GNFC/MoEF/EC/ECU/2013 ByR PAD - Gujarat Narmada …€¦ · GNFC/MoEF/EC/ECU/2013 Date:- 24,06 ... Narmadanagar, Bharuch by M/s Gujarat Narmada Vall ey Fertilizers Company ... trans

GujaratNarmadaValley Fertilizers amp Chemicals Limited

(An ISO 14001 amp OHSAS 18001 Company)

PO Narmadanagar - 392 015 Dis Bharuch Gujarat India Ph (02642) 24700l 247002

Website www gnfcin

GNFCMoEFECECU2013 Date- 24062013 ByR PAD

To Hon Regional Office Western Region Kendriya Paryavaran Bhavan Link Road - 3 E - 5 Ra vi shanka r N aga r Bhopal - 462 016 (M P)

Kind Attn- Shri Dr A Mehrotra Director (S)

Sub Submission of Compliance Report of Environmental Clearances granted to Gujarat Narmada Valley Fertilizers amp Chemicals Limited (G NFC)

Ref 1) State Level Environment Impact Assessment Authority Gujarat- Environmental Clearance NoSEIAAGUJjEC5(f)107 2011 dated 09062011

Dear Sir

We have received above referre d e nvironm ental clearance from St te L v I Environment Impact Assessmen t Authority Gujar t for the Ethyl Ace tate plant

Compl ian e report of enviro nmental cl arance No SEIAA GUJ EC5(f)1072011 dated 09062011 issued by the State Level Environment Impact Assess ment Authority Guja ra t is attached herew ith as Annexu re-1 as a part of compliance to condition of environmental cJeara n e nd Environme nt Impact Assessment Notification -2006

We have al ready complied conditions of environmental clearance NoJ-110111 218 2007shylA1 (I) dated 28 0420 08 w as vali d up to 27042013 amp J-11011731 2007-IA (II) dated 19032008 was valid up to 180320 13 granted by Mo EF

Thanking YOll

Yours fa ithfully Fovarmada Valley Fertilizers amp Chemicals Ltd

S KMebta General Manager

Enc as a bove

middotGujarat Narmada Valley Fertilizers amp Chemicals Limited (An ISO 14001 amp OHSAS 18001 Company)

PO Narmadanagar - 392 015 Olst Bharuch Gujarat India Ph (02642) 247001 247002

Website www gnlcin

CC TO 1 Shri B R Naidu Hon Zonal Officer Central Pollution Control Board Parivesh Bhava n

Opp VMC w ard office No10

Subhanpura

Vado dara-39 002 3

2 Hon Member Secretary State Level Environment Impac t Assessment Authority

Gujarat Pollution Control Board

Paryava ran Bhavan

Sector-lOA Gandhin agar-3 8 20l0

3 Shri Hardik Shah Hon Member Secretary Gujarat Pollution Control Board Paryavaran Bhavan

Sector-lOA Gandhinagar-3820l0

1

Gujara l armada Valley Fertilizers amp Chemiclts Limited

24th June-2013

Compliance status report of Environmental Clearance No SEIAAGUJEC5(f)1072011 dated 09062011

SubEnvironmental Clearance for the proposed Ethyl Acetate plant (capdci~y

50OOOMTyear) within the existing complex located a t National Highvvay No8 Notified Industrial area PO Narmadanagar Bharuch by Ms Gujarat Narmada Va ll ey Fertilizers Company Limited in category Set] of schedule annexed with EIA Notification dated 14092006

SR CONDITIONS I COMPLIANCE STATUS NO

A SPECIFlC CO NDITIONS A- l WATER No ground ivater shall be used fo r th e proj ect Additional fresh water requirement of 1093 KLday for the proposed ex pansion shall be insta lled and its records shall be maintained

A di stillation column sha ll be installed to recover Complied Ethanol Ethyl Acetate amp Acetic Acid from wash Distillation column (0 3602) IS

eft1uent and the recovered Ethanol Ethyl Ace tate already installed amp commissioned middot amp Acetic Acid shall be reused in the process The for recovery of ethanol Ethyl co mpany shall continuously thrive to reduce acetate and Acetic acid from vvash recycle and reuse their treated effluent effluent

3 Additio na l was te wat r gene rati n due to the Complied p roposed expa ns io n sha ll no t exceed 503 KLday Pres ntly addit iona l waste w ater [500 KLday indu s tria I+ 3 KLday domes tic] g n ra tion from Ethyl acetate

plant is 400 KLJday 4 Out of 503 KL day of a dd iti o nal wastewa te r 100 Being complie d

KLday of cool ing tower blow down effluent shall 100 KLDay wastewater be conveyed to the Central Effluent Treatment generated from cooling tower PI nt for its reuse for gardening irriga tion bl ow down is sent to Central purpose whereas rest of wastewater quantity of Effluent Treatment Plant for its 403 KLday shall be trea ted in the proposed ETP reuse Presently proposed ETP

for EA plant is unde r ons truction stage hence wastewater generated from EA plant is partly treated at Nitro ETP facility within GNFC and rest of the wastewater is sent for treatment at ETL Ankleshwar as per the permission gra nted by GPC B on 25042013

5 The company shall provide full fled ged separate Being complied Effluen t Treatment Plant comprising of the Separate effluent treatment plant primary secondary and tertiary faciliti es for is under construction sta~~

Complied Ethyl Acetate Plant is already commissioned in Novembershy2012 Prese ntly fresh water requirement is 950 KLday

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treatment of the e ffluent from the Ethyl Acetate (EA) Plant This ETP shall be operated regularly and efficiently to achieve the GPCB norms at the outlet

The trea ted e ffluent from the EA Plant ETP shall be discharged into Bhukhi Creek through Guard Pond of the Central ETP

The unit shall provide metering facility at the inlet and outlet of the EA Plant ETP and maintain records of the same

A p rop er logbook of the EA Plant ETP ope ration also showing quality and q uantity of untreated and treated efflue nts chemicals and power consumed in treatment etc shall be maintained and shall be furnished to the GPC B from time to time The company shall develop rain water harvesting structures to harvest the runoff water The same wa ter shall be used for the various activities of the projects to conserve fresh water as well as to recha rge ground water Before rech a rging the surface run off pre treatment must be done to remove s uspend ed ma tter A-2 AIR W ter scrubb er syst m shall b provided for control of acidic vapors from the Acetic Acid Storage Ta nk Stack of adequate s tack height as per the preva iling norms shall be provided for the scrubber The scrubber shall be operated effic iently and effectively to achieve the norms p rescribed by the GPeB a t stack outlet

will be completed by Augustshy2013 Presently effluent generated from Ethyl Acetate plant is partly treated at Nitro ETP within GNFC and rest of the wastewater IS sent to ETL Ankleshwar for treatment a~ per the permIssIO n granted by Gujarat Pollution Control Boa rd on 25042013 which is valid up to 30082013 (Jetter attached as Annexure-T) Will be complied Separate effluent treatment plant is under construction stage and will be completed by Augustshy2013 After commissioning of proposed ETP effluent of EA Plant will be discharged into Bhukhi Creek through Guard Pond of the Central ET P Will be complied Metering facility at inlet and outlet of EA plant ETP will be provided by August-2013 Will be complied After ETP becomes operational Pr sen tly a ll details about effluent sent to ETL are submi tted to GPCB in the mon thly compliance report Complied Company has already developed 36 recharge wells for rainwater harvesting

Complied Water scrubber system (K-3601) is provided for control of acidic vapors from the Acetic Acid Storage Ta nk Stack of adequate stack height as per the prevailing no rms is provided for the scrubber The scrubber is operated effici ently and

Gujarat Narmada Valley Fertilizers amp Chemicals Limited

effectively to achieve the norms prescribed by the GPCB at stack outle t

11 Natura l gas (a dditi ona l 12 Nm3hr) shall be used as fu el in f1are stack of the proposed Ethyl Acetate Plant and adequate stack height as per the prevailing norms shall be provided

Complied Natural gas (additional 12 Nm3hr) is used as fuel in f1are stack of Ethyl Acetate Plant and adequate stack (X-3604) height as per the prevailing norms is provided

12 Flare stack of 59 5 meter with burner at top shall be provided for Ethyl Acetate plant

Complied Flare stack (X-3604) of 595 meter with burner at top IS

provided for Ethyl Acetate plant 13 All the vessels used in the manufacturing process

shall be closed to reduce the fugitive emission Complied All the vessels used in the manufacturing process are closed to reduce the fugitive emission

14 All the storage tanks of f1ammabletoxic chemicals shall be under negative pressure to avoid any exposure or leakage breathers nitrogen blanketing and condensers shall be provided to the s torage ta nks

Complied Condensers in vapor line amp Nitrogen blanketing are provided to the storage tanks

15 All the pumps and equip ments where there is a likelihood leakage shall be adequately equipped w ith leak detection and repair (LDAR) system The company shall provide well defined leak de tec tion and repair program fo r quantification and co ntrol o f fugi t ive emis sionleakages

Com plied Material of construction is well des igned with the material hand led and pumps are provided with mecha nical seal to avoid leakages Leakage are monitored by the online analyzers (5 nos) placed at different locations in the plant and corrective action will be taken

16 Fugitive emission in the work zone environment sha ll be monitored The emission shall be confirmed to the standard prescribed by the concerned authoritie s from time to time

Complied Online analyzers (5 nos) are installed at different locations in the plant

17 Ambien t ai r quality monitor ing shall be carried out as per the CPCB guidelines and its record shall be maintained and furnished to the SElAA amp GPCB fro m time to time If the any stage any poll utan t is found to exceed the prescribed limit necessary add itional control measures shall be p rovided immediately

Complied Ambient air quality monitoring is carried out as per the CPCB guidelines and its record is being regularly submitted to GPCB

A-3 HAZARDOUSlSOLlD WASTE 18 Th company mus t s tric tly comply w ith the rules

and regula tions wi th regards to handling and di sposa l of haza rdous was te in accordance with _

Will be Complied

_ _ ____ ____ ___ -i

Gujarat Narmada Valley Fertilizers amp Chemicals Limited

the hazardous waste (managementhandling and trans boundary movement) Rules 2008 as may be amended from time to time Authorization from the GPCB must be obtained for collectiontrea tmentstorage dis posal of hazardous w astes

19 The hazardous waste shall be stored in separated Being complied designated hazardous waste storage facility with Hazardous waste storage shed is pucca bottom and leachate collection facility under construction and will be before its disposal completed by August-20 13

20 The EA plant ETP s ludge shall be disposed at the Being complied TSDF of BElL Ankleshwar ETP sludge generated from EA

plant ETP will be sent to BElL Ankleshwar by August 201 3

21 The reactor r es idue shall be sent to the com mo n Complied hazardous waste incineration facility of BElL GNFC already have started Ankl eshwar for its disposal by incineration disposal of reactor residue by

incineration at BElL - Ankleshwar since 0405 13 as pe r process requirement

22 The records of the haza rdou s waste generated Being Complied and disposed shall be maintained as per haza rdous waste management and handling rul es

23 Used oi l waste oil shall be sold to only to the Being Complied regi tered recyclers Reused in the gasification process

of existing Ammonia plant 24shy Disca rded con tainersdru ms bagsliners sha ll be Being Complied

sold only to the registered r ecyclers after decontami na tion A-4 Safety

25 The project management shall str ictly comply Complied with the provisions made in Manufacture Storage a nd Im port of Hazardous Chemicals Rules 1989 as amended in 2000 for handling of haza rdous che micals Necessary approval s for the Go vt Authorities shall be obtained before commiss ioni ng of the pro ject if applicable

26 All necessary preca utionary measures shall be Complied taken as per the Factories Act Rules to avoid any kind of accident during storage amp handling of tOXichazardous chem icals

27 Necessa ry flameproof fittings shall be provided in Complied the wo rk area Electrical fitting are provided as

per the area classification 28 Proper ventilation shall be provided in the work Complied

a rea 29 All venting eq ui pment shall have vapour recovery Complied

ujarat Narmada Valley Fertilizers amp Chemicals Limited

system All the pumps a nd other equipments As per point no 15 and a lso where the re is a likelihood of leakages shall be provision for immediate iso lation provided with Leak Detections and Repair of such equipment is provided in (LDAR) system Provision for immediate isolation case of a leakage of such equipment in case of a leakage shall also be made The detector sensitivity shall be in ppm levels

30 The project management shall prepare a detailed Complied Disaster Management Plan (DMP) for the project Disaster Management Plan (DM P) as per the guidelines from Directorate of for the project is already included Industrial Sa fety and Health It1 existing onsite and Offsite

emergency plan of GNFC 31 Hazardous materials s torage shall be at an Being Complied

isolated designated locatio n bund dyke walls shall be provided for storage tanks for Hazardous Chemicals

32 Storage and use of haza rdous chem ica ls shall be Noted minimized to the extent possible and all necessary precautions shall be taken to mitigate th e ris k genera ted out of it

33 Storage of hazardous chemicals shall be in Complied multi p le small capacity tanks containers instead Ethyl Acetate three storage tanks of one single large capacity tank for safety of 175 m3 and one storage tank purpose of 3400 m3 capacity are installed

For raw material SDS two storage tanks each of 4207 m3 a re provided All tanks a re provided with all safety p recautions

34 AJI the storage tanks shall be fi tted with Complied I

approp riate controls to avoid any leakages Bunddyke walls shall be provided for storage tanks for hazardous chemicals Close handling sys te m for ch emical s shall be provided

35 Ha ndling a nd charging of the chemicals shall be Noted done in such a man ner that minimal huma n exposure occurs

36 Personal Protective Equipments shall be Noted provided to w orkers and its usage shall be ensured and supervised

37 Fi rst Ai d box and required Antidotes for the First Aid box is made readily chemicals used in the un it shall be made readily available No specific Antidote is available in adequate quantity available Any liquid antacid like

milk of Magnesia is a part of symptomatic treatment for any acidic substance ingestion Same is available in adequate quantity

38 Periodi c tra ini ng sha ll be im parted to all the Noted

G ujarat Narmada Valley Fertilizers amp Chemicals Li mited

workers on safe ty and heal th aspects of chemicals handling

39 Occupational health surveillance of the workers shall be done and its records shall be maintained Pre employment and periodical medical examination for all the workers shall be undertaken as per the Factories Act amp Rules

Being complied

40 Transpor tatio n of hazardous chemicals shall be done as per the provisions of the Motor Vehicle Act amp Rules

Being complied

41 All transporting routes within the factory premise shall have paved roads to minimize splashes and spillages

Complied

A-S NOISE 42 To mini mize the noise pollution the following

noise control measures shall be implemented Selection of any new plant equipment

shall be made with specifica tion of low noise levels

Manufacturerssuppliers of major noise generating machinesequipments like air compressors feeder pumps turbine generators etc shall be instructed to make required design modifications wherever possible before supply and installation to mitigate the noise generation and to comply with the nationalinternational rmiddotegulatory norms with respect to noise generat ion for individual units

Regular maintenance of machinery and vehi les shall be undertaken to reduce the noise impact

No is suppression measures such as enclosures buffers and or protective measures shall be provided

Employees shall be provided with ear protection measures like earplugs or ea rmuffs

Prope r oiling lub rica tion and preventive maintenance shall be carried out of the machineries and equ ipments to reduce nois e generation

Construction equipment generating minimum noise and vibration shall be chose n

Ear plugs andmuffs shall be made compulsory for the construction workers w orki ng near the noise generating acti vit ies machinesLeguipment

Complied

G ujarat Narmada Valley Fe r t ilizers amp Chemicals Limited

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Vehicles and co nstruction equipment with internal combustion engmes without proper silencer shall not be allowed to operate

Construction equipment meeting the norms specified by ETP Act 1986 shall only be used

Noise control equipment and baffling shall be employed on generators especially when they are operated near the residential and sensitive areas

Noise levels shall be reduced by the use of adequate mufflers on all motorized equipment

43 The overall noise level in and around the plant area shall be kept well within the prescribed standards by providing noise control measures including acoustic insulation hoods silencers enclosures vibration dampers etc on all sources of noise generation The ambient noise levels shall confirm to the standards prescribed under the Environment (Protection) Act and Rules Workplace noise levels for workers shall be as per the Factories Act and Rules

Complied

A-6 ENERGY CONSERVATION

44 The proj ect proponent shall install energy effici ent devices and appliances conforming to th e Burea u of Energy Efficiency no rms

Complied

45 The energy audit shall be conducted at regular inte rvals and the recommendations of the audit report shall be implemented

Being complied

46 The project p roponent shall implement the a pplication of solar energy which shall be utilized as solar ligh ti ng for illumination of common areas lighting of internal roads and passages in add ition to uti liza tion of solar water heating systems

Energy savers are install ed in lighting services

47 The tra nsformers and moto rs shall mini mum effi Cie ncy of 85

have Complied Motors of EFF 1 efficiency class as per IS 12615 are used

48 Var iable freq uency d r ives shall be install ed VFDs have been ordered and its delivery are expecting shortly

49 nergy con servati on measures shall include use of electronic lighting system use of CFL tubes to min imize energy use use of p rogrammable t imers fo r pumping system and lighting water level controllers for water centralized

Complied Energy savers are installed in lighting services Instrument controllers with DCS operation

pumps are provided Centralized cooling cooling etc are prOVided

Guja rat Narmada Valley Fertilizers amp ChemicHls Limited

50 Energy saving practices as follows shall be Noted practiced

Constant monitoring of energy consumption and defining targets for energy onservation

Adjusting the setting and illumination Implemented levels to ensure minimum energy used for desired comfort level

Use of solar cells for lighting Energy savers are installed

Use of solar water heater fo r canteen amp washing area

Proper load factor shall be maintained by the unit

Provision of day light roof to utilize maximum natural light in the production plant instead of electr ical li ghting

Use of electronic ballast to save energy

Use of automatic switching system for lighting and water tank pumping system

To the maximum extent possible and technically feasible energy equipment like motors pumps air conditioning systems shall be selected

Capacitor bank installed at MRS to improve load factor Implemented

Implemented Implemented

Refer poi nt no 47 for motors

Gravity f10w shall be preferred wherever Noted possib le to save pumping energy

Promoting awareness on energy conservation Training is imparted to all the

i r in ing to s ta ff on methods of energy employe s conservation and to be vigilant for the sam e

A6 CLEANER PRODUCTION AND WASTE MINIMISATION

51 The company shall undertake the Cleaner Production Assessment study through a reputed insti tuteorganization and shall form a CP team in the company The recomm endations thereof a long w ith the compliance shall be furnished to the GPCB

It will be explored

52 The unit shall al so undertake following waste m inimization m easures a) Mete ring and control of quantities of active

ingredi en ts to minimize waste b) Us of automated and enclosed filling to

minimize s pillage c) Reuse of by-p roducts from the process as raw

materials d) Ve nting equipment through vapour recovery

sys tem

Being complied

e) Use of high pressure hoses for _e_-u_i--pm_e_n_t--shy_ _ __---t~~r~eftIle~~~_4__~-----

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clean ing to reduce wastewater generation f) Use of close feed system into batch reactors A-7 GREENBELT AND OTHER PLANTATION

53 The company shall develop green belt within the premises as per CPCB guidelines

On World Environment Dayshy2013 GNFC has planted 200 nos of trees in nearby area of Ethyl Acetate plant This is ongOing process and more plantation is planned during the year 2013-14

54 The unit shall al s o ta ke up adequate plantation at Note d suitable open land on road sides and other open areas in Bharuch GIDC nearby villages or schools in consultation with GPCB and submit an action plan for the same for next three years to the GPCB GENERAL CONDITIONS

55 In the event of failure of any pollution control system adopted by the unit the unit shall be

Note d

safely closed down and shall until the desired efficiency equipment has been achieved

not of

be restarted the control

56 The project management shall ensure that unit complies with all the environment protection meJs ures risk mitigation measures amp safeguards recommended in the EIA EMP report and as

Noted

57

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propo sed by them

A separate Enviro nment Management Cell equ ip ped with full fledged laboratory facilities shall be set up to carry out the Environment Managemen t and Monito r ing fun ctions The funds ea rmarked for environment protection measures shall be maintained in a separate account and there shall not be any diversion of these fun ds fo r any other purpose A year-wise

Being complied

Noted

expenditure on environmental safeguards shall

59

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be reported The company shall take up necessary socioshyecono mic upliftment activities as Corporate Soci I Responsibility and shall submit list of activi t ies with annual budget allocation to the SEIAA Pucca flooringim pervious layer shall be provided in the work a reas chemical storage area and chem ical ha ndling areas to minimize

Already s u bmitted

Complied

so il contam ination

61 Leakag s fro m the pipes pumps shall be minimal and if occurs shall b e a rrested prom ptly

Noted

62 During ma terial transfer spillages shall be Noted ~ ize~

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avoided and garland drain be constructed to avoid mixing of accidental spillages with domes tic wastewater or storm water

63 The applicant shall also comply with any Noted additional condition that may be imposed by the SEAC or the SEIAA or any other competent authority for the purpose of the environmental protection and management

64 No further expansion of modifications in the Noted plant shall be carried out without prior approval of the MoEF jSEIAAjSEAC for clearance a fresh reference shall be made to the SEIAAjSEAC to assess the adequacy of conditions imposed and to add additional environmental protection measures req uired if any

65 The project authorities shall earmark adequate Noted fund s to implement the conditions stipulated by SEIAA as well as GPCB along with the implementation schedule for all the conditions stipulated herein The funds so provided shall not be diverted for any other purpose

66 The applicant shall inform the public that the Complied project has been accorded environmental clearance by the SEIAA and that the copies of the clearance letter are available with the GPCB and may also be seen at the website of SElAAjS EACjGPCB This shall be advertised withi n seven days fro m the date of the clearance lett r in at least two local newspapers that are widely circulated in the region one of which shall be in the Gujarati language and the other in Engli sh A copy each of the same shall be fo rward ed to the concerned Regional Office of the Mini st ry

67 It shall be mandatory for the project management Being complied to sub mit half-yearly compliance report in respect of the stipulated prior environmental clea rance terms and conditions in hard and soft copies to the regulatory authority concerned on 1st June and 1st December of ea ch calendar year

68 The pro ject authorities shall also adhere to the Noted stip ulations made by the Gujarat Pollution

69

Control Board

The project autho ri ties shall inform the GPCB Regio nal Office of MoEF and SEIAA a bout the date of financial closure and final approval of the proj ect by the concerned authorities and the date of start of the projec t

Complie d

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G ujarat Narmada Valley Fertilizers amp hemica is Lim ited

70 The SEIAA may revoke or suspend the cleara nce if implementation of any of the above conditions is not found satis factory

Noted

71 The above cond itions sha ll be enforced inter-alia under the provision of the Water (Prevention amp Control of Pollution) Act 1974 Air (Prevention amp Control of Pollution) Act 1981 the Environment (Protection) Act 1986 Hazardous wastes (Management Handling and Transboundary Movement) Rules 2008 and the Public Liability Insurance Act 1991 along with their amendments and rules

Noted

72 Th is Environmental Clearance is valid for five years from the date of issue

Noted

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