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Chapter 8
ENVIRONMENTAL MANAGEMENT IN
INDIAN FERTILISER PLANTS
The study covered a representative group of six major fertiliser producers in
the country. The methods of pollution control and environmental management
adopted in respect of each of the causative factors for pollution are thoroughly
reviewed. An assessment was also done as to how far existing technologies are
effective in mitigating pollution from plants to the required level of standard being
practiced in India as well as abroad. Areas where strengthening is required, both in the
technology at the plant level and management perspective at the corporate level, are
highlighted.
All the units studied have specific environmental policies and are maintaining
the characteristics of the emissions to atmosphere and effluents discharged to the local
streams within the limits of the stipulations of the regulatory authorities. This is
achieved by treating pollutants in effluent streams in suitably designed pollution
control plants following the end-of-pipe treatment approach. New plants such as those
belonging to Tata Chemicals and Indo Gulf Fertiliser Corporation, have modem
process technologies where considerable integration have taken place at the inception
stage itself to see that pollution prevention is a part of the process design itself. In the
case of units that came to existence long back, pollution control facilities were built
and attached later as and when legislation in this area became effective. In fact, the
study revealed that the pollution and environment control departments of these units
exhibit meticulous care to see that the above objective is achieved. Thus now-a-days
199
states of art control facilities exist in these units and they are operated effectively.
The stipulations of the Pollution Control Boards are with in the achievable limits of
the available technology at hand. Sometimes excursions occur in the analysis of
certain parameters on account of start up, shut down of plants or may be due to
accidental situations. Existing facilities are ensured capable of handling such
situations also.
Table 8.1.1 and 8.1.2 provides a comparIson of pollution control and
environment management techniques being adopted by the various units studied vis~a~
vis the best available technology in the field. It indicates the methods of pollution
control adopted in the various plants in respect of each of the pollutants. In
comparison with the currently available best practices for efficient pollution control in
the industry, projections for further improvement of existing control measures in
these plants are identified.
Table 8.2 show the average effluent and emission characteristics of the
discharged streams from the units studied. In the fertiliser industry key parameters
being monitored universally are pH, ammoniacal nitrogen, nitrates, fluorides,
phosphates, total suspended and dissolved solids and chemical and biological oxygen
demand, toxic metals such as hexavalent chromium, vanadium etc., in the effluent
streams, particulate matter, nitrogen oxides, sulphur oxides and carbon monoxide in
exhaust streams, and temperature at which the effluents are discharged.
Fig.S.1 which is a graphical presentation of the key effluent characteristics
from the plants vis~a~vis the mandatory standards, show that all the units have been 'r\'~." ""' .•
.... .,..,. -" successful in maintaining the respective effluent reters beIo.'W the prescribed .1 \~"
~f \"'.
standards with regard to discharge of effluents. ~\ .. r~' ~
, ,.. . .t •
• , 1 (,l'. , ~ / ... \..".... .. /.4""'(~ ,.~ ... - - .. ,. ... ~.
~",.. . .",,,,..
Tab
le 8
.1.1
Sta
tus
of E
nvir
onm
ent
Man
agem
ent i
n S
elec
ted
Fer
tili
ser
Pla
nts
--
Bes
t A
vail
ble
Pra
ctic
e fo
r U
nit
FA
CT
, C
ochi
n T
ata,
Bab
rala
C
ontr
ol
(1)
Jl)
(3
) (4
) C
apac
ity
MT
/ann
um
a) N
itro
geno
us
3300
00
7425
00
b) P
hosp
hati
c 48
5000
Y
ear
of o
pera
tion
19
72
1994
F
eeds
tock
N
apht
ha
Nat
ural
Gas
Tec
hnol
ogy
Ste
am R
efon
ning
S
team
Ref
onni
ng
Env
iron
men
tal
Pol
icy
stat
emen
t Y
es
Yes
EM
S I
SO
140
00
Yes
Y
es
Gre
en B
elt
Dev
elop
men
t Y
es
Yes
A
mbi
ent
Air
Qua
lity
Mon
itor
ing
Yes
Y
es
EN
VIR
ON
ME
NT
AL
CO
NT
RO
L P
AR
AM
ET
ER
S
Liq
uid
Eff
luen
ts
I. A
mm
onia
pro
cess
con
dens
ate
Sat
urat
ing
stea
m f
eed
to
Str
ippe
d an
d w
ater
rec
over
ed
Rec
ycle
d to
DM
pla
nt
refo
nn
er
2. T
urbi
ne c
onde
nsat
e R
ecyc
le a
nd u
se a
s bo
iler
R
ecyc
led
alon
g w
ith
boil
er f
eed
Rec
ycle
d al
ong
wit
h bo
iler
fe
ed w
ater
w
ater
fe
ed w
ater
3. U
rea
proc
ess
cond
ensa
te
NH
3 an
d C
O2
reco
vere
d an
d N
H3
and
CO
2 re
cove
red
and
Rec
ycle
d to
DM
pla
nt
wat
er r
ecyc
led
wat
er r
ecyc
led
4. W
ater
Tre
atm
ent
Pla
nt E
fflu
ents
N
eutr
alis
ed a
nd s
ent t
o gu
ard
Neu
tral
ised
and
sen
t to
guar
d N
eutr
alis
ed a
nd s
ent
to g
uard
. p
on
ds
pond
s po
nds
5. C
ooli
ng T
ower
Eff
luen
ts
Tre
at in
ET
P,
disp
ose
to
Dis
pose
d to
gua
rd p
onds
D
ispo
sed
to g
uard
pon
ds
guar
d ~onds
6. O
ily
wat
er
Wat
er s
epar
ated
and
oil
W
ater
sep
arat
ed a
nd o
il
Oil
sep
arat
ed a
nd w
ater
.. di
spos
ed o
ff
_.
--
d~osedo!f _
__
-
d~posed
MF
L,
Che
nnai
(5)
2420
00
8400
00
1971
N
apht
ha
Ste
am R
efon
ning
Yes
Yes
Yes
Yes
Str
ippe
d N
H)
and
wat
er
reco
vere
d R
ecyc
led
alon
g w
ith
boil
er
feed
wat
er
NH
J an
d C
O2
reco
vere
d an
d w
ater
rec
ycle
d
Neu
tral
ised
and
sen
t to
ET
P
Tre
ated
in E
TP
Wat
er s
epar
ated
and
oil
di
spos
ed o
ff
I J I i I I J I IV
o o
· (J)
(2
)
7. B
oile
r bl
ow d
own
Neu
tral
ised
and
sen
t to
tr
eate
d ef
flue
nt p
ond
8. G
ypsu
m p
ond
efil
uent
s D
isch
arge
d as
per
PC
B
stip
ulat
ions
9.
Sul
phur
ic a
cid
plan
t eff
luen
ts
Neu
tral
ised
and
sen
t to
ET
P
Dis
pose
d af
ter
rem
oval
ofF
, 10
. P
hosp
hori
c ac
id p
lant
eff
luen
ts
P0
4, N
H3
and
susp
ende
d so
lids
11.
Sew
erag
e T
reat
ed a
t the
ST
P a
nd
disp
osed
E
mis
sion
s
I. P
etro
leum
sto
rage
em
issi
ons
Flo
ltln
s ro
of t
anks
, rC
lduc
e in
vent
ory
2. B
oile
r st
ack
emis
sion
s B
ette
r co
mbu
stio
n co
ntro
l an
d st
ack
mon
itor
ing
Min
imum
dus
t 3.
Pri
llin
g to
wer
dus
t de
sign
, rec
over
dus
t an
d re
cycl
e
Hig
h ef
fici
ency
mis
t 4.
S02
em
issi
ons
elim
inat
ors,
inc
reas
ed s
tack
he
ight
and
sta
rt u
p sc
rubb
er
5. S
ulph
uric
aci
d m
ist
Hig
h ef
fici
ency
mis
t el
imin
ator
s 6.
Dus
t fr
om b
aggi
ng o
pera
tion
s M
onit
or a
nd c
ontr
ol
7. F
lour
ine
emis
sion
s C
yclo
ne s
crub
bers
and
tr
eatm
ent o
f flo
urid
es i
n E
TP
8. D
ust
from
roc
k gr
indi
ng
Cyc
lone
s, m
ulti
ple
scru
bber
s an
d re
cycl
e 9.
SO
) em
issi
ons
Mis
t eli
min
ator
s
(3)
(4)
Sen
t to
guar
d po
nds
Neu
tral
ised
and
sen
t to
tr
eate
d ef
flue
nt p
ond
Dis
char
ged
as p
er P
CB
st
ipul
atio
ns
Neu
tral
ised
and
sen
t to
ET
P
Dis
pose
d af
ter
rem
oval
ofF
, P
04
, N
HJ
and
susp
ende
d so
lids
Bio
logi
cal
trea
tmen
t T
reat
ed a
t the
ST
P a
nd
disp
osed
Flo
atin
a ro
ofta
nks
to r
educ
e N
o st
orag
es
emis
sion
s B
ette
r co
mbu
stio
n co
ntro
l and
G
aseo
us f
uel
has
litt
le
stac
k monitorin~
emis
sion
s
Dus
t re
cove
red
by s
crub
bing
M
inim
um d
ust d
esig
n an
d ur
ea r
ecyc
led
Hig
h ef
fici
ency
mis
t el
imin
ator
s, i
ncre
ased
sta
ck
NA
he
ight
and
sta
rt u
p sc
rubb
er
Hig
h ef
fici
ency
mis
t N
A
elim
inat
ors
Mon
itor
ing
and
cont
rol
Cyc
lone
scr
ubbe
rs a
nd
NA
tr
eatm
ent o
f flo
urid
es i
n E
TP
C
yclo
nes,
mul
tipl
e sc
rubb
ers
NA
an
d re
cycl
e M
ist
elim
inat
ors
NA
(5)
Tre
ated
In E
TP
Dis
char
ged
as p
er P
CB
st
ipul
atio
ns
Neu
tral
ised
and
sen
t to
ET
P D
ispo
sed
afte
r re
mov
al o
f F,
P
04
• N
HJ
and
susp
ende
d so
lids
Bio
logi
cal
trea
tmen
t
Flo
atin
g ro
of ta
nks
to r
educ
e em
issi
ons
Bet
ter c
ombu
stio
n co
ntro
l an
d st
ack
mon
itor
ing
Dus
t re
cove
red
by s
crub
bing
an
d ur
ea r
ecyc
led
Hig
h ef
fici
ency
mis
t el
imin
ator
s, i
ncre
ased
sla
ck
heig
ht
and
star
t up
sc
rubb
er
Hig
h ef
fici
ency
mis
t el
imin
ator
s
Cyc
lone
scr
ubbe
rs a
nd
trea
tmen
t in
ET
P
Cyc
lone
s, m
ulti
ple
scru
bber
s an
d re
cycl
e M
ist
elim
inat
ors
I I ,
N o
(1)
(2)
(3)
(4)
(5)
10. C
atal
yst d
usts
U
se d
ust
prot
ecti
on
equi
pmen
t It
. V
ent
gase
s B
urnt
off
in
flar
e st
ack
Ven
ted
at e
leva
ted
poin
t B
urnt
off
in
flar
e st
ack
Bur
nt o
ff i
n fl
are
stac
k
12.
Am
mon
ia e
mis
sion
s R
ecov
ered
by
scru
bbin
s_
Rec
over
ed b
y sc
rubb
ing
Rec
over
ed b
y sc
rubb
ing
Rec
over
ed b
y sc
rubb
ing
13.
CO
lea
ks
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
14. N
oise
lev
el
Mai
ntai
n w
ithi
n lim
its
Soli
d W
aste
s 1.
Slu
dge
from
pla
nts
Sto
re i
n ha
zard
ous
was
te p
its
Sto
red
as h
azar
dous
was
te
Sto
red
as h
azar
dous
was
te
Sto
red
as h
azar
dous
was
te
Par
tly
sold
to c
emen
t!gy
psum
P
artl
y so
ld to
cem
ent!
2. G
ypsu
m
Sel
l or
dis
pose
as
per
boar
d m
anuf
actu
rers
and
N
A
gyps
um b
oard
man
ufac
ture
rs
regu
lati
ons
bala
nce
disp
osed
as
per
and
bala
nce
disp
osed
as
per
regu
lati
ons
regu
lati
ons
3. S
pent
cat
alys
ts
Dis
pose
for
met
al r
ecov
ery
Sol
d S
old
Sol
d 4.
Ins
ulat
ion
debr
is
Lan
d fi
llin
g U
sed
as l
and
fill
ing
Use
d as
lan
d fi
llin
g U
sed
as l
and
filli
ng
5. C
onst
ruct
ion
debr
is
Lan
d fi
llin
g U
sed
as l
and
fill
ing
Use
d as
lan
d fi
lIin
g U
sed
as l
and
filli
ng
6. O
ily
slud
ge
Rec
over
oil
and
use
in
Oil
rec
over
ed a
nd u
sed
furn
ace
7. R
edun
dant
equ
ipm
ent
Dis
pose
S
old
and
disp
osed
S
old
and
disp
osed
S
old
and
disp
osed
8.
Haz
ardo
us s
olid
was
te
Saf
e st
orag
e Sa
fe s
tora
ge
Saf
e st
orag
e Sa
fe s
tora
ge
Saf
e st
orag
e w
itho
ut l
each
ing
Saf
e st
orag
e w
itho
ut l
each
ing
Safe
sto
rage
with
out
leac
hing
9.
Pre
cipi
tate
d fl
ouri
des
and
grou
nd w
ater
an
d gr
ound
wat
er
NA
an
d gr
ound
wat
er
cont
amin
atio
n co
ntam
inat
ion
cont
amin
atio
n 10
. Pre
cipi
tate
d ph
osph
ates
R
ecyc
le to
pla
nt
Rec
ycle
d to
pla
nt
NA
R
ecyc
led
to p
lant
Not
e:
The
tab
le p
rovi
des
a co
mpa
riso
n o
f the
pol
luti
on c
ontr
ol a
nd e
nvri
onm
enta
l m
anag
emen
t st
rate
gies
bei
ng a
dopt
ed b
y th
e di
ffer
ent
unit
s vi
s-a-
vis
the
best
ava
ilab
le p
ract
ice
for
effe
ctiv
e co
ntro
l o
f pol
luti
on in
res
pect
of e
ach
of t
he p
ollu
tant
s.
l-l
o t..J
Tab
le 8
.1.2
Sta
tus
of E
nvir
onm
ent M
anag
emen
t in
Sel
ecte
d F
erti
lise
r P
lant
s
Uni
t B
est
A va
ilbl
e P
ract
ice
for
Con
trol
R
eF
, T
rom
bay
lnd
o G
ulf,
Jag
adis
hpur
(1)
(2)
(3)
(4)
Cap
acit
y M
T/a
nnum
a) N
itro
geno
us
4300
00
7260
00
b) P
hosp
hati
c 66
0000
Y
ear o
f ope
rati
on
1978
19
88
Fee
dsto
ck
Nat
ural
Gas
N
atur
al G
as
Tec
hnol
ogy
Ste
am Reformin~
Ste
am R
efor
min
g
Env
iron
men
tal
Pol
icy
stat
emen
t Y
es
Yes
EM
S I
SO
140
00
Yes
Y
es
Gre
en B
elt
Dev
elop
men
t Y
es
Yes
A
mbi
ent A
ir Q
uali
ty M
onit
orin
g Y
es
Yes
EN
VIR
ON
ME
NT
AL
CO
NT
RO
L P
AR
AM
ET
ER
S
Lig
uid
Eff
luen
ts
I. A
mm
onia
pro
cess
con
dens
ate
Sat
urat
ing
stea
m f
eed
to
Str
ippe
d an
d w
ater
rec
over
ed
Str
ippe
d an
d w
ater
rec
ycle
d re
form
er
2. T
urbi
ne c
onde
nsat
e R
ecyc
le a
nd u
se a
s bo
iler
R
ecyc
led
alon
g w
ith
boil
er f
eed
Rec
ycle
d al
ong
wit
h bo
iler
fe
ed w
ater
w
ater
fe
ed w
ater
3. U
rea
proc
ess
cond
ensa
te
NH
3 an
d C
O2
reco
vere
d an
d N
H3
and
CO
2 re
cove
red
and
NH
3 an
d C
O2
reco
vere
d an
d w
ater
rec
ycle
d w
ater
re~c1ed
wat
er r
ecyc
led
4. W
ater
Tre
atm
ent
Pla
nt E
ffiu
ents
N
eutr
alis
ed a
nd s
ent t
o g
uard
N
eutr
alis
ed a
nd s
ent
to g
uard
N
eutr
alis
ed a
nd s
ent
to
pond
s E
TP
ef
fiue
nt c
ondi
tion
ing
sum
p
5. C
ooli
ng T
ower
Eff
iuen
ts
Tre
at i
n E
TP
, di
spos
e to
T
reat
ed in
ET
P
Sen
t to
gua
rd p
onds
thr
ough
gu
ard
pond
s co
ndit
ioni
ng s
ump
6. O
ily
wat
er
Wat
er s
epar
ated
and
oil
O
il s
epar
ated
and
wat
er s
ent
disp
osed
off
to
eff
iuen
t co
ndit
ioni
ngsu
mp
I
KR
IBH
CO
. H
azir
a
(5)
1452
000
I
1986
N
atur
al G
as
Ste
am R
efor
min
g Y
es
Yes
I
Yes
Y
es
Str
ippe
d an
d w
ater
rec
ycle
d ,
Rec
ycle
d al
ong
wit
h bo
iler
I
feed
wat
er
NH
3 an
d C
O2
reco
vere
d an
d I
wat
er r
ecyc
led
Neu
tral
ised
and
sen
t to
ef
fiue
nt c
ondi
tion
ing
sum
p S
ent t
o gu
ard
pond
s th
roug
h co
ndit
ioni
ng s
ump
Oil
sep
arat
ed a
nd w
ater
sen
t to
eff
iuen
t con
diti
onin
g su
mp
I
N o I..J
(I)
(2)
7. B
oile
r bl
ow d
own
Neu
tral
ised
and
sen
t to
trea
ted
effl
uent
pon
d
8. G
ypsu
m p
ond
effl
uent
s D
isch
arge
d as
per
peB
st
ipul
atio
ns
9. S
ulel
turi
c ac
id p
lant
eff
luen
ts
Neu
tral
ised
and
sen
t to
ET
P
Dis
pose
d af
ter
rem
oval
ofF
, 10
. P
hosp
hori
c ac
id p
lant
eff
iuen
ts
P0
4,
NH
3 an
d su
spen
ded
soli
ds
11.
Sew
erag
e T
reat
ed a
t th
e S
TP
and
di
spos
ed
Em
issi
ons
I. P
etro
leum
sto
rage
em
issi
ons
Flo
atin
g ro
of t
anks
,red
uce
inve
ntor
y
2. B
oile
r sta
ck e
mis
sion
s B
ette
r com
bust
ion
cont
rol
and
stac
k m
onit
orin
g M
inim
um d
ust
3. P
rill
ing
tow
er d
ust
desi
gn,r
ecov
er d
ust
and
recy
cle
Hig
h ef
fici
ency
mis
t 4.
S02
em
issi
ons
elim
inat
ors,
inc
reas
ed s
tack
he
ight
and
sta
rt u
p sc
rubb
er
5. S
ulph
uric
aci
d m
ist
Hig
h ef
fici
ency
mis
t el
imin
ator
s
6. D
ust
from
bag
ging
ope
rati
ons
Mon
itor
and
con
trol
7. F
lout
ine
emis
sion
s C
yclo
ne s
crub
bers
and
tr
eatm
ent o
f flo
urid
es in
ET
P
Cyc
lone
s,m
ulti
ple
scru
bber
s 8.
Dus
t fro
m r
ock
grin
ding
an
d re
cycl
e -----
--
-
(3)
(4)
Tre
ated
in E
TP
U
sed
as c
ooli
ng to
wer
mak
e up
D
isch
arge
d as
per
PC
S
NA
st
ipul
atio
ns,
used
in h
orti
cult
ure
Neu
tral
ised
and
sen
t to
Erp
N
A
Dis
pose
d af
ter
rem
oval
of
Flu
orid
es, P
04
, N
H3
and
NA
su
spen
ded
soli
ds
Dis
pose
d af
ter
biol
ogic
al
Dis
pose
d af
ter
biol
ogic
al
trea
tmen
t in
ST
P
trea
tmen
t in
ST
P
No
stor
ages
N
o st
orag
es
Gas
eous
fue
l ha
s li
ttle
G
aseo
us f
uel
has
litt
le
emis
sion
s em
issi
ons
Dus
t re
cove
red
by s
crub
bing
M
inim
um d
ust
desi
gn
and
urea
rec
ycle
d
Hig
h ef
fici
ency
mis
t el
imin
ator
s, i
ncre
ased
sta
ck
NA
he
ight
and
sta
rt u
p sc
rubb
er
Hig
h ef
fici
ency
mis
t N
A
elim
inat
ors
Wet
ded
usti
ng s
yste
m
inst
alle
d W
ater
scr
ubbi
ng a
nd t
reat
men
t N
A
inE
TP
C
yclo
nes,
mul
tipl
e sc
rubb
ers
and
recy
cle,
N
A
Mis
t el
imin
ator
s -
--
-----
--
(5)
Use
d as
coo
ling
tow
er m
ake
up
NA
NA
NA
Dis
pose
d af
ter
biol
ogic
al
trea
tmen
t in
ST
P
No
stor
ages
Gas
eous
fue
l ha
s li
ttle
em
issi
ons
Min
imum
dus
t de
sign
NA
NA
Dus
t re
cove
red
by w
ater
sc
rubb
ing
NA
NA
--
--
---
-- ---
t.J
o .j::
.
-
(1)
(2)
(3)
(4)
(5)
9. S
OJ
emis
sion
s M
ist
elim
inat
ors
Mis
t el
imin
ator
s N
A
NA
10.
Cat
alys
t dus
ts
Use
dus
t pr
otec
tion
eq
uipm
ent
t 1. V
ent
gase
s B
urnt
off
in
flar
e st
ack
Bur
nt o
ff i
n fl
are
stac
k B
urnt
off
in
flar
e st
ack
Bum
t off
in
flar
e st
ack
12. A
mm
onia
em
issi
ons
Rec
over
ed b
y sc
rubb
ing
Rec
over
ed b
y sc
rubb
ing
Rec
over
ed b
y sc
rubb
ing
Rec
over
ed b
y sc
rubb
ing
13.
CO
lea
ks
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
Imm
edia
te l
eak
seal
ing
14. N
oise
lev
el
Mai
ntai
n w
ithi
n li
mit
s
Sol
id W
aste
s E
TP
slu
dge
is u
sed
as p
oult
ry
I. S
ludg
e fr
om p
lant
s S
tore
in
haza
rdou
s w
aste
pit
s fe
ed a
nd i
n bl
endi
ng f
erti
lise
rs
NA
N
A
othe
r sl
ud d
ispo
sed
as
haza
rdou
s w
aste
P
artl
y so
ld t
o ce
men
Ugy
psum
2. G
ypsu
m
Sel
l or
disp
ose
as p
er
boar
d m
anuf
actu
rers
and
N
A
NA
re
gula
tion
s ba
lanc
e di
spos
ed a
s pe
r re
gula
tion
s 3.
Spe
nt c
atal
ysts
D
ispo
se f
or m
etal
rec
over
y S
old
Sol
d S
old
4. I
nsul
atio
n de
bris
L
and
fill
ing
Use
d as
lan
d fi
llin
g U
sed
as l
and
fill
ing
Use
d as
lan
d fi
lling
5.
Con
stru
ctio
n de
bris
L
and
fill
ing
Use
d as
lan
d fi
llin
g U
sed
as l
and
fill
ing
Use
d as
lan
d fi
llin
g
6. O
ily
slud
ge
Rec
over
oil
and
use
in
Use
d fo
r an
tica
king
/ coa
ting
O
il r
ecov
ered
and
use
d O
il re
cove
red
and
used
fu
rnac
e 7.
Red
unda
nt e
quip
men
t D
ispo
se
Sol
d an
d di
spos
ed
Sol
d an
d di
spos
ed
Sol
d an
d di
spos
ed
8. H
azar
dous
sol
id w
aste
S
afe
stor
age
Saf
e st
orag
e S
afe
stor
age
Saf
e st
orag
e S
afe
stor
age
wit
hout
lea
chin
g S
afe
stor
age
wit
hout
lea
chin
g 9.
Pre
cipi
tate
d fl
ouri
des
and
grou
nd w
ater
an
d gr
ound
wat
er
NA
N
A
cont
amin
atio
n co
ntam
inat
ion
I O. P
recipita~d p
hosp
hate
s -
Rec
ycle
to
plan
t R
ecyc
led
to p
lant
N
A
NA
Not
e:
The
tab
le p
rovi
des
a co
mpa
riso
n o
f the
pol
luti
on c
ontr
ol a
nd e
nvri
onm
enta
l m
anag
emen
t st
rate
gies
bei
ng a
dopt
ed b
y th
e di
ffer
ent
units
vi
s-a.
-vis
the
bes
t av
aila
ble
prac
tice
s fo
r ef
fect
ive
cont
rol
of p
ollu
tion
in r
espe
ct o
f eac
h o
f the
pol
luta
nts.
I I , j
t...l o VI
Tab
le 8
.2
Em
uen
t an
d E
mis
sion
Cha
ract
eris
tics
(A
vera
ge V
alue
s)
Par
amet
ers
Uni
t T
oler
ance
F
AC
T
TA
TA
In
do G
ulf
li
mit
(1)
(i)
(3)
(4)
(5)
(6)
Tot
al S
uspe
nded
sol
ids
mg/
I m
ax
100
25
17
33
Tot
al D
isso
lved
Sol
ids
mg/
l m
ax
2100
10
00
1748
64
9
Tem
pera
ture
°C
40
35
36
35
pH
6.
5-8.
0 6.
6--8
.0
7.7-
8.1
7.16
Bio
logi
cal
Oxy
gen
Dem
and
mgl
l m
ax
30
14
14.5
5.
2
Che
mic
al O
xyge
n D
eman
d m
g/I
max
25
0 75
55
11
Dis
solv
ed O
xyge
n m
g/l
min
Oil
& G
reas
e m
g/I
max
10
2.
6 2
ND
Am
mon
iaca
l N
itro
gen
as N
m
g/I
max
75
70
21
26
F
ree
Am
mon
ia
mg/
l m
ax
4 0.
67
0.8
0.15
Tot
al K
jada
hl N
itro
gen
as N
m
g/l
max
15
0 13
6 54
29
Nit
rate
as
N
mg/
I m
ax
20
1.8
1.25
0.
61
Sul
phat
e as
S
04
m
g/I
max
10
00
460
Pho
spha
te a
s P
mg/
I m
ax
5 3.
2 1.
3 0.
75
Sul
phid
e as
S
mg/
I m
ax
Flu
orid
e as
F
mg/
I m
ax
10
2.9
1.5
-
RC
F
MF
L
(7)
(8)
35
38
964
800
38
35
6.5-
8.5
6.9-
7.5
25
22
62
85
2 2
38
35
0.8
0.5
30
45
2 3 540
1 1.
2
1.8
1.1
KR
IBH
CO
(9)
26
469
35
7.8 5 9 2 30
0.16
29
0.56
0.6
1.2
N o 0\
(11
(2)
(3)
(4)
Chl
orid
e as
Cl
mg/
l m
ax
Cya
nide
as
CN
m
g/l
max
0.
2 L
ead
as P
b m
g/I
max
Sel
eniu
m a
s S
e m
g/l
max
Zin
c as
Zn
mg/
I m
ax
5
Cop
pera
s C
u m
g/I
max
Nic
kel a
s N
i m
g/l
max
Cad
miu
m a
s C
d m
g/I
max
Hex
aval
ent C
hrom
ium
as
er
mg/
I m
ax
0.1
NO
Tot
al C
hrom
ium
as
Cr
mg
/lm
ax
2 M
ercu
ry a
s H
g m
g/l
max
Ars
enic
as
As
mg
/lm
ax
0.2
Sod
ium
as
Na
%m
ax
Iron
as
Fe
mg/
I m
ax
3 I
Fre
e C
arbo
n di
oxi
de C
O2
mg
ll m
ax
Phe
nol
as C
6Hs
OH
m
gll
max
Res
idue
l C
hlor
ine
as C
l m
g/I
max
Bar
ium
as
Ba
mg/
I m
ax
Van
adiu
m a
s V
m
g/I
max
0.
2 N
O
Ure
a du
st
mgI
NM
3 50
50
P
arti
cula
r m
atte
r m
gIN
M3
150
140
F10u
ride
m
gIN
M3
25
15
Aci
d m
ist
mgl
NM
3 50
20
(5)
(6)
(7)
0.3
0.4
0.5
NO
N
O
ND
0.23
0.
8 I
NO
N
O
NO
25
25
35
10
0 11
0 12
0 20
20
(8)
1.2
NO
0.5
NO
40
12
0 24
25
(9)
0.35
NO
1 NO
25
92
J I J I J
N o -J
208
Ammoniacal Nitrogen
80
70
60
~ 50 E 40
30
20
10
0
Std FACT Tata Indo gulf RCF MFL Kribhco
Suspended Solids l 120 .-----~--~~~~~~~--~~
100 ..J 80 tn E 60
40
20
o Std FACT Tata, RCF
Indo Gulf MFL Kribhco
Fig.S.I: Key Effluent Characteristics
209
Total Kjeldahl Nitrogen
160
140
120
~ 100 E 80
60
40
20
0 Std FACT Tata lndo gulf RCF MFL Kribhco
1 ____________________ _
Phosphates l 6 r-~~--~--~~------~~--~
5
~4 E 3
2
1
o Std FACT Tata Indo gulf RCF MFL Kribhco
L _________ _ Fig.S.I: Key Effluent Characteristics
210
Fluorides
12
10
8
l' 6
4
2
0
Std FACT Tata Indo guij ACF MFL Kribhco
Nitrates
25
20
~ 15
e 10
5
0
~~ Cl" ~'lt ~ v« ft." ~o «Of " 0($ ~ ~ *"~ ,~
Fig.S.I: Key EftIueot Characteristics
~ Cl E
L
I '§. E
211
-------.-- - -
Biological Oxygen Demand (BOO)
35
30
25
20
15
10
5
0
<::>,-0 v'" ",.;;.'1> ~ d< $'v ~o '<,'i' 0(;$ ~ -~
~ -t-'"
Chemical Oxygen Demand (COD)
300 ,------------------------------. 250
200
150
100
50
o Sld FACT Tata Indo RCF MFL Kribhco
gulf '------- ----- ------_ . ---
Fig.S.I: Key Effiuent Characteristics
212
Table 8.3 indicates the Minimum National Standards (MINAS) for discharge
of fertiliser plant effiuents and emissions stipulated by the" Central Pollution Control
Board (CpeB). These are the statutory limits within which existing operators control
pollutants in their streams. In specifying these limits the long-tenn impact of
pollutants in the environment is not given due regard, instead most often it is the level
achievable by the use of current technologies.
Table 8.4 shows the ambient air quality standards in respect of noise in
different areas including industrial zones as prescribed by the Central Pollution
Control Board. Most equipment in the plant are usually designed in such a way that
the noise level emanating from their operation is less than 85 dB at a point one metre
away from the source of the sound. Besides this design stipulation, proper enclosures
are also provided for operator stations so that the exposure to noise shall not exceed
85 dB for 8 hours.
Table 8.4
Ambient Air Quality Standards in respect of Noise
Area Limits in decibel (dB)
Code Category of Area/Zone
Day Time Night time
(A) Industrial area 75 70
(B) Commercial area 65 55
(C) Residential area 55 45
(D) Silence Zone 50 40
Source: Central Pollution Control Board, 1998.
Notes: 1. Daytime shall mean from 6.00 a.m. to 10.00 p.m. 2. Night time shall mean from 10.00 p.m. to 6.00 a.m. 3. Silence zone is defined as an area comprising not less than 100 metres
around hospitals, educational institutions and courts. The silence zones are zones which are declared as such by the competent authority.
Par
amet
ers
(1)
Tot
al S
uspe
nded
sol
ids
Tot
al D
isso
lved
Sol
ids
Tem
pera
ture
pH
Bio
logi
cal
Oxy
gen
Dem
and
Che
mic
al O
xyge
n D
eman
d
Dis
solv
ed O
xyge
n
Oil
& G
reas
e
Am
mon
iaca
l N
itro
gen
as N
Fre
e A
mm
onia
Tot
al K
jada
hl N
itro
gen
as N
Nit
rate
Nit
roge
n
Sul
phat
e as
S0
4
Pho
spha
te a
s P
-
Tab
le 8
.3
Eff
luen
t C
har
acte
rist
ics
Sta
nd
ard
s
---
Min
imu
m N
atio
nal
Sta
nd
ard
s fo
r F
erti
lise
r In
du
stry
Uni
t N
itro
geno
us
Pho
spha
tic
Com
plex
(2)
(3)
(4)
(5)
mg/
I m
ax
100
100
100
mg/
I m
ax
°C
5°C
abo
ve
recy
clin
g w
ater
6.5
-8.0
7
.0-9
.0
6.5
-8.0
mg/
I m
ax
mg/
I m
ax
mg/
I m
in
mg/
I m
ax
10
10
10
mg/
I m
ax
50
50
mg/
I m
ax
4 4
100
mg/
I m
ax
20
20
mg/
I m
ax
_ m
g/I m~x _
5
5 '-
----
-----
--
N -v)
0)
(2)
Sul
phid
e as
S
mg/
l m
ax
Flu
orid
e as
F
mg/
l m
ax
Chl
orid
e as
Cl
mg/
I m
ax
Cya
nide
as
CN
m
g/l
max
Lea
d as
Pb
mg/
I m
ax
Sel
eniu
m a
s Se
rn
g/l
rnax
Zin
c as
Zn
mg/
I m
ax
Cop
pera
s C
u m
g/l
max
Nic
kel
as N
i m
g/l
rnax
Cad
miu
m a
s C
d . r
ng/I
max
Hex
aval
ent
Chr
omiu
m a
s C
r m
g/l
max
Mer
cury
as
Hg
rng/
l rn
ax
Ars
enic
as
As
mg/
l m
ax
Sod
ium
as
Na
%m
ax
Iron
as
Fe
mg/
l m
ax
Fre
e C
arbo
n di
oxid
e C
O2
rng/
I m
ax
Phe
nol
as C
6Hs
OH
m
g/I
max
Res
idue
} C
hlor
ine
as C
l m
g!l
max
Bar
ium
as
Ba
mg/
I m
ax
Van
adiu
m a
s V
m
g/I
max
(3)
(4)
to
0.2
,
0.1
0.1
0.2
0.2
---
--
(5) to
0.2
0.1
0.2
0.2 --_
.-
t...l
~
215
Table 8.5 provides European Emission Standards as prescribed by the
European Fertiliser Manufacturers' Association (EFMA). European and North
American emission and effluent standards for fertiliser industry are more or less
similar to the Indian standards in the respective areas.
Analysis of the above results show that all the units are successful in
controlling major pollutants below the specified standards. Certain plants have put up
recovery or treatment facilities so that effective reduction of pollutants takes place
well below the stipulations. All the plants studied have extensive facilities for end-of
pipe treatment of all effluents. Attempt to reduce the effluent generation at source in
these plants largely depend on the teclmologies adopted. In all units management
infrastructure exist for regular monitoring and reporting to authorities.
The specific consumption of energy, which measures the energy requirement
per tonne of ammonia, a major intermediate input and urea, a finished fertiliser
product, from plants have shown a continuous trend of reduction over these years.
(Fig. 8.2 and 8.3).
Reduced energy consumption invariably contribute to achieving better
environmental standards and result in gradual reduction in emissions, effluents and
solid waste per tonne of product manufactured.
Major design changes will be required for further improvements and hence
efforts in this line are limited unless it brings about economic incentive by way of
increased productivity, lowering of energy consumption etc.
Em
issi
on L
imit
Val
ues
to w
ater
P
lant
(lJ
Am
mon
ia
Ure
a
Am
mon
ium
Nit
rate
N
PK
-Nit
roph
osph
ate
NP
K M
ixed
Aci
d E
mis
sion
V
alue
s to
A
ir
(EF
MA
) P
lant
Am
mon
ia
Nit
ric
Aci
d S
ulph
uric
Aci
d
Tab
le 8
.S
Eur
opea
n E
mis
sion
Sta
ndar
ds
Em
issi
on
mgl
l kg
/ton
ne o
f pro
duct
(2)
(3)
(4)
(5)
(6)
New
E
xist
ing
New
E
xist
ing
NH
3-N
0.
1 0.
1 U
rea-
N
1 IS
O
0.00
05
0.1
NH
3-N
5
150
0.00
25
0.1
N
100
100
0.2
0.2
P20S
30
28
0.
06
0.11
N
H4-
N
60
120
0.12
0.
5 N
03-N
IS
15
0 0.
03
0.3
Flu
orid
e 26
13
0.
05
0.2
N
0 10
0 0
0.2
Em
issi
on
mg/
Nm
3 kg
/ton
ne o
f pro
duct
New
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218
- 15 -
10 -
5 1 2 3 4 5
Year 1987 1991 1995 1998 2000
Energy MKCallMT 12.54 11.66 11.02 10.18 9.59
Year
----- ---- .. ----.--- _._--
Fig. 8.2: Energy Consumption Trends-Ammonia Plants
,--_._-------- ---,_ .. _---- --- .- - ----.-- _. --- -----
-Year
-Energy
15
10
5
MKCallMT
1 2
1987 1991
10.32 9.61
3 4 5
1995 1998 2000
9.14 8.92 8.72
Year
Fig. 8.2: Energy Consumption Trends-Urea Plants
I
219
By early nineties of the last Century, extensive pollution control efforts have
become common practice in the Indian fertiliser industry and most plants were able to
comply with the Minimum National Standards for emissions and effluents set by the
Central Pollution Control Board (CPCB). It was made possible through adoption of
better technology and improved systems, which helped not only to reduce pollution
but also conserve resources and reduce waste generation. There has been a reduction
of 28% in water consumption of ammonia-urea plants and 38% in complex fertiliser
plants over the last nine years. Also the waste water discharged by fertiliser plants has
been found to be well within the stipulated standards (F AI Website, 1999).
The average energy consumption of 25 ammonia plants commissioned upto
1987 has improved by 6.6% during the last ten years period. The improvement in
energy consumption thus resulted in conservation of natural gas and petroleum
feedstock and hence reduction in C02 emission, a green house gas which is
considered as a major contributor to the global wanning and climate change. Also
there has been reduction of seven kilograms in the weighted average specific
consumption of ammonia for making a tonne of urea. This means reduction in loss of
ammonia to the environment. In the phosphatic sector the sulphur dioxide emission
from sulphuric acid plant, upon adoption of the double conversion and double
absorption (DCDA) technology, have steadily come down from 2.2 kilogram per
tonne to 1.56 kilogram per tonne of sulphuric acid over nine years period as against
the environmental protection standard of 4 kilogram sulphur dioxide per tonne of
sulphuric acid. Other emissions like suspended particulate matter, fluorine, etc. have
also registered a significant reduction (F AI, 1999).
220
In certain cases, as a method of control, the pollutant from effluents is
stripped out to the atmosphere using air or steam resulting in air contamination. There
is no control of pollution in converting the pollutant from water to air and it warrant
for more efficient systems.
Reuse of treated effluents is limited in most plants though they claim that
water conservation is achieved. This is mostly due to certain apprehension in the
minds of the operators that some upsets in the waste water purification systems may
lead to severe damages in other costly equipment.
During start up and shut down of plants effluent generation is high and
provision is made in the pollution control systems of most plants to take care of such
situations. Even though such excursions often cause public outcry and invite punitive
action from statutory authorities. Such systems shall have built in provision for
handling emergency situations also.
Gypsum ponds and stacks, though lined with impervious material still, cause
leaching of pollutants to the water streams and ground water sources. In most of these
plants heavy metals are not removed from the phosphoric acid produced. Phosphate
rock being consumed in Indian plants mostly comes from Asia and Africa and unlike
the Florida rock they have a lower content of radioactive impurities. Hence
monitoring of radioactivity level of phosphogypsum is also not given the requisite
priority and attention in most of the plants.
Much of the pollution prevention methods implemented by the units follow a
prescriptive approach in which a standardized procedure built around questionnaires
and check lists and it relies heavily on past solutions to pollution problems that are
presumed similar to the one at hand. In its place a more descriptive approach in which
221
process operators are challenged to define and study the pollution problems and
derive their own ways of solving them is desirable.
There are substantial efforts towards Green Belt Development and maintaining
greenery around these plants to reduce the impact of green house gases. Green belt
development around fertiliser units, is an important step in the direction of sustainable
environmental control. All the units studied undertook substantial efforts towards
green belt development around the production units through planting of saplings and
protecting vegetation around. Considerable efforts have been made by Rashtriya
Chemicals and Fertilisers towards development of horticulture using factory effluents
and use of sludge from effiuent treatment unit as poultry feed and in blending
fertilisers.
All units have established ISO 14000 Environment Management Systems and
there is corporate environmental set up for regular monitoring and control. These
systems are intended for continuous improvement of existing operations from the
environmental angle. Certain units have adopted Zero Effluent Approach
incorporating total recycle and reuse of effluents back to process. This approach still
remains more a concept than its fruitful implementation to a reasonable degree of
reliability.
These units have been successful in achieving the stipulations of the state and
central pollution control authorities and other statutory agencies without many
problems with the available technology and current efficiency of operation and
management. Most of the environmental problems in these units are addressed exactly
on the lines of those of the developed countries and similar results are achieved.
222
European and North American plant operators use the best available
technology (BAT) in their plants for environmental control. Emission level for
suspended particulate matter (SPM), oxides of nitrogen (NOx), and oxides of sulphur
(SOx) etc., are more stringent in these countries than in India or other developing
nations. European Fertiliser Manufacturers' Association (EFMA) specifies different
standards for new and existing plants. In those countries both effluent specific
standards and product specific standards are prescribed whereas in India, we have
only industry specific effluent standards.
In India also the best available systems are employed in controlling and
reducing pollution from fertiliser plants. These units do not contribute to further
efforts in reducing the pollution effects beyond the limits prescribed by the pollution
control boards (PCB). Potential for total recycle and zero effluent and emission have
to be explored. Sustainable development demand such kind of an effort in order to
enhance the carrying capacity of the geographical location and pave way for further
industrialization. The western manufacturers are well ahead in this area. A change in
this direction will necessitate a change in technology, which involve additional cost.
Thus units who are capable meeting the requisite stipulations of the PCBs do not find
any incentive in this regard.
All plants emit large quantities of carbon dioxide (C02), which is a major
green house gas to the atmosphere. There are no emission standards for CO2 as
prescribed by the statutory bodies. Attempt to reduce green house gas emissions all
over the globe to tackle climate change will bring in specific limits for C02 emissions
also in future.
223
From the management angle it is desirable that the environmental friendliness
of the industry shall improve year by year. This necessitates quantification of the
extent of this improvement. None of the units have made an attempt in this manner.
For this purpose existing environmental burden imposed by these units have to be
quantified by suitable methods for every environmental aspect. No attempts are being
done by any of the units in this regard.
Production of fertilisers and its balanced application are essential for
maintaining food security in today's world. Additional production facilities will have
to be built on new technologies, with least environmental impacts. The industry has
learned several lessons in environmental management from the mistakes of the past
and such knowledge on environmental issues and pollution prevention shall be
incorporated in the design stage itself for the new plants.
Each new plant is more efficient than the last plant built in addressing
environmental issues and there are efforts for continuously learning from collective
experience. There is still a lot of work to be done on the efficient use of our resources
and the balanced application of all fertilisers. There are many success stories in
environment management in the fertiliser industry, but good news alone does not sell.
The fertiliser industry in the country has to be very effective in promoting and
defending themselves, if not the environmental movements can do a great deal of
damage.
All manufacturers recognize that they are required to maintain a safe work
environment for employees and neighboring community. Apart from ensuring utmost
safety at the work place inside the factory, environment management plans are
developed to tackle eventualities in case they occur. In general, the management of
224
the production units are capable of mitigating the risk from most expected crisis
situations, but not all. It is necessary that the operators shall keep on upgrading their
environment management systems and must be cautious of the stringent future
regulatory action by governments.
Information to the public regarding the environmental consequences of these
plants are meagre and no effort is made from the part of the companies to explain the
environmental burden and risk of the installation to them. No environmental report is
published by the companies annually. In this context the Responsible Care
Environmental Reporting of the European Chemical Industry Council (CEFIC) may
be considered as a model. The communities associated with these units have a right
to know the environmental risk they are subjected to. This issue needs to be addressed
at the national level itself. Provisions like the Superfund Amendments and
Reauthorization Act (SARA) of the US to cope with Community Right To Know
requirements have to be enacted and the concerned professionals shall do whatever
necessary to allay the fear of the public.
The Government shall formulate COWltry specific Best Available Techniques
(BATs) for each industry including the fertiliser industry to facilitate continuous
improvement in environmental management. Technically and economically feasible
regulatory as well as non-regulatory measures, for the industry, also will help to
improve environmental management in fertiliser production. Fiscal incentives may
also be considered to encourage adoption of technologies that reduce pollution.
REFERENCES
F AI, Website of the Fertiliser Association of India, New Delhi, 1999.
F AI, Benchmarking of Emissions from Nitrogenous Fertiliser Plants-Indian
Experience, The Fertiliser Association ofIndia, New Delhi, 1999.
CPCB, Pollution Control Acts, Rules and Notifications Issued thereunder, Vol. I,
Central Pollution Control Board, Ministry of Environment and Forests, New Delhi,
1998, p.313.