 Manganese

(as Mn)

IS: 3025 (P-

59) mg/l 0.1 0.3 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10






Requirement

(Acceptable

Limit)

Permissible

Limit in

absence of

alternate

source

Borewell

nearby

Project

Site

GW-1

Saurashtra

Society

GW-2

Dashrath

GW-3

Ranoli

GIDC

GW-4

Ganesh

Nagar

Society

GW-5

Vadodara

GW-6

Koyali

GW-7

Sisva

GW-8

15 Mineral Oil Clause 6 of

IS: 3025 mg/l 0.5

No

Relaxation <0.50 <0.50 <0.50 <0.50 <0.50 <0.50 <0.50 <0.50

16 Nitrate (as

NO3)

IS: 3025 (P-

34) mg/l 45

No

Relaxation 4.16 3.3 12 8.23 12.46 34.2 38.3 16.27

17 Selenium (as

Se)

IS: 3025 (P-

56) mg/l 0.01

No

Relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

18 Silver (as Ag) Annex J IS:

13428 mg/l 0.1

No

Relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

19 Sulphate (as

SO4)

IS: 3025 (P-

24) mg/l 200 400 46.2 36.81 58 54.8 82.16 65 82.19 52.19

20 Sulphide (as

H2S)

IS-3025 (P-

29) mg/l 0.05

No

Relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

21 Alkalinity (as

Ca CO3)

IS: 3025 (P-

23) mg/l 200 600 348 188 274 268 406 410 245 258

22

Total

Hardness (as

CaCO3)

IS: 3025 (P-

21) mg/l 200 600 392 56.11 343 312 561 388 313 321

23 Zinc (as Zn) IS: 3025 (P-

49) mg/l 5.0 15 <0.2 <0.2 0.34 0.25 0.29 0.36 0.38 0.36

24

Phenolic

Compound

as (C6H5OH)

IS: 3025 (P-

43) mg/l 0.001 0.002 BDL BDL BDL BDL BDL BDL BDL BDL

25 Cadmium

(as Cd)

IS-3025(P-

41) mg/l 0.003

No

Relaxation <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

26 Cyanide (as

CN)

IS-3025(P-

27) mg/l 0.05

No

Relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01






Requirement

(Acceptable

Limit)

Permissible

Limit in

absence of

alternate

source

Borewell

nearby

Project

Site

GW-1

Saurashtra

Society

GW-2

Dashrath

GW-3

Ranoli

GIDC

GW-4

Ganesh

Nagar

Society

GW-5

Vadodara

GW-6

Koyali

GW-7

Sisva

GW-8

27 Lead (as Pb) IS-3025(P-

47) mg/l 0.01

No

Relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

28 Mercury (as

Hg)

IS-3025(P-

48) mg/l 0.001

No

Relaxation <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

29 Molybdenum

(Mo) IS-3025(P-2) mg/l 0.07

No

Relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

30 Nickel (as Ni) IS-3025(P-

54) mg/l 0.02

No

Relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

31

Poly nuclear

Aromatic

Hydro

Carbons

APHA 6440 mg/l 0.0001 No

Relaxation <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001

32

Poly

chlorinated

biphenyl

APHA 6630 mg/l 0.0005 No

Relaxation <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001 <0.0001

33 Total Arsenic

(as As)

IS-3025(P-

37) mg/l 0.01

No

Relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

34

Total

Chromium

(as Cr)

IS-3025(P-

52) mg/l 0.05

No

Relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

(NOTE: ND-Not Detected, NR-No Relaxation)

3.9.6.2 Interpretation of Ground Water Quality

Table 3.18 shows the physico - chemical characteristics of ground water samples collected from the selected location during Winter

Season (December,2020 to February,2021) as compared with the standard (IS 10500: 2012).





The analysis results indicate that the pH ranged between 7.09 to 7.62 which are well within the specified standard of 6.5 to 8.5 limit.

Total hardness levels were recorded in the range between 56.11 to 561 mg/l that is within permissible limits of 600 mg/l. Total dissolved

solids were recorded in the range of 312 to 1140 mg/l that falls within permissible limits of 2000 mg/l. Chloride levels were recorded

between 31.3 to 166.32 mg/l that falls within the range of permissible limit i.e., 1000 mg/l. Sulphate levels were observed in the range

of 36.81 to 82.19 mg/l and were within the acceptable limit i.e., 400 mg/l. Bacteriological studies reveal that no coliform bacterial

are present in the samples. The heavy metal contents were observed to be in below detectable limits. Parameters for toxic

substances were recorded within the permissible limits. All physical and general parameters were observed within the permissible

limit as per IS10500:2012 (Second Revision). Thus, it is recommended that water be filtered and disinfected prior to be given for drinking

water requirements.





3.9.7. Water Quality Index

WQI is defined as a rating reflecting the composite influence of different water quality

parameters. WQI is calculated from the point of view of the suitability of water for human

consumption. A quality rating scale (qi) for each parameter is assigned by dividing its

concentration in each water sample by its respective standard according to the

guidelines laid down in the BIS and the result multiply by 100.

qi = (Ci/Si) x 100

Where qi is the quality rating, Ci is the concentration of each chemical parameter in

each water sample in mg/l, and Si is the Indian drinking water standard for each

chemical parameter in mg/l according to the guidelines. For computing the WQI, the SI

is first determined for each chemical parameter, which is then used to determine the

WQI as per the following equation

SIi=Wi x qi

WQI = ∑ SIi

SIi is the sub-index of the ith parameter; qi is the rating based on concentration of ith

parameter and n is the number of parameters. The computed WQI values are classified

in to five types, “excellent water” to “water not suitable for drinking”.

3.9.7.1 Surface Water Quality Index

The quality of surface water in an inland water body have a profound effect on the

ground water table and ground water quality of the nearby aquifers due to existence

of direct interaction between surface and ground water. Hence, surface qater quality

index has a major significance in determination of the water quality status of area. Given

the parameters monitored in India under the NWMP and to maintain the uniformity while

comparing the WQI across the nation, the NSF WQI has been modified and relative

weights been assigned by CPCB. The modified weights as per CPCB are given in Table

3.18 and the equations used to determine the sub index values are given Table No 3.19.

Upon determining the Water Quality Index, the water quality is described for easy

understanding and interpretation.

Table 3.19 : Modified weights for computations for WQI based on DO, FC, pH, and BOD

Parameters Original weights from NSF WQI * Modified weights by CPCB

Dissolved Oxygen (DO) 0.17 0.31

Fecal Colifomr (FC) 0.15 0.28

pH 0.12 0.22

BOD 0.1 0.19

Total 0.54 1

*National Sanitation Foundation Water Quality Index





Table 3.20 : Sub-index equation used to calculate NSF WQI for DO, FC, pH, and BOD

Water Quality

Parameters (Units)

Range

Applicable

Sub-equation Sub-Index

(Sub-equation x

Modified Weights)

Dissolved Oxygen

(DO) (%age

Saturation) *

0-40 0.18 + 0.66 X %

Saturation DO

Sub-equation x 0.31

40-100 (-13.55) + 1.17 X %

Saturation DO

100-140 163.34 - 0.62 X %

Saturation DO

Fecal Coliform (FC)

(Counts/100 ml)

1-103 97.2 - 26.6 X log FC Sub-equation x 0.28

103-105 42.33 - 7.75 X log FC

>105 2

pH 2-5 16.1 + 7.35 X (pH) Sub-equation x 0.22

5-7.3 (-142.67) + 33.5 X (pH)

7.3-10 316.96 - 29.85 X (pH)

10-12 96.17 - 8.0 X (pH)

<2, <12 0

BOD (mg/l) 0-10 96.67 - 7 X (BOD) Sub-equation x 0.19

10-30 38.9 - 1.23 X (BOD

>30 2

*DO (Saturation %) = DO value / 6.5x100 (6.5 has been taken as constant as per DO v/s

Temperature)

Calculations for Surface Water Quality Index

where,

Ii= sub index for water quality parameter

Wi= weight (in terms of importance) associated with water quality parameter

P= number of water quality parameters

QUALITY CLASSIFICATION OF SURFACE WATER

Table 3.21 : Water Quality Classification and Best Designated Use

WQI Quality Classification Class Remarks

63-100 Good to Excellent A Non-Polluted

50-63 Medium to Good B Non-Polluted

38-50 Bad C Polluted

38 and less Bad to very bad D, E Heavily Polluted





RESULTS AND INTERPRETATION OF SURFACE WATER QUALITY INDEX

Table 3.22 : Surface Water Quality Index (Results)

Location WQI Surface Water

Quality Index

Class

Quality

Classification

Remarks

SW-1 (Channi Lake) 53.8 B Medium to Good Non-Polluted

SW-2 (Mahi River) 64.8 A Good to Excellent Non-Polluted

SW-3 (Meni River) 58.7 B Medium to Good Non-Polluted

SW-4 (Parevi River) 57.9 B Medium to Good Non-Polluted

SW-5 (Galiath River) 57.2 B Medium to Good Non-Polluted

SW-6 (Vishwamitri

River) 46.6 C

Bad Polluted

SW-7 (Surya River) 46.8 C Bad Polluted

3.9.7.2 Ground Water Quality Index

The Water Quality Index based on weighted average of 11 parameters (Total Hardness

as CaCO3, Calcium, Alkalinity, Chloride, Magnesium, TDS, Sulphate, Fluoride, pH, Iron,

Nitrates) has been found to range between Good to Excellent as is evident from Table

3.23.

Table 3.23 : Water Quality Classification based on WQI Value for Ground Water

WQI value Water quality

<50 Excellent

50-100 Good water

100-200 Poor water

200-300 Very poor water

>300 Water not suitable for drinking

Table 3.24 : Ground Water Quality Index

Season GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 GW9

Winter

Season

(2020-

2021)

WQI 56 66 40 70 58 98 90 73 57

Classifi

cation

Good Good Excellent Good Good Good Good Good Good

3.10. Air Environment

Under the provisions of the Air (Prevention & Control of Pollution) Act, 1981, the CPCB

has notified fourth version of National Ambient Air Quality Standards (NAAQS) in 2009.

Ambient air is defined as any unconfined part of the Earth’s atmosphere, that the

surrounding outdoor air in which humans and other organisms live and breathe.





3.10.1. Climate and Meteorology

Vadodara district is located south of Tropic of Cancer and in transition zone of heavy

rainfall areas of South Gujarat and arid areas of North Gujarat plains, have sub-tropical

climate with moderate humidity. The various seasons of the year are (a) Monsoon -

middle of June to October, (b) Winter - November to February, and (c) Summer – March

to June. The temperature starts rising from March till it reaches maximum, as high as 41°

C in some parts of the district. January is the coldest month of the year.

Meteorological factors have a direct bearing on the dispersion and dilution of

pollutants/contaminants, discharged into the atmosphere with consequent impact on

air Environment. Micro-meteorological properties of the atmosphere govern the

concentration of pollutants and its variations with time and location with respect to their

sources. Meteorological information is required to understand the climatic profile of the

area as well as for devising the baseline ambient air quality monitoring plans.

The nearest IMD station is in Vadodara Airport located at Harni Aerodrome. The wind

instruments are on the terrace of the flying control building. The climatologically

summary for station at Vadodara is given in Table 3.25 and the interpretation of the data

is given in sub sections. Climatological trend of the area is shown in Figure 3.18.

Table 3.25 : Climate Data of IMD Vadodara (1981-2010)

Month Mean

Temperature

(0C)

Humidity

(%)

Rainfall Predominant

Wind Direction

Wind

speed

(km/hr)

At

8:30

At

17:30

At

8:30

At

17:30

Total

(mm)

Rainy

Days

At

8:30

At

17:30

January 29.7 13.2 67 36 1.2 0.2 N, NE NW, N 7.8

February 32 14.9 59 29 0 0 N, NE NW, W 7.7

March 36.3 19.2 53 25 0.1 0 SW, N NW, W 7.7

April 39.1 23.6 56 23 1 0.1 SW, W W, NW 9.2

May 39.9 27 66 32 6.3 0.3 SW, W SW, W 13.6

June 37.2 27.5 75 51 118.6 4.1 SW, W SW, W 15.1

July 32.6 26 86 74 298.5 12.5 SW, S SW, S 13.2

August 31.5 25.3 88 75 265.5 11.8 SW, W SW, W 11.4

September 33.4 25 83 63 122.4 5.6 S, SW SW, S 8.7

October 35.9 22.2 70 44 24.9 1.2 NE, E N, NE 6.1

November 33.7 17.6 64 41 6.7 0.4 NE, N N, NE 6.4

December 30.9 14.1 67 41 0.8 0.1 N, NE N, NE 7

Annual 34.4 21.3 70 45 846 36.3 SW, W 9.5

{Source: Indian Meteorological Department, Climatologically Tables (1981-2010)}

Temperature Mean minimum temperature (at 8:30 hr) varies from 13.20C (Jan) to 27.50C

(June) while mean maximum temperature (at 17:30 hr) varies from 29.70C (Dec) to

39.90C (May).





Relative Humidity Relative Humidity at 8:30 hr varies from 53% (March) to 88% (Aug)

while at 17:30 hr it ranges from 23% (April) to 75% in (Aug). During the monsoon season

relative humidity generally varies between 75% to 83% in the morning and 51% to 75% in

the afternoon. The driest part of the year is the summer season when in the afternoon’s

relative humidity becomes as low as 23%

Rainfall Total annual mean rainfall was observed to be 846 mm. Around 95% of total

rainfall occur in the months of June to Sep. There are about 36.3 rainy days in a year.

Wind Speed Mean wind speed was observed from 7 kmph (December) to 15.1 kmph

(June).

Wind Direction The wind pattern of the region shows that the predominant wind

direction is SW for October to February and NE for March to September. However, the

annual predominant wind direction is SW.

Figure 3.18 : Climatological Trend of IMD Vadodara (1981-2010)

The trend shows mean maximum temperature is gradual throughout the year with its

peak in March and May. Relative humidity is observed to be lowest during March which

attains its peak in the month of June to September i.e., Monsoon Season. Maximum

rainfall is observed to occur in Monsoon Season. The graphs show the summer in the

area is hot and dry while monsoon is humid and temperate. No major downfall in

temperature is observed during winter. Hence the climatic condition of the area is semi-

arid.

3.10.1.2 Regional Meteorology IMD, Vadodara





Secondary meteorological data has been collected from the nearest IMD Station at

Vadodara, Gujarat (Harni Aerodrome) which located at aerial distance of 6.90 km, SW.

Wind instruments are located on the terrace of Flying Control Building (Latitude: 22°

18'00.00"N and Longitude: 73°15'00.00"E). Surrounding area is generally plain with

excellent exposure. Summarized data for temperature, relative humidity, rainfall, and

wind speed & wind direction are given in Table 3.26. Comparison of 2019 Meteorological

data with 30 years climatological data trend is shown in Figure 3.19-Figure 3.22.

Table 3.26 : Meteorological Data of 2020-2021 (Vadodara)

Month Temperature (0C) Humidity

(%)

Rainfall

(mm)

Rainy

Days

(No.)

Wind

speed

(km/hr) Max Min Avg.

January 29 18 24 40 0.2 1 11

February 35 21 29 24 0 0 11.6

March 36 24 31 31 2.9 2 12.2

April 47 30 37 25 0 0 13.7

May 42 30 37 37 0.6 1 16.2

June 36 29 33 56 152.9 23 19.9

July 34 28 31 67 275.4 30 19.3

August 31 26 29 77 675.1 31 18.8

September 33 28 31 70 188.7 22 9.6

October 35 28 32 50 96.9 11 7.7

November 33 24 29 33 0 0 9.8

December 33 21 27 35 5.8 1 9.8

(Source: https://www.worldweatheronline.com/vadodara-weather-averages/gujarat/in.aspx)

Temperature Maximum temperature of the area varied from 290C to 470C. Minimum

temperature varied from 180C to 300C.

Relative Humidity During the monsoon season, relative humidity was observed to be

213%. The driest part of the year is summer season when the relative humidity was

observed to be 19.3%.

Rainfall Maximum rainfall was observed in the monsoon season with 379.73 mm rainfall

in the area. The driest time was January to March with 1.03 mm rainfall. The total annual

rainfall was observed to be 466.15 mm.





Figure 3.19 : Comparison of Trend between IMD (1989-2010) & 2020 {Temperature}

Figure 3.20 : Comparison of Trend between IMD (1989-2010) & 2020 {Humidity}





Figure 3.21 : Comparison of Trend between IMD (1989-2010) & 2020 {Rainfall & Rainy

Days}

Figure 3.22 : Comparison of Trend between IMD (1989-2010) & 2020 {Wind Speed}





The graphs above represent the trend analysis of IMD (1989-2010) and Regional

Meteorology (2020) for parameters like maximum & minimum temperature, relative

humidity, rainfall (mm) with rainy days and wind speed. The graph shows similar yearly

trend with respect to seasonal variation in the climatic condition.

As per the Figure 3.19, comparison between maximum and minimum temperature was

done. There was increment observed in maximum temperature of IMD and latest data

while minimum temperature was also observed to be increased through the years. As

per the Figure 3.20, overall relative humidity has been observed to increase in the years.

As represented in Figure 3.21, rainfall has been observed to increase in overall years.

However, maximum rainfall was observed to be in Monsoon season. The number of rainy

days was also observed to increase. As represented in Figure 3.22, increment in the wind

speed of overall years has been observed.

3.10.2. Meteorology at Site

The site-specific Meteorological data was collected from Weather Monitoring Station

(WMS) installed at GSFC Vadodara Complex by GSFC. The WMS is installed at a rooftop

of corporate block of complex. The data was collected for the month of December,2020

to February,2021. The parameters monitored at the meteorological station were

temperature, relative humidity, wind speed, wind direction and rainfall. The data

recorded at the site was also validated by secondary meteorological data for

Vadodara, Gujarat IMD. Data recorded is summarized in Table 3.26. Windrose of Winter

season is shown in Figure 3.23. Comparative chart showing the comparison between site

specific data, IMD Vadodara and Climatological data is as shown in Figure 3.25 to Figure

3.27.

Table 3.27 : Summary of Site-Specific Meteorological Data

Parameter December,2020 January,2021 February,2021

Temperature

(°C)

Max 31.2 27.6 32.8

Min 10.4 10.0 11.4

Avg 18.9 18.2 21.0

Relative

Humidity

(%)

Max 99.6 99.5 88.4

Min 15.1 25.0 20.4

Avg 77.3 75.7 51.9

Wind Speed

(m/s)

Max 13.7 11.4 11.7

Min 0.5 0.0 0.3

Avg 5.1 3.9 3.7

Wind Direction NE & SW

(Source: GSFC Vadodara Unit WMS)





Figure 3.23 : Site-specific Windrose Diagram

Figure 3.24 : Wind-Class Frequency Distribution Diagram





Figure 3.25 : Comparative Trend Analysis of site specific data with secondary MET Data

(Temperature)


(Relative Humidity)






(Wind Speed)

Above displayed graphs (Figure 3.25, 3.26 & 3.27) represent comparison between trend

of environmental parameters like temperature, relative humidity, and wind speed. The

graphs show that there is similar trend in parameters. However, due to climate change

and industrialization, increase in individual parameters have been observed to increase.

3.11. Ambient Air Quality

Air pollution can cause significant effects on the environment and subsequently on

human, animals, vegetation, and materials. In most cases, air pollution aggravates pre-

existing diseases or degrades health status, making people easily susceptible to other

infections and development of chronic respiratory and cardiovascular diseases. Further,

environmental impacts from air pollution can include acidic deposition and reduction

in visibility.

The objective of the study is to analyze the existing ambient air quality within the study

area and compare it with the NAAQ standards specified by CPCB to know about the

pollution status of air in and around the project area. To quantify the impact of the

construction activities on the ambient air quality at the construction site and its

surrounding area, it is necessary to evaluate the existing ambient air quality in those

areas.

3.11.1. Causes Attributing to Air Pollution in and around Project Area

The existing causes of air pollution in and around project area are due to industrial

activities, vehicular movement, dust arising from unpaved village roads and domestic

fuel burning. At present neither any new road is under construction in study area nor and

widening of road is underway. GSFC Vadodara is in vicinity of Petrochemical Complex





INA, Ranoli GIDC Industial Estate, Savli GIDC and Nandesari Industries Association. Some

major industries are given below:

Table 3.28 : List of nearby industries

S.No. Name of Industry Type of Industry Distance

1. Spectrochem Private

Limited

Chemical Manufacturing

Industry

0.21 km, E

2. Shiv Tapes Packaging Industry 0.26 km, E

3. Petrochemical Complex INA Petrochemical Complex 2.45 km, W

4. SICGIL Indsutrial Gases

Limited

Dry Ice Manufacturer &

Supplier

1.94 km, N

5. Agarwal Petrochem Limited Chemical Manufacturing

Industry

3.57 km, NW

6. Micron Engineers Industrial Equipment

Manufacturer

3.20 km, N

GSFC Complex consists of several production units like Automobiles, Electrical, Textile

etc., Fertilizers, Plastic, Soil conditioner, Captive power and Petroleum based processing

products. The proposed revamping will not lead to increment in gaseous emissions.

However, GSFC is already maintaining all environment protection measures regarding

air environment and the same will be followed after revamping also.

3.11.2. Rationale for Selecting Monitoring Station

The baseline status of the ambient air quality has been established through a

scientifically designed ambient air quality monitoring network and was based on the

following considerations:

• Meteorological conditions.

• Topography of the study area.

• Representatives of regional background air quality.

• Representatives of likely impact areas within the study area; and

• Location of residential areas representing different activities.

Nine sampling stations located within 10.0 km of the site was considered to provide the

surrounding baseline air quality. For the selection of the monitoring locations, long-term

meteorological trends were taken into consideration to obtain the predominant wind

direction during the sampling period. The monitoring station were selected keeping in

view the sites like High density Residential area near industrial zone in upwind of the site

and downwind of the site to understand the impact of the project in the downwind

direction (AAQ-3 & AAQ-6) compared to upwind polluting load from the industrial and

other sources (AAQ-5), the traffic and other activity related to urban residential

contribute to the pollution source. The monitoring sites in downwind high density urban

area (AAQ-3 & AAQ-6) with surrounding infrastructure and commercial facitlies wer

selected to identify the baseline of the existing pollution load and future impact on the





urban population were selected due consideration of existing baseline and impact on

the urban area surrounding the monitoring location. Location of monitoring stations

AAQ-2 & AAQ-9 were selected to identify existing baseline and impact due to the

industrial areas i.e., Ranoli GIDC & Nandesari. AAQ-4 (Chhani Jakatnaka) i.e., high

density urban residential area and AAQ-8 (Sankarda) i.e., Rural area have been

identified in the crosswind directions to assess baseline in the existing areas. The ambient

air quality monitoring locations are detailed in Table 3.28 and shown in Figure 3.28.

Table 3.29 : Location of Air Monitoring Stations

Station

Code Locations

Latitude

Longitude

Approximate

Distance (km)

Direction

Sensitivity

AAQ-1 Project Site 22°22'17.54"N

73° 9'16.24"E

- Industrial

AAQ-2 Ranoli GIDC 22°24'1.91"N

73° 8'16.63"E

1.54 km, NW

(Crosswind)

Industrial

AAQ-3 Nehru Nagar 22°21'56.24"N

73° 8'55.47"E

0.06 km, S

(Downwind)

Residential

AAQ-4 Chhani Jakatanaka 22°20'54.31"N

73°10'8.29"E

2.08 km, SE

(Crosswind)

Residential

AAQ-5 Savli GIDC 22°26'5.33"N

73°11'44.12"E

7.53 km, NE

(Upwind)

Industrial

AAQ-6 Vrindavan Township 22°18'1.83"N

73° 8'47.26"E

7.12 km, S

(Downwind)

Residenital

AAQ-7 Pratapgunj 22°19'13.08"N

73°10'50.48"E

5.21km, SW

(Cross wind)

Residential

AAQ-8 Sankarda 22°25'47.50"N

73° 7'28.91"E

5.20 km, N

(Crosswind)

Residential

AAQ-9 Nandesari 22°24'36.08"N

73° 5'33.17"E

5.69 km, NW

(Crosswind)

Industrial





Figure 3.28 : Location of the Ambient Air Monitoring Stations





3.11.3. Rationale for Selecting Monitoring Station

The ambient air quality monitoring for pollutants was done by following Guidelines for

Manual Sampling and Analyses (Volume-1) issued by CPCB in May,2011. Sampling

methodology is as mentioned in Table 3.30. The ambient air quality monitoring during

post-monsoon,2019 was conducted, on 24- hourly twice a week basis for PM10, PM2.5,

SO2, NOx, NH3, CO (1 hr) and HC for a season by EIA consultant through NABL

accredited Laboratory.

Table 3.30 : Sampling Methodology

Sampling

Parameters

Standard

referred

Sample

Collection

Sample

Analysis Methodology

Sampling

Equipment

Analytical

Equipment

PM10 IS 5182-

Part 23

Respirable

Dust Sampler

Electronic

Balance

Gravimetric method

PM2.5 -- Fine Dust

Sampler

Electronic

Balance

Gravimetric method

SO2 IS 5182 -

Part 2

RDS with

impinger

Spectrophot

ometer

Improved West & Gaeke

Method

NOx IS 5182 -

Part 6

RDS with

impinger

Spectrophot

ometer

Na- Arsenite Method

CO IS 5182 -

Part 10

Tadler bag GC-FID Chromatography

NH3 APHA 401 RDS with

impinger

Spectrophot

ometer

Indophenol Blue method/

Spectrophotometry

3.11.4. Monitoring Result

Summary results of ambient air quality monitoring data are shown in Table 3.31.





Figure 3.29 : Photographs of Air Quality Sampling





Table 3.31 : Summary of Ambient Air Quality (I)

St. Code

PM10 (µg/m3) PM2.5 (µg/m3) NOx (µg/m3) SO2 (µg/m3)

Min Max Avg. 98%

tile Min Max Avg.

98%

tile Min Max Avg.

98%

tile Min Max Avg.

98%

tile

AAQ-1 52 82 69 81 22 41 32 41 10 17.9 14.7 17.4 5.2 9.2 7.5 9

AAQ-2 51 80 71 80 21 44 32 43 10.6 17.2 14.1 16.9 6.1 9.5 8 9.5

AAQ-3 46 78 65 78 23 42 33 42 9.6 15.8 12.6 15.3 5.5 8.8 7.2 8.8

AAQ-4 68.1 83.3 74.1 82 32.3 43.8 38.8 43.4 11.6 17.6 14.5 17.1 5.4 12.8 8.9 12.8

AAQ-5 40 62 49 61 18 38 27 35 9.2 15.5 12.1 15 5 7.8 6.2 7.7

AAQ-6 46 79 62 78 22 40 32 40 10.2 16.6 14.1 16.4 5.4 9 7 8.7

AAQ-7 41 66 52 64 19 39 28 38 9 14 10.8 13.6 5 8.3 6.5 8.1

AAQ-8 42 68 56 67 20 40 29 39 10.4 16.5 13.7 16.3 5.2 8.6 6.7 8.3

AAQ-9 56 96 77 93 27 49 39 48 15.2 20.6 17.6 20.3 6.6 9.7 8.3 9.7

NAAQS

(24hr) 100 60 80 80

Table 3.32 : Summary of Ambient Air Quality (I)

St. Code NH3 (µg/m3) CO (mg/m3) VOC's HC

Min Max Avg. 98%tile Min Max Avg. 98%tile Mean Mean

AAQ-1 12.8 25.1 18 24.1 0.3 0.77 0.48 0.74 <0.1 ND

AAQ-2 13.2 23.8 18.5 23.5 0.35 0.8 0.53 0.77 <0.1 ND

AAQ-3 13.2 17.6 15.2 17.4 0.28 0.63 0.45 0.63 <0.1 ND

AAQ-4 10.4 16.5 13.4 15.9 0.49 1.22 0.82 1.22 <0.1 ND





St. Code NH3 (µg/m3) CO (mg/m3) VOC's HC

Min Max Avg. 98%tile Min Max Avg. 98%tile Mean Mean

AAQ-5 9.2 14.8 12.5 14.7 0.3 0.59 0.43 0.58 <0.1 ND

AAQ-6 11 19.5 15.2 19.3 0.31 0.66 0.47 0.63 <0.1 ND

AAQ-7 9.5 16.5 13.2 16.4 0.26 0.53 0.4 0.52 <0.1 ND

AAQ-8 12.5 22.5 17.4 22.5 0.29 0.71 0.48 0.69 <0.1 ND

AAQ-9 15.7 27.7 20.2 26.8 0.38 0.82 0.56 0.8 <0.1 ND

NAAQS

(24hr) 400 4 - -





Figure 3.30 : Graphical Representation of Ambient Air Quality (Average)





3.11.5. Category of Air Quality Index

An air quality index is defined as an overall scheme that transforms the weighed values

of individual air pollution related parameters (for example, pollutant concentrations) into

a single number or set of numbers (Ott, 1978). The objective of an AQI is to quickly

disseminate air quality information (almost in real-time) that entails the system to

account for pollutants which have short-term impacts. It is equally important that most

of these pollutants are measured continuously through an online monitoring network.

Since in present case air quality has been monitored manually on 24- hourly twice a

week basis for one season, real- time air quality information is not possible. However, the

data collected over a season can significantly describe the category of air quality in

corresponding period. The AQI Category for each of monitoring station has been found

to be satisfactory (Table 3.33).

Table 3.33 : AQI Category for Monitoring Station

Monitoring Station Winter Season (December,2020-February,2021)

AQI AQI Category

AAQ-1 69 Satisfactory




AAQ-5 49 Good





Good

(0–50)

Minimal Impact

Poor

(201–300)

Breathing discomfort to

people on prolonged

exposure

Satisfactory

(51–100)

Minor breathing

discomfort to sensitive

people

Very Poor

(301–400)

Respiratory illness to the

people on prolonged

exposure

Moderate

(101–200)

Breathing discomfort to

the people with lung,

heart disease, children,

and older adults

Severe

(>401)

Respiratory effects even on

healthy people

(Source: https://app.cpcbccr.com › AQI -Calculator)

3.11.6. Interpretation of Results

The monitoring results of ambient air quality were compared with the National Ambient

Air Quality Standards (NAAQS) prescribed by MoEF; GoI Notification dated 16.11.2009.

The maximum concentration of PM10, PM2.5, SO2, NOX, NH3 & CO was 96 µg/m3, 49 µg/m3,

12.8 µg/m3, 20.6 µg/m3, 27.7 µg/m3, 1.22 µg/m3 respectively.





Particulate Matter PM10 The PM10 values ranges from 40 µg/m3 to 96 µg/m3 in the study

area. The Max. PM10 values were observed to be at AAQ-9 i.e., Nandesari located at

5.69 km, NW in crosswind direction while the minimum value was observed at AAQ-5

(Savli GIDC) at 7.53 km, NW in upwind direction. The results show the values were within

the NAAQS permissible limit (100 µg/m3). Higher pollution levels are observed in the

industrial areas and nearby areas affected. The sources of higher concentration in the

area are industrial activities and vehicular traffic emission.

Particulate Matter PM2 5 The PM2.5 values ranges from 18 µg/m3 to 49 µg/m3 in the study

area. The Max. PM2.5 value was observed at AAQ-9 i.e., Nandesari located at 5.69 km,

NW in crosswind direction while the minimum was observed at AAQ-7 i.e., Pratapgunj

located 5.20 km away from the project. The results show the values were within the

NAAQS permissible limit (60 µg/m3). The sources of higher concentration in the area are

due to industrial activities and vehicular traffic emission as compared to other locations

with lesser values.

Sulphur Dioxide SO2 The SO2 values ranges from 5 µg/m3 to 12.8 µg/m3 in the study

area. Maximum SO2 was observed at AAQ-4 i.e., Chhani Jakatanaka located 2.08 km,

NE from the project while minimum values were observed at AAQ-5 (Savli GIDC) and

AAQ-7 i.e., Pratapgunj. The results show the values were within the NAAQS permissible

limit (80 µg/m3). Higher pollution levels were observed in urbanized area. The sources of

the higher concentration in the area is Heavy duty diesel vehicular traffic emission due

to its proximity to SH4 and industrial emission to some extend as due to supply of natural

gas most of the industry has been shifted to gas based plants/boiler and banned on use

Furnace Oil fuel by GPCB and compulsory installation of APCS system based on the Type

of the fuel used as prescribed by GPCB circular/ instruction to the industry the emission

concentration contributing to the ambient levels are observed to be well within the

limits, the other location baseline values were observed to be in lesser the value

observed in urbanized area and were observed to be similar with minor variation in other

locations.

Oxides of Nitrogen NOx The NOx values range from 9 µg/m3 to 20.6 µg/m3 in the study

area. The Max. NOx values were observed to be AAQ-9 i.e., Nandesari located at 5.69

km, NW and minimum value was observed at AAQ-7 i.e., Pratapunj located 5.21 km, SE

away from the project site. The results show the values were within the NAAQS

permissible limit (80 µg/m3). Higher pollution levels were observed at industrial area due

to industrial activities The sources of the higher concentration in the area is vehicular

traffic emission and industrial emission to some extend as the other location baseline

values were observed to be lesser then value observed in urbanized area and were

observed to be similar with minor variation.

Ammonia The NH3 values ranges from 9.2 µg/m3 to 27.7 µg/m3 in the study area.

Maximum NH3 values were observed at AAQ-9 i.e., Nandesari located at 5.69 km, NW in

crosswind direction while the minimum value was observed at AAQ-5 (Savli GIDC) at





7.53 km, NW in upwind direction. The results show the values were within the NAAQS

permissible limit (400 µg/m3).

CO The CO values ranges from 0.26 mg/m3 to 1.22 mg/m3 in the study area. Maximum

CO values were observed to be at AAQ-4 i.e., Chhani Jakatanaka located 2.08 km, NE

from the project while minimum values were observed at AAQ-5 (Savli GIDC) and AAQ-

1 i.e., Project site. The results show the values were within the NAAQS permissible limit (4

mg/m3).

3.11.7. Inference from Results

The 98%tile of all pollutant parameter are observed to be within the limits of standards

prescribed by NAAQS, 2009. The graph Figure 3.31 below shows the comparison of

upwind location with downwind location baseline 98%tile concentrations of the

monitored pollutant. The major source of pollution in the area is observed due to

urbanization and vehicular traffic emission for the pollutants. NH3, CO and HC were

observed to contribute to the atmosphere from the fertilizer plant resulting in minor

higher concentrations.

On the criteria of AQI, the AQI Category for each of monitoring station has been found

to be satisfactory. Concentration of pollutants was within the limits of standards

prescribed by NAAQS, 2009.





Figure 3.31 : Baseline Comparative Chart





3.12. Noise Environment

Ambient Noise Level monitoring is one of the essential components of EIA study. Such

assessment helps in evaluating the existing noise levels and suggesting appropriate

mitigation measures to minimize the potential impact from proposed development in

the projects.

3.12.1. Attributing to Noise Pollution in and around Project Area

The existing causes of ambient noise in and around project area are due to community

sources, construction activities, vehicular movement, and industrial activity. The

proposed revamping of project will be within the existing unit. There will be de-

comissioning of machineries, demolition of few units within the plant, construction for

refurbishing under revamping of Urea-II & installation of few machineries that will lead to

noise pollution.

3.12.2. Methodology

The noise monitoring was done on following CPCB protocol of Noise Monitoring which

inter alia include the following cardinal principles:

• The Noise measurements shall be made with a Type 1 integrating sound level

meter. The station should be located at the ambient level i.e., away from the

direct source, away from any vibration and any obstruction.

• Microphone must be placed 1.2 -1.5m above the ground level.

• The instrument should be isolated from strong vibration and shock.

• The monitoring should be carried out minimum 75% of the prescribed Day time

(06.00 am to 22.00 pm) and Nighttime (22.00 pm to 06.00 am).

• During ambient noise monitoring sound comes from more than one direction, it is

important to choose a microphone and mounting which gives the best possible

omni directional characteristics.

• Noise measurements should not be made in fog and rain.

• A wind shield will always be used to prevent interference of reflecting noise.

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.

3.12.3. Selection Criteria for Noise Monitoring Location

An assessment of baseline noise quality was undertaken to

(a) establish the status of exposure of the major sensitive receptors, and

(b) to identify the noise pollution levels in and around the site.

The baseline study for noise levels in the study area has been carried out by selecting a

noise monitoring station based on the following criteria

• Environmental setting of the area.

• Source of the noise.





• Proximity of the noise generating source to the human settlements.

Based on the above, noise monitoring was carried out at eight monitoring location.

Details of the Monitoring location and map showing the location in the study area is as

shown in Table 3.34 and Figure 3.32 respectively

Table 3.34 : Ambient Noise Quality Monitoring Locations

Station

Code Locations

Latitude

Longitude

Approximate

Distance (km)

Direction

Sensitivity

N-1 Project Site 22°22'17.54"N

73° 9'16.24"E - Industrial

N-2 Ranoli GIDC 22°24'1.91"N

73° 8'16.63"E 1.54 km, NW Industrial

N-3 Nehru Nagar 22°21'56.24"N

73° 8'55.47"E 0.06 km, S Residential

N-4 Chhani

Jakatanaka

22°20'54.31"N

73°10'8.29"E 2.08 km, SE Residenital

N-5 Pratapgunj 22°19'13.08"N

73°10'50.48"E 5.21km, SW Residential

N-6 Sumant Park 22°19'18.20"N

73° 8'33.83"E 4.85 km, SW Residential

N-7 Dashrath

22°23'7.55"N

73° 9'24.87" 0.79 km, NE Residential





Figure 3.32 : Map of Soil Monitoring Locations Maps





3.12.4. Result and Conclusion

Location wise result for daytime and nighttime Leq is presented in Table 3.35.

Table 3.35 : Ambient Noise Leq at Monitoring Location

Location Classification of

Area

Noise level Values Leq dB(A) Applicable CPCB

Standard Leq dB(A)

Day Night Day Night

N1 Industrial 54.6 42.1 75 70

N2 Industrial 56.2 45 75 70

N3 Residential 51.8 41.5 55 45

N4 Residenital 50.2 38.8 55 45


N6 Residential 57.2 45 55 45


3.12.5. Interpretation and Inference

The noise levels observed in the project site and study are within prescribed limits except

at N-6 i.e., Sumant Park located 4.85 km in SW direction of the project. As per the results,

it has been observed that noise levels are higher at residential areas than industrial areas.

Sumant Park (N-6) is surrounded by various residential areas and townships which loeas

to community noise. Vehicular traffic in the area also contribute to the increased noise

levels in the area.

3.13. Ecology and Biodiversity

Biological environment is the environment where life forms can exist. The sum of

environments where life forms exist is called the biosphere, these includes a portion of

land, water, and air. Generally, biological environment of an area is good indicators of

climatic and edaphic factors. Studies on biological aspects of ecosystems are important

in Environmental Impact Assessment for safety of natural flora and fauna. The biological

environment includes terrestrial and aquatic ecosystems. The animal and plant

communities co-exist in a well-organized manner. Their natural settings can get disturbed

by anthropological activities or by naturally occurring calamities or disaster. So, once

this setting is disturbed, it sometimes is either practically impossible or may take a longer

time to come back to its original state. Hence changes in the status of flora and fauna

are an elementary requirement of Environmental Impact Assessment studies. In view of

the need for conservation of biodiversity detailed baseline assessment is required and

considering the project impacts on ecology biodiversity mitigation measures shall be

drafted accordingly.





The ecological survey was focused on identification of floral and faunal species, sensitive

habitats and RET species found in the study area. Secondary data was also collected

from the Forest Department of Gujarat. The purpose of the study was to establish the

ecological baseline of the study area and to understand the impacts of the Project on

floral and faunal species and their habitats in the surrounding areas.

3.13.1. Methodology

The baseline study for existing ecological environment was carried out during Winter

Season (December,2020 to February,2021). Field sampling efforts covered the proposed

project site and 10 km area around the proposed site. One season field survey was

conducted for vegetation, wildlife, aquatic flora & fauna, and avifauna. In addition,

public consultations were also done in the communities around the site. A phased and

consultative approach was followed to carry out ecological assessment. Successive

phases of the assessment include (i) Secondary data collection through desktop review

of available literature and (ii) Onsite data collection for determining vegetation and

wildlife in the study area & Reconnaissance survey (iii) Public consultation.

Secondary Data Collection: An extensive desktop review of available published

literature (books, websites, scientific papers, articles etc.) was conducted. The Forest

Working Plans of Forest Divisions was also referred for secondary information. Additional

information was sourced from the project proponent, governmental institutions, and

residents of the survey-area. Literature was sourced from the govt. source like Forest

department, MOEF&CC, IUCN, and other related departments. Additional data sources

include published articles in journals, gazettes, and technical reports, maps, internet,

amongst others. The secondary data was appropriately supplemented by a field survey

for primary data collection.

3.13.2. Primary Data Collection & Reconnaissance Survey

Flora: As there is no forest present with the study area hence quadrate sampling was not

carried out for tree vegetation. However, transect walks were made at different location

for flora and fauna listing. At each flora/fauna sampling point, the floral diversity and

population density of key economic species composition were obtained using 50 m

transects walk at different sampling points. Sampling points were randomly selected at

10 different locations in the study area. Samples of plants that could not be identified in

the field were collected, pressed and carried to the herbarium for further identification.

The health status of the vegetation was visually determined. Wildlife observations were

conducted during the day and at night to cover for diurnal and nocturnal animals.

Binoculars were used to enable the study of birds and other far distant animals.

Public consultation: Beside above local people were also consulted during the site

survey. Literature review and gathering publicly available data: The literature review

encompassed background information on the Flora and fauna of the area including

recent environmental studies.





3.13.3. Forest Cover in Study Area

There is no protected and reserved forest is present in the study area (10 km area

around proposed site.

3.13.4. Sensitive Ecosystem

There is no national park, wildlife sanctuary, biosphere reserve, wetland, protected and

reserved forest is present in the study area (10 km area around proposed site). The

nearest wildlife sanctuaries to the project are Jambuughoda Wildlife Sanctuary and

Vadhvana Bird Sanctuary located 51.80 km, E and 41.46 km, SE respectively. The details

given in Table 3.36 below:

Table 3.36 : Sensitive Environment Features within study area

S No Environmental Features Within 500 m

area around

Project Site

Within 2.0 km

area around

Project Site

Within 10 km

area around

Project Site

A Presence of Wildlife

Sanctuary National

Park Biosphere

Reserves

None None None

B Reserved Protected

Forests

None None None

C Wetland of state and

national interest

None None None

D Migratory route for wild

animals

None None None

E Presence of Schedule I

Fauna

Yes Yes Yes

3.13.5. Description of Vegetation in Project Area

GSFC Vadodara Unit is in notified industrial area validated by Industries, Mines and

Energy Department. Being an industrial area, the vegetation is restricted only along the

roadside and in the form of greenbelt developed by individual industries. GSFC has also

developed a dense greenbelt in approx. 123.2 Ha. Of land area. The GSFC has

developed green belt along the periphery of the plant site and in common premises

available outside the company premises, township after consultation with horticulture

expert. Total 179001 no. of the tree species like Arjun, Ashok, Neem, Gulmohar, Kadam,

Ficus, and other many species along with herbs and shrubs have been planted by

GSFCL in existing plant area.





3.13.6. Flora of Study Area

As per the land use analysis in study area about 84% of the area is under agriculture uses,

8% land is under settlements and only 4 % land is under vegetation rest in other uses.

There is no reserve, protected and revenue forest present in the study area. Hence the

vegetation is restricted only along the roadside, riparian area of the river/streams and

boundaries of the agriculture fields. The vegetation is meager despite the favorable

environmental conditions. The common tree species observed in the study area are F.

benghalensis, Pongamia pinnata, Azadirachta indica, Acacia nilotica, Mangifera

indica, Eucalyptus species, Cassurina equisetifolia Tamarindus indica, Ziziphus

mauritiana, Ficus racemes, Delonix regia and Albizia lebbeck etc.

The structure and composition of vegetation was studied by observing each individual

plant species growing in a habitat. Ground vegetation covered by dominant by the

herbs and shrub species like Zyziphus mauritiana, Argemone mexicana, Solanum

surattense, Xanthium strumarium, Ipomea cornia, Ipomea fistulosa, Dhatura metal,

Nerium indicum, Hibiscus rosa Calotropis procera, Sida cordifolia, Polygonum glabrum,

Cassia tora, Canabis sativa, Chenopodium album, Cyanodon dactylon, Parthenium

hysterophorus and Achyranthus aspera. The list of the plant species observed in the

study area is given Table 3.37

Floristic Composition

During primary and secondary study carried out under present project, 47 tree species,

20 shrub species and 30 herbs, 06 climbers and grasses were recorded from the study

area. The comprehensive list of the plant species for 10 km study area (tree, shrubs,

herbs, climbers, and grasses) observed in the study area is given Table 3.37.

Table 3.37 : Tree Species recorded in the Study Area

Sl. No. Botanical Name Family

Vernacular

Name

Common

Name

LIST OF TREE SPECIES

1. Carissa congesta Apocynaceae Karmada Karanda

2. Phoenix sylvestris Arecaceae

Khajuri Wild Date

Plum

3. Cordia gharaf Boraginaceae Godni Gondni

4. Garuga pinnata Burseraceae Kaked Garuga

5.

Tecomella

undulate

Bignoniaceae Ragat

Rohido

Roheda

6. Terminalia bellerica Combretaceae Behdo Myrobalan

7. Terminalia chebula Combretaceae Herde Chebulic

Myrobalan

8.

Terminalia

cranulata Combretaceae Sadad -

9.

Terminalia

catappa

Combretaceae Badam Indian Almond






Vernacular

Name

Common

Name

10. Carica papaya Caricaceae Papaya Papaya

11.

Casuarina

equisetifolia Casuarinaceae

Sharu Whistling pine

12. Capparis grandis Capparaceae Thikari Tree Caper

13. Emblica officinalis Euphorbiaceae Amla Gooseberry

14. Tamarindus indica Fabaceae Amli Tamarind

15. Pongomia pinnata Fabaceae Karanj Pongam

16. Prosopis juliflora Fabaceae Gando Baval Mesquite

17. Samanea saman Fabaceae Rato Sarasdo Rain Tree

18. Bauhinia purpurea Fabaceae Kachnar Butterfly Tree

19. Albizzia procera Fabaceae Killai (kevlo) White siris

20. Bauhinia racemosa Fabaceae Ashitro Bidi Tree

21.

Acacia

auriculiformis

Fabaceae Bengali

Baval

Earleaf Acacia

22. Senegalia catechu Fabaceae Khair Cucth Tree

23. Acacia nilotica Fabaceae Desi Baval Babul

24. Cassia fistula Fabaceae Garmalo Amaltas

25. Senna auriculata Fabaceae Aval Tarwar

26.

Dalbergia

paniculata

Fabaceae Patrali -

27. Dalbergia sissoo Fabaceae Sissoo Sissoo

28.

Dendrophthoe

falcate Loranthaceae

Vando Honey suckle

mistletoe

29. Melia azedarach Meliaceae

Bakam

Limdo

Chinaberry

30. Azadirachta indica Meliaceae Limdo Neem

31. Bombax ceiba Malvaceae Shimdo Silk Cotton

32. Eucalyptus species Myrtaceae Nilgiri Safeda

33. Ficus bengalensis Moraceae Vad Banyan

34. Ficus glomerata Moraceae Umero Cluster fig

35. Ficus religiosa Moraceae Pipdo Peepal

36.

Ficus carica

Moraceae Anjir Anjir

37.

Artocarpus

heterophyllus

Moraceae Phanas Kathal

38. Morus alba Moraceae Shetur Mulberry

39.

Mallotus

philippensis

Euphorbiaceae Kapilo Kapilo

40. Ziziphus mauritiana Rhamnaceae Bor Inidan Jujube

41. Ziziphus xylopyrus Rhamnaceae Ghat Bor Bhorghoti

42. Aegle marmelos Rutaceae Bili Bel






Vernacular

Name

Common

Name

43. Cirtus limon Rutaceae Limbu Lemon

44. Madhuca indica Sapotaceae Mahudo Mahua

45. Borassus flabellifer Arecaceae Tad Tad

LIST OF SHRUB SPECIES

Polygonum glabrum, Canabis sativa, Chenopodium album, Cyanodon dactylon,

Parthenium hysterophorus and Achyranthus aspera

46. Nerium indicum Apocynaceae

Karen Indian

Oleander

47.

Jathorpha

gossypifolia Euphorbiaceae

Ratanjot

Black

Bellyache Bush

48. Jatropha curcas Euphorbiaceae Ratanjot Physic Nut

49. Tephrosia purpurea Fabaceae

Sartankho Purple

Tephrosia.

50. Lawsonia inermis Lythraceae Mehndi Henna

51. Vitex negundo Lamiaceae Nagod Chaste Tree

52.

Hibiscus rosa-

sinensis Malvaceae

Jasud China Rose

53. Solanum surattense Solanaceae - -

54.

Xanthium

strumarium, Asteraceae

Gokhuru -

55.

Salvadora oleoides

Salvadoraceae

Pilu -

56.

Nyctanthers

arbortristis oleaceae

Parijatak -

57. Hibiscus vitifolius

Malvaceae Van Kapas Grape Leaved

Mallow

58.

Thespesia

populnea

Malvaceae ParasPiplo Indian tulip

59.

Nyctanthus arbor

tristis Oleaceae

Parijatak Night-

flowering

Jasmine

60. Zizyphus oenoplia Rhamnaceae Boydinovelo Jackal Jujube

61.

Euphorbia

antiquorum Euphorbiaceae

Thor Thor

62. Leea edgeworthii Vitaceae Dussorudi Leea asiatica

63. Calotropis procera Apocynaceae Akdo Rubber lush

64. Lantana camara Verbenaceae Lantana -

65. Vitex negundo Verbenaceae Nagud Nigod

LIST OF HERB SPECIES

66.

Catharanthus

roseus Apocynaceae Barmasi

Madagascar

periwinkle

67.

Aerva

sanguinolenta

Amaranthaceae Karadia Climbing Wool

Plant






Vernacular

Name

Common

Name

68. Centella asiatica Apiaceae Bhrami Centella

69.

Launaea

procumbens

Asteraceae Bhonyadand

i

Creeping

Launaea

70. Brassica juncea Brassicaceae Rai India mustard

71.

Chenopodium

album Ameranthaceae Bethu

Bathua

72.

Polygonum

glabrum, Polygonaceae -

-

73. Canabis sativa Cannabaceae Bhang Bhang

74.

Parthenium

hysterophorus Asteraceae

Congress

grass Congress grass

75.

Cyanodon

dactylon, Poaceae Dub

Dub

76.

Trichodesma

amplexicaule Boraginaceae Undhafuli

Indian borage

77. Cassia tora Caesapiniaceae Kunvandio Sickle Senna

78.

Ipomoea aquatica

Forsk

Convolvulaceae Mali Ni Bhaji Swamp

Morning-Glory

79. Ocimum sanctum Lamiaceae Tulsi Holy Basil

80. Capsicum annuum Solanaceae Marcha Mirch

81.

Lavandula

bipinnata

Lamiaceae Roth -

82. Leucas aspera Lamiaceae Kubi Thumbai

83. Musa paradisiacal Musaceae Kela Banana

84. Sida cordata Malvaceae Bhoyabala Long-stalk Sida

85. Hibiscus lobatus Malvaceae Tali Lobed Leaf

Mallow

86. Sesamum indicum Pedaliaceae Fal Sesame

87.

Phyllanthus

fraternus Phyllanthaceae Bhonya Amli

Gulf Leaf-

Flower

88.

Argemone

mexicana

Papaveraceae Darudi Mexcian

prickly poppy

89. Foxtail millet Poaceae Kang -

90.

Bothriochloa

pertusa

Poaceae Zenzvo Hurricane

Grass

91. Indigofera linnaei Papilionaceae Fatakiya Birdsville

Indigo

92. Capsicum annum Solanaceae Marchi Chilli pepper

93.

Datura metel Solanaceae Ganthovalo

Dhanturo

Devil's Trumpet

94. Tribulus terrestris Zygophyllaceae BethuGokhru Bindii

LIST OF CLIMBER/GRASS SPECIES






Vernacular

Name

Common

Name

95. Cucurbita maxima Cucurbitaceae

Kolu Autumn

squash

96. Quisqualis indica Cucurbitaceae Madhu Malti Rangoon

creeper

97.

Asparagus

racemosus

Liliaceae Satavai Satawari

98.

Aristidaa

dscensionis

Poaceae - -

99.

Bongainvillea

spectabilis

Nyctaginaceae Boganvel Great

Bougainvillea

100.

Passiflora edulis Passifloraceae Krishna

Kamal

Passion fruit

101.

Ampelocissus

latfolia

Vitaceae Jungli Wild Grape

102.

Bothriochlo

apertusa

Poaceae Zenzvo Hurricane

grass

103. Cynodon dactylon Poaceae Darbh -

104.

Cymbopogon

citratus

Poaceae Lilli chaha -

Rare Threatened and Endangered Species

Recorded floral species from the study area were assessed for their conservation status

by cross-checking with red data book of Indian plants (Nayar & Sastri, 1987-90) and none

of the plant taxa were found under RET category.

Plants of Ethno botanical/Medicinal Importance

Ayurveda says, There is no plant on the earth, which does not possess medicinal

property , this means that each plant is equally important for its biological activities,

ecology and environment The conservation of medicinal plants means every species

of plants in its natural habitat should be protected and preserved Conservation of

invaluable biodiversity is a national and international agenda Because of continuous

exploitation of medicinal plants from their natural habitats, it is required to replant and

regenerate them in other areas having similar habitat or environment Due to over

exploitation of natural resources many plant species have become extinct from the

world

Among ancient civilizations, India has been known to be rich repository of medicinal

plants. The forest in India is the principal repository of large number of medicinal and

aromatic plants, which are largely collected as raw materials for manufacture of drugs

and perfumery products. About 8,000 herbal remedies have been codified in AYUSH

systems in INDIA. Ayurveda, Unani, Siddha and Folk (tribal) medicines are the major





systems of indigenous medicines. Among these systems, Ayurveda and Unani Medicine

are most developed and widely practised in India.

During present study knowledgeable and elderly persons of study area villages were

interviewed and information on plant parts (bark, seed, leaf, root, and fruit) used and

indigenous knowledge was gathered. People use these locally available plant species

internally for treating diarrhea, dysentery, cough, cold, fever and asthma and externally

for rheumatism, skin diseases, cuts, boils and injuries. A list of medicinal plants located in

the project study area is given in Table 3.38.

Table 3.38 : Medicinal Plants recorded in Study Area

S.

No Name Family Medicinal Use

1. Aegle

marmelos

Rutaceae • Antidiuratic, antithetmintic, antipyretic,

carminative tonic.

• Fruit used in chronic diarrhoea &

dysentery

2. Catharanthus

roseus

Apocynaceae • Plant: In Cancer, Diabetes

• Plant Extract: Antimitotic

• Root: In Cancer & as emetic,

hypotensive, sedative and antiviral.

• Leaf: In Menorrhagia

3. Datura metel Solanaceae • Seed: aphrodisiac, narcotic and

antispasmodic and useful in dontalgia,

otalgia, gastropathy and skin diseases

and for treatment of dandruff and lice;

EtOH (50%) extract of plant: anticancer,

anthelmintic, spasmogenic and blood

pressure depressant; Aquous extract of

plant: nematicidal; Leaf extract: antiviral;

EtOH extract of leaf and aquous extract

of fruit: anticholinergic.

4. Emblica

officinalis

Euphorbiaceae • Fruit: pronounced expectorant,

antioxidant, anticancerous; EtOH (50%)

extract of fruit: antiviral, carminative,

stomachic; Aqueous extract of fruit:

increases cardiac glycogen level and

decreases serum GOT, GPT and LDH in

rats; Fruit-juice: (i) mixed with turmeric

powder and honey: cures diabetes

insipidus; (ii) in ghee: used for abdominal

and glandular tumours; a constituent of

the medicine SG-1-Switradilepa used





S.

No Name Family Medicinal Use

against vitiligo, and of an antibiotic drug

Septilin.

5. Azadirachta

indica

Meliaceae • Oil extracted from seed as local

stimulant, insecticide, and antiseptic

6. Mangifera

indica

Anacardiaceae • Controls stomach pain, diarrhea, urine

sugar

7. Tamarindus

indica

Caesalpiniaceae • Leaves are used to reduce inflammatory

swellings & ringworm

• Fruit is tonic to heart and antithelmintic

8. Acacia nilotica Mimosaceae • In pharmacy, used in preparing

emulsions, tablets, pills etc.

9. Calatropis

procera

Asclepiadaceae • Root bark used for leprosy

10. Lantana

camara

Verbenaceae • Useful as an antiseptic for wounds

11. Vitex negundo Verbenaceae • Leaves are used in rheumatism

• Dried leaves smoked for relief from

headache

12. Argemone

Mexicana

Papaveraceae • Latex is laxative and used in cataract

• Seed oil used in asthma

13. Ocimum

sanctum

Lamiaceae • Leaf juice used in curing cold, bronchitis

• Flower decoction in dyspepsia

Major Crops in the Study Area: About 84% of the land in the study area is covered under

the agriculture. There are well irrigarion facilities available in the district. The common

season wise crops grown in the study area are discussed below in Table 3.39.

Table 3.39 : Major crops in the study area

Sl. No. Kharif Rabi Summer

1 Paddy Wheat Bajara

2 Tobacco Potato Paddy

3 Bajara Rustica Tobacco Vegetables

4 Banana Mustard Greengram

5 Castor Vegetables Groundnut

6 Vegetables Gram

7 Cotton Forage

8 Pigeon pea - -





3.13.7. Faunal Diversity

Since observations of fauna and wildlife take long time, primary surveys were limited to

field visits and direct and indirect sightings of animals. The presence of wildlife was also

confirmed from the local inhabitants depending on the animal sightings and the

frequency of their visits in the study area. In addition to these, secondary sources were

referred for the preparation of a checklist and other analysis in the study of animals and

wildlife in the region. Though faunal surveys were carried out for the species of Mammals,

Birds, and reptiles. The study of mammals and birds were studied by placing systematic

transects at different sampling locations in the study area. This exploration of the species

was carried out with respect to the habitat types where they can be occurred.

There is no reserve and protected forest present within the study area and core zone of

the site is mostly urban area. Hence the wildlife is restricted to commonly found

mammals.

Mammals, Reptiles and Amphibians

The mammals in the area studied have largely the population of domestic mammals

that coexist with the human settlements. Domestic animals are integral part of the

ecosystem of the area. They feed on agricultural remains and in the open scrubland.

Domestic animals like crow, buffalo, goat and dog were commonly observed in almost

all the sampling locations of the study area.

Among wild animals Nilgai were observed in villages area away from the urban areas.

The other common mammalian species reported are mouse, rat and newala etc.

Among the reptiles’ lizards, rat snake and Cobra are common. List of the Mammals and

reptiles reported in the study area are presented in Table 3.40 and 3.41.

Table 3.40 : List of mammalian species recorded (direct or indirect evidence) from

study area

S.No. Family Zoological name Common Name Schedule

Class-Mammalia (Order: Primates)

1. Craseonycteridae Chiroptera sps. Bat V

2. Herpestidae Herpestes edwardsi Mongoose II

3. Muridae Rattus rattus Rat V

4. Muridae Mus musculus Mouse V

5. Sciuridae Funambulus penanti Khiskoli IV

6. Bovidae Bubalus bubalis Buffalo -

7. Bovidae Bos taurus Cow -

8. Bovidae Capra aegagrushircus Goat -

9. Canidae Canis lupus familiaris Dog -





Table 3.41 : Reptiles observed in Study Area

S.No. Common

Name

Zoological

Name

Vernacular

Name Family

Schedule

1. Oriental

Garden Lizard

Calotes

versicolor

Kachindo Agamidae Not listed

2. Green Forest

Lizard

Calotes calotes Kachindo Not listed

3. Indian

chameleon

Chameleon

zeylanicus

Sarado Chamaeleonidae Not listed

4. Common

ratsnake

Ptyas mucosus Dhaman Colubridae IV

5. Checkered

Snake

Xenochrophis

piscator

Dendu Colubridae II

6. Crocodile Crocodylus

palustris

Muggar Crocodylidae I

7. Indian cobra Naja naja Nag Elapidae II

8. Northern

House Gecko

Hemidactylus

flaviviridis

Garoli Gekkonidae Not listed

9. Flap shell

Indian Turtle

Lissemys

punctata

Kachbo Trionychidae I

10. Common

worm

Ramphotyphlops An-sap Typhlopidae -

Terrestial RET Mammals

The Indian Wildlife Protection Act (1972) has also scheduled the animals in various

categories for given them varying degree of protection. Among recorded mammals,

no species comes under Schedule-I category of Indian Wildlife Protection Act (1972).

The listed animal all so cross checked with IUCN red data book and found that most of

the animals recorded in this study were listed as “Least Concern” category of IUCN Red

Data Book.

3.13.8. Avifauna

Bird survey was conducted on the same transects and trails marked for mammal’s

survey. The whole sampling was carried out in a fixed width trails of 2-4 km wherever the

terrain permits, and point counts were carried out at a fixed distance at regular intervals.

A prismatic field binocular (10X50) was used for the bird watching during transect walk

mostly during morning and evening hours at nearby habitations as well as near to water

bodies in the study area. An on-spot identification of birds has been carried out with the

help of pictorial guides/literature published by Grimmettet al. (2011). (Table 3.42)

Table 3.42 : List of Avifauna recorded during the study

S. No. Common Name Scientific Name Family IUCN/

Schedule

• Avifauna

1. Black winged kite Elanus caeruleus Accipitridae LC/ IV






Schedule

• Avifauna

2. Black kite Milvus migrans Accipitridae LC/IV

3. Shikra Accipiter badius Accipitridae LC/ IV

4. House swift Apus nipalensis Apodidae LC/IV

5. Pied kingfisher Ceryle rudis Alcedinidae LC/ IV

6. White throated

kingfisher

Halcyon smyrensis Alcedinidae LC/IV

7. Pond heron Ardeola grayii Ardeidae LC/IV

8. Cattle egret Bulbucus ibis Ardeidae LC/IV

9. Little egret Egretta garzetta Ardeidae LC/IV

10. Median Egret Mesophoyx intermedia Ardeidae LC/IV

11. Red wattled

lapwing

Vanellus indicus Charadriidaea

LC/IV

12. Tailor bird Orthotomus sutorius Cisticolidae LC/IV

13. Blue rock pigeon Columba livia Columbidae LC/IV

14. Laughing Dove Spilopelia senegalensis Columbidae LC/IV

15. Eurasian Collard

Dove

Streptopelia decaocto Columbidae LC/IV

16. Red Turtle Dove Streptopelia

tranquebarica

Columbidae LC/IV

17. Indian Roller Coracias benghalensis Coraciidae LC/IV

18. Common crow Corvus splendens Corvidae LC/V

19. Crow- pheasant Centropus sinensis Cuculidae LC/IV

20. Indian koel Eudynamys

scolopaceus

LC/IV

21. Black drongo Dicrurus adsimilis Discruidae LC/IV

22. Indian silverbill Lonchura malabarica Estrildidae LC/IV

23. Wire tailed

Swallow

Hirundo smithii Hirundinidae LC/IV

24. Grey shrike Lanius excubitor Laniidae LC/IV

25. Jungle babbler Turdoides striatus Leiothrichidae LC/IV

26. Coppersmith

barbet

Megalaima

haemacephala

Megalaimidae LC/IV

27. Green bee- eater Merops orientalis Meropidae LC/IV

28. White Wagtail Motacilla alba Motacillidaea LC/IV

29. Indian robin Saxicoloides fulicatus Muscicapidae LC/IV

30. Oriental Magpie

Robin

Copsychus saularis Muscicapidae LC/IV






Schedule

• Avifauna

31. Purple sunbird Nectarinia asiatica Nectariniidae LC/IV

32. House sparrows Passer domesticus Passeridae LC/IV

33. Little cormorant Microcarbo niger Phalacrocoraci

dae

LC/IV

34. Grey francolin Francolinuspondicerian

us

Phasianidae LC/IV

35. Rose ringed

parakeet

Psittacula krameri Psittaculidae LC/IV

36. Red vented bulbul Pycnonotus cafer Pycnonotidae LC/IV

37. White eared bulbul Pycnonotus leucotis Pycnonotidae LC/IV

38. White-breasted

waterhen

Amaurornis

phoenicurus

Rallidae LC/IV

39. Common

sandpiper

Actitis hypoleucos Scolopacidae LC/IV

40. Bank myna Acridotheres

ginginianus

Sturnidae LC/IV

41. Peafowl Pavo cristatus Phasianidae LC/I

Common myna Acridotheres tristis Sturnidae LC/IV

42. Brahminy Starling Sturnus pagodarum Sturnidae LC/IV

Status: IUCN Status/ Migratory Status/ Schedule as per Wildlife Protection Act, 1972

LC = Least Concerned

RET Avifauna

As per present study, 42 avifauna species have been recorded in the study area, most

of the species belong to Schedule-IV & V. These species were also reviewed as per the

IUCN Red list and all the recorded species listed as “Least Concern” in IUCN list. Peacock

(Pavo cristatus) are the Schedule-I species observed within the study area.

3.13.9. Aquatic Ecology

There are many surface water bodies present in the study area. Mahi and Vishwamitri

river and their tributaries are the main water bodies present in the study area However,

distributaries of rivers located nearby project are dry riverbeds. Mahi River is one of the

important perennial rivers of central Gujarat, flowing westward to terminate into Gulf of

Cambay. The details of the water bidies present in the study area are presented in table

below in Table 3.43:





Table 3.43 : List of Surface water bodies in study area

Sl. No. Water Body Distance from Plant Site

1. Galiath River 4.58 km (NE)

2. Meni River 7.00 km(W)

3. Parevi River 7.08 km(N)

4. Vishwamitri River 5.71 km (E)

5. Surya River 8.04 km(E)

6. Mahi River 9.35 km(W)

Aquatic Flora in the Study Area

The aquatic biological organisms are the best indicators of aquatic environmental

quality. The abundance or absence of certain organisms thus often serves as indicators

of a healthy or polluted aquatic environment. Information about the impact

(environmental stress) on the community structure serves as inexpensive and efficient

"early warning and control system" to check the effectiveness of control measures to

prevent damage to a particular ecosystem (e.g. adjustments of emission norms,

management of installations and sanitation etc.).The nature and quality of such

biological species in a particular environment depend on various physico-chemical

characteristics of water such as pH, conductivity, nutrients, BOD etc. Ecology of Mahi

River includes different biological species, such as Plankton (both phyto and zoo),

different species of algae, Aquatic Macrophytes, Aquatic Insect and Fishes. The main

fishes observed in the rivers present in the study area are Indian major carps, minor carps,

rohu, katla etc. The fish species are present in study area specially in Mahi River2 are

presented in Table 3.44:

Table 3.44 : List of fish species in study area (Mahi River)

Sr. No. CLASS: PISCES SUB-CLASS: TELEOSTEI

Order Family Genus and species

1.

Acanthoptergii

Percidae Ambassis ranga

2. Therapon jarbua

3. Gobiidae

Gobius giuris

4. Boleophthalmus glaucus

5. Rhynchobdellidae

Mastacembelus pancalus

6. Mastacembelus armatus

7. Mugilidae

Mugil belank

8. Mugil corsula

2 Gohil Mahendrasinh N. and Mankodi Pradeep C.et al Diversity of Fish fauna from downstram zone of River Mahisagar,

Gujarat State, India. The M.S. University of Baroda 2013





Sr. No. CLASS: PISCES SUB-CLASS: TELEOSTEI

Order Family Genus and species

9. Ophiocephalidae

(channadae)

Ophiocephalus marulius

10. Ophiocephalus punctatus

11. Cichlidae Oreochromis mossambicus

12. Ancanthini Pleuronectidae Cynoglossus macrolepidotus

13.

Physostomi

Siluridae Macrones seenghala

14. Arius nenga

15. Scombresocidae Belone annulata

16.

Cyprinidae

Labeo boggut

17. Labeo rohita

18. Cirrhina reba

19. Cirrhina fulungee

20. Barbus sarana

21. Barbus ticto (Puntis ticto)

22. Rohtee cotio

23. Chela bacaila

24. Notopteridae Notopterus kapirat

25. Clupeidae

Engraulis mystax

26. Clupea fimbriata

Reptiles: The water bodies present in the study area habituated the Crocodile and turtle

species. Crocodiles are reported from the Mahi River system.

RET Fauna Species: Among record of reptiles, Crocodylus palustris (Crocodile) and

Lissemys punctata (Flap shell Indian Turtle) have been categorized under Schedule-I

Category. Also, Pavo cristatus (Peacock) have been observed under Schedule-I species

observed in the study area.

Table 3.45 : List of Schedule-I species in study area

S. No Common

Name

Zoological

Name

Vernacular

Name Family

Schedule

1. Flap shell

Indian Turtle

Lissemys

punctata

Kachbo Trionychidae I

2. Crocodile Crocodylus

palustris

Muggar Crocodylidae I

3. Peacock Pavo cristatus Common

Peafowl

Phasianidae I





3.14. Socio Economic Environment

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 & Socio-economic features of the area, Census data 2011,

for the concerned District Gandhinagar, Ahmadabad and Mahesana of Gujarat state

was compiled and placed in the form of tabulation and graphical representation

3.14.1. Demographic of the District

Vadodara city is governed by Municipal Corporation which comes under Vadodara

Metropolitan Region. The Vadodara city is located in Gujarat state of India. As per

provisional reports of Census India, population of Vadodara in 2011 is 1,670,806; of which

male and female are 869,647 and 801,159 respectively. Although Vadodara city has

population of 1,670,806; its urban / metropolitan population is 1,822,221 of which 949,998

are males and 872,223 are females.

Hinduism is majority religion in Vadodara city with 85.39 % followers. Islam is second most

popular religion in city of Vadodara with approximately 11.40 % following it. In Vadodara

city, Christinity is followed by 1.22 %, Jainism by 1.32 %, Sikhism by 0.45 % and Buddhism

by 0.45 %. Around 0.06 % stated 'Other Religion', approximately 0.10 % stated 'No

Particular Religion'.

3.14.2. Methodology

In order to assess the Demographic & Socio-economic features of the 10 km radius study

area based on field surveys and public consultations undertaken during the baseline

field study period and Census records 2011, for the concerned district namely

Gandhinagar of Gujarat state was compiled and placed in the form of tabulation and

graphical representation. Entire study area is observed predominantly rural and urban

3.14.3. Purpose of the Study

Socio-economic study was conducted to establish the baseline demographic features

and impacts due to proposed revamping of existing units, as construction of any major

industrial project invariably leads to Socio-economic changes. The construction of the

project could lead to unplanned and haphazard development of slums of various size

and description with little or rudimentary.

3.14.4. Description of the Environment

Population Distribution within 10 km Radial Zone of the Study Area

As per the census records 2011, the total population of 10-km radius study area was

recorded as 1892817 persons of 34 revenue villages/towns in Vadodara and Anand

District in Gujarat state. All the villages fall under Tehsil Vadodara (26) Savli (5) and

Ankalav (3) in Gujarat state.

Total number of ‘Households’ was observed as 421959 in the study area. Male-female

wise total population was recorded as 986022 males and 90695 females, respectively.





There are Three (03) major towns in the study area named Vadodara, Ranoli and

Nandseri in Vadodara District. As per the census record 2011. Caste-wise and male-

female population breakup of the entire study area villages falling in districts named

Jabua is shown in Table 3.46 as follows.

Caste wise population distribution of the 2.0 km radial study zone is shown in Table 3.46

as follows.





Table 3.46 : Caste-Wise Population Distribution of 2.0 km Radial Zone

Name of the

Village/Town

No of

Households

Total

Population

Total Population

(Male)

Total Population

(Female)

Scheduled

Castes

(Male)

Scheduled

Castes

Female

Scheduled

Tribes (Male)

Scheduled

Tribes

(Female)

Amaliyara 344 1618 857 761 83 72 412 362

Ankodiya 937 4608 2406 2202 342 319 286 270

Sukhlipur 185 942 477 465 50 44 140 117

Sokhda 2454 12610 6546 6064 295 276 379 319

Padmala 1059 5446 2851 2595 264 225 46 49

Ajod 526 2661 1388 1273 150 117 87 79

Asoj 827 3801 1992 1809 184 164 186 177

Sisva 533 2799 1448 1351 114 98 69 56

Virod 506 2461 1289 1172 92 66 533 473

Dena 480 2565 1350 1215 80 66 264 237

Kotali 266 1269 672 597 0 0 291 251

Ampad 296 1610 827 783 23 14 1 7

Mahapura 268 1601 806 795 18 20 18 18

Sherkhi 1841 9464 4874 4590 141 134 64 59

Sindhrot 1480 7027 3604 3423 29 36 72 60





Name of the

Village/Town

No of

Households

Total

Population

Total Population

(Male)

Total Population

(Female)

Scheduled

Castes

(Male)

Scheduled

Castes

Female

Scheduled

Tribes (Male)

Scheduled

Tribes

(Female)

Anagadh 2815 14780 7650 7130 260 230 41 35

Dhanora 864 4006 2099 1907 97 85 59 46

Kotna 594 2902 1462 1440 6 8 0 0

Nandesari

Industries

Association (NIA)

833 3679 2007 1672 29 26 48 50

Dodka 716 3724 1969 1755 128 91 1 0

Rayaka 361 1981 1026 955 78 55 0 0

Sankarda 1472 7460 3908 3552 150 147 43 42

Vasna-Kotariya 796 3974 2129 1845 117 91 0 0

Khanpur 304 1466 799 667 30 34 68 61

Ranoli (CT) 2511 11726 6275 5451 674 623 143 145

Vadodara (M

Corp. + OG)

393887 1752371 912721 839650 60097 56129 37773 33522

Lamdapura 161 880 504 376 22 29 217 147

Zumkal 65 271 138 133 3 5 41 38

Pilol 646 3242 1654 1588 60 58 208 199





Name of the

Village/Town

No of

Households

Total

Population

Total Population

(Male)

Total Population

(Female)

Scheduled

Castes

(Male)

Scheduled

Castes

Female

Scheduled

Tribes (Male)

Scheduled

Tribes

(Female)

Kunpad 581 2788 1442 1346 65 55 2 0

Manjusar 1024 5001 2582 2419 353 304 82 86

Bhetasi Vanta 966 5304 2702 2602 92 83 2 1

Bhanpura 322 1512 781 731 2 2 0 0

Amrol 1039 5268 2787 2481 20 24 1 0

Total 421959 1892817 986022 906795 64148 59730 41577 36906

%Age

Composition

- 100 52.09 47.91 3.39 3.16 2.20 1.95





3.14.5. 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 data reveals the sex ratio as 919 females for every

1000 males in the study area. The male-female wise population distribution of the study

area is shown by graphical representation in Figure 3.33 as follows.

Table 3.47 : Details of Sex Ratio in Study Area

S.No. Particulars Quantity (In No.) %Age Composition

1 Male Population 986022 52.09

2 Female Population 906795 47.91

Total Population 1892817 100

Figure 3.33 : Male Female wise Population Distribution in the study area

3.14.6. Scheduled Caste & Scheduled Tribe Population

Based on the village/town wise SC & ST population distribution for the study area during

2011, the ‘Scheduled Castes’ population was observed as 123878 consisting of 64148

males and 59730 females respectively which accounts as 6.54% to the total population

in the study area. ‘Scheduled Tribes’ population was observed as 78483 accounting as

4.14% to the total population of the study area consisting of 41577 males and 36906

females. It implies that the rest of the total population belongs to the General category.

https://en.wikipedia.org/wiki/Women_in_India





Male-female wise SC & ST population distribution of the study area is graphically shown

in Figure 3.34 & 3.35 as follows.

Table 3.48 : Details of ST & ST Population in Study Area


1 SC

Population Male 64148 3.39

Female 59730 3.16

2 ST

Population Male 41577 2.20

Female 36906 1.95

Figure 3.34 : Scheduled Caste Population in the Study Area

Figure 3.35 : Scheduled Tribes Population in the study area





3.14.7. Literacy Rate

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

region. Total literates’ population was recorded as 1532136 (80.94%) in the study area.

Male-Female wise literates are observed as 826484 & 705652 respectively, implies that

the ‘Literacy Rate’ is recorded with male-female wise percentages being 43.66% &

37.28% respectively. The total illiterate’s population was recorded as 360681 (19.05%) in

the study area. Male-Female wise illiterates were observed as 159538 (8.42%) and 201143

(10.62%) respectively. The male-female wise graphical representation of literates &

illiterates’ population in study area villages/town is shown in Figure 3.36.

Table 3.49 : Details of Sex Ratio in Study Area


1 Literates

Male 826484 53.94

Female 705652 46.06

Total 1532136

2 Illiterates

Male 159538 44.23

Female 201143 55.77

Total 360681

Total 1892817

Literacy Rate 80.94

Figure 3.36 : Male Female wise Distribution of Literates & Illiterates





3.14.8. 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 3.51

Occupation Pattern wise distribution of Population and Graphical representation of

‘Workers Scenario’ of the study area are shown as Table 3.37 respectively as follows.

Table 3.50 : Distribution of Work Participation Rate

Occupation Class Quantity (In No.) %Age Composition

Main Workers 596383 31.50

Male 508952 85.33

Female 87431 14.66

Marginal Workers 50204 2.65

Male 30453 60.65

Female 19751 39.34

Non-Workers 1246230 65.83

Male 446617 35.83

Female 799613 64.16

Total Population 1892817

(Source: Census of India Records, 2011)

Figure 3.37 : Workers Scenario of Study Area





3.14.9. Composition of Main Workers

The ‘Main Workers’ were observed as 596383 (31.50%) persons to the total population of

the study area and its composition is made-up of Casual laborers as 15276 (3%),

Agricultural laborers as 23107 (4%), Household workers 5986 (1%) and other workers as

552014 (92%) respectively. Composition of Main workers is shown below as Figure 3.38.

Figure 3.38 : Composition of Main Workers

3.14.10. Composition of Marginal Workers

The total marginal workers are observed as 50204 (2.65 %) of the total population

comprise of Marginal Casual Laborers as 1929 (4%), Marginal Agricultural Laborers as

7546 (15%), Marginal Household laborers as 1544 (3%) and marginal other workers were

also observed as 39185 (78%) of the total marginal workers, respectively. Details about

marginal workers in the study area are tabulated in Table 3.50. Composition of Marginal

workers is shown in Figure 3.39 as follows.





Figure 3.39 : Composition of Marginal Workers

3.14.11. Composition of Non Workers

Details about total non-workers population of the study area with Graphical

representation are compiled in Table 3.51 and shown by Figure 3.40 as follows.

Table 3.51 : Composition of Non Workers

Non-Workers Population

Persons Males Females

1246230 (65.83%) 446617 (35.83 %) 799613(64.16 %)

Figure 3.40 : Composition of Non Workers





Table 3.52 : Village Wise Basic Amenities Availability

Village

Name P M SS SSS

CH

C

PH

C

PH

SC

MC

WC H D

F

W

C

T W H

P

T

W R Tk CT PO

Tele

p

hon

e

BS RS P

R

K

R NW FP ED

E

Ag. EC EA

Nearest

Town

Name

Nearest

Town

Distance

from Village

(in Km.)

Dodka 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 1 1 2 1 1 2 1 1 1 1 1 RANOLI 9

Rayaka 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 20

Sankarda 1 0 0 1 0 1 1 0 0 1 0 2 2 1 1 2 2 2 2 1 1 2 1 2 2 1 1 1 1 1 VADODARA 14

Vasna-

Kotariya 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 2 2 1 1 1 1 1 RANOLI 10

Sokhda 1 0 1 1 0 1 2 1 1 0 0 2 2 1 1 2 1 2 1 1 1 2 1 1 2 1 1 1 1 1 RANOLI 8

Padmala 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 18

Anagadh 2 0 1 1 0 0 1 0 0 0 0 2 2 1 1 2 2 2 2 1 1 2 1 1 2 1 1 1 1 1 JAWAHAR

NAGAR 6

Ajod 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 20

Asoj 1 0 1 0 0 1 2 0 0 0 0 2 2 1 2 2 2 2 2 1 1 2 2 1 2 1 1 1 1 1 VADODARA 14

Virod 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 9

Sisva 0 0 0 0 0 0 1 0 0 0 0 2 2 2 1 2 1 2 2 1 1 2 1 2 2 1 1 1 1 1 VADODARA 15

Dhanora 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 JAWAHAR

NAGAR 5

Kotna 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 JAWAHAR

NAGAR 8

Dena 1 0 0 0 0 0 0 0 0 0 0 2 1 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 8

Sukhlipur 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 1 1 2 2 2 2 1 1 1 1 1 VADODARA 12

Amaliyara 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 1 1 2 1 2 2 1 1 1 1 1 VADODARA 12

Kotali 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 2 1 2 1 2 2 1 1 1 1 1 VADODARA 10

Ankodiya 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 JAWAHAR

NAGAR 6





Village

Name P M SS SSS

CH

C

PH

C

PH

SC

MC

WC H D

F

W

C

T W H

P

T

W R Tk CT PO

Tele

p

hon

e

BS RS P

R

K

R NW FP ED

E

Ag. EC EA

Nearest

Town

Name

Nearest

Town

Distance

from Village

(in Km.)

Sherkhi 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 2 1 2 1 1 2 1 1 2 1 1 1 1 1 VADODARA 13

Sindhrot 2 0 0 0 0 0 1 0 0 0 0 2 1 1 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 1 VADODARA 12

Ampad 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 2 2 2 1 1 2 1 1 2 1 1 1 1 1 PADRA 7

Mahapura 1 0 0 0 0 0 0 0 0 0 0 2 2 1 2 2 1 2 2 1 1 2 1 1 2 1 1 1 1 1 VADODARA 8

Bhetasi

Vanta 3 0 0 0 0 0 1 0 0 0 0 2 2 1 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 1 ANKLAV 8

Bhanpura 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 1 1 2 1 1 2 1 1 1 1 1 ANKLAV 10

Amrol 4 0 0 0 0 0 1 0 0 0 0 2 2 1 1 1 2 2 2 1 1 2 1 2 2 1 1 1 1 1 ANKLAV 5

Kunpad 2 0 0 0 0 0 0 0 0 0 0 2 2 2 1 2 2 2 2 1 1 2 1 1 2 1 1 1 1 1 SAVLI 12

Manjusar 1 0 0 0 0 0 1 0 0 0 0 2 1 1 1 1 1 2 2 1 1 2 1 1 2 1 1 1 1 1 SAVLI 13

Lamdapur

a 1 0 0 0 0 0 0 0 0 0 0 2 1 1 1 2 1 2 2 1 1 2 1 1 2 1 1 1 1 1 SAVLI 15

Zumkal 2 0 0 0 0 0 0 0 0 0 0 2 1 1 1 1 1 2 2 1 1 2 1 1 2 1 1 1 1 1 SAVLI 17

Pilol 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 1 2 2 2 1 1 1 1 2 2 1 1 1 1 1 SAVLI 20

Khanpur 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADO

DARA 12

Dodka 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 1 1 2 1 1 2 1 1 1 1 1 RANOLI 9

Rayaka 1 0 0 0 0 0 0 0 0 0 0 2 2 1 1 1 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADO

DARA 20

Sankarda 1 0 0 1 0 1 1 0 0 1 0 2 2 1 1 2 2 2 2 1 1 2 1 2 2 1 1 1 1 1 VADO

DARA 14

Vasna-

Kotariya 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 2 2 1 1 1 1 1 RANOLI 10

Sokhda 1 0 1 1 0 1 2 1 1 0 0 2 2 1 1 2 1 2 1 1 1 2 1 1 2 1 1 1 1 1 RANOLI 8

Padmala 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADO 18





Village

Name P M SS SSS

CH

C

PH

C

PH

SC

MC

WC H D

F

W

C

T W H

P

T

W R Tk CT PO

Tele

p

hon

e

BS RS P

R

K

R NW FP ED

E

Ag. EC EA

Nearest

Town

Name

Nearest

Town

Distance

from Village

(in Km.)

DARA

Anagadh 2 0 1 1 0 0 1 0 0 0 0 2 2 1 1 2 2 2 2 1 1 2 1 1 2 1 1 1 1 1 JAWAHAR

NAGAR 6

Ajod 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 20

Asoj 1 0 1 0 0 1 2 0 0 0 0 2 2 1 2 2 2 2 2 1 1 2 2 1 2 1 1 1 1 1 VADODARA 14

Virod 1 0 0 0 0 0 1 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 2 1 1 1 1 1 VADODARA 9

(Source-http://www.censusindia.gov.in/2011census/dchb/DCHB.html)

Abbreviations:

Educational Facilities: P-Primary School, M-Middle School, SS-Higher Secondary Schools, SSS- Senior Secondary School

Medical Facilities: CHC- Community Health Centre, PHC-Primary Health Centre, PHSC-Primary Health Sub-Centre, MCWC-Maternity and

Child Welfare Centre, H-Hospital, D- Dispensary, FWC-Family Welfare Centre

Drinking Water Facilities: T-Tap Water, W-Well Water, HP-Hand Pump, TW-Tube Well Water, R-River Water, Tk-Tank Water, O-Other Drinking

Water Facility

Communication and Transport Facilities: PO-Post Office, SPO-Sub-Post Office, PTO- Post & Telegraph Office, Tel. - Telephone

Connection, Mob. - Mobile Phone Coverage, BS-Bus Services, RS-Railways Services

Sanitation: CT-Community Toilets

Approach to Village: PR- Paved Roads, KR-Kuchha Road, FP-Foot Path

Power Supply: ED-Power Supply for Domestic use, E Ag. - Power Supply for Agricultural use, EC- Power supply for Commercial use, EA-

Electricity for All Purposes

http://www.censusindia.gov.in/2011census/dchb/DCHB.html





3.15. Traffic Study

The site is approachable via NH-8 which is located adjacent to the unit. Traffic count

study was undertaken at NH-8 as it is the main road for transportation of raw materials

and finished products. Existing traffic load conditions and the traffic count observation

are given in Table 3.53 below:

Figure 3.41 : Photographs of Traffic Study and Counting





Table 3.53 : Traffic Load Conditions at NH-8

S.No. Hours

Baseline

Two

Wheelers

Three

Wheelers

Four-

Wheeler

Six-

wheeler

(Bus/Truck)

More

than Six

wheelers

(Trailers)

Baseline

PCU/Hr

Increment

PCU/Hr

Predicted

PCU/Hr

Capacity

of Road

in

PCU/Hr

LOS

Baseline

LOS

Predicted

%

Increase

1 06:00- 07:00 70 52 80 150 120 1222 32 1254 10286 0.12 0.12 2.62

2 07:00- 08:00 80 67 99 50 45 727 13 740 10286 0.07 0.07 1.79

3 08:00-09:00 135 49 99 40 56 751 10 761 10286 0.07 0.07 1.33

4 09:00-10:00 145 65 100 46 70 903 11 914 10286 0.09 0.09 1.22

5 10:00-11:00 156 73 104 143 101 1295 7 1302 10286 0.13 0.13 0.54

6 11:00-12:00 132 40 90 56 77 845 7 852 10286 0.08 0.08 0.83

7 12:00-13:00 100 23 67 40 29 460 23 483 10286 0.04 0.05 5.00

8 13:00-14:00 80 21 78 12 69 585 17 602 10286 0.06 0.06 2.90

9 14:00-15:00 50 12 50 29 49 435 21 456 10286 0.04 0.04 4.83

10 15:00-16:00 100 10 56 46 56 551 19 570 10286 0.05 0.06 3.45

11 16:00-17:00 148 24 34 59 50 630 15 645 10286 0.06 0.06 2.38

12 17:00-18:00 152 48 83 48 60 788 13 801 10286 0.08 0.08 1.65

13 18:00-19:00 153 80 110 45 32 782 18 800 10286 0.08 0.08 2.30

14 19:00-20:00 200 73 120 34 45 853 4 857 10286 0.08 0.08 0.47

15 20:00-21:00 230 50 139 23 80 965 5 970 10286 0.09 0.09 0.52

16 21:00-22:00 159 42 99 79 99 1042 6 1048 10286 0.10 0.10 0.58

17 22:00-23:00 50 32 69 160 130 1190 30 1220 10286 0.12 0.12 2.52

Average 126 45 87 62 69 825 15 840 10286 0.08 0.08 35





Figure 3.42 : Graphical Representation of Traffic Load at NH-8

The above graph represents that there shall be negligible change in LOS in the main

approach road i.e., NH-8 due to the proposed revamping.





CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

4.1. Introduction

Any developmental activity in its wake will bring about some impacts associated with its

origin, which can be broadly classified as reversible, irreversible, long, and short-term

impacts. In this chapter, an endeavor has been made to identify various Environmental

Impacts associated with the plant operation and other activities wherein, there may be

a chance of pollution. Based on the possible worst-case emissions and waste generation

from the proposed revamping project and taking into consideration the baseline

Environmental status at the existing project site, the environmental factors that are likely

to be affected (Impacts) are assessed and identified.

Both beneficial (positive) and detrimental (negative) impacts are accounted for this

purpose. The prediction of impacts helps in the preparation of a sound Environmental

Management Plan which must be executed during the on-going activities for the

proposed project to minimize the adverse impacts on the environmental quality. In some

case, mathematical models were used to quantitatively describe the cause-effect

relationships between the sources of pollution and different components of

environment. In case if the mathematical models are not available or it is not possible

to identify/validate a model for situation, predictions would be made through available

scientific knowledge.

The possible impacts on various components of environment by proposed revamping of

fertilizer project of GSFC can be assessed in terms of:

• Physical and Biological Environment and

• Demographic and Socio-economic Environment.

The following sections list out potential impacts on the environment from proposed

project due to the nature and extent of various activities associated during the

implementation and operation stages and status of the environmental quality at the

project site by considering both positive and negative impacts.

4.2. Impact Assessment Criteria

The impact has been identified by the following methods:





1. Matrix method: Interaction between the various project activities (during pre-

construction, construction, and operation phase) and environmental

components using the grid like table. “✔” Tick sign is being used wherever;

activity is interfering with the environmental component. This matrix method also

helps in preparing checklist.

2. Checklist: Checklists are comprehensive lists of environmental effects and impact

indicators designed to stimulate the analyst to think broadly about possible

consequences of contemplated actions. This method is being used to identify the

direct and indirect impact due to the project.

3. Scaling Checklist: It is like the descriptive checklist with additional information on

subjective scaling of the parameters. Impacts will be assessed on basis of their

duration, nature, scale and severity. Impact assessment criteria is given in Table

4.1

Table 4.1 : Impact Assessment Criteria

Criteria Description

Duration of Impact Long term

Short term

Nature of Impact Reversible

Irreversible

Scale Core zone

Buffer Zone

Severity Low

Moderate

High

After assessment of the impacts, significance of the impact will be judge. An impact can

be of low significance, moderate significance or high significance depending on its

effect on the environment and social parameters to be affected due to project

development. Significance criteria have been designed for various permutation and

combinations of above given impact assessment criteria. Impact significance matrix is

given in Table 4.2.

Table 4.2 : Impact Assessment Criteria

Significance Scenarios

High Significance Long term, Irreversible, buffer/core zone & high;

Short term, irreversible, buffer/core zone & high

Moderate

Significance

Long term, Irreversible/reversible, core zone & moderate;

Short term, irreversible, buffer/core zone & moderate;

Long term, reversible, core/buffer zone & high/moderate;

Short term, reversible, buffer/core zone & high;

Long term, Irreversible/reversible, buffer zone & low;

Low Significance Long term, Irreversible/reversible, core zone & low;

Short term, reversible, buffer/core zone & moderate/low





Nil No Impacts

4.3. Summary of Baseline of Project Area

Data on existing baseline quality and status of all the physical, biological, and social

environments is collected for the project area through primary and secondary sources

and is summarized in Table 4.3.

Table 4.3 : Summary Baseline Scenario of Project Area and Likely extent of Impact

S.

No.

Environmental

Component

Baseline Scenario Sensitivity Level

of baseline

scenario

Probability and

Significance of likely

impact on valued

Environmental

Components

1. Road

Connectivity

& Traffic

Pattern

Good Road

Connectivity

The site is

approachable

via NH-8 which is

located

adjacent to the

unit.

- The site is well

connected to

NH-8.

- Rail Yard is also

developed in

the plant for

transportation of

finished product

all over India.

Nil

Finished product i.e.

(Prilled Urea) will be

transported through rail.

2. Air Quality Mean

concentration:

PM10 :40-96µg/m3,

PM2.5: 18-49

µg/m3,

SO2: 5-12.8 µg/m3,

NOx:9-20.6µg/m3,

NH3: 9.2-

27.7µg/m3 and

CO: 0.26-1.22

mg/m3

The overall air

quality of the

project area is

within the

prescribed

National

ambient air

quality standard

of 2009

Nil/Minimal

Emission levels will not

increase due to

proposed revamping.

However, there will be

dust generation and air

emissions due to

demolition and

construction phase.

3. Noise Level Day Time Leq

level: 51.8 dB(A)

to 57.2 dB(A) and

Nighttime Leq

level: 38.8 dB(A)

to 45 dB(A)

Within the norms

both during

night and during

daytime as per

prescribed

Ambient Noise

level standards

Nil/Minimal

Noise limit will be

maintained by using

noise protection

measures.

4. Seismicity II Moderate Risk

Zone

Low/Minimal

Refurbishing of existing

plants will be done for

proposed revamping.

5. Topography Almost plain

(35 to 60 amsl.)

-- Nil





S.

No.

Environmental

Component


of baseline

scenario

Probability and


impact on valued

Environmental

Components

6. Drainage No nala or stream

is crossing the site.

As no nalla or

drain present no

impact on

drainage

Nil

7. Flora & Fauna Green Belt of

approx. area

123.2 Ha. (37.56%

of total plot area)

has already been

developed.

Biodiversity is

being

maintained in

the project

complex and

township as well.

Nil/Low

There will be neither tree

cutting nor transplantion

of existing trees for

proposed revamping.

However, due to

demolition and

decommissioning of

machinery, minimal

disturbance maybe

experienced by flora

and fauna nearby

project.

8. Demography Existing

employees: 5338

no. Around the

project site, there

are minor

settlements

located and

there are

industrial areas

developed

nearby the site.

Urban Good

Employment will be

given to local labours

during construction

phase. However, there

will be decrement in

manpower during

operational phase as

there will be running of

only 1 urea plant i.e.,

revamped urea unit.

9. SW quality No water body

traverses through

the project area.

Treated water

from ETP is being

discharged into

sea via VECL

Channel only

after maintaining

suitable norms as

prescribed by

GPCB.

Low Nil

For proposed

revamping, there will be

reduction in wastewater

discharge, as the

revamping unit will reuse

the treated w/w to the

maximum possible

extent and discharge

mode shall remain as per

the present practice

scenario.

10. GW Quality Ground water

quality is found

good at the study

area.

Nil

Groundwater is

not being used

at all.

Nil





S.

No.

Environmental

Component


of baseline

scenario

Probability and


impact on valued

Environmental

Components

11. Land Use Land use of site is

industrial

No change Nil

(Primary and secondary sources)

4.4. Identification Linkage between Project Activities and Associated Impact

The linkage between natural (physical & biological) and human (social) environmental

components that have scientific, economic, social, or cultural archaeological, historical,

or other significance and are considered in the environmental assessment process.

Project activities which may have impact on environmental components includes the

following:

• Construction of different plant process units, and utilities infrastructure and various

required buildings.

• Operational activities (during operational phase) of the project.

As per the nature of activities involved, it is apparent that during both construction as

well as operational phases certain impacts are anticipated during implementation of

the project. Matrix for impact identification on the different environmental components

for each of the project activity during construction phase is given below in Table 4.4:





Table 4.4 : Impact Identification Matrix

Project Activities Physical Components Biological

Components

Social

Component

s AQ NL SWQ GWQ SQ Traffic Drainage LU Resources EB

Construction activities

Demolition √ √ × × √ √ × × × √ √

Material storage yards,

casting yards, etc.

× × × × × × × × × × ×

Heavy Equipment Operations √ √ × × × √ × × √ √ √

Transportation of construction

material,

√ √ × × √ √ × × √ √ √

Disposal of construction waste √ √ × × × √ × × × × ×

Generation of Sewerage × × × √ √ × × × × × √

Influx of construction workers × × × × × √ × × × × √

Operation Phase

Product Manufacturing √ √ × × √ √ × × √ √ √

Transportation of raw material

and finished product

× × × × × × × × × × ×

Utility requirements (water,

power, manpower etc.)

√ √ × × × × × × √ × √

Wastewater and solid waste

generation

√ × × × √ × × √ X √ √

Source: EQMS Assessment





4.5. Impact Assessment and Evaluation

Identification of project activities (project pre-construction, construction, and operation

phases) and environmental components which may be impacted due to different

project activities is carried out and is given in Table 4.4. Significance of impact on each

of the identified environmental components for all the activities is assessed and

evaluated using qualitative and quantitative techniques. Thereafter, cost-effective but

appropriate mitigation measures are proposed to eliminate or minimize the identified

impacts. An EMP has been designed to ensure the effective implementation of

proposed mitigation measures. Impact assessment and evaluation along with the

mitigation measures is given in sections below.

4.6. Impacts during Construction & Operation Phase

4.6.1. Impact on Air Environment

Construction Phase

Under proposed revamping project, demolition of few parts in both the plants will be

done. There will be de-commissioning of machineries and equipments and replacement

of existing with new equipments to attain the target of energy norms and increase

efficiency of the plant. G+1 story electrical substation will be built for installation of new

PMCC electrical panels & VFDs. Mechanical maintenance workshop also shall be

developed. However, due to some demolition in the plant, there might be generation

of PM and dust in the plant, but it will be limited to construction activities only. However,

the impact anticipated will be very minimal. The complex is maintaining levels of air

emissions as per CPCB/GPCB norms. Any impact anticipated will be taken care of during

construction phase.


• Internal roads have already been well developed at the project site, so this will

reduce the abrasion and thereby reduce the dust generation.

• Wind breakers will be installed.

• Barricading will be done around the construction site to control dust dispersion


• Construction material vehicles will be covered during transportation.

• Dust suppression will be done by regular water sprinkling in and around the

project site.

It can be concluded from the above discussion that the integrated implementation of

the above said control measures shall control the dust pollution at the site so that

surrounding will not be affected.

Operation Phase





GSFC Vadodara Complex is an operational unit that sincerely complies to all possible

environmental protection measures to the best extent. As discussed already in baseline

description, ambient air quality within the project is being well maintained within limits

prescribed by CPCB (PM10: 69 µg/m3, PM2.5: 32 µg/m3, NOx: 14.7 µg/m3, SO2:7.5 µg/m3,

NH3: 18 µg/m3, CO: 0.48 mg/m3). Nehru Nagar is the nearest residential area to the

complex located at 0.06 km, S in the downwind direction. It was observed that the

ambient air quality the area was within the limits with satisfactory air quality index.

Additionally, it can also be observed that another residential area located in downwind

direction i.e., Vrindavan Township located at (7.12 km, SW), ambient air quality was

within CPCB prescribed limits with satisfactory air quality index. Therefore, it can be noted

that the existing complex does not pose major negative impact to its nearby sensitive

areas. In existing Urea-II plant, vibropriller has been installed to reduce dust emissions.

APCM like water scrubber and H2SO4 scrubber with efficiency of 99.5% have been

installed in the units to curb emissions. Regular monitoring of urea emissions is done via

third party laboratory to keep in check with the emissions. The emissions are within the

norms specified by GPCB.

Under proposed revamping project, new section consisting of Hydrolyzer and desrober

will be installed that will recover NH3, CO2 and Urea contained in the process.

Additionally, modifications in the existing equipments like replacement of ammonia

pump with new ammonia pump, refurbishing of turbine driven centrifugal pump,

modification in existing Urea reactor will help in better efficiency of the unit. New

Reactor (XU-R101N) will be installed with full set of Casale High Efficiency trays to achieve

optimal conversion. Crystallization section will be replaced by new modern evaporation

section to improve the steam balance of the plant and achieve energy saving target.

Considering such modifications, the plant will be able to maintain air emissions within the

limits of GPCB norms. Infact, due to proposed revamping, there will be reduction in dust

emission by elimination of crystallizer, centrifuge, dryer and other handling equipments

with installation of new vacuum evaporation section. Hence, it will also lead to decrease

in fugitive emissions too. Hence, plant will not impact the ambient air quality within the

site and surroundings in a negative extent.

Emissions from DG Sets:

During normal conditions, electricity is provided by Windmill/Cogeneration Plant and

MGVCL. DG sets located within the premises will be used during emergency only.

Various DG Sets have been installed for different units. After revamping, 1 DG set of

capacity 500 kVA will be installed with appropriate stack height. Details of which have

been mentioned in Section 2.8.2 of Chapter-2 above. DG Sets have been installed to

keep the most essential equipment inline in the event of temporary power failure and to

provide a safe shutdown of the plants in case of prolonged power failure. The emissions

from DG sets are PM, SO2 & NOx.

Emissions from Vehicular Movement:





There will be minimal impact due to transportation of raw materials and finished good

through trucks as raw materials are transported to the project via pipeline and mostly

finished products will be transported via rails.

The unit already follows several air pollution mitigation measures and will abide by the

same in proposed revamping phase. The following are few of the mitigation measures

adapted by complex for minimizing air pollution:

Mitigation Measures

• Adequate air pollution control system has been installed to achieve prescribed

norms.

• Approx. 123.2 Ha. of Green Area i.e.,37.56 of total plot area has been provided

in the plant.

• Online Stack Monitoring System has been installed in the plant for online air

parameters measurement and is connected to CPCB/GPCB.

• Natural gas is being used for boilers to control air emissions.

• Adequate stack height has been provided in all the units as per CPCB norms.

• Urea Plants are operational having forced draft prilling tower. Both these plants

have scrubbers to achieve existing norms of urea dust emission. The emissions are

within the norms specified by GPCB. Moreover, Vibropriller has been installed in

prilling tower for reduction of dust emissions.

• GSFC carries out regular ambient air quality monitoring at the periphery and

nearby villages about SO2, NOX, PM10, PM2.5 and Ammonia as well as SO3,

Flouride and Acid Mist parameters. Monthly average results are online submitted

to GPCB. Moreover, 4 no. of online AAQMS are in operation at the periphery of

premises and connected to GPCB and CPCB server.

• Stack monitoring facilities like portholes, ladder/platform etc. have been

provided to all stacks/vents and chimney.

• The roads are made of asphalt in the company premises. All internal roads are

made of concrete.

• Measures for control of fugitive emissions are given in Section 2.9.2.

4.6.2. Impact on Noise Environment

Construction Phase

There will be construction and demolition activities for proposed revamping project. Few

modifications in existing machineries including de-comissioning and refurbishing and

installation of new equipments have been planned for the project. There may be noise

generation during the construction activities but will be limited to a short span of time.

Noise levels within the plant are maintained within the limits by maintenance of thick

green belt around the boundary of site. However, impact due to construction activities

will be consized to low level by abiding of following mitigation measures:





• Acoustic enclosures will be installed for DG sets in accordance with CPCB norms.

• Green Belt has been provided around the project boundary to curb excessive

noise emissions from the construction site.

• Construction machineries will be provided with acoustic pads for noise reduction

during operation.


• Construction activities, including receipt of material will be done during daytime

only.

• Proper maintenance of noise generating transport vehicles will be done.

Operation Phase

GSFC Vadodara Unit is maintaining noise levels prescribed by CPCB/GPCB. As per the

baseline studies done, noise levels of project site are within the limit {Leq Day: 54.6 dB(A)

& Leq Night: 42.1 dB(A)}. The main sources of noise generation in the plant are various

types of ID fans, pumps & compressors, turbines, DG sets, etc. However, noise generating

machineries and equipments are well insulated for noise reduction to mitigate noise

generation. Green development has been done in and around the project site to

minimize noise. Necessary engineering controls like silencers have been provided in the

plants to reduce noise. Nearest residential area located to the project site is Nehru

Nagar located at 0.06 km in S direction of the project site. The noise levels in the area

are within the limits of residential zone i.e., Leq Day: 55 dB(A) & Leq Night: 45 dB(A). Similar

results have been observed in nearby areas like Chhani Jakatanaka (N-4) and Dashrath

(N-7). Thus, areas in vicinity to the project site also validate that noise levels are well

maintained in the plant.

Under proposed revamping project, there will be barely minimal increment to noise after

its operation. The noise generated from the project activities will not be attenuated

significantly due to atmospheric attenuation. Also, by using standard practice of

operation, these impacts will be minimized and made insignificant. It is, therefore,

concluded that the existing noise level in the area will remain practically unchanged.


within the premises so as to maintain ambient air quality standards in respect to noise to

less than 75 dB(A) during daytime and 70 dB(A) during nighttime. Daytime is reckoned

in between 6:00 am to 10:00 pm and nighttime is reckoned between 10:00 pm to 6:00

AM. Noise measurement is being carried out periodically.


• Noise monitoring is carried out at 80 different locations within the premises. The

ambient noise levels conform to the standard prescribed under EPA Rules, 1986.

• Various engineering controls are taken at different plants like on exhaust, acoustic

enclosures, soundproof cabin, preventive maintenance etc.

• Noise levels at periphery are monitored through NABL approved laboratory.





• Approx. 123.2 Ha. of Green Area i.e., 37.56% of total plot area has been provided.

• Equipment meeting standard of noise shall be used.

• All engineering control practice shall be undertaken during installation of

machinery to maintain noise level.

• Acoustical Enclosures and Mufflers are provided at all required locations.

• Vibration pads and foundation is provided at all heavy machinery areas.

• Noise generating units like machinery area, canteen etc. are well insulated with

enclosed doors.

• Earmuffs are being used while in high noise areas. Separate cabins are provided.

• Acoustic treatment rooms are provided at appropriate location

• Well-developed road is constructed within plant, for smooth and hassle-free

movement of personnel.

• Proper and timely maintenance of machineries and preventive maintenance of

vehicles is being done.

• Important Instructions are displayed all over the plant area.

4.6.3. Impact on Water Quality

Construction Phase

All existing facilities like drinking, sanitation shall be used during the

installation/construction purposes. Existing supply of water shall be used for meeting

requirement of labour. Wastewater generated from toilets shall be disposed as same as

existing practice i.e., disposed through soak pits. Thus, no impact on water quality is

envisaged during construction phase. However, all standard practices shall be

maintained to maintain water quality.

Approx. 10 KLD water will be required during construction phase of proposed revamping

project. 4 KLD freshwater will be used in domestic purposes for labours that will be

supplied by existing source of GSFC Complex i.e., 4 no. of French wells of Mahi River.

Domestic sewage will be disposed in septic tanks with soak pits.

Operation Phase

Existing Phase: As described in Section 2.9.1 above, the total water requirement of

existing units is 6046.1 KLD (251.92 m3/hr). Out of which, raw water requirement of units is

5035.7 KLD (209.82 m3/hr) being supplied by existing source of GSFC i.e., 4 no. of french

wells of Mahi River. Wastewater generation is 1060.08 KLD (44.17 m3/hr). Out of total, 144

KLD (6 m3/hr) is being sent to Phosphoric Acid Chalk Pond/Urea lagoon that is sent to PA

Plant for reuse. Rest of wastewater i.e., 916.08 KLD (38.17 m3/hr) to sea via VECL Common

Effluent Channel. There is no treatment scheme for wastewater generated from the units

as most of the wastewater is being disposed to the effluent disposal pond. 5 KLD of

domestic sewage is being disposed off to soak pits located within the complex.





Proposed Revamping: Under proposed project, the raw water requirement of the

project will get reduced by approx. 2907.6 KLD (121.15 m3/hr). There will be increase in

water recycle/reuse practices by installation of new wastewater treatment section that

will recover NH3, CO2 and urea contained in the process water and produce clean

process condensate for reuse within the plant. The total wastewater generation will be

757.68 KLD (31.57 m3/hr). Process condensate generated from plant i.e., mainly vacuum

evaporator section will be treated in Wastewater Section and treated water i.e., 691 KLD

(28.8 m3/hr) will get directly reused in cooling tower makeup. 144 KLD (6 m3/hr) will be

sent to Phosphoric Acid Plant for recycle. Rest of wastewater i.e., 613.68 KLD (25.57 m3/hr)

CT blowdown will be directed to effluent disposal pond as per existing practices. 3 KLD

of domestic sewage will be discharged to soak pits as per existing practices as

operational manpower will be reduced.

However, to maintain water quality within the project and keep consumption and

wastewater generation inline, following mitigation measures are being followed and

same shall be followed after proposed revamping too.

Mitigation Measures

• Analysis of final discharged effluent is being carried out regularly.

• Effluent from the process plant and associated facitlies are not discharged to storm

water drain to prevent contamination of storm water.

• Development of many rainwater harvesting systems like ponds, recharge wells, etc.

• Real-time online monitoring system have been installed fro effluent parameters like

COD BOD, pH, TSS etc. and is connected to GPCB as well as CPCB server.

• Treated Industrial effluent from final discharge ponds conforming to GPCB norms is

being discharged into common effluent conveyance channel of VECL.

• Metering facility (Magnetic flow meter) on effluent discharge line has been provided.

• The quality of total effluents discharged from GSFC which includes lean streams

through open channel to disposal pond. It is being monitored as and whenever

required.

• In case of spills of chemicals, dry adsorbents/cotton are being used for cleaning

instead of water

• Spillage during loading, unloading & storage are channelized properly to drains

• Spillage are managed by detection of leaks in the first place from structures or

vessels.

• Collection of effluent are in closed pipeline

• Cushion are provided to the materials to prevent chemical container breakage

• The transportation of the raw material, chemicals & products is being done in Leak

Proof MS Tankers/Drums while transporting through trucks & tempo.

• All probable leakage areas such as pipelines, joints, pumps, and structure of reactor/

storage vessel are inspected and maintained proactively.

• Cleaning of storm water drain/open channel in the complex is carried out before

monsoon season.





4.6.4. Impact due to Waste

Construction Phase

There will be few amounts of construction and demolition wastes generated during

construction phase. Improper handling of C&D Wastes may lead to damage to nearby

soil environment and biotic environment. However, it will be made sure that C&D wastes

will be sent to designated sites. Discarded machinery will be sold and used oil shall be

stored in drums for further disposal to registered recyclers. Municipal waste will also be

generated by labourers during construction stage that will be disposed off to designated

Municipal Waste Disposal Site.

Operation Phase

There are generation of different kind of Industrial hazardous wastes from production

process and other activities. Process residue spent catalyst are generated which are

hazardous, which may cause harm if met skin and sludge and any other may cause

nuisance if not maintained properly. There is potential for accidental spills while re-

fuelling or servicing vehicles and through the breakage due to wear and tear. Thus,

proper disposal of waste is required for to maintain hygiene at site.

GSFC Vadodara complex being hub of several products generate various kinds of

hazardous and non-hazardous wastes. However, waste is being effectively managed

and handled to neutralize damaging effects in and around the project site. The unit

does not discharge any hazardous/non-hazardous waste into the water or soil.

Groundwater quality results of nearby validate the same. The groundwater quality of

nearby site (GW-2; Borewell nearby Project Site) validates the same as its hydrochemistry

does not indicate any elevated levels of toxic substances like heavy metals (Cd, Pb

etc.), Cyanide etc. GWQI of the nearest monitoring location with Index Value of 56

(Good) has also inferred the same.

Since, there will be no increment in production capacity after revamping, there will be

no increment in hazardous waste generation. However, following mitigation measures

are being followed in existing practice and the same will be followed after revamping.

Mitigation Measures

• Industrial hazardous wastes such as spent lube oil, spent catalyst are sold to recyclers.

ETP sludge generated is disposed off at TSDF site while other solid wastes are

segregated in saleable and non-saleable waste. All wastes are disposed as per

Hazardous & Other Waste (Management and Transboundary Movement)

Amendment Rules, 2021.

• Wastes are dried, packed, and stored in separate designated hazardous waste

storage facility before its disposal. GSFC strictly complies with the rules and

regulations with regards to handling and disposal of hazardous waste in accordance





with Hazardous & Other Waste (Management and Transboundary Movement)


• Waste is packed in drums/HDPE bags and stored at designated area. All measures

are taken to avoid littering.

• All the safety precautions are taken for safe handling and storage i.e., illumination of

its piping and storage area, ensuring leak proof system, use fo PPE, keeping eye on

all process parameters day to day through DCS on round the clock basis, required

trips and alarm aystem etc.

• Safety department co-ordinates regularly for necessary compliance pertaining to

Factory Act and Manufacture, Storage and Import of Hazardous Chemical Rules.

• Necessary alarms/trips/interlock like high level, temperature have been installed in

hazardous material handling area.

• The spent catalysts are packed in drums and stored in separatestorage area and

sold to MoEF&CC/CPCB registered recylers. The details of the catalysts sold are being

regularly submitted to GPCB.

• Separate paved storage area for Hazardous/ Non-Hazardous/ Municipal is provided

within the plant area.

• Adequate measures and technologies are adopted in the plant to reduce the waste

generation.

4.6.5. Impact on Land Environment

Land Acquisition

No additional land has been proposed for the proposed project. GSFC Complex has

been in possession of GSFC since 1967. The site has been been classified under Notified

Area by Industries, Mines and Energy Department. The land-use of the project is

Industrial. There will be no acquisition of land for propsoed revamping project.

Construction Phase

There will be no Land use / Land cover change as the proposed project is revamping of

existing units that will be refurbished and redesigned to form a better and efficient

revamped urea manufacturing plant based on latest technology. There will be no tree

cutting for the proposed project. However, there will be demolition of few units and civil

structures for the project. C&D wastes and de-commissioned machineries will be

disposed off at designated sites. Solid Waste Management Rules, 2016 and Construction

and Demolition Waste Management Rules, 2016 shall be adhered to.

Operation Phase

The units for proposed revamping exist in a vast complex having several varieites of

chemical products and fertilizers. Since there is no additional land for proposed

revamping, there will neither be change in land-cover or land-use for the same. Since,

there will be no increment in production capacity, hazardous waste generation will no





be increased. The following mitigation measures are being implemented regularly in the

industry and the same will be followed afte revamping.

Mitigation Measures

• Municipal Waste (Domestic and or commercial waste) is being disposed as per

Solid Waste Management Rules, 2016.

• Hazardous waste generated in the Plant is being disposed as per Hazardous &

Other Waste (Management and Transboundary Movement) Amendment Rules,

2021.

• All precautions are being taken to avoid spillage from storage during existing

phase and shall be taken during further phase.

• Spillage are managed by detection of leaks in the first place from structures or

vessels. Spillage during loading unloading is channelized properly to drains.

• Paved area is provided near the process area to avoid soil contamination

• The loading unloading activity are done within a safe zone defined and in a

marked safe area.

4.6.6. Impact on Soil Quality

Construction Phase

Soil erosion may happen if open areas are left without paving or plantation. Thus, it is

required to either pave or green the open areas. Soil may get contaminated, if sewage

is disposed of on the soil, littering of municipal waste, e-waste and spillage of HSD, oil

and fuel. Mitigation measures proposed are given below:


• Existing Sanitation and waste management practice shall be adopted during

construction phase during influx of local labour.

• Replacement or discarded machinery shall not be with kept on unpaved surface.

Discarded machinery will be given to approved recycler.

• Used oil shall be stored in drums and shall be sold to registered recycler.

• Dry absorbent cleaning method shall be adopted.

• Drains are already provided near machinery area to collect spillage or leakage.

• Best management practices shall be adopted to avoid the contamination of soil.

Operation Phase

Spillage of material like effluent, chemical, hazardous waste, used oil and fuel may

contaminate the soil. Due to improper disposal of solid waste & liquid waste includes the

leaching from biodegradable waste and effect on flora from spillage of waste on soil.

Improper disposal of Effluent during shutdown may encounter soil and contaminate.

However, the complex does not discharge neither liquid effluent nor solid waste directly

into the soil. Soil quality of project site as well as nearby places with medium to high

fertility status validate the same. Soil analysis of project site has indicated that there is no





presence of toxic elements. Infact, the site had high considerable amounts of macro

and micronutrients.

The complex abides by various protection measures that avoid soil pollution. The details

have been provided below. Similar practices will be maintained after revamping also.

• All underground tanks are provided with extra prevention to avoid leakage. Sensors

are provided to detect leakage.

• Hazardous waste is managed, transported, and disposed as per Hazardous & Other

Waste (Management and Transboundary Movement) Amendment Rules, 2021.

Separate shed/designated area with paved area is provided at plant for storage of

Hazardous waste.

• Closed Effluent channelization is provided all over the plant area. Domestic sewage

wastewater is being disposed through soak pits.

• Solid waste collection and disposal area is paved area to avoid contamination of

soil through leachate.

• Water less cleaning is adopted wherever spill occurs to avoid runoff.

• No area shall be left excavated or open after any repair & maintenance works

• Used oil shall be stored drums and shall be sold to registered recycler.

• Drains are already provided near machinery area to collect spillage or leakage.

4.6.7. Impact on Ecology and Biodiversity

Construction Phase

The proposed land is already under possession of GSFC. Due to demolition and

refurbishing activities for proposed revamping, there will be generation of noise and

waste inside the premises which might impact components of surrounding biotic

environment. However, the location of Urea-I & II is in the center of the complex where

other manufacturing plants like Melamine, Caprolactam etc. are located. Urea plants

are surrounded by industrial units in the plant where there is very low to minimal density

of flora and fauna located. There will be no tree cutting for proposed revamping project.

However, noise levels will be maintained under limits and C&D waste will be carefully

disposed off to designated C&D facility.

Operation Phase

The impact on the surrounding ecology during the operation of the project will mainly

occur from the deposition of air pollutants. Air pollution affects the biotic and abiotic

components of the ecosystem individually and synergistically with other pollutants.

Chronic and acute effects on plants and animals may be induced when the

concentration of air pollutants exceeds threshold limits.

Since there will be no increase in production capacity, no increment in air emissions is

expected. Additionally, under proposed technology, there will be recovery of ammonia





and carbon di-oxide that would eventually lead to decrease in air emissions due to

proposed revamping. Hence, there will be no detrimental impact on ecological

components.

There will be no increase in air emissions and waste discharge from proposed revamping.

Infact, both will get decreased due to installa reduction in dust emission by elimination

of crystallizer, centrifuge, dryer and other handling equipments with installation of new

vacuum evaporation section and reduction in freshwater requirement. Amount of

treated water recycle will be increased.

The project is therefore planned with most efficient air pollution control systems for

achieving air emissions norms, so that the impact on nearby ecosystem are minimized.

Most of the fugitive dust emission generation points are also fitted with efficient air

pollution control systems.

a) Impact on Forest Ecosystem

No reserved forest area is present within the study area (10 km radius). As per the

baseline study, all parameters are within limit of the national ambient air quality

standards and only minor increase in production of fertilizer is proposed that will not pose

threat to the ecosystem. There will be decrement in discharge of treated effluent into

sea via VECL Channel. Treated effluent is being monitored regularly before discharge

asn the same will be maintained. Thus, no major impact is anticipated due to the

proposed project. All GPCB and MoEF&CC standards shall be maintained. Beside above

dense green belt has been already developed all along the boundary premises which

will act as a barrier for noise and air pollution.

b) Impact on Aquatic Ecosystem

The generation and discharge of untreated waste into nearby area may pollute the

surrounding aquatic system. Treated Industrial effluent from final discharge ponds

conforming to GPCB norms is being discharged into common effluent conveyance

channel of VECL. Process effluent will be reused within the plant to maximum extent.

Thus, no impact on the aquatic ecology is envisaged. However, Crocodiles and turtles

(Schedule-I species) exists in Vishwamitri River.

c) Impacts on RET species

No national park, wildlife sanctuary, biosphere reserve exists within 10 km area of the

project. No endangered or rare or threatened plant or animal species was observed

within 10 km area of the project site hence impact on RET species is negligible. However,

Crocodiles and turtles (Schedule-I species) exists in Vishwamitri River. Also, Indian

Peafowl (Schedule-I species) have been observed in the study area.

Mitigation Measures

• The project is planned with most efficient air pollution control systems for achieving

air emissions norms, so that the impact on nearby ecosystem is minimized. Most of





the fugitive dust emission generation points are also fitted with efficient air pollution

control systems.

• Water sprinkling system will be used to suppress the generation of fugitive dust.

• No wastewater shall be discharge outside the plant premises. The treated effluent

shall be recycled and re-utilized within the premises for de-dusting and maintenance

of green belt.

• All the solid and hazardous waste shall be disposed as per the norms

• Approx. 123.2 Ha. of Green Area i.e., 37.56 % of total plot area has been provided in

the plant. More than 9-10 m wide green belt is provided all around the boundary wall

of project site.

4.6.8. Socio-economic environment

Construction Phase

There will be employment generation for 70 no. of local labourers that would be required

for proposed construction and demolition activities. Most of the unskilled and semi-skilled

labour will be hired from nearby villages. The project construction activity will have

positive impact on the social environment. Accident and Noise related problems in the

plant are the main concerns for local labour. Accident may cause disability or life loss

and working in noisy area may cause speech interference, annoyance, hearing

impairment, increase in heartbeat/ blood pressure of the human. Thus, measures are

necessary to be adopted to overcome these impacts.

Mitigation Measures

• All basic facility like sanitation, toilets, canteen, camps shall be provided within the

plant area.

• Hygiene conditions shall be maintained at site.

• PPEs shall be given to all labour working in noise-prone area.

• Health and safety officer shall be deputed all the time during construction phase.

• MSDS and safety instruction shall be displayed in working area.

Operation Phase

There will be reduction of manpower to 64 no. only due to running of only one urea plant

at a time. Health and safety of employees are taken seriously at GSFC, and every

measure is being followed. However, due to operation & maintenance there may be

various risks for the staff and other nearby people. The risks associated are accident of

people, collapse of structures, fall/slip while working, electrical shocks, electrical fire, fire

in DG sets & fuel tanks, health impact due to air & noise pollution etc. Various safety

measures are proposed to be followed which should be taken to prevent the accidents

and near miss. Also, improper storage and disposal of waste may decrease the aesthetic

value, lead to risk of disease may occur foul smell which will cause nuisance in staff and

nearby area. At the extent, all possible measures are already adopted by the GSFC to

reduce impact on staff and nearby area.





Mitigation Measures

• Medical Compliance (six monthly) of employees is carried out on regulat basis by

Occupational Health Centre located within premises. Records are maintained at

OHC.

• Regular training on safety and health aspects are organized by safety and

medical services department and workers are depute for the same.

• All the workers are continuously trained for proper handling and transportation of

hazardous materials as per Hazardous & Other Waste (Management and

Transboundary Movement) Amendment Rules, 2021.

• Solid waste generation in operational phase are Domestic waste, landscape

waste. That are managed as per Solid Waste Management Rules, 2016.

• Plant will be shutdown during failure of APCS.

• All measures are adopted to reduce fugitive emission as discussed in earlier

sections.

• The greenbelt area is already developed which help in enhancing the aesthetics

value of the area.

• Less noise generation machinery equipment’s are installed to maintain the noise

levels within permissible limits.

• PPE’s are being provided to workers.

• A well-developed Township is already developed besides the project site for

operational workers.

• Adequate storage area for the safe storage of products, raw materials and

hazardous chemicals are provided.

• Apart from Plant utility and manufacturing area, R&D lab, Canteen, admin, Guest

House, drinking water, Water treatment, etc facilities are provided within the

plant.

Occupational Health & Safety

• All the staff is given training for carrying out the work assigned keeping the safety

as priority.

• All staff are provided with personal protective equipment like ear plugs/mufflers,

masks, gloves, etc as required.

• Periodic inspection of PPE is done to ensure that they are in proper condition by

keeping the records

• All OHSAS guidelines are followed in the plant.

• Workers medical Tests are undertaken periodically.

• The unit has full fledged 25 bed hospital central oxygen 24x7 facilities, fully

equipped indoor facilties, full fledged physiotherapy, ECG parameter and various

equipments have been provided.

• Proper signage about the stations, entry, exit, fire exit, directions, safety messages,

conservation of energy & water, non-spitting, non-littering, restricted entry etc.





are provided at all the place to make the staff about the risks involved and

required safety measures to be taken

• Proper guards/safety provision are made. Entry without entry pass is restricted.

• Entry to the control rooms, firefighting rooms, Boiler room and DG area and other

similar areas are restricted to limited persons

• Dos and Don’ts during the natural calamity and accidents are displayed for staff

so as they know what is to be done during and after emergency.

• Trainings are conducted on regular basis to train about the safety procedures

and strictly following the rules

• Fire-fighting equipment are provided at all the locations

• Eyewash facility and a safety shower is provided at all locations

• Fire and safety Dept, Occptional Health centre are available, which handles all

the safety issues related to man, machine & materials.

4.6.9. Traffic Impacts

The site is approachable via NH-8 which is located adjacent to the unit. Raw materials

for revamped urea plant will be transported via pipeline and most quantity of finished

product is being transported via rails. There will be negligible increment of vehicles and

transportation due to proposed project. As per traffic count conducted in baseline

studies, there shall be negligible change in LOS in the main approach road i.e., NH-8

due to the proposed revamping project.

Existing infrastructure of highway is adequate to take the load. As per the traffic survey

done on the existing road, the traffic level at the road is smooth and can bear the

additional traffic load.

4.7. Conclusion

From above analysis, it is found that the impacts anticipated vary from moderate to low

significance and magnitude. No Major impact is anticipated during the construction

phase as only some mechanical work is required to be done for proposed revamping

and all basic facilities are available at the site to overcome the impact. The project also

has various positive impacts like indirect employment generation, reduction of energy,

availability of latest technology fertilizer products for better productivity & sustainability.

It is believed that the project will be provide more benefits both to environmental and

socio-economic aspects of environment than negative impacts. However, minimal

negative impacts can be normalized by taking the proposed mitigation measures.

Analysis of significance of the impacts pre & post implementation of the mitigation

measures is given in Table 4.5. Proper environment and social management plans are

to be prepared for ensuring implementation of the proposed mitigation measures.





Table 4.5 : Analysis of Significance of with & without Mitigation Measures

S.

No.

Activity Impact Significance -Pre mitigation

measures

Impact Significance –

Post mitigation

measures

Pre-Construction

1. Pre-

construction

No Impacts Nil

Construction Phase

1. Air short term, reversible, core zone and

low severity, i.e. low significance

Nil

2. Noise short term, reversible, core zone and


Low significance (will be

further reduce)

3. Water short term, reversible, core zone and


Nil

4. Waste short term, reversible, core zone and


Nil

5. Land No Impacts Nil

6. Soil Long term, Irreversible, core zone

and low severity, i.e. low significance

Low significance

7. Ecology No Impacts Nil

8. Socio-

economic

Long term, Irreversible/reversible,

core zone & moderate, i.e.,

moderate Significance

Low Significance

9. Traffic

Impact

No Impacts Nil

Operation Phase

1. Air Short term, reversible, spread over

buffer zone and of low intensity, i.e.

low significance

Low significance (will

further reduce)

2. Noise Short term, reversible, spread over


low significance


further reduce)

3. Water Short term, reversible, spread over


low significance


further reduce)

4. Waste No Impacts Nil

5. Land Short term, reversible, spread over


low significance


further reduce)

6. Soil Short term, reversible, spread over


low significance


further reduce)

7. Ecology Short term, reversible, spread over


low significance


further reduce)





8. Socio-

economic

Long term, reversible, spread over

buffer zone and of high severity, i.e.,

Moderate Significance

Low significance

9. Traffic

Impact

Short term, reversible, spread over


low significance

Low significance





Chapter 5. ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITES)

5.1. Analysis of Alternative Site

No alternative site has been examined as the proposed project is revamping of existing

Urea Plant (Urea-I & II) under which there will be demolition (existing canteen & UG

foundation etc.), refurbishing to existing equipment & machinery and installation of new

equipment to make a more sustainable unit based on latest technology for urea

manufacturing that will not only result in decrease of energy consumption but also

decremental pollution load. No additional area has been proposed for revamping. New

equipment’s will be installed within available area of Urea Plants. GSFC Complex is an

existing operational project equipped with infrastructural and civil facilities. Additional

advantages of project site are the following:

• The plant is well connected to road via National Highway-8 in the east of project

site.

• Since the project is a notified area. The land use of the project is Industrial and

there will be no need for conversion.

• Basic infrastructure for transportation of raw materials and finished product

• There are no environmentally sensitive areas like National Parks, Sanctuaries,

forest land, within the 5 km radius of project site.

• Supply of raw materials like Natural Gas, Electricity and Water is within easy reach

of the project.

• Utilities, Equipments and machineries have already been provided within the

site.

• Project site is away from flood prone area and coastal areas.

• Adequate Green Area i.e., 37.56% of total plot area has already been

developed in the premises.

• Skilled, semi-skilled and unskilled labour is available near the site.

• The ambient air quality at and around the project site is within the national

ambient air quality standards.

• No rehabilitaton and resettlement is required.

• No forest land is involved in the project and there will be no cutting of trees too.

There will not be any major impact on the environment due the project location as per

the above said reasons.

This chapter presents a comparative analysis of various alternatives considered to

avoid or minimize impacts that would be inevitable if technically (based on design)

best-fit technology and site are followed.





5.2. Alternative Technology

GSFC plants went into production of fertilizers in 1967. The unit thrives to produce fertilizers

and chemical products bases on latest technology with methods to improve production

and environmental sustainability. GSFC has added state-of-the-art technology at the

design/installation stage itself in all its plants to take care of the emissions. This practice

will be maintained for new plants also. It has also been the practice of GSFC to

incorporate latest technology in existing plants to meet with the required standards from

time to time.

Under proposed revamping project, latest technology for urea manufacturing i.e.,

Ammonia Stripping has been planned.

The existing Urea plants are based on M/s TOYO Technology supplied Total Recycle C

process. The plants consume major portion of liquid Ammonia; thus, continuous, and

reliable operation of both vintage urea plants is utmost important for efficient and

continuous operation of Ammonia-IV plant. The specific energy consumption of existing

Urea plants is 6.523 GCal/MT.

As per latest Urea Policy 2015 stipulated by GOI, the targeted energy norms for Urea

plants are 5.773 GCal/MT. To achieve energy target and improve reliability of old existing

plants, GSFC has proposed for revamping of existing units and adopt the latest

technology i.e., Ammonia Stripping process.

5.2.1. Advantages of Revamping

A revamp ordinarily reduces the cost of the product, does not require an excessive

investment, and has a shorter payout time than that required for a new plant.

Revamping a plant usually includes one or more of the following changes:

• Reducing raw materials and utilities consumption

• Reducing pollution

• Reducing maintenance costs

• Increasing the on-stream factor

• Reducing labour

• Improving product quality.

In the proposed revamping, GSFC has planned for reducing pollution, maintenance

cost and energy consumption. Ammonia stripping technology is particularly suitable

when stripping and conventional total recycle plants are to be revamped.

5.2.2. Concept of Ammonia Stripping Technology

In the ammonia stripping process the synthesis section is operated at slightly higher

pressure than in CO2 stripping plants, namely at 160 bar and 185-190°C. A molar ratio of

3.2-3.4 is typically maintained in the reactor, achieving a CO2 conversion of up to 62%.

The urea-carbamate solution, after leaving the reactor, enters the stripper where a large

part of the unconverted carbamate is decomposed by the stripping action of the

excess ammonia. The residual carbamate and carbon dioxide are recovered





downstream of the stripper in two decomposition stages operating at 17 bar (medium

pressure) and 3.5 bar (low pressure) respectively. Ammonia and carbon dioxide vapours

from the stripper top are mixed with the recovered carbamate solution from the

medium-pressure (MP) and low-pressure (LP) sections, condensed in the HP carbamate

condenser and recycled to the reactor. The heat of condensation is used to produce

LP steam. The urea solution leaving the LP decomposition stage is later concentrated in

the evaporation section further downstream.

5.2.3. Technological Differences between Total Recycle Process and Ammonia

Stripping Process

TOTAL RECYCLE PROCESS

The total recycled process consists of following steps:

1. Synthesis Section


3. Concentration/Filtration

4. Finishing Section- Crystallization/Centrifuge

5. Drying, Melting and Prilling

6. Recovery Control

7. Emission Control

AMMONIA STRIPPING PROCESS

In ammonia stripping, there 2 additional steps than total recycle process, i.e., Ammonia

pumping and Carbon dioxide compression and wastewater treatment section due to

which, there will be better recovery of NH3, CO2 and process condensate will be reused

into the process.




4. Urea Concentration and Vacuum Condensation

5. Recovery Section

6. Prilling Section



Above mentioned key developments in Ammonia stripping process which conventional

method (Total Recycle process) cannot provide.





Total Recycle Process

Ammonia Stripping Process

Figure 5.1 : Difference of Process Flow Diagram (Total Recycle & Ammonia Stripping)





The below mentioned will be technological differences between the existing and

proposed technology:

• Conversion of existing Total Recycle Process into Ammonia Stripping process and

operation of high-pressure synthesis section at reduced pressure i.e., ~ 165

kg/cm2g instead of existing operating pressure of ~ 205-210 kg/cm2g.

• Installation of new High Pressure Carbamate Condensers (2 Nos.) for generation

of Low-Pressure Steam (5.5 kg/cm2g) and Low- Pressure Steam (3.8 kg/cm2g) by

condensation of process vapors generated from HP Stripper using carbamate

solution.

• Generated Steam will be used for internal consumer and hence, there will be

reduction in specific steam consumption of plant.

• Replacement of existing crystallization section with new vacuum evaporation

section, which will reduce solid handling and thereby minimization in dust

emission in the plant.

• Installation of wastewater treatment section (Hydrolyzer) for decomposition of

ammonical waste generated from Vacuum evaporation package into

Ammonia, Carbon dioxide and water vapour. These gases are recovered in the

process plant. The condensate produced from the wastewater treatment section

will be used as cooling tower make up.

• Installation of new safety valve blow down tank for collection of discharge of the

safety valves of new HP section as well as existing HP Section.

• Installation of closed drain tank for collection of all process drains from new HP

loop as well as existing items, which will be then treated in wastewater treatment

section.

5.2.4. Benefits due to Proposed Revamping


• Operation of high-pressure section @ 165 kg/cm2g instead of current pressure of

205 kg/ cm2g. Lower operating pressure will have a positive effect on the


• Addition of Vacuum package & wastewater Treatment section to recover the


export to grid.










5.2.5. Proposed Existing Plant Configurations and Modifications

1. CO2 Compressors

Existing CO2 Compressors of Urea-II Plant (XU-K101A/B) and Urea-I Plant (U-K101A) will

be refurbished for their operation at lower compressors discharge pressure (~165

kg/cm2g) compared to existing discharge pressure of ~220 kg/cm2g.

2. HP NH3 Pumps

Existing one ammonia Pump XU-P101A will be replaced with new ammonia pump of

lower capacity with new electric motor. New Pump will be placed at the location of

existing pump after dismantling existing pump.

3. HP RC (Recycle Carbamate Solution) Pumps

Existing Turbine Driven Centrifugal Pump (XU-P102A) will be refurbished for operation at

lower speed considering lower flow rate. Existing motor driven reciprocating pump XUP-

102C will be replaced with new warehouse spare centrifugal pump same as XUP-102A

with new electric Motor. New Pump will be placed at the location of existing pump after

dismantling existing XU-P102C.

4. HP Urea Reactors (XU-R101, XU-R102 and XU-R101N)

Existing Reactor XU-R101 is not in operation at present. Existing reactor XU-R102 will be

refurbished. Modification in Top Cover and Inlet Nozzles will be carried out for Reactor

XU-R102. New Reactor (XU-R101N) will be installed in a new structure in nearby area of

existing reactor XU-R102 and will be provided with a full set of Casale High Efficiency

Trays to achieve optimal conversion.

5. High Pressure Decomposer (XU-V201) and HP Decomposer Reboiler (XU-E201)

Bottom internals of XU-V201 will be changed (Chimney Tray will be installed) in order to

change the urea solution circulation mode from thermosiphon reboiler to single pass.

On the other hand, with the aim to optimize the energy consumption, HP Decomposer

Reboiler XU-E201 will be replaced with a new item (XU-E201A/B).

A small steam condensate separator XU-V251 will be installed to collect steam

condensate from the lower part of HPD reboiler XU-E201A and sends it to the 2nd HP

Carbamate condenser.

6. Cooler for HP Absorber (XU-E501)

Due to the increased efficiency of synthesis section and the presence of the new

Vacuum Pre-Concentrator (XU-E551A), the duty of XU-E501 will be significantly lower

compared to current value notwithstanding the increased plant capacity. Being the

existing crystallization section idled, slurry circulation is replaced by cooling water in the

entire bundle. The upper part of XU-E501 will be modified to have only one tube pass

instead of 2 tube passes to optimize heat exchanger pressure drop.

7. Crystallization Section





To improve the steam balance of the plant and achieve the required energy saving

target, the existing finishing method based on crystallization technology will be replaced

by a modern evaporation section. The crystallization section will be idled. Crystallizer XU-

V301 will be maintained as additional tank to store either urea solution or process

condensate

5.2.6. New Installations for Proposed Revamping

1. New HP Synthesis Section

This is completely new section and following equipment will be installed in this section.

This section will reduce the load on downstream sections i.e., Decomposition Section

HP Stripper (XU-E151), HP Carbamate Condensers (XU-E152 & XU-E153), HP Ejector (XU-

J151), HP Carbamate Separator (XU-V151).

2. Evaporation and Prilling Section

New Evaporation section will be installed comprising following equipment.

• Vacuum Pre-Concentrator XU-E551A

• 1st Stage Evaporator XU-E551B

• 1st Stage Separator XU-V551

• 2nd Stage Evaporator XUE552

• 2nd Stage Separator XU-V552

• Vacuum Evaporation package (XU-X551) , which includes indirect CW

condensers and steam ejectors

Existing Prilling Tower of Urea-I and Urea-II will be used.

3. New Wastewater Treatment Section

It will be installed in order to recover NH3, CO2 and UreaContained in the process water

and, at the same time, to produce clean process condensate, which can be used as

Cooling Tower Makeup. Following equipments and machinery will be installed in new

section.








4. New Blowdown and Close Drain Section

New Blow down Vessel (XU-V852) will be installed to collected new HP Section and WWT

Section Safety Valve discharge. Liquid collected in blow down vessel will be then sent

to WWT section for treatment.





New Close Drain Tank will be installed (XU-V855), to recover all process drains from new

HP loop as well as existing items.

5.2.7. Anticipated Water Conservation due to Revamping

New section is going to be installed which comprises equipment such as hydrolyzer and

Desorber to recover NH3, CO2 and Urea contained in the process water and, at the same

time, to produce clean process condensate, which can be used as Cooling Tower

Makeup. Approx. ~28-30 m3/hr. of treated process condensate generated from this

section will be utilized as cooling water makeup.

5.2.8. Anticipated Energy Conservation due to Revamping

Total specific energy consumption will get reduced to 5.773 GCal/MT of Urea.

As total Urea manufacturing capacity will remain same after revamping, there will not

be any increase in pollution load. Emission at the outlet of existing stacks will remain as it

is and will be within the norms stipulated by government. Energy is reduced also on

account of reduction in specific consumption of Ammonia and Power in addition to

Steam.

5.2.9. Energy Conservation Measures already adopted within the plant

The following measures implemented in the latest years have provent to conserve

energy and natural resources in the plant:

Table 5.1 : Measures for Energy Conservation in GSFC Plant

S.No. Plant Action Taken Benefits from Action

Undertaken

1. Urea-II

plant, Capro-I Steam saving by

replacing existing Ejector with energy

efficient Ejector, at Urea II Plant

NG saving by 84 Sm3/hr,

equivalent to Rs. 160 lacs/year.

2. Urea-II Replacement of ejectors with better

design in Urea-II Plant


equivalent to Rs. 245.8

lacs/year.

3.

Urea-I

Steam saving by replacing existing

Ejector with energy efficient Ejector,

at Urea I Plant


equivalent to Rs.91.24

lacs/year.

5.2.10. Implementation of Additional Energy Conservation/Resource Optimization

Measures

Few of the additional measures have also been done for energy conservation and

resource optimization. Following are the details mentioned:

• 10 MW Solar power plant was successfully commissioned at Charanka, Dist.

Patan, Gujarat. It is operated at about 21% Capacity Utilization Factor (CUF).





• Online Monitoring System has been installed at total 29 nos. of stacks and

connected to GPCB as well as CPCB server. Moreover, Online AAQMS & Real

Time Effluent monitoring system is in operation and connected to GPCB & CPCB

server.

• GSFC has 152.8 MW Windmills. Power generated from windmills is utilized in

different units of GSFC. This has resulted in reduction of use of fossil fuels for

generation of equivalent power and in turn reduces CO2 emission to the

environment. 32 to 35 % of GSFC’s all unit’s power requirement is fulfilled from wind

power.

• GSFC’s total area is 328 Ha from that 37.56% covered under plantation.

• GSFC has been certified for ISO 50001 (Energy management System):2018, ISO

14001:2015 (EMS), ISO 9001:2015 (QMS), ISO 45001:2018 and Responsible Care

logo.

5.2.11. Green Initiatives Implemented by GSFC

As a responsible corporate citizen, GSFC ensures to leave a legacy of clean and green

environment to the future generations. Being already green, GSFC aspires for getting

greener. With the objective of combating climate change, GSFC aligns its business

objectives with practices of resource conservation and environment protection. GSFC is

deeply committed to satisfy its social obligations and has made consistent and effective

endeavors for creating better environmental conditions through abatement of pollution

and adopting sustainable development practices. Regular technological initiatives are

pressed into service with great vigor to improve and retain the purity of air, water and

soil. GSFC's clean development mechanism (CDM) initiatives bear testimony to the drive

to reduce greenhouse emissions. The first CDM project envisages use of waste gas from

company's plants to manufacture Ammonia, thereby obviating the need for natural gas

fuel for its production. It is a matter of pride that the technology for replacing the fossil

fuel has been developed through in-house R&D efforts. Meanwhile, the second CDM

initiative is for generating 152.8 MW green energy through a cluster of windmills. Some

other green initiatives are:

• Concerted efforts towards achieving Zero pollution levels by investing substantial

funds for preventing, minimizing, recycling/reusing of liquid effluents, gaseous

emissions and hazardous solid wastes.

• Implementation of zero process effluent discharge system for Phosphoric group

of plants.

• Installation of sophisticated air pollution devices like ESP, De-Nox unit, ECS,

scrubbers and filters for abatement and recovery of gaseous pollutants.

• Adoption of new Technologies and up gradation in the existing process plants for

energy and resource conservation and reduction of pollution potential.

• Reuse of treated sewage for gardening and tree plantation purpose and

recycling/reuse of process water within the plant to the extent possible, thereby

conserving natural resource 'Water' to large extent.





• Continual Implementation of schemes for improved effluent treatment and

disposal.

• Supporting Vadodara Enviro Channel Ltd (VECL) for promotion of 56 km long

common effluent channel for discharge of effluents into the sea and ensuring

cleaner environment in the region.

• Online round the clock monitoring of ambient air through four online Ambient Air

Monitoring stations installed at the periphery of GSFC for efficient and better

controls.

• Installation of SO2 and Ammonia gas detectors in various process plants for

monitoring of gaseous emissions at source and subsequently better control and

implementation of proactive corrections.

• For avoiding probability of leakages due to old age of lines, GSFC has rerouted

and replaced the treated effluent disposal lines of about 7 km length from GSFC

premise to Koyali outfall at the cost of @Rs. 15.5 crores.

• Environment training and awareness to employees and surrounding villages for

joining hands in the noble cause of environment protection.

• GSFC has always remained in forefront to make the company green & clean by

Landscaping, development of large & beautiful gardens within the complex & in

colony and massive green belt in 123.2Ha area (37.5% of the total land area).

• Development of a beautiful lotus pond with garden, ducks, and natural

landscaping within sulphuric acid plant area.

• Preserving a natural habitat for the national bird - Peacocks (can be seen

roaming in the premises as well as in the colonies) speaking volumes about GSFC's

concern for the environment.

• Development of many rainwater harvesting systems like ponds, recharge wells,

etc.

• Practicing QEHS policy to ensure safe working environment for the employees &

affiliated people.

• GSFC has carried out assessment of Biodiversity in and around the premises

through M/s. Gujarat Ecology Society (GES), Vadodara in the year 2011, which

shows positive changes with respect to biodiversity.





Chapter 6. ENVIRONMENT MONITORING PROGRAMME

6.1. Objective

Monitoring program has the underlying objective to ensure that the intended

environmental mitigations are realized and these results in desired benefits to the target

population causing minimal deterioration to the environmental parameters. Such

program targets proper implementation of the EMP. The broad objectives are:

• To evaluate the performance of mitigation measures proposed in the EMP.

• To evaluate the adequacy of Environmental Assessment.

• To suggest ongoing improvements in management plan based on the monitoring

and to devise fresh monitoring based on the improved EMP.

• To enhance environmental quality through proper implementation of suggested

mitigation measures.

• To meet the requirements of the existing environmental regulatory framework and

community obligations.

The purpose of environmental monitoring is to evaluate the effectiveness of implantation

of Environmental Management Plan (EMP) by periodically monitoring the important

environmental parameters within impact area, so that any adverse effects are detected,

and timely action can be taken.

6.2. Performance Indicators

The significant physical, biological, and social components affecting the environment

at critical locations serve as wider/overall Performance Indicators. However, the

following specific environmental parameters can be quantitatively measured and

compared over a period, therefore selected as specific Performance Indicators (PIs) for

monitoring because of their regulatory importance and the availability of standardized

procedures and relevant expertise.

• Air Quality & Stack monitoring with respect to Particulate Matters (PM10, PM2.5),

NOx, SO2, Urea dust, NH3

• Weather Station

• Water Quality for parameters defined in IS 10500: 2012, MoEF&CC notification-

G.S.R. 1607 (E) dated 29.12.2017 & The Environment (Protection) Rules, 1986 and

as per CTO granted by GPCB.

• Noise levels as per CPCB Guidelines and at selected locations.

• Soil Quality

• Survival rates of trees planted and green area development

This chapter presents a monitoring programme for pollution control at source,

monitoring pollutants at receiving environment for appropriate notified parameters,

specific programme to monitor safety and health protection of workers.





• Workspace Monitoring

• Occupational Health & Safety

• Energy Audit

Regular monitoring of pollutants in air emission, liquid effluent and receiving environment

is carried out day to day basis by in-house laboratory, third party and OMS. Environment

monitoring is being done monthly through third party agency (accredited by NABL) and

three times in a year through Schedule I auditor appointed by GPCB as a part of

Environment Audit. Environment Audit is carried out through GPCB appointed Schedule-

I Environment Auditors on regular basis and submitted to GPCB as per time schedule.

6.2.1. Ambient Air Quality Monitoring System (AAQMS) and Online Continuous

Emission Monitoring System (OCEMS)

The monitoring of different parameters from different sources are being done. Any

Deviation from the standards is being examined and action are taken to control. Emission

from stack is monitored as per MoEF&CC and CPCB guideline. Regular maintenance of

stack is done to control the emission. Ambient air analysis is being carried out by inhouse

laboratory once in a week. The monitoring of stacks by inhouse laboratory is analyzed

only when required. For gasesous emission monitoring, following equipments are

available within the plant as mentioned below in Table 6.1:

Table 6.1 : Instruments for Gaseous Emission Monitoring available at GSFC

S.No. Parameter Instrument used/Equipment

1 SO2 Glass Scrubbing Bottle

2 NH3 Glass Scrubbing Bottle, Dragger Tube

3 F Spectrophotometer & Glass Scrubbing Bottle

GSFC carries out regular ambient air quality monitoring at the periphery and nearby

villages with regard to SO2, NOx, PM10, PM2.5 and Ammonia. Sample Preservation

Technique for Ambient Air Quality is being done as per IS:5182, CPCB & AWMA and Data

Analysis is being done as per as per IS:5182, CPCB & AWMA. Monthly average results are

online submitted to GPCB. There are 5 no. of ambient air quality monitoring stations

located within the plant at 5 different locations. The locations are: One at the centre and

four at periphery of premises in four directions. Online emission monitoring systems are

located at 29 no. of stacks across the plant. Monitoring of flue gas emissions through

stacks are attached to source are carried out through NABL approved laboratory i.e.

M/s Ecosystem Resource Management, Surat. (NABL Certificate No.: TC-6603, Validity-

14/1/2021). Monthly stack monitoring results are submitted online to GPCB.

6.2.2. Weather Station

An automatic weather station is installed at the plant to note the Humidity, Daily

temperature, wind speed, wind direction, and rainfall. The data can be used to predict

the dispersion of the pollutants from stacks.





6.2.3. Water Quality Monitoring and Online Continuous Effluent Monitoring System

(OCEMS)

Outlet of ETP, STP and surface water quality i.e., Mahi River are being examined by plant

to check water quality and maintain norms given in EPA, MoEF&CC and GPCB. Any

Increase in parameter is recorded and corrective action taken. Plant also have inhouse

laboratory for analysis of final treated water from ETP. Stringent monitoring protocols will

be followed for the proposed revamping project.

Online instruments / analyzer for measurement of pH, Flow and ammonical nitrogen at

the outlet of Effluent Treatment Plant (ETP) have been installed. Online data is captured

in data logger and connectivity has also been established with both GPCB & CPCB

servers. Details of parameter-wise equipments available for in-hosue environmental

monitoring have been provided below in Table 6.2:

Table 6.2 : Instruments for Water Monitoring available at GSFC

S.No. Parameter Instrument used/Equipment

1 pH pH meter

2 Total Dissolved Solids Analytical Balance, Water Bath, Oven, Dessicators

3 Suspended Solids Analytical Balance, Filter Assembly, Oven, Dessicators

4 Ammoniacal Nitrogen Volumetric Analysis

5 Total Nitrogen Kjehldal’s Distillation, Auto Distillation, Apparatus &

Digester

6 Phosphates Spectrophotometer

7 Chemical Oxygen

Demand

COD Digester, Stirrerm Volumetric Analysis by Titration

8 APHA Visually by comparing with standard APHA Solution

9 Flouride Flouride Ion Selective Electrode/Spectrophotometer

10 Oil and Grease Separation by separating funnel, Water bath, Oven,

Dessicator, Analytical Balance

Groundwater monitoring is being done carried quarterly for nearby villages (Bajwa,

Dasharath, Chhani, Karachia, Omkarpura) through in-house laboratory and also being

carried out quarterly through third party at nearby villages. Since July 2014, Online

monitoring system (pH, COD, BOD, NH3-N, TSS) has been installed on final effluent disposal

line.





Figure 6.1 : Water Quality Monitoring Equipment

6.2.4. Noise Level Monitoring

The measurements for monitoring noise levels are being carried out at sensitive receptors

and at high noise areas. Sound pressure levels are monitored on twenty-four-hour basis.

Noise is recorded at “A” weighted frequency using a “slow time response mode” of the

measuring instrument. GSFC monitors noise in around 80 identified locations of different

plants.

6.2.5. Soil Quality

The physical and chemical parameters of soil will be monitored regularly to check soil

contamination. Mitigation measures are being taken in case of contamination will be

noted. Also, the NPK of soil are monitored to check fertility of the soil.

6.2.6. Green Area Development

The green area development is monitored during the installation and operation phase.

The main indicator is survival rate of the plantation.

6.2.7. Workplace Monitoring

The monitoring is also done in work zone area to monitor airborne pollutant as per Factory

act and Gujarat Factory Rules. Statutory norms are followed in the unit to control the

pollutant at work site and maintain the threshold limit given by ACGIH. Workplace

monitoring is carried out at regular intervals at 52 different locations in the plant. Regular

monitoring of work environment for air contaminant is done by third party and record is

being maintained at Safety Department. For existing plants, Emissions in the workplace

are confirmed to limits imposed by DISH i.e., NH3 & NOx <25 ppm; SO2<2 ppm, HF<3 ppm,

Benzene<0.5 ppm. The same will be followed for proposed revamping.





6.2.8. Occupational Health & Safety

Different plans and measures are adopted by the Plant to ensure the occupational

health & safety of all contract and casual workers. Occupational Health & Safety policy

is developed at the plant. Pre-placement and periodically examination (Physical

examination, Urine Routine examination, Hematology, LFT, Blood Sugar, chest x rays,

Audiometry, Spirometry, Vision testing, ECG, etc) of Staff and works is being done by

GSFC to analyze the health status as per DGMS guideline. Record of the same has been

maintained in the plant and submitted to the concerned department.

As a part of Periodic medical checkup of contract workers, six-monthly medical

examination of employees is careid out on regulalr basis by Occpational Health Centre

within the premises. Records are being maintained at Occupational Health Centre.

Examination being done for Periodical Medical Examination comprises physical

examination, history of past and present illnesses or personal and family, history of any

medication and drug and allergic reaction, ECS, PFT, counselling for habits (tobacco,

alcohol, smoking), counselling (Nutrition, stress, ergonomics, hazard specification), health

screening of lifestyle diseeases, screening of hypersensitivity of any chemical or drug, X-

ray/USG, Blood Investigation (CBC, LFT, RFT, Lipid Profile, RBS/FBS) and Urine Examination

(Glucose, Protein).

The complex has a full- fledged 25 bed hospital with 6 full time medical officers. 8 no. of

beds with central oxygen(24x7) facilities, 125 no. of first aid boxes have been provided

with fully equipped indoor facitlities. OHC has many facilities like Digital X-ray, full fledges

physipotherapy etc. An employee during periodical medical examination undergoes

primary cardiac evaluation by ECG to detect early cardiac abnormalities. The complex

shall also regulate medical check-ups and provide services for proposed revamping.

6.2.9. Energy Audit

Monthly energy audit based on inputs, detailed plant wise energy audit is carried out by

in-house energy cell or selected technical audit team. The policy and SOPs are

developed in the plant for energy saving to meet the norms under New Urea Policy-2015.

The accredited energy auditor shall have documented system for preparing the plan for

verification or check-verification functions and the said plan shall contain all the tasks

required to be carried out in each type of activity.

At GSFC, Energy Audit is carried out at every three years as per Energy Act. 2001. GSFC-

Vadodara is certified for Energy Management System as per ISO 50001:2018 standards

by TUV NORD CERT GmbH.

6.3. Environmental Monitoring Laboratory

GSFC has established laboratory facilities in the plant with 19 skilled analysts for

monitoring. Facilities for chemical & biochemical analysis is set up in plant premises.

Various quality monitoring instruments are available at Central Laboratory for analysis of





(a) raw materials (b) gaseous and liquid composition (c) Final product (Standard

methods are used for collection of liquid and gaseous samples. All the relevant

Environment and quality monitoring instruments are calibrated periodically through

external agency / inhouse. Standard operating procedures for analysis of various

parameters have been prepared and followed.

GSFC has a well-equipped Research and Development Centre that provides monitoring

of water quality in GSFC plant, non-routine chemical analysis of process stream samples

and carries out studies required for trouble shooting of plants. Research center evaluates

and advises on selection of appropriate material for construction of plant machineries,

equipment and components, establishing process conditions to minimize corrosion,

onitor corrosion in plant and undertake failure analysis of components, Ferrographic

analysis, etc.

Treated water from ETP & STP is analyzed for specific parameters every shift of 8 hours

duration. PM 2.5, PM 10, Ammonia, SOx, NOx in ambient air and noise level at four

locations on four sides of the complex are analysed as per prescribed frequency

(Ambient – twice in a week and Noise-Quaterly). All Environment related parameters

w.r.t Process & Fuel stack emission, ETP outlet and noise level at various locations,

Ambient Air are analyzed / measured by NABL approved Laboratory on monthly basis.

List of Instruments available in laboratory pertaining to environmental of Laboratory is

shown in Table 6.3:

Table 6.3 : List of Instruments available in laboratory

Sr. No Name of Instrument Qty. Make & Model

1 Atomic Absorption

Spectrophotometer 1 Thermo Fisher

2 Auto Distillation Tester AD-6 2 Tanaka

3 Auto Flash Point Tester 1 Tanaka/ APM-7/FC-7

4 Analytical Balance 5 Mettler Toledo

5 Top Load Balance 4 Mettler Toledo/MS-1602-S

6 Conductivity meter 4 Global / Ana lab

7 Flame Photometer Digital 1 Elico CL-361

8 Gas Chromatograph - FID 3 Thermo Scientific / Shimadzu

9 Gas Chromatograph (TCD) 3 Shimadzu/ Thermo Fischer

10 Karl Fisher Titrator 3 Metrohm 870Titrino Plus

11 Nitrogen Dist. Unit. 5 BUCHI / VELP

12 pH meter 6 Orion Star/ Global / Metrohm

13 Refractometer 1 ATAGO/RX-5000 i-plus

14 Spectrophotometer 4 Thermo Fisher / Shimadzu

15 Turbidity meter 1 Systronics/NTM-132





6.4. Environment Monitoring Plan

The purpose of environmental monitoring is to evaluate the effectiveness of

implementation of Environmental Management Plan (EMP) by periodic monitoring. The

important environmental parameters within the impact area are selected so that any

adverse effects are detected, and time action can be taken. The project proponent will

monitor the following environment component in accordance with an approved

monitoring schedule as shown in Table 6.4.

Table 6.4 : Environmental Monitoring Program

Sr. No. Type Locations Parameters Period and

Frequency

During Construction Phase

1. Ambient Air

Quality

Four locations

around the

Premises

SO2, NO2, PM2.5 & PM10 Twice in a week

at regular

interval.

2. Portable

Water

Drinking water

supply

Drinking water parameters as

per IS 10500.

Monthly

3. Water Quality

Monitoring of

construction

water

Water being

used for

construction

work

Water parameter as per IS

456

Monthly

4. Groundwater Nearby

complex

pH, P, F, TDS, SS, BOD, COD,

Total Hardness, Total

alkalinity, Chloride, Sulphate,

Nitrate Nitrogen, and Heavy

metals.

Quarterly

5. Ambient

Noise

Around the

Premises

dB (A) levels (Morning and

Nighttime)

Quarterly

6. Soil quality One location in

Project site

N, Alkalinity, Acidity, EC,

Phosphate, Fluoride, Heavy

metals and trace metals,

Half Yearly

7. Occupational

health &

Safety

Construction

sites material

storage site

Availability and use of

Barricades, Availability of

traffic marshals, Safety kit, Use

of PPE by workers, Availability

of fire fighting equipment,

Outcome of daily safety

meetings, analysis of

incidents/accidents if any

Half yearly

8. Waste Construction

sites, labour

camps, site

office &

Storage Yards

Compliance to EMP

requirements about storage,

transportation & disposal of

Debris, excess earth and

other waste.

Daily






Frequency

9. Construction

Vehicle

Construction

sites and

material

storage sites

Availability of Safety kit, first

aid kit, maintenance

&service records, DL (driving

license), PUC, drivers training

records, driver awareness

Daily

10. Sanitation Construction

sites, labour

camps, site

office &

Storage Yards

Condition of toilets,

availability of water in toilets,

provision of septic tank,

availability of clean drinking

water

Daily

During Operation Phase

1. Meteorology Project Site Humidity, Daily temperature,

wind speed, wind direction,

and rainfall

Online

Monitoring

System

2. Ambient Air

Quality

Four locations

around the

Premises

NH3 , SO2, NO2, PM2.5 & PM10 Twice in a week

at regular

interval.

3. Stack

Monitoring

All Existing

stacks

NH3 , SO2, NO2, PM, F, Acid

Mist

(Manual-

Quarterly) and

Existing Online

Monitoring

System

4. Portable

Water

Drinking water

supply

Drinking water parameters as

per IS 10500.

Monthly

5. Treated

Effluent

discharge to

VECL.

Final effluent

discharge to

VECL.

pH, oil & grease, SS, BOD,

COD, Ammonical Nitrogen,

TKN, CN, Nitrate Nitrogen, V,

As, Hexavalent Chromium,

Total Chromium, TDS,

Chloride, Nitrate,

Temperature, Zinc, Sulphate,

Colour, Phenolic Compound,

Sulphide, Copper, Lead,

Mercury, Nickel, Zinc,

Cadmium, SAR, TKN,

Phosphate, F,

Insecticides/Pesticides & Bio-

assay test.

Monthly

6. Ambient

Noise

around the

Premises and

DG sets

dB (A) levels (Night & Day

time)

Quarterly

(DG set – Once

in a Year)

7. Soil quality Two locations

within the

project Site

N, Alkalinity, Acidity, EC,

Phosphate, Fluoride, Heavy

metals and trace metals

Half Yearly






Frequency

8. Green Belt All over the

project site

Maintenance of Vegetation,

greenbelt / green cover

Daily

9. Waste Complex Storage, segregation,

handling

Daily

characterization of waste Quarterly

10. Occupational

health &

Safety

All workers

working in the

site.

Health check up of Workers

Training related to

Environment, Health and

Safety

Half Yearly

11. Energy Audit

Complex

As per guideline laid by BEE

and New Urea Policy-2015

Once in 3 years

under Energy

Act 2001

12. Workplace

monitoring

Project Site -

Work Zone- 5

locations

Dust Weekly

Ammonia, Benzene, SO2 Monthly

Noise Once in two

months

6.5. Submission of Compliance & Audit Report

• As per the MoEF&CC guideline, Environment monitoring report and compliance

of conditions mentioned in the environment clearance will be submitted to the

RO-MoEF&CC, SPCB, MoEF&CC online portal i.e., parivesh and shall be uploaded

on company’s website. Compliances will be submitted in month of June and

December for the period of April to September and October to March,

respectively. Third party laboratory (approved MoEF&CC and NABL laboratory)

shall be appointed for carrying out the monitoring. Also, self-environmental audit,

Health & safety audit and Energy audit shall be conducted annually.

• GSFC has implemented all guidelines laid down by CPCB and MoEF for CREP

(Corporate Responsibility for Environmental Protection) and submitting the

annual compliance of the same to the GPCB.

• GSFC is also regularly submitting Environmental Statement (Form V) to Pollution

Control Board in accordance with the provisions of Rule-14 of the Environment

(Protection).

• The unit has been certified for Integrated Management System (ISO 9001, ISO

14001, ISO 45001, ISO 50001 from TUV CERT Certification Body & Responsible Care

logo from ICC).





CHAPTER 7. ADDITIONAL STUDIES

7.1. Introduction

Industrial plants deal with materials, which are generally hazardous in nature by virtue of

their intrinsic chemical properties or their operating temperatures or pressures or a

combination of these. Fire, explosion, toxic release, or combinations of these are the

hazards associated with industrial plants using hazardous chemicals. More

comprehensive, systematic, and sophisticated methods of Safety Engineering, such as,

Hazard Analysis and Quantitative Risk Assessment have now been developed to

improve upon the integrity, reliability and safety of industrial plants.

The primary emphasis in safety engineering is to reduce risk to human life, property, and

environment. Some of the more important methods used to achieve this are:

➢ Quantitative Risk Analysis: Provides a relative measure of the likelihood

and severity of various possible hazardous events by critically examining

the plant process and design.

➢ Work Safety Analysis: The technique discerns whether the plant layout and

operating procedures in practice have any inherent infirmities.

➢ Safety Audit: Takes a careful look at plant operating conditions, work

practices and work environments to detect unsafe conditions.

Together, these three broad tools attempt to minimize the chances of accidents

occurring. Yet, there always exists, no matter how remote, probability of occurrence of

a major accident. If the accident involves highly hazardous chemicals in sufficiently

large quantities, the consequences may be serious to the plant, to surrounding areas

and the populations residing therein. 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

M/s Gujarat State Fertilizers & Chemicals Ltd (henceforth GSFC) has proposed for

“Revamping of existing Urea-I & II plants by replacing existing total recycle process to

latest ammonia stripping process” located at P.O. Fertilizernagar, Dist.-Vadodara,

Gujarat-391750. The scope of the study is to model and appraise the risks associated

This Chapter provides the details about the Quantitative Risk Assessment and

emergency plan as proposed for the proposed project.





with all toxic and flammable hazards resulting from potential loss due to likely accident

scenarios from M/s Gujarat State Fertilizers & Chemicals Ltd 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 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 project have been discussed.

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. Methodology of HIRA

The main hazard potentials in the proposed Plant, 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 toxic environment, 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 small local pockets

7.5. Hazardous Material at GSFC Plant

GSFC is producing a diverse range of fertilizers and petrochemical products at their

Vadodara Plant. Few of the products may be hazardous also. Additionally, many of

chemicals/raw materials are toxic/inflammable and are being stored in bulk. The

project involves transportation of ammonia to the plant via pipeline.

Table 7.1 : Bulk Storages of Hazardous Chemicals involved in Proposed Revamping

Project

S. No Chemical Storage Capacity (MT) Remarks

Existing Total after Revamping

1 Ammonia 2 X 10000 MT 2 X 10000 MT No additional

storage required

7.5.1. Hazard Analysis of Bulk Storage Materials

GSFC will be using one main raw material i.e., Ammonia is stored & listed under “List

of hazardous and Toxic Chemicals” category under MSIHC Rules, 1989. Hazard

analysis of products and raw materials stored in bulk) is given in Tables 7.2 & 7.3

below:





Table 7.2 : Hazard Analysis of Products

S No Material S. No & Threshold Quantity (TQ in Kg) as

per MSHIC Rules

Chemicals Hazards Potential Remarks

Schedule-

1, Part-II

Schedule-2,

Part-I

Schedule-

3,

Part-I

Hazards Toxic

DT->---mg/Kg.

OT----mg/Kg.

IT----mg/l; (Rats)

1. Urea

CAS No: 57-13-6.

White

granules/prills

Ammonia like

odour; MP: 131 -

135 °C

---- ---- ---- May cause irritation of

respiratory tract This

product does not

contain any hazardous

materials; Thermal

decomposition can

lead to release of

irritating gases and

vapors.

OT--- 8471 mg/kg (Rat).

(Rats)

Stable under

normal conditions.

Incompatible

material: Strong

oxidizing agents;

Excess heat. Avoid

dust formation.

Protect from

moisture.

Table 7.3 : Hazard Analysis of Bulk Storage Raw Materials

S

No

Material S. No & Threshold Quantity (TQ in Kg) as

per MSHIC Rules


Schedul

e-1,

Part-II

Schedule-2,

Part-I

Schedule-3,

Part-I

Hazards Toxic

DT->---mg/Kg.

OT----mg/Kg.

IT----mg/l; (Rats)

1. Ammonia

CAS No:7664-41-

7

31 2

TQ-1: 60 MT

TQ-2: 600 MT

105

TQ-1: 50 MT

TQ-2: 500 MT

Fire Hazards: Mixing of

ammonia with several

chemicals can cause

ERPG-1: 25 ppm

ERPG-2: 150

ppm

Stable product

Ammonia is a base. Reacts

exothermically with all





S

No

Material S. No & Threshold Quantity (TQ in Kg) as

per MSHIC Rules


Schedul

e-1,

Part-II

Schedule-2,

Part-I

Schedule-3,

Part-I

Hazards Toxic

DT->---mg/Kg.

OT----mg/Kg.

IT----mg/l; (Rats)

UN No:1005

Cryogenic liquid

Odour threshold:

17 ppm

Highly soluble in

water

BP: --33.35 0C

LEL: 16%

UEL:25%

severe fire hazards

and/or explosions.

Ammonia in container

may explode in heat of

fire. Health Hazards:

Vapors cause irritation

of eyes and respiratory

tract. Liquid will burn skin

and eyes. Poisonous;

may be fatal if inhaled.

Contact may cause

burns to skin and eyes.

Contact with liquid may

cause frostbite.

ERPG-3: 750

ppm

IDLH: 300 ppm

acids. Violent reactions are

possible; Highly reactive

oxidising agents etc.





Note:

• CAS No.: Chemical Abstracts Service Number

• UN No.: United Nations Number

• DT; Dermal toxicity LD50 (mg/kg)

• OT: Oral toxicity LD50 (mg/kg)

• IT: Inhalation toxicity LC50 (mg/l)

• F: Flammable Liquid

• HF: Highly Flammable Liquid

• VHF: Very Highly Flammable Liquid

• ERPG: Emergency Response Planning Guidelines

• TQ: Threat Quotient

• BP: Boiling Point

• MP: Melting Point

• LEL: Lower Explosive Limit

• UEL: Upper Explosive Limit

• IDLH: Immediately Dangerous to Health

Hazard Analysis of Products

GSFC has proposed for revamping of two Urea Plants to develop revamped Urea plant.

The total production capacity after revamping will remain same as the combined

capacity of existing plants i.e., 3,67,200 MTPA. Urea is a fertilizer and is not listed as

hazardous as per MSIHC Rules. However, the product should be handled carefully with

all precautions. The product should not come in contact with incompatible materials

and fire/excessive heat. Though products are non-flammable but case of excessive

heat the decomposition products are hazardous gases. The products should be stored

as per guidelines.

Hazard Analysis of Raw Materials

Raw materials for the proposed revamping are in liquid state only. Ammonia has been

mentioned in all the three schedules with limits in storages. All the raw materials are being

handled and stored in existing plant. The products will be packed in drums/bags and

stored in product godowns as per market demand.

The risk is through gaseous materials which are volatile material. The toxic vapours due

to spillage of such material can travel to some distance (as they are stored in covered

godowns) and cause damage.

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 7.4

Table 7.4 : Risk Classification

Stage Description

High

(> 10-2/yr.)

A failure which could reasonably be expected to occur within the

expected lifetime 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

(10-2 --10-4/yr.)

A failure or sequence of failures which has a low probability of

occurrence within the expected lifetime of the plant.

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

(<10-4)

A failure or series of failures which have a very low probability of

occurrence within the expected lifetime of plant.

Examples of ‘low’ likelihood are multiple instruments or valve failures

or multiple human errors, or single spontaneous failures of tanks or

process vessels.

Minor Incidents Impact limited to the local area of the event with potent for ‘knock

– on- events’

Serious Incident One that could cause:

1. Any serious injury or fatality on/off site.

2. Property damage of $ 1 million offsite or $ 5 million onsite.

Extensive Incident One that is five or more times worse than a serious 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

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,

in-animate objects like equipment, piping, cables, etc. may also be affected and need

to be evaluated for damages. Tables 7.5, 7.6 and Table 7.7 (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 microseconds). 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 7.5 : Effects due to Incident Radiation Intensity

Incident

Radiation

kW/m2

Damage Type

0.7 Equivalent to Solar Radiation

1.6 No discomfort on long duration

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn

are likely).

9.5 Pain threshold reached after 8 sec. Second degree burn after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting of

plastic tubing etc.

25 Minimum Energy required for piloted ignition of wood, melting, plastic

tubing etc.

37.5 Sufficient to cause damage to process equipment.

62.0 Spontaneous ignition of wood.

Table 7.6 : Thermal Radiation Impact to Human

Exposure

Duration

Radiation Energy {1%

lethality; kW/m2}

Radiation Energy for

2nd degree burns;

kW/m2

Radiation Energy for

1st degree burns;

kW/m2

10 sec 21.2 16 12.5

30 9.3 7.0 4.0

Table 7.7 : Tolerable Intensities for various objects

Sl. No Objects Tolerable Intensities (kw/m2)

1 Drenched Tank 38

2 Special Buildings (No window,

fireproof 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.

GSFC is storing highly hazardous raw materials (Sulphuric acid and liquid Ammonia) in

isolated places with full safety measures. Damage estimates based on overpressure are

given in Table 7.8 below:

Table 7.8 : Damage due to Overpressure

Sl. No Overpressure

(psig / bar)

Damage

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 demolished

9. 10 Probable destruction of houses

10. 200 Limits of crater lip

In GSFC, there is mere possibility of explosion.

7.6.2. Toxic Release

Hazardous materials handled and stored in bulk in GSFC proposed revamping project

are toxic gas (Ammonia) and chemicals (as detailed in Table 7.2) and other raw





materials as defined in MSHIC rules and indicated in Table 7.2. Some of these chemicals

are stored in bulk.

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 and Consequence Analysis

These incidents/accident scenarios are divided in two categories considering the

consequence seriousness and occurrence frequency.

• Maximum credible loss scenario (MCLS).

• Worst possible scenario.

Incidents/accidents may be caused due to natural causes or consequence of these,

human failure, terrorist acts. Natural causes such as earthquake, lightening, heavy rain

flooding etc. are not frequent and their quantum/severity cannot be predicted and

controlled. Their impact can be managed/reduced by active system.

However human failures and resulting incidents can be minimized if not eliminated by

training/ process safety system (process automation unit will adopt SCADA (supervisory

control and data acquisition) and PLC (programmable logic controller) system).

Maximum Credible Loss Scenario (MCLS) is one of the methodologies evolved to access

the events in realistic and practical way. An MCLS can be described as the worst

“credible” accident or as an accident with a maximum damage distance, which is still

believed to be probable. The analysis, however, does not include a quantification of the

probability of occurrence of an accident. The MCLS aims at identifying undesirable and

hazardous events causing the Maximum damage to human beings /environment

around the industry under the consideration.

Leak from piping/valves/flange failure (resulting in puddle) are quite probable events.

Such accidental release is considered as MCLS.

WORST POSSIBLE SCENARIO

Worst Case Scenario/ MCA (Maximum Credible Accident) Accident Scenario

considered are based on hazard analysis of bulk storages/ chemicals:

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 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 7.9 below:

Table 7.9 : Different Failure Scenarios

S. No. Scenario Remark

RM-1 Ammonia Spillage Toxic

7.7.2. Weather Effect

The effect of ambient conditions on the impact of fire / heat radiation and GLC of

hazardous / toxic material can be beneficial as well as harmful. A high wind (turbulence)

can dilute the toxic material while stable environment can extend the reach of IDLH or

IT (inhalation LC50 rats for products) concentration to long distance. Any inflammable

gas / vapour release in turbulent weather will soon dilute the hazardous gases below LEL

and thus save the disaster.

7.8. Hazardous Incidents Impact

The identified failure scenarios in Table 7.10 have been analysed (Using) for the impact

zones considering damage due to toxic impacts. 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 7.10:

Table 7.10 : Hazard Scenario Impact

Scenario

No.

Scenario Impact Zone (m) Remarks

Scenario Raw Material

RM-1 Heavy Ammonia

Spillage/Puddle~

20 M dia.

(equivalent)

❖ 1200

❖ 3700

IDLH; Stability Class D; Template-

7.2

IDLH; Stability Class F; Template-

7.3





Template 7.1. : GSFC Plant Area – Outline





Template 7.2. : Ammonia Evaporating Puddle- Toxic Impact Zone (Stability Class -D)

Template 7.3. : Ammonia Evaporating Puddle- Toxic Impact Zone (Stability Class -F)

7.9. Consequence Analysis

Since the materials involved in this study are toxic as well as flammable, the possible

scenarios are toxic impacts due to evaporating puddle and fire in Sulphur godown (less

probable Templates show proposed storage tanks failures / hazardous incidents and

consequential impact zone

7.9.1. Toxicity

Toxic hazards are mainly due to Ammonia and other toxic chemicals leakage and the

impact can cross the plant boundary (in case of Ammonia) only if not controlled in time

depending upon wind direction.

Other hazardous chemicals including products their impact will be limited to spillage

area. The acid spillage (Sulphuric acid) if comes in contact with metal parts will produce

hydrogen which is highly flammable gas. Any person moving in area and getting splash

will get the injury. In addition, the spillage will cause pollution problem. The spillage is to

be collected and neutralized for toxic contents before disposal.

7.9.2. Thermal Hazards

Thermal hazards are mainly due to inflammable chemicals/fuel other organic chemicals

storage which are limited within plant boundary.

7.10. Hazardous Scenario Chemicals

Hazardous Scenario Chemicals further analysis is given in Table 7.11 below:





Table 7.11 : Details of Hazardous Scenario Chemicals

Scenario Hazardous Chemical Specific Safety Measures Remark

Conditions Reactivity/Incompatibility

RM-1 Heavy Ammonia

Spillage/Puddle~ 20

M dia. (equivalent)

CAS No: 7664-41-7

Non-Flammable Gas

LEL: 150000 ppm

UEL: 280000 ppm

Ambient Boiling

Point: -33.4˚ C

Flammable Gas

Reactivity Profile: AMMONIA is a base.

Reacts exothermically with all acids.

Violent reactions are possible. Readily

combines with silver oxide or mercury

to form compounds that explode on

contact with halogens. When in

contact with chlorates. It forms

explosive ammonium chlorate. Reacts

violently or produces explosive

products with fluorine, chlorine,

bromine and iodine and some of the

interhalogen compounds (bromine

pentafluoride, chlorine trifluoride).

Mixing of bleaching powder

(hypochlorite solution) with ammonia

solutions produces toxic/explosive

ammonia trichloride vapors.

Reactivity Alerts---Water-Reactive

Health Hazard: Vapors cause irritation of eyes

and respiratory tract. Liquid will burn skin and

eyes. Poisonous; may be fatal if inhaled.

Contact may cause burns to skin and eyes.

Contact with liquid may cause frostbite.

Firefighting: Wear positive pressure breathing

apparatus and full protective clothing.

Small fires: dry chemical or carbon dioxide.

Large fires: water spray, fog or foam. Apply

water gently to the surface. Do not get water

inside container. Move container from fire area

if you can do it without risk. Stay away from ends

of tanks.

Isolation and Evacuation: As an immediate

precautionary measure, isolate spill or leak area

for at least 100 meters (330 feet) in all directions.

FIRE: If tank, rail car or tank truck is involved in a

fire, ISOLATE for 1600 meters (1 mile) in all

directions; also, consider initial evacuation for

1600 meters (1 mile) in all directions. (ERG, 2016)

-





7.11. Conclusions and Recommendations

Risk Assessment is carried out with the objective to identify the potential hazards from

bulk storage facilities Important conclusions and recommendations arising out of the

Risk Analysis for the proposed revamping are listed below:

• The existing ammonia storage facilities will be used.

• The safety measures and emergency actions being taken for risk and associated

hazards are adequate and are being followed properly.

• On-site and off-site emergency action plan should be regularly followed and

complied.

• Regular mock-drills should be done, and the assessment should be done via

audits.

• Provision of ammonia detectors/sensors at strategic locations in the common


• Other hazardous pipelines (acid/hazardous materials/inflammeable materials)

should be located away with all safety measures.

• Regular hazard survery should be done to ensure detection of leakage in the

plant.

7.12. Safety Measures

7.12.1. Safe Operating Procedures

Safe operating procedures should be available for all operations practices and

equipment.

The workers should be informed of the consequences of failure to observe the safe

operating procedures.

Ventilation

• Adequate ventilation should be provided in the work floor environment.

• The work environment should be assessed and monitored regularly.

• Local ventilation is most effective method for controlling dust and gaseous

emissions at work floor.

Static Electricity

• All equipment and storage tanks/containers of flammable chemicals should be

bounded and earthed.

• Electrical resistance for earthing circuits should be maintained. Periodic

inspections should be done for earth pit and record should be maintained.

Instruments

All the instruments like pressure, temperature transmitters/gauges and alarms switch, and

safety interlocks should be tested for their intended application as per the preventive





maintenance schedule. Similarly, the emergency shutdown system should be tested as

per the preventive maintenance schedule.

Limit -Access

• Limit quantity of material in storage up to 80 %.

• Restrict access to storage area.

• Post warning signs when appropriate.

7.12.2. Safety Measures to prevent spillage/leakage of Toxic Chemicals

• The preventive maintenance will be planned and carried out as per plan to avoid

the failure of flanges, pipelines, and other component of transferring line. The

leakage/spillage will be confined to the dyke area underneath the vessel.

• In case of leakage/spillage outside the Dyke wall/in plant, try to control its

spreading by putting temporary barrier of sand/other neutral/non-soluble-

reactive material. Try to reclaim the material as much as possible. Dispose-off the

barrier material safely.

• The resultant splash of such chemicals will result in exposure of toxic chemicals to

employees.

• Decontamination facilities (Safety shower and eye wash fountains) will be

provided in the plant area, which can be used to decontaminate the affected

employees. Suitable decontamination procedure will be used to decontaminate

the spilled or leaked material. The SOP for decontamination will be available with

all related department.

Spillage-Fire- Decomposition Products

In case of Spillage-Fire in addition to thermal hazards there are much more danger due

to chemicals thermal decomposition products which may include (but not limited to):

o Hazardous combustion products --Sulphur dioxide etc.

o Chemicals Vapours may form explosive mixtures with air.

In the case fire involving products- the hazardous decomposition products may include

Sulphur dioxide, Nitrogen oxides (NOx) etc. While fighting fire spillage- puddle or product

godown /storages, firefighters/staff should take care for hazards due to toxic

decomposition products.

7.12.3. Safety Measures for transportation and unloading of Hazardous Chemicals

• Chemicals unloading standard procedure will be in place and will be

implemented for safe unloading of road tanker.

• Static earthing provision will be made for tanker unloading.

• Drum handling trolleys will be used for transportation of drums up to plant and

internal handling from storage to process area.

• Fire extinguishers will be provided as required.

• First aids boxes will also be provided at different places.

• Water showering system will be provided to the flammable chemicals storage

area.





• Area will be declared as “NO SMOKE ZONE”.

Instruments:

All the instruments like pressure, temperature transmitters/gauges and alarms switches

and safety interlocks should be tested for their intended application as per the

preventive maintenance schedule. Similarly, the emergency shutdown system should

be tested as per the preventive maintenance schedule.

7.13. Occupational Health and Safety

Safety in the workplace is critical to the success of running a business, no matter what

size it is Arrangements for ensuring health and safety of workers ENGAGED in handling

of toxic materials

The significance of Safety & Health in plant has been a vital issue in achieving

productivity and quality standard. Following is an effort for safety & health of workers

working in the plant. Numbers of chemicals are used in plant have specific health

hazards in nature. Following are some basic fundamental principles/rules for all the

workers working in the plant. Occupational health and safety is about preventing

people from being harmed by work or becoming ill from work by taking adequate

precautions and providing a safe and healthy work environment. Consideration of each

should be encouraged before beginning work as part of the culture of safety within the

plant.

• Plan. Determine the potential hazards associated with production/ operation

in the Plant.

• Minimize exposure to chemicals. Do not allow toxic chemicals to come in

contact with skin. Provide proper ventilation devices to prevent/minimize

airborne hazards.

• Do not underestimate hazards or risks. Assume that any mixture of chemicals

will be more toxic than its most toxic component. Treat all the chemicals as

toxic substances.

• Be prepared for accidents. Before beginning of any batch reaction, know what

specific steps to take which cause to accident if any hazardous substance

release accidently.

Unit will assess is careful examination of what, at work, could cause harm to

workers, accidents and ill health. All risks in the workplace must be identified and

assessed for control measures to be put in place.

Follow the five steps of hazard identification by unit namely.

• Identify the hazards

• Decide who might be harmed and how

• Evaluate the risks and decide on precautions

• Record your findings and implement them

• Review your assessment and update if necessary





Following Information each worker should know regarding hazardous chemicals

Unit shall ensure that the employee is adequately trained with regard to:

• The contents of the hazardous chemical substances,

• Potential source exposure to chemicals,

• Measures taken by the employer/employee to protect self and other

employees against risk,

• Precautions to be taken by an employee to protect himself against the health

risks associated exposure,

• Correct use, maintenance of safety equipment, facilities and engineering

controls,

• Importance of good housekeeping at the workplace,

• Safe working procedures,

• Procedures to be followed in the event of spillages or leakages.

• Risk assessments should be carried out to consider the potential dispersal of

toxic chemicals from non furnace processes & combustion products, and the

potential impact of an explosion on the surrounding areas

• Regular safety audits should be undertaken to ensure that hazards are clearly

identified, and risk control measures maintained at an optimum level

Safety’ has unique features:

a. If no accident has happened so far probability of incident/accident occurring

increases.

b. ‘No accident’ / good safety record develops complacency inertia/over

confidence in the team. This attitude gives rise to gaps/soft spots in the system

giving chances to incidents/accidents.

c. Safety requires novelty. Routine training practices get stale with no positive

results. Look for novel scheme of training/ safety practices to build up fresh

impetus in safety. Involvement of employees with refreshed outlook for safety

is to be achieved.

7.14. Disaster Management Plan

GSFC is storing hazardous chemicals namely in quantity more than Threshold Limit as

specified in MSIHC Rules. However, GSFC already has prepared Disaster Management

Plan (DMP-Onsite as well as off site in association with District authorities).

Hazards described in the Risk Assessment and prediction of various hazardous

scenarios The DMP addresses the range of thermal and mechanical impacts of these

major hazards so that potential harm to people onsite and off site, plant and





environment can be reduced to a practicable minimum The scenarios of loss of

containment are credible worst cases to which this DMP is linked.

CAPABILITIES OF DISASTER MANAGEMENT PLAN

The emergency plan envisaged will be designed to intercept full range of hazards

specific 'to Ammonia & other hazardous chemicals such as fire, explosion, gas leakages,

major spill etc In particular, the DMP will be designed and conducted to mitigate the

losses of containment situations, which have potentials to escalate into major perils

Emergency medical aids to those who might be affected by incident heat radiation flux,

shock wave overpressures and toxic exposure will be inherent in the basic capabilities

The most important capability of this DMP will be the required speed of response to

intercept a developing emergency in good time so that disasters such as explosion,

major fire etc are never allowed to happen

No additional storage of any hazardous material. The existing DMP and Mock Drill report

has been reviewed and observed sufficient. More similar mock drills should be carried

out to keep the team alert/trained.

7.15. Emergency Action Plan/Onsite Emergency Plan

GSFC follows detailed emergency action plan for each worst-case scenario for every

plant. Specific consequence analysis of risk assessment of raw material/product have

been configured out by risk experts in the industry and their onsite emergency plans

have been deciphered out. Onsite Emergency Plan has been annexed as Enclosure-IX.

Emergency Action Plans for risks related to Ammonia are listed below:

1. Leakage/Rupture of Pump Suction Line of Ammonia Transfer Pump

• Person who notices, the leakage/rupture will inform the control room either by

rushing to control room or using any communication media.

• After wearing respiratory and body protection appliances rush to the site from

windward direction and assess the situation.

• Isolate the ruptured/leaked line from upstream by closing automatic pneumatic

operated valve from control room.

• Cordon off the area.

• Evacuate the area, Evacuation warning should be given immediately to the

plants/area which are likely to be affected in the downward direction. (1%

lethality damage dist. for inlet line of Ammonia Absorber Emergency is 125 mtr.

and for liquid Ammonia Export line is 1050 mtr.)

• Don’t allow anybody to enter the affected area without respiratory protection.

• Stop all hot jobs and other spark producing operations around the affected area.

• Inform the fire department about the leakage.

• Start to knock down the vapour by water curtain or water spray till the arrival of

fire crew, and then guide and assist them in further activities.

• Don’t put water directly on the liquid NH3 pool.

• Isolate all temporary power supply in the affected area from electrical substation.

Do not use mobile phones in the vicinity.





• Care should be taken to avoid entry of water into nearby electrical substation.

• Afterwards spillage / leakage area should be washed with plenty of water for

dilution of ammonia in drains trenches.

• Incase of fire, start fire fighting with the available extinguishers, till the arrival of fire

crew. On reaching fire crew guide and assist them in controlling fire.

• Cool the nearby vessel, structure, pipeline by spraying water.

2. Leakage/Rupture of Outlet Line of Screw Compressor to Condenser





• Isolate the ruptured/leaked line from upstream by closing automatic pneumatic

operated valve from control room.



plants/area which are likely to be affected in the downward direction.

• Don’t allow anybody to enter the affected area without respiratory protection.

• Stop all hot jobs and other spark producing operations around the affected area.


• Start to knock down the vapour by water curtain or water spray till the arrival of

fire crew, and then guide and assist them in further activities.

• Isolate all temporary power supply in the affected area from electrical substation.

Do not use mobile phones in the vicinity.


3. Road Tanker Loading Hose Failure

• Normally Ammonia filling station is to be considered at isolated area, however

operator and truck driver/cleaner is continuously monitoring the filling operation

so as soon as anybody notice the leakage/failure of hose & flange, if possible he

will inform to control room on telephone or will rush across the wind

directionputting wet handkerchief on his nose to inform to S.E. from Ammonia

filling station.

• After wearing respiratory and body protection appliances Shift

Engineer/Operator should rush to the site from windward direction and assess the

situation.

• After assessing the situation, instruct Sr. Operator/Operator to inform all essential

services as well as all downstream plant about leakage of Ammonia. It is

advisable to use Logistic Office/Argon filling station telephone for necessary

communication.

• Simultaneously close the liquid Ammonia line battery limit valve.

• Cordon off entire area.

• Suspend all the hot jobs and other spark producing operation in surrounding area.

• Do not allow anybody to enter the affected area without full body protection as

well as BA set.





• Direct fire crew to locate the spot of leakage and guide them to put water curtain

from all possible approaches. Also inform them to knock down the Ammonia gas

by water spray.

• Do not put water directly on the liquid NH3 pool.

• Isolate temporary power supply, if any in the affected area from electrical sub-

station. Do not use Mobile phones in the vicinity.

• Cool the nearby pipeline/structure by spraying water.

• Incase of fire, start fire fighting with the available extinguishers, till the arrival of fire

crew.

• Afterwards spillage/leakage area should be washed with plenty of water for

dilution of Ammonia in drains trenches.

4. Leakage of Liquid Ammonia in Outlet Flange of Flash Drum





• Isolate the ruptured/leaked line from upstream by closing automatic

pneumatic operated valve from control room.



plants/area which are likely to be affected in the downward direction.

• Don’t allow anybody to enter the affected area without respiratory

protection.

• Stop all hot jobs and other spark producing operations around the affected

area.


• Start to knock down the vapour by water curtain or water spray till the arrival

of fire crew, and then guide and assist them in further activities.

• Don’t put water directly on the liquid NH3 pool.

• Isolate all temporary power supply in the affected area from electrical

substation. Do not use mobile phones in the vicinity.


• Afterwards spillage / leakage area should be washed with plenty of water for

dilution of ammonia in drains trenches.

7.16. Offsite Emergency Plan

The Off-site Emergency plan deals with those incidents, identified in the On-site plan,

which have the potential to harm persons or the environment outside the boundary of

the premises. In the recent past, inspite of safety planning of a very high order, some

major hazards have occurred in few countries as well as in our country.

The plan has been drawn up with a view to mobilize resources and integrate with District

Contingency Plan / District Off Site Plan / Disaster Management Plan for an effective

system of command and control in combating the emergency.

The two main purposes of the Off-site Emergency Plan are:





• To provide the local / district authorities, Police, fire brigade, Doctors, surrounding

industries and the public, the basic information of risk and environmental impact

assessment and to appraise them of the consequences and the

protection/prevention measures and control plans and to seek their help to

communicate with the public in case of a major emergency.

• To assist the District Authorities for preparing the Off-site Emergency

(Contingency) plan for the district or area and to organise rehearsal from time to

time and initiate corrective actions based on the lessons learnt.

Off-site Emergency Plan followed by industry has been annexed as Enclosure-X.





Chapter 8. PROJECT BENEFITS

8.1. Environmental Benefits

GSFC ensures that the complex activities inspire the other industries to save environment

and prevent pollution by using state-of-the art technology and pollution control

equipments. With the objective of combating climate change, GSFC aligns its business

objectives with practices of resource conservation and environment protection.

Adoption of proposed technology for revamping will lead to following environmental

benefits:


• Operation of high-pressure section @ 165 kg/cm2g instead of current pressure of

205 kg/ cm2g. Lower operating pressure will have a positive effect on the


• Addition of Vacuum package & wastewater Treatment section to recover the


export to grid.






8.2. Social Developmental Activities

8.2.1. Development of Physical Infrastructure

GSFC has developed several facilities like Banking, School, University, Library, Hospital,

Parks, Recreation Centre, Shopping Complex, Temple, Post-office, Sport facilties,

Internal Road and its maintenance for improvement of nearby areas. GSFC has also

developed rainwater harvesting structures and ponds to store rainwater. GSFC is also

supplying to nearby villagers.

Proposed project will need to offer statewide social, environmental, and economic

benefits that are greater than the capital and operating costs of its implementation.





Figure 8.1 : Social Development Activities

8.2.2. Socio-Developmental Activities at Corporate Level

To achieve the desired goal and effective implementation of different programmes, a

separate department called 'Agro Development & Agro Services (AD & AS)' has been

created where technical experts of different fields and well-trained staff undertake and

coordinate various activities to generate and transfer agriculture technologies for

overall improvement.





i. Sardar Agrinet Cell Farm

To provide online agricultural information and scientific guidance to the farmers, Sardar

Agrinet Cell Farm has been launched. Immediate solution and advice to the farmers on

various day to day problems faced by farmers related to Agricultural practices, pest,

diseases & their control etc. is being provided by Agrinet though telephone. Their Toll-

Free Phone No. is 1800 123 5000.

Detailed information of 131 different crops like cereals(wheat, Bajra, Jowar, Maize etc),

Oilseeds(Groundnut, Castor, Sesamum, Soyabean, Mustard etc), Pulses(Greengram,

Blackgram, Gram etc),Vegetables(potato, tomato, Okra, Bottleguard, bitterguard

etc),Fruits(Mango, Sapota, Guava etc) cash crops(Cotton, Sugarcane, Tobacco etc),

ornamental plants(Flowers), medicinal plants, spices, forest trees etc. with their

agricultural Practices like- - Atmosphere & type of Soil suitable for the crops, Soil

preparation, Latest improved varieties, methods of sowing, Irrigation management,

intercropping, Fertilizers requirement, weeds & their control measure, Inter culturing

operations, Details of pest and disease likely to attack with photographs & their control

measure, Harvesting method, production and Economic viabilities are already available

on Sardar Agrinet Cell.

Major topics to interaction are cultivation practices of all major crops, plant protection

methods, harvesting and post harvest technologies, marketing of farm produces, soil

and water testing with amendments, balanced use of fertilizer and application, use of

biotechnology products and advances in irrigation system and technology.

ii. Farm Youth Training Programme

Farm Youth Training Programme (FYTP) of eight days duration is conducted since 1986 in

collaboration with four Agricultural Universities of Gujarat to educate farm youth. They

are advised to form a Club 'Sardar Yuva Krishak Harmayee' after going back to their

villages with a motto of overall development of village. From time to time a refresher Re-

orientation Programme is organized for ex-participants of FYTP.

iii. Crop Demonstrations

GFSC conducts various crop demonstrations and special trials on farmers' fields to

demonstrate the importance of chemical fertilizers, their efficient utilization, Bio-fertilizers,

new varieties, Tissue Culture plants, Urea, Gypsum and Zinc and Biological inputs etc.

iv. Krishi Jivan

Since 1968, GSFC publishes a monthly magazine in Gujarati language” Krishi Jivan” with

a mass circulation of copies every month. 'Krishi Jivan' is also published in Hindi language

quarterly. It contains information on latest research and new technologies of agriculture

and related fields through various articles from the eminent scientists and experts of

Agriculture Universities for the benefits of the farmers. Articles covering the important

topics like Seeds, Plant Protection, Vegetables, Underground Water Recharging, Farm

Forestry, Weather Forecasting, Dairy, Animal Husbandry etc. are also released





periodically. In view of the coverage, content, quality, and regularity, it has been

awarded International Standard Serial Number (ISSN) - 0971 - 6440 by the National

Standard Bureau.

v. Soil Testing Laboratory

To create awareness among farmers for soil quality& fertility, appropriate amount of

fertilizer input and water quality, GSFC possess a state-of-the-art Soil & Water Testing

Laboratory that provides Soil testing (for Macro & Micronutrient) & Irrigation Water testing

services at minimal rates.

1. Socio Economic Benefits

• It is expected to gain income and upsurge the turnover rof GSFC.

• It will ease the availability of chemical fertilizers to farmers.

• The proposed revamping project would generate direct and indirect

employment opportunities, which will benefit the local people during

construction period that would help in decrease fo migration.

• Business opportunities to the local people shall be available during the

construction phase

• It will improve the economy of the local nearby vendors.

• The Project shall contribute towards local training and employment programmes.

• There will be some boost to the state’s business sector, including manufacturing,

construction, transport, engineering, and related consultancies.

8.3. Corporate Social Responsibility (CSR)/Enterprise Social Commitment (ESC)

CSR Activities are undertaken by GSFC since its inception in some or the other form. The

company has developed CSR as a very special concept to promote the overall

development, progress and betterment of the people belonging to weaker sections of

society with a view to improving ‘Human Development Index’ (HDI) in core areas like

education, health, safe drinking water, vocational training, livelihood, special children,

support during natural calamities and various in-house projects. The following Table 8.1

describes various roles played by GSFC in social economic development of people

through CSR:

Table 8.1 : Contributions in Socio-development activities by GSFC

S.NO Particulars Details

1 EDUCATION

a. Empowering youth for

better prospect

GSFC University

b. Shaping future of Nation Schools developed at Vadodara Unit, Sikka Unit &

Fibre Unit

c. A healthy body leads to

healthy mind

Sports Coaching in Schools

2 SPECIAL CHILDREN





a. Osmosis Centre GSFC in association with GCSRA has established

‘Osmosis Centre’ at Urban PHC, Chhani, Vadodara.

The main goal of Centre is to help children with

learning difficulties by adopting inclusive education

with developmental therapy and enhance the

growth curve of children. Osmosis runs therapy

centre for children who learn differently.

3 DEVELOPING CSR CULTURE

a. We Rise by Lifting Others Employee Engagement Activtiies

b. Non-Just Human,

Humane too

Wall of Humanity

c. Making World a Better

Place

Support Beyond Boundaries

4 RURAL DEVELOPMENT

a. Jal he Jivan Hai Drinking Water Supply to nearby villages

b. Creating Inclusive

Structures

Infrastructure Development in Villages

c. I have a Dream Skill Development

5 PAST INITIATIVES

a. Fighting Hunger Support to Akshaya Patra Foundation

b. Swachta Tyan Prabhuta Construction of HSLs- House Sanitary Latrines

6. CONTRIBUTIONS AND DONATIONS

a. Together We Can Regular Support to various NGO’s and other

institutions for upliftment of the society

8.3.1. Social Activities carried out by GSFC

• Identifying the Stakeholders and engaging with them through multiple channels

in order to hear what they have to say about our products and services are

essential parts of our sustainability plan. The health and wellbeing of the

communities has always been an important facet of our Company’s operations.

Our Company extends its social responsibility beyond the statute book and by

engaging in strategic and trust-based community development interventions.

• While our CSR approach focuses on the development of communities around the

vicinity of our plants and beyond, we have also developed innovative

programmes that leverage our capabilities as a fertilizer and chemical company

to ensure equitable distribution of its fertilizers as per Govt. supply plan, thus

adding value to the food security of the Nation. While on chemical business plan,

the Company strives to touch all walks of life to make a comfortable living.

• Three schools at our Vadodara, Sikka and Fibre unit in which students from nearby

communities are enrolled. Company has tied up with TENVIC Sports Pvt Ltd., a

reputed agency for improving the sports talent amongst the schools run by GSFC

at its Vadodara and Fibre Unit and Akshar Trust, a school for deaf and mute

children. Karate training is conducted with emphasis on girl students to empower

them. We are working with government schools to develop students through

coaching in English and Maths.





• GSFC does give special attention to disadvantaged stakeholders as evident from

Special Children Centre established at Chhani. We provide safe drinking water to

four nearby villages. Rejuvenation of Ajwa Garden is a project which not only

ensures benefit to society but helps maintain ecological balance. We ensure

support to NGOs that are doing excellent for upliftment of the communities but

lack resources like United Way of Baroda, Art and Culture Foundation, SVADES

etc.

• CSR initiatives are undertaken in coordination with government where we are not

able to reach the communities in need; recently GSFC contributed for CM’s relief

fund for the victims of Banaskatha floods. The details of initiatives taken by our

Company in the area of community and society development have been

provided in the Corporate Social Responsibility which is part of the Annual Report.

• In nutshell it fulfils the vision of company’s CSR Policy, which is to commit and to

integrate its business values, ethics and professional skills to meet the expectations

of all our stakeholders by developing, encouraging and supporting various social

and economic initiatives, without any duplication of government policies,

through our industrial expertise for Sustainable Development.

• Company has specified programme as a CSR Activities which has been the part

of core business philosophy at GSFC ever since its inception. Today, company has

developed CSR as a very special concept to promote the overall development,

progress and betterment of people belonging to the weaker sections of society

with a view to improve ‘Human Development Index’ (HDI) with core areas like

education, environment, health and sanitation, improvement in nutrition level,

support to NGOs, rural development (social & infrastructural), industry-academic

interface, support during natural calamities and various other in-house projects.

• The CSR projects at GSFC are undertaken through the ideal blend of in-house as

well as support of specialized implementing agencies/NGOs. Company has

carried out the impact assessment of its CSR initiative. The contribution towards

Corporate Social Responsibility for F.Y. 2020-21 was to the tune of Rs. 16.09 Crores.

GSFC is not restricting to 2% as mandated to achieve its CSR objectives, which is

clearly shown in detail as CSR report forming part of the Director’s Report.

• Company believes in hand holding with a view to develop the beneficiary in such

a way that there is self-sufficiency over a period and the project is handed over.

One such example is Contribution to Mid-Day-Meal Scheme through The Akshaya

Patra Foundation, where GSFC has supported for capital expenditure plus

running expenditure for five years and then project has started showing its fruitful

results on its own.

• GSFC University is insightful CSR initiative from GSFC with a vision to boost quality

education needs and eco-friendly technology for urban sustainability. Cutting-

edge skill dissemination with a drive to facilitate state-of the art infrastructure and

technology for academic pursuits and to fulfil industry requirements to

supplement and nourish region’s landscape of learning and research is the idea

behind establishing this academic institute with industrial support. It is an





innovative step towards preparing youth interested in joining the mainstream of

development, by moulding their minds, expanding their comfort zones and

boosting confidence to deliver quality results all backed by digital knowledge

with online course material.

Figure 8.2 : Existing CSR Activities carried out by GSFC





8.3.2. Monetary Contribution by GSFC towards CSR

In year 2020-2021, GSFC has contributed Rs. 16,09,44,442 towards Corporate Social Responsibility. Funds utilized by GSFC for CSR

activities frmom year 2014-2021 have been provided in Table 8.2 below:

Table 8.2 : Funds utilized under Corporate Social Responsibility (from 2014- 2021)

Sr. Details FY 2014-15 FY 2015-16 FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20 FY 2020-21 Cumulative

Calculated 2% Amount 15,92,00,000 12,22,00,000 10,99,00,000 9,48,00,000 9,31,00,000 9,90,00,000 7,92,00,000 75,74,00,000

1 Construction of HSL 61,50,000 2,61,80,000 23,24,000 ~ ~ 34654000

2 GSFC University 9,48,31,000 2,85,00,000 5,00,00,000 10,07,19,000 1,60,00,000 5,35,85,463 2,95,00,000 373135463

3

Rejuvenation of

Ajwa Garden ~ 2,51,81,000 67,25,153

2,36,00,000 1,65,93,847 7,21,00,000

4

Contrubution to

Mid-Day-Meal 1,06,88,000 55,00,000 ~ ~ ~ 16188000

5

Contributions and

Donations 55,00,000 96,00,416 62,77,780

86,00,000 3,67,11,349 56,93,964 10,93,58,341

181741850

6

Rural

Developments

Projects 90,00,000 ~ ~ ~

6,84,103 13,95,456 5,11,000

11590559

7

Support for J & K

Floods 21,26,000 ~ ~ ~ ~ 2126000

8 Drinking Water 1,75,00,000 92,80,000 97,00,000 1,15,00,000 22,65,000 24,15,200 23,15,000 54975200

10 GSFC run Schools 1,25,00,000 96,48,000 82,74,000 1,25,00,000 1,45,29,400 3,05,04,100 1,61,10,400 104065900

11 Sikka Unit 17,00,000 1,19,29,534 1,36,93,138 2,73,22,672 65,46,514 54,05,817 31,49,701 850576972

12

Projects through

GCSRA ~ ~ 1,30,00,000 ~ ~ 13000000

13

Support for

Banaskatha Floods ~ ~ ~ 5,00,00,000 ~ 50000000

Total 15,99,95,000 12,58,18,950 10,99,94,071 20,69,19,000 9,33,30,213 9,90,00,000 16,09,44,442 1,76,41,53,944





Proposed Plan of CSR for 2021-2022

The company has proposed to contribute Rs. 12 Crores for activities to be taken under Corporate Social Responsibility.

Detailed plan has been provided in Table 8.3 below:

Table 8.3 : Proposed CSR Fund (2021-2022)

Sr. Description Amount (Rs.)

1 GSFC University 4,00,00,000

2 Education at BU, SU and FU 2,50,00,000

3 Drinking Water Facility in nearby villages of BU 30,00,000

4 CSR Activities in villages around Sikka Unit 45,00,000

5 Other Local Activities 25,00,000

6 Special Projects (Endorsed by GoG) 1,00,00,000

7 Other locations where GSFC has business interest e.g., wind/solar park 50,00,000

8 Support for PSA Oxygen Generation Plant (GCSRA) 3,00,00,000

Total 12,00,00,000





Chapter 9. ENVIRONMENT COST BENEFIT ANALYSIS

As the proposed project is of revamping and replacement of equipment/machineries

in the existing plant, environment cost benefit analysis study is not done. However, GSFC

has dedicated the cost for Environment Management Plan and Corporate Environment

Responsibility against the total cost of the project which will positively lead company to

be benefitted with the cost of proceeding with the project.

This chapter defines the benefits on Environment due to the proposed project.





Chapter 10. ENVIRONMENT MANAGEMENT PLAN

10.1. Introduction

The Environmental Management Plan (EMP) is synthesis of all proposed mitigation and

monitoring actions, set to a time frame with specific responsibility assigned and follow-

up actions defined. EMP is a plan of actions for avoidance, mitigation and management

of the impacts associated with construction and operation stages of the project. A

detailed set of mitigation measures have been compiled in view of the likely impacts

associated with the proposed project.

10.2. Objectives of EMP

The EMP consists of a set of mitigation, monitoring and institutional measures to be taken

up during the design, construction, and operation stages of the project. The EMP has

been designed keeping in view of the regulatory and other requirements to ensure the

following:

• Minimum disturbance to the environment and social components

• Compliance with the environmental acts, rules, and guidelines of the GoI &

maintaining the quality of air, water, soil and noise as per the prescribed norms

by regulatory bodies.

• Compliance to the Operational Policies and Guidelines of the Funding Agency

• Conservation of natural resources to the extent possible

• Enhancement of Project benefits for Society & Environment

• Sustainable development and operation of project

10.3. Environment Management System and Policy

Environment management system includes four major elements:

• Commitment & Policy: The management will strive to provide and implement the

Environmental Management Plan that incorporates all issues related to air, water,

land and noise.

• Planning: This includes identification of environmental impacts, legal requirements

and setting environmental objectives.

This chapter provides mitigation and control measures to attenuate or eliminate

environmental impacts, which are likely to be caused by the proposed project. An

Environmental Management Plant (EMP) has been developed to mitigate the

potential adverse impacts and to strengthen the beneficial environmental impacts

during the construction and operation phases. In addition to that during the

operation phase, the industry will have an additional responsibility to comply with

the statutory requirements as per the guidelines of Central/ State Government.





• Implementation: This comprises of resources available to the developers,

accountability of contractors, training of operational staff associated with

environmental control facilities and documentation of measures to be taken.

• Measurement & Evaluation: This includes monitoring, counteractive actions and

record keeping.

10.4. Environment Management Plan

GSFC Complex is an existing operational fertilizer, chemical and petrochemical

products manufacturing unit. GSFC has now proposed for Revamping of Urea-I & II

plants within the complex for development of revamped urea plant. Construction

activities will involve demolition and refurbishing of units within the plants along with

commissioning of new machineries for technical developments proposed under

revamping through new technology i.e., Ammonia Stripping.

Major activities associated with the proposed project are construction and operation of

the project. A detailed environmental management plan for each activity of

construction and operation phases are prepared. EMP lists the activities involved along

with environmental impacts associated with each activity, suggestive impact mitigation

measures, and implementation plan covering monitoring and supervisory responsibilities.

The environmental management plan is included in Table 10.1 and 10.2 for construction

and operation phase, respectively. To effectively manage the environmental

management (including social management) of the project, greenbelt development

plan, Resource Conservation Plan, Compliance to the CREP guidelines, facilities for

employees Occupational Health Management Plan, Environment management cell,

Budget for Environmental Management Plan has-been prepared separately and

integrated with EMP. These shall be followed for effective implementation of the EMP.





Table 10.1 : Environment Management Plan during Construction Phase

S. No Environmental

Component

Aspect Management Applicable Norms

1. Air

Environmental

• Generation of

PM and other

gases

• Dust and Debris

Generation

• Internal roads have already been well

developed at the project site, so this will

reduce the abrasion and thereby reduce

the dust generation.

• Wind breakers will be installed.

• Barricading will be done around the

construction site to control dust dispersion


• Construction material vehicles will be

covered during transportation.

• Dust suppression will be done by regular

water sprinkling in and around the project

site.

• Air Act (Pollution Prevention &

Control), 1981

2. Noise

Environment

• Generation of

Noise

• Green Belt has been provided around the

project boundary to curb excessive noise

emissions from the construction site.

• Construction machineries will be provided

with acoustic pads for noise reduction

during operation.


• Construction activities, including receipt of

material will be done during daytime only.

• Proper maintenance of noise generating

transport vehicles will be done.

• Noise Pollution (Regulation and

Control) Amendment Rules,

2017





S. No Environmental

Component


3. Water Quality • Wastewater

Generation

• There will be no absraction of groundwater

for proposed revamping. Existing source

will be used for construction purposes.

• Wastewater generated from toilets shall

be disposed as same as existing practice

i.e., disposed through soak pits.

• Water Act (Pollution Prevention

& Control), 1974

• Ground Water Guidelines for

Withdrawal and Policies of

Irrigation Department

4. Waste • Generation of

Municipal Waste

• Generation of

discarded

machinery and

used oil

• Generation of

C&D Wastes

• Waste will be collected, segregated, and

will be disposed by approved agency.

• Discarded machinery will be given to

approved recycler and used oil shall be

stored in drums and sold to recycler.

• C&D wastes will be discharged to

CPCB/GPCB designated C&D dumping

site.

• Municipal waste will also be generated by

labourers during construction stage that

will be disposed off to designated

Municipal Waste Disposal Site.

• Construction & Demolition

Waste (Management &

Handling) Rules, 2016

• Solid Waste Management Rules,

2016

• Hazardous & Other Waste

(Management and



5. Land/Soil • Contamination

in Soil and Land

• Existing Sanitation and waste

management practice shall be adopted

during construction phase during influx of

local labour.

• The land use has already been changed

to Industrial use.

• Drains are already provided near

machinery area to collect spillage or

leakage.


Waste (Management &


• Solid Waste Management Rules,

2016


(Management and







S. No Environmental

Component


• Proper care will be taken that there is no

spill that would cause soil contamination.

• Replacement or discarded machinery

shall not be with kept on unpaved surface.

Discarded machinery will be given to

approved recycler.

• Used oil shall be stored in drums and shall

be sold to registered recycler.

• Best management practices shall be

adopted to avoid the contamination of

soil.

6. Ecology &

Biodiversity

• Tree Cutting

• PM & gaseous

emissions

• Noise

Generation

• Dust generation due to construction

activities be confined mostly to the initial

period of the construction phase and

would be minimized through paving of

roads, surface treatment, regular water

sprinkling in dust generating areas and

green area.

• All project activities shall be undertaken

with appropriate noise mitigation

measures to avoid disturbance to human

as well as faunal population in the region.

• No tree cutting shall be done.

• Water sprinkling shall be done at the site at

regular intervals.

• Green belt and boundary wall has been

provided to reduce the impact of air and

noise.

• State Forest Act.

• Forest (Conservation) ACT, 1980

with Amendments Made in

1988.

• Wildlife Protection Act of 1972.





S. No Environmental

Component


• C&D waste will be carefully disposed off to

designated C&D facility.

7. Socio-

Economic

• Infrastructure

needs

• Accident and

Noise problem

• Employment

Generation

• All basic facility like sanitation, toilets,

canteen, camps shall be provided within

the plant area.

• Hygiene conditions shall be maintained at

site.

• PPEs shall be given to all labour working in

noise-prone area.

• Health and safety officer shall be deputed

all the time during construction phase.

• MSDS and safety instruction shall be

displayed in working area.

• OHSAS

• BOCWA

• Labour Act, 1970

8. Traffic • Generation of

Traffic.

• Nuisance in the

main

approachable

road.

• There will be increment of traffic due to

influx of 70 no. of labourers within the

project. However, nearby local labourers

will be employed.

• Common bus services will be provided for

entry and exit of labourers.

• Traffic rules will be always followed.

• Motor Vehicle Act,2019

Table 10.2 : Environment Management Plan during Operational Phase

S. No Environmental

Component


1. Air • Spillage/leakage

• Process emission

• Adequate air pollution control system has

been installed to achieve prescribed norms.

• Air Act (Pollution Prevention

& Control), 1981





S. No Environmental

Component


• Dust and Urea

emission

• Flue gas

emissions

• Approx. 123.2 Ha. of Green Area i.e.,37.56 of

total plot area has been provided in the

plant.

• Online Stack Monitoring System has been

installed in the plant for online air parameters

measurement and is connected to

CPCB/GPCB.

• Natural gas is being used for boilers to control

air emissions.

• Adequate stack height has been provided in

all the units as per CPCB norms.

• Urea Plants are operational having forced

draft prilling tower. Both these plants have

scrubbers to achieve existing norms of urea

dust emission. The emissions are within the

norms specified by GPCB. Moreover,

Vibropriller has been installed in prilling tower

for reduction of dust emissions.

• GSFC carries out regular ambient air quality

monitoring at the periphery and nearby

villages about SO2, NOX, PM10, PM2.5 and

Ammonia as well as SO3, Flouride and Acid

Mist parameters. Monthly average results are

online submitted to GPCB. Moreover, 4 no. of

online AAQMS are in operation at the

periphery of premises and connected to

GPCB and CPCB server.

• MoEF&CC notification-

G.S.R. 1607 (E) dated

29.12.2017 & The

Environment (Protection)

Rules, 1986





S. No Environmental

Component


• Stack monitoring facilities like portholes,

ladder/platform etc. have been provided to

all stacks/vents and chimney.

• The roads are made of asphalt in the

company premises. All internal roads are

made of concrete.

2. Noise • Generation of

Noise • Noise monitoring is carried out at 80 different

locations within the premises. The ambient

noise levels conform to the standard

prescribed under EPA Rules, 1986.

• Various engineering controls are taken at

different plants like on exhaust, acoustic

enclosures, soundproof cabin, preventive

maintenance etc.

• Noise levels at periphery are monitored

through NABL approved laboratory.

• Approx. 123.2 Ha. of Green Area i.e., 37.56%

of total plot area has been provided.

• Equipment meeting standard of noise shall

be used.

• All engineering control practice shall be

undertaken during installation of machinery

to maintain noise level.

• Acoustical Enclosures and Mufflers are

provided at all required locations.

• Noise Pollution (Regulation

and Control) Amendment

Rules, 2017





S. No Environmental

Component


• Vibration pads and foundation is provided at

all heavy machinery areas.

• Noise generating units like machinery area,

canteen etc. are well insulated with

enclosed doors.

• Earmuffs are being used while in high noise

areas. Separate cabins are provided.

• Acoustic treatment rooms are provided at

appropriate location

• Well-developed road is constructed within

plant, for smooth and hassle-free movement

of personnel.

• Proper and timely maintenance of

machineries and preventive maintenance of

vehicles is being done.

• Important Instructions are displayed all over

the plant area.

3. Water • Generation of

Domestic

Wastewater

• Generation of

Effluent

• Requirement of

Fresh water

• Analysis of final discharged effluent is being

carried out regularly.

• Effluent from the process plant and

associated facitlies are not discharged to

storm water drain to prevent contamination

of storm water.

• Development of many rainwater harvesting

systems like ponds, recharge wells, etc.

• Water Act (Pollution

Prevention & Control), 1974

• MoEF&CC notification-

G.S.R. 1607 (E) dated

29.12.2017 & The

Environment (Protection)

Rules, 1986





S. No Environmental

Component


• Water

Contamination

• Real-time online monitoring system have

been installed for effluent parameters like

COD BOD, pH, TSS etc. and is connected to

GPCB as well as CPCB server.

• Treated Industrial effluent from final

discharge ponds conforming to GPCB norms

is being discharged into common effluent

conveyance channel of VECL.

• Metering facility (Magnetic flow meter) on

effluent discharge line has been provided.

• The quality of total effluents discharged from

GSFC which includes lean streams through

open channel to disposal pond. This is

monitored as when required.

• In case of spills of chemicals, dry

adsorbents/cotton are being used for

cleaning instead of water

• Spillage during loading, unloading & storage

are channelized properly to drains

• Spillage are managed by detection of leaks

in the first place from structures or vessels.

• Collection of effluent are in closed pipeline

• Cushion are provided to the materials to

prevent chemical container breakage





S. No Environmental

Component


• The transportation of the raw material,

chemicals & products is being done in Leak

Proof MS Tankers/Drums while transporting

through trucks & tempo.

• All probable leakage areas such as

pipelines, joints, pumps and structure of

reactor/ storage vessel are inspected and

maintained proactively.

• Cleaning of storm water drain/open channel

in the complex is carried out before

monsoon season.

4. Waste • Generation of

Municipal Waste

• Generation of

discarded

machinery and

used oil

• Generation of

Hazardous waste

• Industrial hazardous wastes such as spent

lube oil, spent catalyst are sold to recyclers.

ETP sludge generated is disposed off at TSDF

site while other solid wastes are segregated

in saleable and non-saleable waste. All

wastes are disposed as per Hazardous &

Other Waste (Management and


Rules, 2021.

• Wastes are dried, packed, and stored in

separate designated hazardous waste

storage facility before its disposal. GSFC

strictly complies with the rules and


Waste (Management &


• Solid Waste Management

Rules, 2016


(Management and



• Plastic Waste Management

Rules, 2016

• E-Waste (Management)

Rules, 2016





S. No Environmental

Component


regulations with regards to handling and

disposal of hazardous waste in accordance

with Hazardous & Other Waste

(Management and Transboundary


• Waste is packed in drums/HDPE bags and

stored at designated area. All measures are

taken to avoid littering.

• All the safety precautions are taken for safe

handling and storage i.e., illumination of its

piping and storage area, ensuring leak proof

system, use fo PPE, keeping eye on all

process parameters day to day through DCS

on round the clock basis, required trips and

alarm aystem etc.

• Safety department co-ordinates regularly for

necessary compliance pertaining to Factory

Act and Manufacture, Storage and Import of

Hazardous Chemical Rules.

• Necessary alarms/trips/interlock like high

level, temperature have been installed in

hazardous material handling area.

• The spent catalysts are packed in drums and

stored in separatestorage area and sold to

• Battery Waste Management

Rules, 2020

• Bio-medical Waste

Management Rules, 2016





S. No Environmental

Component


MoEF&CC/CPCB registered recylers. The

details of the catalysts sold are being

regularly submitted to GPCB.

• Separate paved storage area for

Hazardous/ Non-Hazardous/ Municipal is

provided within the plant area.

• Adequate measures and technologies are

adopted in the plant to reduce the waste

generation.

5. Land/Soil • Contamination in

Soil and Land

• Municipal Waste (Domestic and or

commercial waste) is being disposed as per

Solid Waste Management Rules, 2016.

• Hazardous waste generated in the Plant is

being disposed as per Hazardous & Other



• All precautions are being taken to avoid

spillage from storage during existing phase

and shall be taken during further phase.

• Spillage are managed by detection of leaks

in the first place from structures or vessels.

Spillage during loading unloading is

channelized properly to drains.


Waste (Management &


• Solid Waste Management

Rules, 2016


(Management and







S. No Environmental

Component


• Paved area is provided near the process

area to avoid soil contamination

• The loading unloading activity are done

within a safe zone defined and in a marked

safe area.

• All underground tanks are provided with

extra prevention to avoid leakage. Sensors

are provided to detect leakage.

• Hazardous waste is managed, transported,

and disposed as per Hazardous & Other



Separate shed/designated area with paved

area is provided at plant for storage of

Hazardous waste.

• Closed Effluent channelization is provided all

over the plant area. Domestic sewage

wastewater is being disposed through soak

pits.

• Solid waste collection and disposal area is

paved area to avoid contamination of soil

through leachate.

• Water less cleaning is adopted wherever spill

occurs to avoid runoff.





S. No Environmental

Component


• No area shall be left excavated or open after

any repair & maintenance works

• Used oil shall be stored drums and shall be

sold to registered recycler.

• Drains are already provided near machinery

area to collect spillage or leakage.

6. Ecology &

Biodiversity

• Tree Cutting

• PM & gaseous

emissions

• Noise Generation

• Disposal of

untreated water

in gardening.

• The project is planned with most efficient air

pollution control systems for achieving air

emissions norms, so that the impact on

nearby ecosystem is minimized. Most of the

fugitive dust emission generation points are

also fitted with efficient air pollution control

systems.

• Water sprinkling system will be used to

suppress the generation of fugitive dust.

• No wastewater shall be discharge outside

the plant premises. The treated effluent shall

be recycled and re-utilized within the

premises for de-dusting and maintenance of

green belt.

• All the solid and hazardous waste shall be

disposed as per the norms

• Approx. 123.2 Ha. of Green Area i.e., 37.56 %

of total plot area has been provided in the

• State Forest Act

• Forest (Conservation) ACT,

1980 with Amendments

Made in 1988

• Wildlife Protection Act of

1972





S. No Environmental

Component


plant. More than 9-10 m wide green belt is

provided all around the boundary wall of

project site.

7. Socio-

Economic

• Infrastructure

needs

• Accident and

Noise problem

• Medical Compliance (six monthly) of

employees is carried out on regulat basis by

Occupational Health Centre located within

premises. Records are maintained at OHC.

• Regular training on safety and health

aspects are organized by safety and

medical services department and workers

are depute for the same.

• All the workers are continuously trained for

proper handling and transportation of

hazardous materials as per Hazardous &

Other Waste (Management and


Rules, 2021.

• Solid waste generation in operational phase

are Domestic waste, landscape waste. That

are managed as per Solid Waste

Management Rules, 2016.

• Plant will be shutdown during failure of APCS.

• All measures are adopted to reduce fugitive

emission as discussed in earlier sections.

• The greenbelt area is already developed

which help in enhancing the aesthetics

value of the area.

• OHSAS

• BOCWA

• Labour Act, 1970





S. No Environmental

Component


• Less noise generation machinery

equipment’s are installed to maintain the

noise levels within permissible limits.

• PPE’s are being provided to workers.

• A well-developed Township is already

developed besides the project site for

operational workers.

• Adequate storage area for the safe storage

of products, raw materials and hazardous

chemicals are provided.

• Apart from Plant utility and manufacturing

area, R&D lab, Canteen, admin, Guest

House, drinking water, Water treatment, etc

facilities are provided within the plant.

8. Traffic • Traffic

Generation

• Nuisance on

Roads

• Since, there will be no increment in

manpower, there will be no detrimental

impact on traffic.

• Most of the staff and employees are residing

within the complex only i.e., GSFC Township.

• However, traffic rules will be maintained.

• Motor Vehicles Act, 2019





10.5. Occupational Health & Safety System at GSFC

Occupational Health and Safety (OHS) is an area concerned with the safety, health and

welfare of persons engaged in work or employment. Main aim of occupational safety

and health plan is to foster a safe and healthy work environment, which also protect co-

workers, family members, employers, customers, and many others who might be

affected by the workplace environment.

OHS is widely referred as occupational health, occupational and non-occupational

safety includes safety for activities outside work. GSFC is awarded ISO 9001:2015 Quality

Management System, ISO 14001:2015 Environment Management system, ISO 45001:2018

Occupational Health and Safety Management System and ISO 50001:2011 Energy

Management Certification for Vadodara Unit.

Figure 10.1 : ISO 45001:2018 OH&S Management System Certificate





Figure 10.2 : ISO 9001:2015 Quality Management System Certificate





Figure 10.3 : ISO 14001:2015 Environment Management System Certificate





Figure 10.4 : ISO 50001:2018 Energy Management System Certificate





10.5.1. Safety Department

Safety Department comprises of well-qualified and experienced safety officers and

safety representatives equipped with latest equipments, instruments for monitoring safe

work environment.

Main Functions of Safety Department are the following:

• Ensuring compliance of safety management system by plant.

• Imparting safety training to newly recruited manpower & contract labourers &

supervisors and existing employees.

• Maintaining & procuring of PPE (personal protective equipment).

• Conducting mock drills & evacuation drills for ensuring preparedness to deal with

emergency.

• Conducting routine & random safety inspection of plants & licenced premises for

ensuring & improvement of safety management system.

• Renewal of various licences.

• Preparation & updation of onsite emergency action plan, MSDS & other safety

literature.

• Playing vital role during real emergencies.

• HAZOP studies of modifications in existing plants/new rojects and special

Study/surveys.

• Compliance of various statutory requirements.

• Analysis & investigation of various accidents/incidents/near miss.

• Safety vigil is exercised in all activities to achieve zero fatality & minimize reportable

accidents.

Occupational Health and Safety Measures

• Hazard Identification and Risk Assessment.

• Work Permit System procedure has been established for safely execution of job.

• Electrical isolation/Lock Out and Tag Out procedure has been established for

Isolation of energized equipment’s/ machineries.

• Standard Operating procedures.

• Start-up procedure Shut down procedure, emergency procedure is being followed.

• Inbuilt safety measures such as trips, alarms, logics.

• Mechanical integrity through Preventive Maintenance for all the machineries at

regular intervals.

• Safety instrumentation- DCS System for plant process monitoring has been

established. For the proposed revamping project, DCS shall be established.

• Insulation of all the process equipment’s which are subjected to high temperature

conditions.

• Worker’s participation in Safety Management system: - Safety committee meetings,

employee suggestion schemes.

• Incident Investigation & reporting.





• Online near miss reporting.

• DISH Approved training center to impart training for all the level of employees/

Contract workmen.

• MSDS related to all the chemicals used in complex are available.

• Explosive concentration checking for the flanges.

• Fire resistant construction for all reaction vessels.

• Flame Retardant Low Smoke (FRLS) Cables are installed for electrical network.

• All the electrical fittings are provided with fuses, relays, circuit breakers.

• Management level Visual Inspection committee carries out Hazardous Installation

Inspection at these places every six months.

• Various internal and external safety audits, Plant Safety committee, House keeping

committees formed which conduct their audits regarding OS & H and demand time

bound compliance.

• Hazardous areas already barricaded and separated from other operating units by

proper separation distances. In such area, all equipment’s used are flameproof and

intrinsically safe.

• Plant Safety Inspections.

• Hazard communication by the means of Safety Bulletin, Safety Posters, Caution

boards.

• Chemicals are stored at isolated storage facility and labelling also done for

identification of the container/chemicals.

• On-site emergency Plan.

• Mock drills.

• Various PPES, Fire extinguishers, safety showers, first aid boxes (filled) & air masks, Gas

masks etc are provided at various Hazardous installations.

PERSONAL PROTECTIVE EQUIPMENTS AVAILABLE AT GSFC

Table 10.3 : Details of Personal Protective Appliances for Emergency Handling

Safety Systems PPE’s (Quantity in Number)

Urea-I & II SA-III SA-IV AS-I & II Total

RESPIRATORY

B.A. Set 5 2 2 2 11

Air line Respirator

- Control

Room

6 1 2 1 10

- Cupboard 12 1 1 1 15

Resuscitator 2 1 1 1 5

Dust Respirator 4 1 3 0 8

Benzene/Organic

Vapour Cartridge

6 6 3 5 20

Cloth Mask 0 0 5 0 5

Gas Mask 3 2 0 3 8





Safety Systems PPE’s (Quantity in Number)

Urea-I & II SA-III SA-IV AS-I & II Total

NON-RESPIRATORY

Suits

- PVC 3 3 1 2 9

- Flame

Retardant

1 1 1 1 4

Safety Belt 1 1 1 1 4

Panoramic

Goggles

2 1 1 7 11

Apron-Rubber 1 1 1 1 4

Hand Gloves 5 15 5 7 32

Chlorine

Emergency Kit

1 1 1 0 3

Blue Safety

Helmet

1 1 1 1 4

OTHERS

Communication

Chart

1 1 1 1 4

OEHS Policy 1 1 1 1 4

GSFC Plot Plan 1 1 1 1 4

GSFC Safety

Manual

1 1 1 1 4

Emergency

Action Plan

1 1 1 1 4

COSHH Manual 1 1 1 1 4

Windsack 1 1 0 1 2

Eyewash &

Shower

6 9 9 5 29

Chemical

Information Panel

2 6 3 3 14

Noise Level

Display Board

1 2 1 0 4

TOTAL 69 62 48 47 226

10.5.2. Safety Training & Mock Drills

10.5.2.1 Safety Training

Industry is regularly providing training to all its workers on work safety. All the accidents

are analyzed investigated and remedial measures are being taken to avoid

reoccurrence of the same. Constant follow up is done by the management to rectify

the unsafe working conditions & practices etc. The industry has Hazard identification

Group as well as Safety Committee. Both these groups study accident and unsafe

working conditions and provide necessary innovative suggestions for accident

prevention.





Regular training on safety and health aspects are organized by safety and medical

services department and workers are deputed for the same. The record of latest training

held in year 2020-2021 are provided below:

Table 10.4 : Details of Safety Training (2020-2021)

Sr.

No. Date Title of Training

Duration of

Training

(Hrs.)

No. of

Employees

Attended

Training

Training

Man-Hours

1 01.10.2020 Refresher Safety Induction Training 1 1 1

2 17.10.2020 Electrical Safety & Hazardous Area

Classification 2 17 34

3 24.10.2020 Laboratory Safety 2 28 56

4 07.11.2020 Safety during Working at Height 2 40 80

5 21.11.2020 Chemical Safety 2 45 90

6 28.11.2020 Safety during Working at Height 2 32 64

7 12.12.2020

Safety Training/Refresher Programmes

for Emergency Support Team (EST)

Members

2 25 50

8 15.12.2020 Safety Induction Training to ETs 3 5 15

9 19.12.2020



Members

2 21 42

10 26.12.2020



Members

2 21 42

11 01.03.2021 Occupational Disease &

Precautionary Measures 1.5

51 76.5

12 02.03.2021 Safety Before or After, Choice is Yours 1.5 81 121.5

13 03.03.2021 Rotating Machine Safety 1.5 44 66

14 05.03.2021 Behavior Based Safety in Process

Industries 1.5

28 42

15 06.03.2021 Tips on Disaster Mitigation 1.5 60 90

16 08.03.2021 Safety & Fire Prevention in Chemical

Industries 1.5

33 49.5

17 09.03.2021 Safety during Working at Height 1.5 34 51

18 10.03.2021 Electrical Safety 1.5 31 46.5

10.5.2.2 Mock Drills

1st Mock Drill for the year 2021 was conducted on 16th January,2021 at Sulphuric Acid-IV

Plant. Emergency Scenario for Fire at Junction of Conveyor Belts (BC-1&2) was

considered. Mock Drill was overseen by members of Mock Drill Observers Committee

members. General Awareness regarding co-ordination, communication during

emergency was practiced. Actions of identified personnel and usage of fire protection

methods was practiced and observed. With such practices being performed within the

plant, mock drills and practice of safety proves a good measure of occupational health

and safety protocol within the complex.





10.5.3. Fire Fighting Department

All the plants in GSFC are provided with state-of-the-art fire protection facilities. An ISO

9002 certified department for adopting standard operating practices has been

established and being maintained regularly. Tank farm facilties conform to the most

stringent standards like NFPA, BS, OISD.

The three main functions of Fire and Safety Department at GSFC are the following:

A. Fire Prevention

B. Fire Fighting

C. Fire Protection

Fire Prevention Methods

• Hot work permit procedure & preparedness while executing of work

• Regulated manpower and vehicle control

• Designated permits for various jobs

• Report on the job training

Fire Protection System of Plant

• Deluge foam protection system.

• Conventional foam system.

• Water spray system for critical equipment.

• Fire hydrant network with hydrants & monitors located as per NFPA & TAC guidelines.

Communication System of Fire Unit

• Analogue addressable fire alarm & detection system.

• PC-based conventional panel with graphic interface.

• Wireless network.

• Hot line facilities to mutual aid industries.

• OIECR communication network.

Tank Farm Fire Protection System

• Manual foam system.

• Water spray protection system.

• 1000 GPM long range foam monitors.

• Inert gas blanketing.

Fire Fighting Appliances and Equipment

• 7 Foam crash tenders equipped with Firex and Rosen Bauer pumps.

• 2 300 lbs. DCP tailors.

• One Rosenbauer trailer pump.

• One hydraulic platform of 42 m height equipped with 4000-LPM Rosenbauer pump

with one remote controlled monitor and one hand-controlled monitor. This

equipment is the tallest in the state of Gujarat.





• Enough fire hydrant and riser valves have been provided to fulfill fire extinguishing

needs. Apart from this, fire extinguishers kept at various locations inside plant. They

are hydrostatistically tested and refilled at intervals specified by statutory body.

Training

• All employees are given fire-fighting training.

• Emergency response training is given through mock drills.

• Refresher training is conducted on regular basis.

• Fire brigade response and performance amongst mutual aid industries is checked

by mock drills and other offsite emergency exercises conducted by OIECR.

Manpower

• The manpower is trained with the latest equipment and discipline is the key for this

department.

• Officers are professionally qualified with training imparted from reputed fire college.

Fire Stations

• There are two fire stations in the complex manned round-the-clock. They are

equipped with the latest fire control equipment. All equipment is checked and

tested at regular basis.

• A separate Emergency Control Centre (ECC) equipped with all necessary

communication facilities is manned round-the-clock.

• Regular fire audits, both internal and external, are conducted to ensure best

preparedness against any eventuality.





Figure 10.5 : Fire Prevention Methods practiced at GSFC

GSFC complex is divided in six zones based on the fire water pump houses and Hydrant

Locations. The brief description of the area under each fire protection zones is as below:

Zone A: Ammonia Group of plants, Urea plants, old Argon filling station & Ammonia filling

stations. Naphtha Tank farm, Methanol plant, Highway gate & ADM Building. (Fire pump

house in front Ammonia - III plant.)

Zone B: Phosphatic group of plants, Acid group of plants, Utilities & Co-Generation

plants, OSG plant, Workshops, General Stores, R & D, Steam Generation, Safety, Fire

Station, Pilot plant, SAN, Gas cylinder Storage, GAD, S90WDG, Stores. (Fire pump house

in WT - I plant.)

Zone C: Caprolactam-I plants & its Tankfarm Ammonia storage, Melamine– I & II plants,

Nylon-6 plant, old Argon filling stations, Nylon-6 plant –II, Nylon 6 Compounding. (Fire

pump house in WT – III plant and in front of Ammonia - III plant.)

Zone D: Caprolactam Expansion plants their Tankfarms & Entry Gate. (Fire pump house

in utility DMW plant – Capro -II).

Zone E: Naphtha & Methanol Storage area in Vadnagar tank farm area. (Fire pump

house in Vadnagar tank farm area.)





Zone F: Ammonia-IV Plant, GAIL Station (outside Buttery Limit) (Fire pump house near

Cooling Tower.)

Zone G: Miscellaneous Area (GSFC Township, Medical Centre, FNC Shopping Complex,

Pump House, LPG Gas Godown, Training Institute, GGRC, Shin Aatami Guest House,

Gymkhana, Officers club etc)

ALARM AND DETECTION SYSTEM

Table 10.5 : Zone-wise Alarm & Detection Points

ZONES

A B C D E F Total

CR SS - CR N-6-II

plant SS Anone Lactam CR SS

Fire Detectors

34 22 -

08 19 14 92 132 -- 87 102 510

CR –Control Room; SS –Sub Station

Table 10.6 : Plant-wise Alarm & Detection Points

Zone Plant Location No. of Fire Detectors

A

Ammonia-I Control Room 4

Methanol Electrical S/S 22

Control Room 30

B -- -- --

C

Nylon-6-II Control Room 8

Capro.I Plant 19

Elec. Sub Station 14

D

Capro.II

Anone Section 92

Lactam Section 132

E -- -- --

F

Ammonia-IV

Control Room 87

Elec. Sub Station 102

TOTAL 491

Table 10.7 : Fire Tender Details

Sr.

No

.

Tender

No.

Make

&Model

Water

Capacit

y

Foam

Capacit

y

Dcp

Capacit

y

Pump

Capacity

Additional

Facilities

1 GJ6 4135 TATA -

TURBO

2500

LITERS

1000

LITERS 1000 KG

LPM:3000

, 10 Bar

06 nos. Of

Nitrogen

Cylinders





Sr.

No

.

Tender

No.

Make

&Model

Water

Capacit

y

Foam

Capacit

y

Dcp

Capacit

y

Pump

Capacity

Additional

Facilities

2416 -

1992

2 GJ6 W

8101

Ashok

Leyland

Tusker -

1999

2500

LITERS

1500

LITERS ----

LPM:2800

, 10 Bar ----

3 GJ6 Y

8828

TATA -

WADIA

2516 -

2003

4000

LITERS

4000

LITRES ----

LPM:4000

, 10 Bar ----

4 GJ06 AT

5766

Ashok

Leyland

1616-

2011

5000

LITERS

1500

LITERS ----

LPM

:4000/10

Bar

----

5 GJ06 AT

5801

Ashok

Leyland

1616-

2011

5000

LITERS

1500

LITERS ----

LPM:

4000/10

Bar

----

6 GJ06 AT

5769

Ashok

Leyland

1616-

2011

5000

LITERS

1500

LITERS ----

LPM:

4000/10

Bar

----

7 GJ06 AT

5792

TATA251

8 - 2011

5000

LITERS

1500

LITERS ----

LPM :

4000/10

Bar

----

8 GJ06 AT

5778

TATA251

8 - 2011

5000

LITERS

1500

LITERS ----

LPM :

4000/10

Bar

----

9 GJ06 AT

5804

TATA251

8 - 2011

8000

LITERS ---- 2000 KG

LPM :

4000/10

Bar

06 nos. Of

Nitrogen

Cylinders

10 GJ06 U

7710

TATA161

3 - 1994

2700

LITERS

450

LITERS ----

LPM :

2250 LPM





Sr.

No

.

Tender

No.

Make

&Model

Water

Capacit

y

Foam

Capacit

y

Dcp

Capacit

y

Pump

Capacity

Additional

Facilities

11

GJ6 W

8266

(SNORKEL

)

Ashok

Leyland

HIPPO -

1997

---- ---- ---- ----

• Max.

Height

42

meter.

• Rotate

360*.

• 400 kg or

04 nos.

of

personal

lifting

capacit

y in

hydrauli

c

platform

.

• Used

both

purpose

fire

fighting

and

Rescue.

10.5.4. Occupational Health Centre

GSFC has a full fledged 25 bed hospital with various facilities like central oxygen facilities

(25x7), first aid boxes (125 no.). The hospital posses fully equipped indoor facilities like the

following:

• Digital X-ray

• Full fledged Physiotherapy

• ECG multi parameter, defibrillator ventilator

• Fully equipped advanced laboratory

• Advanced Pharmacy

• ICU Beds, Sterilized Dressing Pad

• First responder facilities with splint, eye wash bottles, safety shower

• Emergency communication

• No Tobacco Policy

Detailed List of facilities at Occupational Health Center has been provided below in Table

10.8:





Table 10.8 : Details of Facilities at OHC

Unit Equipments

Doctor’s Room Stethoscope, Mercury Sphygmomanometer, Titmus 2a Vision Testing

Machine, Peak Flow Meter, Examination Bed with Stairs, Revolving

Chair, Revolving Chair, Table (Large), Four Sitting Chair, One Stool

(Medium Size), X-Ray Viewing Box, One Wall Clock, One Table

Calculator

Dressing Room Dressing Table With Macintosh, Observation Bed, 2-Sitting Chairs,

Dressing Tray With Bowels, Dressing Drums- 1, Oxygen Cylinder With

Stand, Enameled Tray Big-1,Small-1, Scissors, Glass Cupboard

Containing, Enameled Bowel, Enameled Drum, Steel Kidney Tray

Small-2, Steel Bowels Big-3, Steel Bowels Small-2, Plastic Urinal-2, Ambu

Bag-2, Dressing Items & Splint, Small Steel Tray With Cover,Injection

Tray, Antiseptic Solution &Liquids, Antiseptic Powder & Ointments, Eye

& Ear Drops, Allis Forceps-1, Mouth Gags-1, Spatula-1, Proctoscope-1,

Mosquito Forcep-1, Artery Forceps, Toothed Forcep, Plain Forcep,

Plastic Airway-1, Steel Airway-1, Retractor-1, Ear Speculum-1, Plastic

Measuring Cup-3, Steel Scissors

Driver’s Room Oxygen Cylinders,2, Wooden Bench-3, Steel Locker- 1, Metal Cot,

Wooden Rack for Files

Laboratory

Room

Collection Table With Drawer No.3, Revolving Chair, Patient Chair 6

No.(Combined), One Sitting Chair, Small Iron Stool, Two Test Tube

Stand(Metallic), Two Test Tube Stand(Plastic), Cupboard, Drawer No.1

{Tray, Bulb Holder ,Five Plastic Pipette Stand, Six -250ml Beaker Glass,

Six-100ml Beaker Glass, Six-500ml Beaker Glass, Plastic Esr Stand, Three

Test Tube Stand(1-Metallic), Four Test Tube Stand(1-Metallic) ,500ml

Glass Flask 4 No., Seven-250ml Glass Flask, One-100ml Glass Flask, Wo-

Spirit Lamp, Three Boiling Flask, Two Measuring Flask, One Funnel ,Ten-

1ml Pipette(Glass), One Test Siere, Two Wooden Box, One Glass Stand,

Ambulance Spare Part}

Pharmacy

Room

Weighing Machine, Wooden Counter with Rack, Wooden Table, Steel

Cupboard-3, Revolving Chair, One Wall Clock, One Ceiling Fan, One

Table Fan, Computer, Snellen's Chart, One Steel Stool

Storeroom Ceiling Fan, Metal Cupboard Medium Size with Glass Doors, Steel

Rack-3, Bed Pan-3 (Metal)

A team of well experienced medical officers has been assigned at the complex. The

details are mentioned in following Table 10.9:

Table 10.9 : Details of Examination under Periodical Medical Check-up

S.No. Name Designation Qualification Experience 1 Dr. Manju Ramnani Chief, MS MBBS. MS. CIH, PGD,

MCH, PGDHHM

22 years

2 Dr. T.B. Shah Manager MBBS, AFIH 22 years 3 Dr. Anil Pania Manager MD, UKRAINE, CIH 13 years





S.No. Name Designation Qualification Experience 4 Dr. Richa Malhotra Deputy

Manager

MBBS, AFIH 9.5 years

5 Dr. Mohit Singh Deputy

Manager

MD Phy. Russia 8.5 years

Regular six-monthly medical examination of employees is carried out on a regular basis

by Occupational Health Centre located within the premises. As a part of Periodic

medical checkup of contract workers, medical check of Contract workers at

Occupational Health Centre (OHC) is being carried out. An employee during periodical

medical examination undergoes primary cardiac evaluation by ECG to detect early

cardiac abnormalities. Records are maintained at OHC. Periodical and pre-medical

examination and tests/investgations carried out during medical examination are

provided below in Table 10.10 below:

Table 10.10 : Details of Examination under Periodical Medical Check-up

S.No. Examinations

1 Physical Examination

2 History of past and present illnesses of personal & family

3 History of any medication and drug and allergic reactionECG

4 ECG

5 PFT

6 Counselling for habits (Tobacco, Alcohol, Smoking)

7 Counselling (Nutrition, Stress, Ergonomics, Hazard Specification)

8 Health Screening of Lifestyle diseases

9 Screening of Hypersensitivity of any chemical or drug

10 X-ray/USG

11 Blood Investigation CBC, LFT, RFT, Lipid Profile, RBS/FBS (PP2BS)

12 Urine Examination Glucose, Protein

Latest Medical Health Check-up Report of employee have been provided as Enclosure-

XI.

10.5.4.1 Plan and Fund Allocation for Safety of Workers

The amount planned for safety of workers is being utilized for procurement, distribution,

and maintenance of various personal protection appliances (PPAs), safety equipment

e.g., Safety helmet, safety shoes, various types of hand gloves, full body suits, breathing

apparatus set, safety shower and eye wash shower, explosimeters, noise level meters

etc.

10.6. Green Belt Development

The objective of the green cover or plantation in industry is to reduce the air pollution,

restoring water balance, checking soil erosion, attenuate noise pollution and

improvement in the overall environment & aesthetics of the plant site.

Approx. 123.2 ha. of green area i.e., 37.56% of total plot area has been developed. Out

of total, 32.8 ha of green area has been developed within the plant premises while 90.4

ha. green area has been developed in GSFC township part of GSFC complex plot. GSFC





has also made adequate plantation on roadsides and other open areas. Greenery

inside the existing plant premises has been improved in a big way by developing green

lawn in and around the plant and township. The company has developed green belt

alogn the periphery of the plant site and in common premises available outsie the

company, premises, township after consultation with horticulture expert. The following

points have been considered for selection of plant species to be grown:

• Greenbelt absorbs both gaseous as well as particulate pollutants to a great

extent. Thus, removes/reduce pollutant from the atmosphere. For absorbance of

gases, the duration of the foliage should be longer.

• Characteristics of tree/plants including shapes of crowns considered necessary

for effective removal of dust particles.

• Greenbelt/Plant species having good root system will be selected, so that soil

erosion rates can be controlled significantly.

Total 179001 no. of trees & plantations have been developed within the premises.

Regular monitoring and care is being taken with all necessary works like thick plantation,

re-plantation (if required), pest control and other allied factors to achieve adequate

growth of greenbelt. The details of existing plantion in the GFSC Complex has been

provided in Table 10.12 below:

Table 10.11 : No. of trees planted in GSFC Complex

Sr. No. Particular Nos. Area (sq. mt) Area (hectare)

1 Garden

a BL (Battery Limit) 55 55702

b OB (Outside battery

Limit) 45 295543

c Total 100 351245 35.12

2 Plantations

a BL 64836 258400

b OBL 71401 280923

c Total 136237 539323 53.93

3 Orchard plantations

a BL 636 15000

b OBL 3182 66292

c Total 3818 81292 8.13

4 Nursery 60000 6.00

5 Farm 24000 2.4

6 Roadside 9578 104120 10.41

7

Plantations in

residents quarter

garden

36000 72000

7.2





Total Area under vegetation/greenbelt 1231980 sq. mt 123.20 Ha

GSFC complex area 328.00 Ha

Greenbelt area 123.20 Ha

%Wise area covered under Green Belt 37.56

(BL: Boundary Line, OBL: Outside Boundary Line)





Detailed list of types and species of trees and plantation has been provided in Table 10.13 below:

Table 10.12 : Types and Species of Trees in GSFC

Roadside

Tree

Ornamental plants Palm Plants Fruit Plants Flowering Plants Medicinal Plants Cactus Bulb Creepers

Arjun

(Sadad)

Alocassia Areca palm Almond Aboli Ajamo Grafted Cana Alamenda

Ashoka Acalipha Bismakia Coconut Adenium Alovera Euphorbia Lily Bignonia

Venusta

Bakam

Neem

Aglonima Chamedoria Custrud

apple

Bahumia Ardushi Self

rooted

- Clero-

dendron

Banyan

Plant

AlpiniaRubra Cycus Guava Bouganveil Aspergus succulent - Madhumalti

Billi AlpiniaVarigated Fishtail Italian

lemon

Cordia Baheda - - Money

plant

Borasalli Arelia Foxtail Jamun cuphia Black pepeer - - Vadellia

Champo Bamboo Grass Jambia Kagdilemon Dadlicanthus Brahmi - - Thumbergia

grandiflora

Garmalo Birbaljia Kentia Mango Dayking Bryophylum - - Parda veil

Gulmohar Brassia Latina Sapota Deshi rose Fudino - - Jeemonsia

Gultora Chlorophytum Nolino Sarbati

lemon

Devchakli Harsankal - - Vedellia

creeper

Jerul Chocholate Plant Phoenix setur Galphemia Kadineemkariyatu - - -

Kadam Coleus Pichardia - Gardenia Kevdo - - -

Mahogani CordylineAtropurpurea Raffis - Garbera Lindi paper - - -

Neem Croton Royal - Gulmahedi Nagarveil - - -

Paltoforum Diphanbaccia Shampion - Hibiscus Parijatak - - -

Pendula Dreacena Table - Ixora Stevia - - -

Pipal Eranthemum Thraix - Jasmine Tulsi - - -





Roadside

Tree

Ornamental plants Palm Plants Fruit Plants Flowering Plants Medicinal Plants Cactus Bulb Creepers

Putranjiva Exoclodia dichor Traveller - Jetropha - - - -

Saliparni Fern Triangle - Jui - - - -

Saptaparni Ficus umbrella - Kamini - - - -

Saru

Umedo

Furkeria - - Lantana - - - -

- Golden duranta - - Musanda - - - -

- Graptophylum - - Nerium - - - -

- Helicornia - - Pentas - - - -

- Hemisghraphis - - Plumbegocapensis - - - -

- - - - Ratrani - - - -

Photogrophs of Existing GreenBelt are depicted in Figure 10.6 below:





Figure 10.6 : Existing Green Belt at GSFC





10.7. Resource Conservation Waste Minimization

10.7.1. Anticipated Water Conservation due to Revamping

New section is going to be installed which comprises equipment such as hydrolyzer and

Desorber to recover NH3, CO2 and Urea contained in the process water and, at the same

time, to produce clean process condensate, which can be used as Cooling Tower

Makeup. Approx. ~28-30 m3/hr. of treated process condensate generated from this

section will be utilized as cooling water makeup.

10.7.2. Anticipated Energy Conservation due to Revamping

Total specific energy consumption will get reduced to 5.773 GCal/MT of Urea.

As total Urea manufacturing capacity will remain same after revamping, there will not

be any increase in pollution load. Emission at the outlet of existing stacks will remain as it

is and will be within the norms stipulated by government. Energy is reduced also on

account of reduction in specific consumption of Ammonia and Power in addition to

Steam.

10.7.3. Energy Conservation Measures already adopted within the plant

The following measures implemented in the latest years have provent to conserve

energy and natural resources in the plant:

Table 10.13 : Measures for Energy Conservation in Urea Plants at GSFC

S.No. Plant Action Taken Benefits from Action Undertaken

1. Urea-II

plant, Capro-I Steam saving by

replacing existing Ejector with energy

efficient Ejector, at Urea II Plant


equivalent to Rs. 160 lacs/year.

2. Urea-II Replacement of ejectors with better

design in Urea-II Plant


equivalent to Rs. 245.8 lacs/year.

3.

Urea-I

Steam saving by replacing existing

Ejector with energy efficient Ejector, at

Urea I Plant


equivalent to Rs.91.24 lacs/year.

GSFC has implemented several measures for Energy Conservation, Water Conservation.

The same have been provided in Section 5.2 of Chapter-5.

10.8. Facilities for Employees

Company will give preference to local people Skilled People for employment The

Company is more concern for the safety and health of its people, including the larger

community outside of the company and the environment All employees will be trained

to work on sites in the safest possible manner and shall be made aware of the

consequences of unsafe act Company also provides the shelter, safe drinking water,





sanitation facility The company will allocate adequate budget for safety and

Occupational health management of the employees. Adeqaute sanitary facility like

bathroom, latrine, urinal, washroom, shower stalls and eye showers have been provided.

10.9. Rehabilitation and Resettlement Plan

The proposed development is proposed within the plant area. No additional land is

purchased or acquired. Thus, no R& R is applicable on the project.

10.10. Compliance of CREP Guidelines

GSFC has implemented all guidelines laid down by CPCB and MoEF&CC for CREP

(Corporate Responsibility for Environmental Protection) and submitting the annual

compliance of the same to the GPCB. The compliance of the guideline for Fertilizer plant

is given below in Table 10.15:

Table 10.14 : Compliance of CREP Guidelines

S No. Action Point Action desired and Status

Wastewater Management

1. Efforts will be made for

conservation of water,

particularly with a target to

have consumption less than

8.12 and 15 m3 tonne of urea

produced for plant based on

gas, naphtha and fuel oil,

respectively. In case of plants

using Naptha and Gas both as

feed stocks, water

consumption target of less

than 10m3/ tonne will be

achieved. An action plan for

this will be submitted by June

2003 and targets be achieved

by March 2004.

Urea plants at GSFC utilize gas a feedstock. The

water consumption in Urea Plants is 4.87 m3/MT

for year 2019-20 and 5.17 m3/MT for year 2020-

21 that is within the specified water

consumption target set under the action plan.

2. Use of arsenic for CO2

absorption in ammonia plants

and chromate-based

chemicals for cooling system,

which is still continuing in some

industries, will be phased out

and replaced with non- arsenic

and non- chromate systems by

December 2003. In this regard,

GSFC’S Ammonia -I & II plants were operating

with Arsenic as an activator in the CO2 removal

system. The CO2 Removal System process of

Ammonia-I Plant changed to Glycine in 1978

and subsequently, it was revamped to

Methano, Plant.

After commissioning of Ammonia-IV plant that

used non-arsenic process, Ammonia-II which

only uses arsenic was scrapped. Ammonia-III

plans has GV (GIAMMARCO-VETROCOKE)

based CO2 remobal system.






action plan will be submitted

by June 2003.

The cooling water treatment systems at GSFC

are non-chromate systems.

3 Adequate treatment for

removal of oil, chromium (till

non- chromate-based cooling

system is in place) and fluoride

will be provided to meet the

prescribed standards at the

source (end respective process

unit) itself. Action plan will be

firmed up by June 2003 for

compliance by March 2004.

GSFC is having a system for removal of oil from

effluent (API oil separator). The fluoride

containing effluent from phosphatic plants is

being completely recycled within the plant.

Therefore, the effluent discharged from GSFC

meet the standards for oil/chromate/fluoride

presecribed by Gujarat Pollution Control Board

(GPCB).

4 Proper and complete

nitrification and de-nitrification

will be ensured wherever such

process used for effluent

treatment, by September 2003,

GSFC manufactures Urea, DAP, APS etc. Urea

plant effluent is being reusedin Phosphoric

Acid Plant and it is a “Zero Liquid Discharge”

Plant.

5 Ground water monitoring

around the storage facilities

and beyond the factory

premises will be carried out at

regular intervals particularly for

pH. Fluoride CPCB will finalize

the guidelines for groundwater

monitoring by December 2003.

Quality of ground water from bore wells/hand

pumps located nearby villages area

monitored periodically and submitted to the

GPCB.

6 No effluent arising from process

plants and associated facilities

will be discharged to the storm

water drain. The quality of

storm water will be regularly

monitored by all the industries.

Lean streams like cooling tower and boiler

blow down are collected to the pond through

storm water channel and then discharged

along with treated effluent streams to common

effluent channel of M/s VECL for ultimate

discharge to sea.

The quality of total effluents discharged from

GSFC which includes lean streams in storm

water drain is monitored on daily basis.

7 The industries, where

wastewater/ effluent flows

through the storm water drains

even during the dry season will

install continuous systems for

monitoring the storm water

quality for pH, ammonia and

Lean streams like cooling tower and boiler

blow down are collected at the pond through

open channel and then discharged along with

treated effluent streams to common effluent

channel of M/s VECL for ultimate discharge to

sea.






fluoride. If required, storm

water will be routed through

effluent treatment plant before

discharging. An action plan will

be submitted by June 2003 and

necessary action will be taken

by June 2004.

The quality of total effluents discharged from

GSFC which includes lean streams through

open channel to disposal pond. This is being

monitored as and when required.

Air Pollution Management

1. All the upcoming urea plants

will have urea prilling towers

based on natural draft so at to

minimize urea dust emissions.

Natural draft system will be considered.

2. The existing urea plants

particularly, the plants having

forced draft prilling towers will

install appropriate systems (

e.g. scrubber. etc.) for

achieving existing norms of

urea dust emissions. In this

regard, industries will submit

action plan by June 2003 and

completion of necessary

actions by June 2004.

Urea plants have forced draft prilling towers.

They have scrubbers to achieve existing norms

of urea dust emissions. The emissions are within

the norms specified by GPCB. Moreoverm

Vibropriller has been installed in Urea-II for

reduction of dust emissions.

3. The sulphuric acid plants

having SCSA system will switch

over to DCDA system by March

2004 to meet the emission

standard for SO2 as 2kg/tonne

of H2SO4 produced. An action

plan for this will be submitted

by June 2003.

The Sulphuric Acid plants have DCDA systems.

The emissions of SO2 is less than the specified

limit i.e. 2 kg/ton of sulphuric acid production.

4. Sulphuric acid plants having

DCDA system will improve the

conversion and absorption

efficiencies of the system as

well as scrubbers to achieve

SO2 emission of 2kg tonne of

acid produced in case of

plants having capacity above

300 tpd and 2.5 kg tonne in

case of plants having capacity

upto 300tpd. An action plan

Complied with. The existing Sulphuric Acid

Plants have DCDA system. They are already

achieving SO2 emissions with optimum

efficiencies.






will be submitted by June 2003

and emission levels will be

complied with by September

2004.

5. Stack height for sulphuric acid

plants will be provided as per

the guidelines and on the basis

of normal plant operations

(and not when the scrubbers

are in use) by June 2003. The

scrubbed gases are to be let

out at the same height of the

stock.

Stack height for sulphuric acid plants has been

provided as per guidelines. Gaseous emissions

are released only through stacks. The same will

be followed for proposed Sulphuric Acid-V

Plant.

Stack Height:

SA-III: 52 m

SA-IV Plant: 100 m

6. An action plan for providing

proper dust control systems

rock phosphare grinding unit in

phosphoric acid plants/ single

super phosphate plants, so as

to achieve particulate emission

of 150 mg/Nm3 will be

submitted by September 2003

and complied with by March

2004.

Scrubbing system has been provided at rock

phosphate grinding mill to control dust emission

below of 150 mg/nm3.

7. Particulate as well as gaseous

fluoride will be monitored, and

adequate control systems will

be installed by June 2004 to

achieve the norms on total

fluoride emissions (25

mg/Nm3).

Particulate as well as gaseous fluoride are

monitored regularly at GSFC. Due to adequate

control systems, total fluoride remains well

below the specified norm of 25 mg/nm3.

8. Continuous SO2 emission

monitoring systems will be

installed in sulphuric acid plants

(having capacity 200 tpd and

above) by March 2004. Action

plan for this will be submitted

by June 2003.

Continuous SO2 emission monitoring systems

have been installed in sulphuric acid plants

and the same will be done for proposed plant.

9. Regular monitoring of ambient

air quality with regard to SO2

NOx, PM, SO3, fluoride and

acid mist will be carried out.

Ambient air quality in terms of Sox, NOx, NH3,

PM10 & PM2.5 is carried out on weekly basis

and the parameters are within the prescribed

limited.






Solid Waste Management

1. Gypsum will be effectively

managed by providing proper

lining, dykes with approach

roads and monitoring of

groundwater quality around

storage facilities. Accumulated

gypsum will be properly

capped. In this regard, action

plan will be submitted by June

2003 and for compliance by

December 2003.

Gypsum ponds at GSFC are lined with

impervious liner. Proper approach roads are

also provided around the gypsum storage site.

The gypsum taken from the gypsum pons is

stored on impervious lined area from where it is

sold to the farmers for soil conditioning.

Monitoring of groundwater quality is also

carried out on quarterly basis at surrounding

areas.

2. An action plan for proper

handling, storage and disposal

of spent catalyst having toxic

metals will be submitted by

June 2003 and implemented

by September 2003. The

industry will also explore

recovery/buy-back of spent

catalyst by September 2003.

The spent catalyst is packed in drums and

stored in separate storage area. The spent

catalysts are sold to CPCB registered recylers.

The details of catalyst sold are being regularly

submitted to GPCB. Spent V2O5 catalyst is

disposed off at landfill site.

3. Carbon slurry, Sulphur muck

and chalk will be properly

managed and disposed of in

properly designed landfill

either within premises or in

common facility. Action plan

on this will be submitted by

June 2003 and implemented

by March 2004.

The chalk generation through gypsum route

has been discontinued since 1997. The chalk

accumulated till 1997 has been encapsulated

as per recommendation of National

Productivity Council & NEERI (National

Environment Engineering Research Institute).

The encapsulated heap is also being

monitored by Management approved

committee every year. Ground sulphur muck is reused by mixing with

Phosphogypsum from Feb.2018.

4. Existing stock of chromium and

arsenic bearing sludge will be

properly disposed by

December 2003. industries will

also explore recovery of

chromium from the sludge.

CPCB will provide guidelines for

proper disposal of the sludge.

Arsenic Sludge generated from old ammonia

plants had been disposed off after

solidification and stabilization in secured landfill

site of M/s Gujarat Enviro Protection &

Infrastructure Ltd. (GEPIL) in 2004.





10.11. Institutional Framework for implementation of EMP

For effective implementation of the proposed environmental management plan, it is

necessary to have permanent organizational set up charged with the task of ensuring

effective implementation of EMP and to monitor the implementation efficiency. GSFC is

agency for planning, implementation and operating the project.

GSFC has separate Environment Cell and fully-feldged laboratory facilities for

environment management and monitoring. Members of EMC with designation and

technical qualification has been mentioned below in Table 10.16:

Table 10.15 : Members of Environment Management Cell, GSFC

S.no Name of Employees Designation Technical Qualification

1 S.J. Parikh SVP (U &EC) B.E. (Chemical)

2 K.S. Badlani VP (I &MB, U &

EC, FU)

B.E. (Chemical)

3 P.D. Kachchhi Chief (EC) &

Dy. Mr.

B.E. (Env.), PDIS

4 S.Y. Singh Sr. Mgr (EC) B.E. (Civil)

5 Prashant U Kadu Sr. Mgr (EC) B.E. (Textile)

6 Jaxesh P. Trivedi Mgr (EC) B.E. (Chemical), M.Tech (EPD),

PDIS

7 Ashok H Shah Addl. Mgr (EC) B.Sc. Chemistry

8 Jayesh M Dave Addl. Mgr (EC) B.Sc. Chemistry

9 Prateek Jain Dy. Mgr (EC) B.Tech (Chem.)

10 Pankaj Kumar Sharma Plant Engineer B.Tech (Chem.)

11 Mosmi M Patel Env. Engg. B. Tech (RE &EE)

12 Rajesh K Desai Foreman B.Sc. Chemistry, DIPC, MS in Envt

Sci. under DLP

13 Ambalal K Rana Sr. Operator B.Sc. Chemistry

14 Anil L Arora Sr. Operator B.Sc. Chemistry

15 M.R. Chandlekar Sr. Operator ITI

16 Vipul R Upadhyay Sr. Operator B.Sc. Chemistry

17 PC Maisuriya Sr. Operator Old SSC

18 H.V. Shah Sr. Operator B.Sc. Chemistry

19 Jayesh Solanki Sr. Operator Old SSC

20 Rajesh H Patel Sr. Operator B.Sc. Chemistry

21 Kanubhai B Padhiyar Operator B.Sc. Chemistry

22 Hitesh D Patel Operator M.Sc. (Env. Sci.)

23 Bhavesh C Patel Operator M.Sc. (Indus Chem)

24 Pankaj C Patel Jr. Operator HSC Pass

25 Biren R Patel Jr. Operator M.Sc. Env. Sci.

Cert. Disaster Management (PDIS)

26 Purvish S Shah Jr. Operator M.Sc. Env. Sci.

Cert. Disaster Management

27 V.R. Rabari Jr. Operator HSC

28 Jayesh S Patel Attendant B.Sc. Chemistry





S.no Name of Employees Designation Technical Qualification

29 Bhavdip S Vamja Assistant

Operator

B.Sc. Chemistry

30 Gami Ravi Kumar Assistant

Operator

B.Sc. Chemistry

Total 15 no. of workmen are available which include 5 regular empoyees and 10 no of

contract workman.

GSFC has been awarded ISO 9001:2015 Quality Management System, ISO 14001:2015

Environment Management system, ISO 45001:2018 Occupational Health and Safety

Management System and ISO 50001:2011 Energy Management Certification for

Vadodara Unit.

During construction stage, EMC of GSFC will work in coordination with the Technical and

Maintenance Dept and contractor to ensure implementation of the EMP and safety

procedure. In operation stage EMC will ensure the implementation of the EMP. Progress

of the EMC shall be reviewed by Unit Head every year. Third party safety audits will be

conducted to ensure the compliance of proposed EMP system.

10.11.2. Hierarchical of Environmental Management Cell (EMC)

The EMP cell is headed by SVP who reports to Executive Director directly. Hierarchy of

EMC cell is given in Figure 10.7. The responsibility of EMC is given below:





Figure 10.7 : Organogram of Environment Management Cell, GSFC

Responsibilities of EMC Cell are:

i. Environmental monitoring of the surrounding area.

ii. Developing and maintenance of green belt with Horticulture Department.

iii. Ensuring water use is minimized.

iv. Ensure to carry out Environmental Management Plan / programme as per the

schedule.

v. Monitoring hazardous work through work permit system

vi. Regular training to employees on Safety and Environment Topics.





vii. Regular monitoring of, stacks, ambient air, noise etc either internally or by

appointing external agency and data analysis. Corrective and preventive

action, wherever required.

viii. Hazardous wastes management and handling.

ix. Preparation of various reports like environment statement, carrying out

environment audit by Schedule I auditor appointed by GPCB, preparation of

various consent applications and renewal under Water (Prevention and Control

of Pollution) Act, 1974 and Air (Prevention and Control of Pollution) Act, 1981 as

well as application for authorization and its renewal under Hazardous & Other

Waste (Management and Transboundary Movement) Amendment Rules, 2016,

and amendment thereof under Environment Protection Act, 1986. A team of well-

trained and experienced staff carry out the tests (as desired) in the laboratory.

10.11.3. Intergated Management Policy of GSFC

GSFC has adopted Integrated Management Policy for sustainability, quality

management and Environment Health & Safety in the plant. Policy is given below in

Figure 10.8





Figure 10.8 : Integrated Management System Policy of GSFC





10.11.4. Grievance Redress Mechanism

A grievance mechanism shall be established to receive the concerns and issues being

faced by community in the project area both during construction and operation phase.

Information of such system shall be made available to the public through consultations,

notices, advertisements, displaying on website etc.

Through the grievance redressal mechanism, community is free to lodge their concerns

and submit their suggestions. The grievance mechanism will be scaled to the risks and

adverse impacts of the project. It will be address concerns promptly, using an

understandable and transparent process that is culturally appropriate and readily

accessible to all segments of the affected communities, and at no cost and without

retribution. The Project proponent will inform the affected communities about the

mechanism. Grievance redressal system will include provision of a box at the site gate.

Grievances can be dropped by aggrieved into this box. Also, a registered for grievance

redressal shall be maintained at entry gate of all above mentioned areas where

aggrieved can register its complaint along with his details like name, contact number

and can take the reference complaint number. Grievance redressal box or register will

be reviewed every week and first response to the grievance to the aggrieved will be

given within 7 days of grievance submitted by the receiver. Grievance redressal cell shall

consider the following points for functioning

• The grievance cell shall be chaired by the Unit Head.

• The decision on the grievance would be communicated to the aggrieved person

within a timeframe (1 week).

• All grievances shall be documented and indexed for future reference. The

grievance received shall be communicated to all the concerned person.

10.11.5. Reporting

• As per the MoEF&CC guideline, Environment monitoring report and compliance

of conditions mentioned in the environment clearance will be submitted to the

RO-MoEF&CC, SPCB, MoEF&CC online portal i.e., parivesh and shall be uploaded

on company’s website. Compliances will be submitted in month of June and

December for the period of April to September and October to March

respectively. Third party laboratory (approved MoEF&NABL laboratory) shall be

appointed for carrying out the monitoring. Also, self-environmental audit, Health

& safety audit and Energy audit shall be conducted annually.

• GSFC has implemented all guidelines laid down by CPCB and MoEF&CC for CREP

(Corporate Responsibility for Environmental Protection) and submitting the

annually compliance of the same to the GPCB.

• GSFC is also regularly submitting Environmental Statement (Form V) to Pollution

Control Board in accordance with the provisions of Rule-14 of the Environment

(Protection).





10.12. Budget for Environmental Management Plan

GSFC has provided adequate funds to implement the conditions stipulated by

MoEF&CC and it is integral part of the project. The fund earmarked to implement the

conditions has been utilized for intended purpose only.

Capital Expenditure spent on last 3 years have been provided below in Table 10.17:

Table 10.16 Budget for Environmental Management Plan

Description Expenses (in Lakhs)

2018-19 2019-20 2020-2021

Investment in Pollution

Control

4129.21 4150.89 4197.49

Total Investment 505740.60 515347.37 521649.49

Budget planned for Environment Management Plan for the proposed plant has been

provided below:

Table 10.17 Budget for Environmental Management Plan

Sr.No. Particulars Expenditure (in Rs. Lakhs)

Capital

1 Air Pollution Control Schemes Existing

2 Water Pollution Control Schemes 400

3 Solid Waste Management Existing

4 Occupational Heath Existing

5 Greenbelt Development Existing

Total 400





Chapter 11. SUMMARY AND CONCLUSION

11.1. Project Description

GSFC has proposed for “Revamping of existing Urea Plants (Urea-I & II) by replacing

existing total recycle process to latest ammonia stripping process”. The combined

capacity of revamped urea project will be 3,67,200 MTPA. The details of the project after

revamping have been provided below in Table 11.1.

Since both the plants were established before the 1994, they did not come into the

purview of EIA Notification, 1994 and its subsequent amendments. The proposed

revamping project falls under Activity 5(a); Category A as per EIA Notification,2006 and

its subsequent amendments. Due to legitimate advantages of the proposed project and




GSFC Complex being a Notified Area by Industries, Mines and Energy Department vide

Notification No. GU-87-46-GID-1086(I) 2338 dated 21.08.1987, the project has also been

exempted from Public Hearing as per clause 7 (i) (III) of EIA notification 2006 & OM J-

11011/321/2016-IA. II(I) dated 27.04.2018.





Table 11.1 : Consolidated Details of Project (Post Revamping Urea Unit)



1. Production

Capacity

MTPA Urea-I

Unit 103200

0

(Revamping) Post

Revamping

Urea Unit

367200

No Change

Urea-II

Unit 264000

2. Technology - M/s Toyo Engineering

Corporation, Japan,

using MTC (Mitsui Toastu

Corporation) Total

Recycle

“C” process.

Ammonia

Stripping

Ammonia

Stripping Process

Ammonia Stripping

Process is more

conservational and

efficient technology.

3. Total Plot Area Ha. 328 No Change

4. Green Area Ha. 123.2 (37.56% of total plot area) No Change

5. Cost of Project Rs.

(in Crores)

- 306 306 -

6. Employment No. 124 -60 64 Decrease

7. Total Water

Requirement

KLD 6046.1 -2144.2 3901.9 Decrease

m3/hr 251.92 -89.34 162.6

8. Freshwater

Requirement

KLD 5035.7 -2128.1 2907.6 Decrease

m3/hr 209.82 -88.67 121.15

9. Wastewater

Generation

KLD 1060.08 -302.4 757.68 Decrease

m3/hr 44.17 -12.6 31.57







10. Wastewater

Treatment

Scheme

- Nil WWT Section Wastewater Treatment

Section

(Hydrolyser, Desorber,

Hydrolyser Pre-heater,

Treated Water Final

Cooler, Hydrolyser Feed

pump, Treated

Condensate Pump).

To Recover NH3, CO2

and Urea contained in

the process water and

to produce clean

process condensate

that can be used in

Cooling Tower

Makeup.

11. Treated Water

Recycle

KLD 0 691.2 691.2 Increase

m3/hr 0 28.8 28.8

12. Process Effluent

going to PA Plant

KLD 144 0 144 No Change

m3/hr 6 0 6

13. Steam

Condensate

Export Credit-

Recycle as Water

KLD 1010.4 -707.3 303.12 Decrease

m3/hr 42.1 -29.47

12.63

14. Power

Consumption

kWh/MT 205 -22 183 Decrease

15. Power Backup kVA - 500 500 Increase





Details of changes in Environmental paramaters due to proposed revamping have been provided below:

Table 11.2 : Changes in Environmental Parameters

S.No. Particulars Unit Existing Proposed Post Revamping Impact/

Remarks

1. Prill Tower PM

(kg/MT of Urea)

2 0 2 No Change

NH3

(mg/Nm3 of Urea)

175 0 175

2. Total Water Consumption m3/MT of Urea 5.38 -1.88 3.50 Decrease

3. Freshwater Consumption m3/MT of Urea 4.48 -1.87 2.61 Decrease

4. Liquid Effluent/

Wastewater Generation


5. Energy Consumption GCal/MT of Urea 6.523 -0.750 5.773 Decrease





11.2. Description of the Environment

11.2.1. Site Characteristics


The proposed revamping will be established within the existing premises only. The plant

is spread over an area of 328 Ha. The site is approachable via NH-8 which is located

adjacent to the unit. It is situated 8.09 km away from Vadodara City in SE direction.

Nearest Railway Station to the project is Bajuwa Railway Station located at 0.99 km, SW

direction. Nearest Airport located to the project is Vadodara Airport located at 8.80 km,

SE. Galiath River is the nearest river flowing at 4.58 km (NE) from the project site. Mahi

River is flowing at 9.35 km (W) from the site. There are several rivers located in 10 km area

of the project site. There are no environmentally sensitive components within study area.

11.2.2. Topography and Meteorology

The project site lies in Mahi and Narmada Doab. Topography around 10 km area of the

proposed site is plain The average elevation in 10 km study area ranges between 25

to 60 metres above mean sea level The topography of proposed site is almost plain

The site elevation ranges between 35 to 60 amsl

11.2.3. Climate and Meteorology

Temperature Mean minimum temperature (at 8:30 hr) varies from 13.20C (Jan) to 27.50C

(June) while mean maximum temperature (at 17:30 hr) varies from 29.70C (Dec) to

39.90C (May).

Relative Humidity Relative Humidity at 8:30 hr varies from 53% (March) to 88% (Aug)

while at 17:30 hr it ranges from 23% (April) to 75% in (Aug).

Rainfall Total annual mean rainfall was observed to be 846 mm. Around 95% of total


Wind Speed Mean wind speed was observed from 7 kmph (December) to 15.1 kmph

(June).

Wind Direction The wind pattern of the region shows that the predominant wind

direction is SW for most of the months.

Seismicity

As per Seismic map of India the study area falls in Zone II Moderate Risk Zone

11.2.4. Soil Environment

The soil sampling was done at seven locations in the study area. As per the grain size

distribution the percentage of Sand in all sampled soil was found varied from 54.9% to

62.52%, Silt varied from 17.17% to 22.1% and Clay from 16.32% to 24.6% during study

season. Thus, the soil texture is Sandy Clay loam. The soil pH ranges were observed from





7.1 to 8.01 during study season, thereby indicating the soil is “Slightly alkaline” in nature.

The Organic Carbon content of sampled soil during study seasons varied from 0.048% to

1.48%, thereby implying that soils are low with organic carbon content except at S-4

where Organic Carbon content is 1.48%. Available nitrogen content in the surface soils

ranges between 242 kg/ha to 378 kg/ha thereby indicating that soils are medium to high

in available nitrogen content. Available phosphorus content ranges between 19.6

kg/ha to 22.4 kg/ha thereby indicating that soils are medium in available phosphorus

content. Available potassium content in these soils ranges between 158 kg/ha to 218

kg/ha thereby indicating that the soils are medium in potassium content.

Based on Nutrient Index Value for N, P and K, the soils of study area fall into Medium

Fertility Status.

11.2.5. Water Environment

Observations on Ground Water Quality: Ground water was monitored at eight locations

in the study area. The analysis results indicate that the pH ranged between 7.09 to 7.62

which are well within the specified standard of 6.5 to 8.5 limit. Total hardness levels were

recorded in the range between 56.11 to 561 mg/l that is within permissible limits of 600

mg/l. Total dissolved solids were recorded in the range of 312 to 1140 mg/l that falls within

permissible limits of 2000 mg/l. Chloride levels were recorded between 31.3 to 166.32

mg/l that falls within the range of permissible limit i.e., 1000 mg/l. Sulphate levels were

observed in the range of 36.81 to 82.19 mg/l and were within the acceptable limit i.e.

400 mg/l. Bacteriological studies reveal that no coliform bacterial are present in the

samples. The heavy metal contents were observed to be in below detectable limits.

Parameters for toxic substances were recorded within the permissible limits. All physical

and general parameters were observed within the permissible limit as per IS10500:2012

(Second Revision). Thus, it is recommended that water be filtered and disinfected prior

to be given for drinking water requirements.

Observations on Surface water Quality: Surface water was monitored at seven locations

in the study area. The pH values of all analyzed samples ranged between 7.12 – 7.86.

TDS levels were observed to be in range from 206 to 482 mg/l. Total hardness levels were

observed to be in the range of 118 to 220 mg/l. Dissolved Oxygen values ranged

between 4.9 to 6.9 mg/l. The chlorides level was observed to be in range of 29.35 to 125

mg/l. Sulphate level were found to be ranging from 18.05 to 48 mg/l. Nitrate levels were

found to be observed within the range of 1.34 to 12.36 mg/l. Total Coliform levels were

found to be in the range of 0.94*103 to 1.7*103 MPN/100 ml. Biochemical Oxygen

Demand (BOD) was observed to be in range of 2.6 to 12 mg/l. Comparing the values as

per classification for designated best use water quality criteria by CPCB, all surface

water locations were classified under “Class C- Drinking water source after conventional

treatment and disinfection” except SW-4 i.e., Parevi River which has been categorized

under “Class B- Outdoor Bathing (Organized)”.





11.2.6. Air Environment

Air quality was monitored at nine locations within 10km study area. The monitoring results

of ambient air quality were compared with the National Ambient Air Quality Standards

(NAAQS) prescribed by MoEF; GoI Notification dated 16.11.2009. The maximum

concentration of PM10, PM2.5, SO2, NOX, NH3 & CO was 96 µg/m3, 49 µg/m3, 12.8 µg/m3,

20.6 µg/m3, 27.7 µg/m3, 1.22 µg/m3 respectively.

11.2.7. Noise Environment

Noise monitoring was done at seven locations within the study area. The noise levels

observed in the project site and study are within prescribed limits except at N-6 i.e.,

Sumant Park located 4.85 km in SW direction of the project. As per the results, it has been

observed that noise levels are higher at residential areas than industrial areas. Sumant

Park (N-6) is surrounded by various residential areas and townships which loeas to

community noise. Vehicular traffic in the area also contribute to the increased noise

levels in the area.

11.2.8. Traffic

The site is approachable via NH-8 which is located adjacent to the unit. Traffic count

study was undertaken at NH-8 as it is the main road for transportation of raw materials

and finished products. The finished products are being stored in Bagging Unit and

transported through trucks/rails. Major transportation of products is being done by rails

only. However, there is some quantity of products and raw materials which are

transported via road too. As per baseline survey, the capacity of approach road is 10286

PCU/hr while the existing traffic of the road is 825 PCU/hr.

11.2.9. Biological Environment

There is no protected and reserved forest is present in the study area (10 km area around

proposed site. GSFC has already developed approx. 123.2 Ha. of green area in the

complex. The company has developed green belt along the periphery of the plant site

and in common premises available outside the company premises, township after

consultation with horticulture expert. Total 179001 no. of trees have been planted till now

in the complex. Most of the land is under industrial use, settlement, agriculture, and water

bodies. No reserved and protected forest patches are present in the study area.

Degraded and scrub vegetation is the prime feature of the flora. Under the schedule of

Inidan Wildlife Protection Act 1972, list of reptiles has also been listed in various categories

to raise concern over varying degree of protection. Among record of reptiles,

Crocodylus palustris (Crocodile) and Lissemys punctata (Flap shell Indian Turtle) have

been categorized under Schedule-I Category. As per present study, 33 avifauna species

have been recorded in the study area, of which peafowl is the only Schedule-I species





while the rest belong to Schedule-IV & V. Mahisagar is one of the important perennial

rivers of central Gujarat, flowing westward to terminate into Gulf of Cambay. This river

sustains good level of fresh water as well as estuarine fishery as capture fishery and

contributes to economy of Gujarat state.

11.2.10. Socio-economic Environment

Vadodara city is governed by Municipal Corporation which comes under Vadodara

Metropolitan Region. The Vadodara city is in Gujarat state of India. As per provisional

reports of Census India, population of Vadodara in 2011 is 1,670,806; of which male and

female are 869,647 and 801,159 respectively. Although Vadodara city has population of

1,670,806; its urban / metropolitan population is 1,822,221 of which 949,998 are males

and 872,223 are females.

Hinduism is majority religion in Vadodara city with 85.39 % followers. Islam is second most

popular religion in city of Vadodara with approximately 11.40 % following it. In Vadodara

city, Christinity is followed by 1.22 %, Jainism by 1.32 %, Sikhism by 0.45 % and Buddhism

by 0.45 %. Around 0.06 % stated 'Other Religion', approximately 0.10 % stated 'No

Particular Religion'.

Vadodara City runs through the golden corridor, from Ahmedabad to Vapi, and is one

of India’s foremost industrial centres with dominant groups of chemicals and

pharmaceuticals, cotton textiles and machine tools. The city witnessed a sudden spurt

in industrial activity with the establishment of the Gujarat refinery in 1962. Various large-

scale industries such as Gujarat State Fertilizers and Chemicals (GSFC), Reliance

Industries Limited (RIL) and Gujarat Alkalis and Chemicals Limited (GACL) have come up

in the vicinity of the Gujarat Refinery. The establishment of large industrial units in this

region has automatically brought into existence a number of smaller enterprises. Several

factors like raw material availability, product demand, and skilful mobilisation of human,

financial and material resources by the government and private entrepreneurs had

contributed to Vadodara’s efflorescence as one of India’s foremost industrial centres.

But, with increased competition in the global market and failures to cope with the

economic momentum, Vadodara’s economy has slowed down.

11.3. Anticipated Environmental Impacts and Mitigation Measures

11.3.1. Air Pollution

During Construction Phase, demolition of few parts in both the plants will be done. There

will be de-commissioning of machineries and equipments and replacement of existing

with new equipments to attain the target of energy norms and increase efficiency of

the plant. However, due to some demolition in the plant, there might be generation of

PM and dust in the plant, but it will be limited to construction activities only. However,

the impact anticipated will be very minimal. The complex is maintaining levels of air

emissions as per CPCB/GPCB norms. Any impact anticipated will be taken care of during

construction phase.





Under proposed revamping project, new section consisting of Hydrolyzer and desrober

will be installed that will recover NH3, CO2 and Urea contained in the process.

Additionally, modifications in the existing equipments like replacement of ammonia

pump with new ammonia pump, refurbishing of turbine driven centrifugal pump,

modification in existing Urea reactor will help in better efficiency of the unit. New

Reactor (XU-R101N) will be installed with full set of Casale High Efficiency trays to achieve

optimal conversion. Crystallization section will be replaced by new modern evaporation

section to improve the steam balance of the plant and achieve energy saving target.

Considering such modifications, the plant will be able to maintain air emissions within the

limits of GPCB norms. Hence, plant will not impact the ambient air quality within the site

and surroundings in a negative extent.

The unit already follows several air pollution mitigation measures and will abide by

the same in proposed revamping phase. However, mitigation measures like regular

monitoring, adequate stack provision, green belt development etc. are being

maintained and the same will be done after followed revamping. All measures are

adopted in the plant to eliminate the fugitive emission, gaseous emission, Urea dust,

etc. Good Housekeeping is maintained in the plant.

11.3.2. Noise Pollution

There will be construction and demolition activities for proposed revamping project. Few

modifications in existing machineries including de-comissioning and refurbishing and

installation of new equipments have been planned for the project. There may be noise

generation during the construction activities but will be limited to a short span of time.

Noise levels within the plant are maintained within the limits by maintenance of thick

green belt around the boundary of site.

Under proposed revamping project, there will be barely minimal increment to noise after

its operation. The noise generated from the project activities will not be attenuated

significantly due to atmospheric attenuation. Also, by using standard practice of

operation, these impacts will be minimized and made insignificant. It is, therefore,

concluded that the existing noise level in the area will remain practically unchanged.


within the premises so as to maintain ambient air quality standards in respect to noise to

less than 75 dB(A) during daytime and 70 dB(A) during nighttime. Daytime is reckoned

in between 6:00 am to 10:00 pm and nighttime is reckoned between 10:00 pm to 6:00

AM. Noise measurement is being carried out periodically.

11.3.3. Water Pollution

During Construction Phase, all existing facilities like drinking, sanitation shall be used

during the installation/construction purposes. Existing supply of water shall be used for

meeting requirement of labour. Wastewater generated from toilets shall be disposed as

same as existing practice i.e., disposed through soak pits. Thus, no impact on water





quality is envisaged during construction phase. However, all standard practices shall be

maintained to maintain water quality. Approx. 10 KLD water will be required during

construction phase of proposed revamping project. 4 KLD freshwater will be used in

domestic purposes for labours that will be supplied by existing source of GSFC Complex

i.e., 4 no. of French wells of Mahi River. Domestic sewage will be disposed in septic tanks

with soak pits.

11.3.4. Waste Management

During Construction Phase, there will be few amounts of construction and demolition

wastes generated during construction phase. Improper handling of C&D Wastes may

lead to damage to nearby soil environment and biotic environment. However, it will be

made sure that C&D wastes will be sent to designated sites. Discarded machinery will

be sold and used oil shall be stored in drums for further disposal to registered recyclers.

Municipal waste will also be generated by labourers during construction stage that will

be disposed off to designated Municipal Waste Disposal Site.

During Operation Phase, there are generation of different kind of Industrial hazardous

wastes from production process and other activities. Process residue spent catalyst are

generated which are hazardous, which may cause harm if met skin and sludge and any

other may cause nuisance if not maintained properly. GSFC Vadodara complex being

hub of several products generate various kinds of hazardous and non-hazardous wastes.

However, waste is being effectively managed and handled to neutralize damaging

effects in and around the project site. The unit does not discharge any hazardous/non-

hazardous waste into the water or soil. Since, there will be no increment in production

capacity after revamping, there will be no increment in hazardous waste generation.

11.3.5. Land Environment

During Construction Phase, no additional land has been proposed for the proposed

project. GSFC Complex has been in possession of GSFC since 1967. The site has been

been classified under Notified Area by Industries, Mines and Energy Department. The

land-use of the project is Industrial. There will be no acquisition of land for proposed

revamping project.

During Operation Phase, the units for proposed revamping exist in a vast complex having

several varieites of chemical products and fertilizers. Since there is no additional land for

proposed revamping, there will neither be change in land-cover or land-use for the

same. Since, there will be no increment in production capacity, hazardous waste

generation will not be increased.

11.3.6. Soil Quality





During Construction Phase, Soil erosion may happen if open areas are left without

paving or plantation. Thus, it is required to either pave or green the open areas. Soil may

get contaminated, if sewage is disposed of on the soil, littering of municipal waste, e-

waste and spillage of HSD, oil and fuel. Discarded machinery will not be kept on

unpaved surface & will be given to approved recycler. Used oil will be stored and sold

to registered recyclers. Best management practices shall be adopted to avoid the

contamination of soil.

During Operation Phase, Spillage of material like effluent, chemical, hazardous waste,

used oil and fuel may contaminate the soil. Due to improper disposal of solid waste &

liquid waste includes the leaching from biodegradable waste and effect on flora from

spillage of waste on soil. Improper disposal of Effluent during shutdown may encounter

soil and contaminate. However, the complex does not discharge neither liquid effluent

nor solid waste directly into the soil. No area shall be left excavated or open after any

repair & maintenance works Used oil shall be stored drums and shall be sold to

registered recycler.

11.3.7. Ecology and Biodiversity

During Construction Phase, the proposed land is already under possession of GSFC. Due

to demolition and refurbishing activities for proposed revamping, there will be

generation of noise and waste inside the premises which might impact components of

surrounding biotic environment. However, the location of Urea-I & II is in the center of

the complex where other manufacturing plants like Melamine, Caprolactam etc. are

located. Urea plants are surrounded by industrial units in the plant where there is very

low to minimal density of flora and fauna located. There will be no tree cutting for

proposed revamping project. However, noise levels will be maintained under limits and

C&D waste will be carefully disposed off to designated C&D facility.

During Operation Phase, the impact on the surrounding ecology of the project will

mainly occur from the deposition of air pollutants. The incremental emission of air

pollutants is not likely to induce any significant changes in the ecology, because during

operation of proposed project the ambient air quality is likely to remain within the

national ambient air quality standards. Since there will be no increase in production

capacity, no increment in air emissions are expected. Additionally, under proposed

technology, there will be recovery of ammonia and carbon di-oxide that would

eventually lead to decrease in air emissions due to proposed revamping. Hence, there

will be no detrimental impact on ecological components. Most of the fugitive dust

emission generation points are also fitted with efficient air pollution control systems.

Water sprinkling / dry fog type system will be used at to suppress the generation of

fugitive dust.

No national park, wildlife sanctuary, biosphere reserve exists within 10 km area of the

project. No endangered or rare or threatened plant or animal species was observed

within 10 km area of the project site hence impact on RET species is negligible. However,





Crocodiles and turtles (Schedule-I species) exists in Vishwamitri River. Among avifauna,

Indian Peacock are Schedule-I species observed in the study area. Wildlife Conservation

Plan has been approved by DoF-Vadodara.

The project is planned with most efficient air pollution control systems for achieving air

emissions norms, so that the impact on nearby ecosystem is minimized. Most of the

fugitive dust emission generation points are also fitted with efficient air pollution control

systems. For proposed revamping, there will be reduction in wastewater discharge, as

the revamped units will reuse the treated w/w to the maximum possible extent and

discharge mode shall remain same as per the present practice scenario. All the solid

and hazardous waste shall be disposed as per the norms.

11.3.8. Socio-Economic Environment

During Construction Phase, there will be employment generation for 70 no. of local

labourers that would be required for proposed construction and demolition activities.

Most of the unskilled and semi-skilled labour will be hired from nearby villages. The project

construction activity will have positive impact on the social environment. Accident and

Noise related problems in the plant are the main concerns for local labour. All basic

facility like sanitation, toilets, canteen, camps shall be provided within the plant area.

Hygiene conditions shall be maintained at site.

During Operation Phase, there will be no change in manpower for revamped Urea plant

as existing staff of Urea-I & II plants will be utilized for operation of the same. However,

due to operation & maintenance there may be various risks for the staff and other

nearby people. Thus, all the workers are continuously trained for proper handling and

transportation of hazardous materials as per Hazardous & Other Waste (Management

and Transboundary Movement) Amendment Rules, 2021. All staff are provided with

personal protective equipment like safety helmet, safety shoes, ear plugs/mufflers,

masks, gloves, etc as required”. OHSAS guidelines are followed in the plant.

Conclusion

From above analysis, it is found that the impacts anticipated vary from moderate to low

significance and magnitude. No Major impact is anticipated during the construction

phase as only some mechanical work is required to be done for proposed revamping

and all basic facilities are available at the site to overcome the impact. However, during

operation phase, impact is anticipated due to increased polluted air quality,

wastewater generation and increased noise level. The project also has various positive

impacts like indirect employment generation, reduction of energy, availability of latest

technology fertilizer products for better productivity & sustainability. It is believed that

the project will be provide more benefits both to environmental and socio-economic

aspects of environment than negative impacts. However, minimal negative impacts

can be normalized by taking the proposed mitigation measures.





11.4. Environmental Monitoring Programme

Environmental monitoring plan will be implemented as per regulatory requirement to

comply the necessary compliances. As per the MoEF&CC guideline, Environment

monitoring report and compliance of conditions mentioned in the environment

clearance will be submitted to the RO-MoEF&CC, SPCB, MoEF&CC online portal i.e.,

parivesh and shall be uploaded on company’s website. Compliances will be submitted

in month of June and December for the period of April to September and October to

March respectively. Third party laboratory (approved MoEF&NABL laboratory) shall be

appointed for carrying out the monitoring. Also, self-environmental audit, Health & safety

audit and Energy audit shall be conducted annually.

11.5. Additional Studies

Risk assessment study has been undertaken to identify the Hazard and preparation of

mitigation. All measures are already adopted as per the guideline. On-site and Off-site

Emergency plan is in place in the plant. Following conclusions and recommendations

provided during risk assessment are:

• The existing ammonia storage facilities will be used.

• The safety measures and emergency actions being taken for risk and associated

hazards are adequate and are being followed properly.

• On-site and off-site emergency action plan should be regularly followed and

complied.

• Regular mock-drills should be done, and the assessment should be done via

audits.

• Provision of ammonia detectors/sensors at strategic locations in the common


• Other hazardous pipelines (acid/hazardous materials/inflammeable materials)

should be located away with all safety measures.

• Regular hazard survery should be done to ensure detection of leakage in the

plant.

GSFC has been awarded ISO 9001:2015 Quality Management System, ISO 14001:2015

Environment Management system, ISO 45001:2018 Occupational Health and Safety

Management System and ISO 50001:2011 Energy Management Certification for

Vadodara Unit. Following safety measures are adopted by the plant.

• Hazard Identification and Risk Assessment.

• Work Permit System procedure has been established for safely execution of job.

• Electrical isolation/Lock Out and Tag Out procedure has been established for

Isolation of energized equipment’s/ machineries. Standard Operating procedures.

• Start-up procedure Shut down procedure, emergency procedure is being followed.

• Inbuilt safety measures such as trips, alarms, logics.





• Safety instrumentation- DCS System for plant process monitoring has been

established. For the proposed revamping project, DCS shall be established.

• DISH Approved training center to impart training for all the level of employees/

Contract workmen.

• MSDS related to all the chemicals used in complex are available.

• On-site emergency Plan.

• Mock drills.

• Various PPES, Fire extinguishers, safety showers, first aid boxes (filled) & air masks, Gas

masks etc. are provided at various Hazardous installations.

11.6. Project Benefits


• There will be decrease in freshwater consumption after proposed revamping.


crystallizer, Centrifuge, Dryer, and other solid handling equipment with installation of

new vacuum evaporation section.

11.7. Environment Management Plan

OH&S policy and EHS policy is adopted by the plant for sustainability. A separate EMP

cell, Fire & Safety cell and Occupational Health Centre is provided in the plant for

compliance of Environmental management plan and OHSAS guidelines.

Total cost for proposed project is Rs 306 Crores. Being a revamping project, all the

activities will be carried out without disturbing existing plant operations. Plant shut down

will be taken for hook-up activities. The anticipated month for completion of project is

June,2023. GSFC has spent approx. Rs. 515347.37 Lakhs on Environment Management

and Protections in year 2019-2020.

GSFC has implemented all guidelines laid down by CPCB and MoEF&CC for CREP

(Corporate Responsibility for Environmental Protection) and submitting the annual

compliance of the same to the GPCB.





CHAPTER 12. DISCLOSURE OF CONSULTANT

EQMS India Pvt. Ltd. is one of the leading Environmental Consultancy having

accreditation in more than 17 sectors. We have experience of more than 20 years in the

field of environmental consultancy services with providing services all over India and in

the neighbouring countries Sri-Lanka, Nepal, Bangladesh, Bhutan, Saudi Arabia and Abu

Dabi in the sectors like Building Construction and Area Development, Inland Waterways,

Metro and Railways, Highway Bridges, Wind and Solar Power, Industrial, Due Diligence,

Cement Projects, Mining Projects, and many more.

We also have experience of working on various projects which are funded by bilateral

and multilateral funding agencies like World Bank, ADB and IFC etc. We have enormous

experience of working on various Building constructions and Area Development Projects

We have the team of well experienced and qualified professional who can undertake

titanic projects with ease.

The EQMS is a NABET accredited A Category consultant and is authorize to carryout EIA

study for 5 (a) – A category projects also as per schedules. Therefore, EQMS India Pvt Ltd.

has been accorded work of carry out environment impact assessment of the proposed

project- “Revamping of existing Urea Plants (Urea-I & II) in GSFC Complex at P.O.

Fertilizernagar, Tal. and District- Vadodara, Gujarat-391750 by M/s Gujarat State

Fertilizers & Chemicals Limited (GSFC). The key person deployed for the project is listed

below:

PK Srivastava, having total 30+ years of working experience and worked as EIA

coordinator and Risk Hazard expert on various projects related to pharmaceutical

industries, fertilizer and pesticide projects. Tendered advice on several environmental

matters to the company and their clients. Represented the company at the MoEF Expert

committee meetings and State SEAC meetings for presenting the EIA reports and

successfully obtained environmental clearances to various projects.

Function Area Expert:

Mr. Ratnesh Kotiyal (EC and FAE-EB), Deputy General Manager accredited FAE by

NABET has worked in the current project as an Ecology and Biodiversity expert. He has

over 17 years of experience in EIA and is technical group head for EIA related activities

and infrastructure projects.

Mr. Anil Kumar (FAE-LU and SE), Deputy Specialist, NABET accredited A category Expert

for Socio-economic and Land use, has vast experience in carrying out GIS based studies

and social impact assessment for various types of industries &infrastructure projects. He

has provided technical assistance throughout the project and co-ordinate the field

activities during assessment.





Mr. Sanjay Kumar Jain (FAE (AP, WP, SHW, RH) Technical Director of EQMS having more

than 33 years experience to carry out the various impact assessment studies of various

industrial, infrastructure projects and carry out various multinational bilateral and

multilateral world bank funded project.

Empanelled Expert

Mr. Hardik Patel (FAE Geo) has more than 10 years experience in carrying out EIA studies

for various types of Geology related projects.

Mr. Yamesh Sharma (FAE Hydrogeology) has more than 40 years experience in carrying

out EIA studies for various types of hydrogeology related projects.

Mr. Dipil K Pandey (FAE NV) has more than 30 years experience in carrying out EIA studies

for various types of noise & vibration related projects.

Team Members

Mr. Kapil Singh (AP & NV) B. Tech (Environment), having experience of 3 years in carrying

out the various studies of EIA like Air Environment, Noise Environment & provides his

assistance to carry out the EIA studies in various construction and Industrial Projects. He

provides technical assistance during discussions and field work for the projects.

Ms Sweta Shah (EIA Coordinator and FAE NV, AQ, AP, SHW) having 10 years of

experience shares her valuable information in the functional areas and technical

assistance during discussions and field work for the projects.

The remaining team members too have the experience of working on various aspects

of EIA studies. All have the site experience for collection of the environmental data and

have prepared EIA/EMP report.





NABET ACCREDIATION OF EQMS INDIA PVT. LTD.

REVAMPING OF UREA- I & II PLANTS AT GSFC COMPLEX

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