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Environment
environment
With an objective of maintaining the right balance for sustainable development, PPL has taken appropriate measures towards building a safe environment within and outside the plant.
environment
The ISO 14001 certification awarded to PPL in August 2002 for its environmental policy and systems and the upgraded certificate of ISO 9001: 2000 in April 2004 reflect the company’s concern for the environment.

PPL took a major step towards treating effluents and maintaining an eco-friendly environment with the construction of the Effluent Treatment Plant (ETP), one of the largest of its kind in India, which was commissioned in June, 2002. It is the largest of its kind amongst all the fertiliser plants in the country. ETP has the potential to treat and meet any sort of effluents, even in worst case scenarios.

In order to achieve its avowed goals the company has adopted an environmental policy as given below.

Compliance of Conditions in Environmental Clearance dtd Oct,05-2010
FOR ENHANCED CAPACITY
Specific Conditions :
 Sl No  Conditions  Compliance status
1 The company shall comply with all the conditions stipulated in the environmental clearance issued vide letter no. J -11011/17/86-IA-II dated 23rd July ,1990 Complied
2 On line SO2, NOx and NH3 analyzer shall be installed to monitor ambient air .The National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. Nom 826(E) dated 16th November, 2009 shall be followed. Near ETP area, we have installed continuous AAQ monitoring instruments for the parameters of SO2, NOx & NH3. Near Time Office, the equipment installed for the monitoring of PM2.5, SO2, and NOx & NH3. The results obtained are within the limit. Now we are in the process of real time data transfer to OSPCB, MoEF & CPCB server from online continuous AAQ analyzer. M/s Sunjray Info system Pvt ltd, Bhubaneswar, has been appointed as consultant for the said purpose.
3 The gaseous emissions (PM2.5, PM10, SO2, NOx, HCl, and NH3 and urea dust) from various units shall conform to the prescribed standards. At no time, the emission levels shall go beyond the stipulated standards. In the event of failure of pollution control system (s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency. We are having online gaseous monitoring provision for SO2 at SAP and online particulate matter emission monitoring provision at DAP plant.
Regarding on line NH3 monitoring we are interacting with various suppliers , once it is finalized the results will be communicated / furnished on regular basis.
As far as HCl and urea dust are concerned these two parameters are not applicable in our case.
Analysis results for SO2 and PM are given in Annexure-1.
4 As proposed, wet scrubbing system to DAP and Alkali scrubbing system to PAP plant shall be provided to control fluoride and emissions. Cyclones, Venturi scrubbers and mist eliminators along with stack of adequate height shall be provided to DAP plant to control particulate emissions. Alkali scrubber shall be provided to Sap unit to control SO2 and SO3 .V2O5 catalyst and candle filters shall be provided to SAP unit to improve efficiency and reduce emissions. PM2.5,PM10, SO2,NOx, HCl,NH3 and fertilizer dust emissions shall be monitored. Wet scrubbing system at DAP plant is already installed.

Scrubbing system is already provided at PAP for control of fluoride & particulate emission. Alkali scrubber is provided to SAP unit to control SO2 & SO3 .V2O5 catalyst & candle filters are already provided to SAP unit .
Height of SAP stack is 120 meters above ground level.
Height of PAP stack is 50 meters above ground level.
Height of DAP stack is 50 meters above ground level.
The heights of those stacks are adequate for better dispersion in the ambient.
5 Double Contact Double Absorption (DCDA) process shall be adopted in Sulfuric Acid Plant (SAP) . Continuous SO2 monitoring system shall be provided in the stack of SAP unit. Fluorine Recovery Unit (FRU) shall be installed for recovering Fluoro- silicic acid and fluoride levels shall be monitored in ambient air. The SAP is based on DCDA process. Continuous SO2 monitoring system is already provided in the stack of SAP.
FRU will be commissioned in December-2011. In AAQ station HF analyzer will be installed by 31st of December -2011
6 Fugitive emissions from different sources shall be controlled, regularly monitored and reports submitted to the Regional Office at Bhubaneswar. To control fugitive emissions, regular monitoring of sub floor environment shall be carried .Leakages in form of gases, liquid and dust emission shall be checked and mitigative measures taken. The company shall provide de-dusting system at all the transfer points in the bagging system. De dusting arrangements are made at raw material unloading & transfer points , sulfur and rock silo but because of the hygroscopic nature of the product de-dusting system is not suitable at bagging plant.
Regular monitoring of fugitive emissions will be started from September-2011and the report will be submitted to the regional office at Bhubaneswar regularly from December-2011.
7 The company shall upload the status of compliance of the stipulated environmental clearance conditions including results of monitored data on its web site and shall update the same periodically. It shall simultaneously be sent to the Regional office of MoEF, the respective zonal office of CPCB and the Orissa Pollution Control Board. The levels of RSPM (PM10, PM2.5), NH3 and NOx (ambient levels) and emissions from the stacks shall be monitored and displayed at a convenient location near the main gate of the company and at important public places. We are updating the data in the PPL web site on monthly basis. Six monthly compliance report will also be uploaded from the next report. Until now we are sending monthly reports to SPCB and half yearly report to MoEF, now we will be sending half yearly compliance report to CPCB also from December -2011 onwards.
8 Specific energy consumption shall not exceed 5.127G.cal/MT of Urea production. Optimization of cycle of concentration (COC) to 6 and blow down frequency from the cooling towers shall be reduced.. It is not applicable to us as we are not producing urea in our plant.
9 Steam stripping system shall be installed in the ammonia plant to recover ammonia as well as bottom water from condensate. Not Applicable.
10 Total water requirement from Taladanda Canal shall no exceed 15,000 m3 /day and prior permission shall be obtained for drawl of water fro the competent authority. A copy of permission shall be submitted to the Ministry’s Regional Office at Bhubaneswar within 3 months of issue of environment clearance letter. Permission for drawl of 15,000 m3/day of water from Taladanda Canal was obtained from Water Resources Department, Govt. of Odisha on dt.13.12.2007.Presently applied for renewal agreement and it is awaited.
11 All the pond water shall be completely recycled and reused. Zero discharge shall be adopted and no waste water shall be discharged outside the premises. Pond water is being completely recycled in PAP .Maximum water is being reused in the plant and for gardening purpose .No waste water is discharged outside except power plant regeneration water. for which consent from State Pollution Control Board was previously obtained vide the consent order No. 22515/ IND-I/779 dtd.26.09.2007. However we shall try to control discharge of power plant regeneration water to outside.
12 The specific water consumption and waste water generation shall not exceed 5.1m3/MT of urea and 0.9 m3/MT of urea respectively. Accordingly the company shall undertake measures for water conservation. Not Applicable as we are not manufacturing urea.
13 The waste water from Phosphoric acid Plant (gypsum slurry) shall be sent to gypsum pond. the overflow from PAP,DAP plant ,Offsite and entire effluent from SAP shall be treated in effluent treatment plant (ETP).The waste water from Captive Power Plant (CPP) shall be treated in neutralization tank. Waste water from the existing Gypsum pond shall be pumped to ETP for further treatment. Treated from ETP shall be reused in Ball Mill of PAP .The Sewage and all other effluents shall treated in the Sewage treatment plant (STP) and used for green belt development after meeting the norms specified by CPCB and OSPCB.
  1. All gypsum slurry is taken to Gypsum Pond and is completely recycled in the PAP with a provision of treatment of excess overflow through ETP.
  2. Overflow of PAP are also taken to Gypsum Pond.
  3. Overflow of DAP plant is recycled within the DAP plant as make up water in the process.
  4. Offsite and SAP area effluent / surface runoff water are taken to common Effluent Treatment Plant.
  5. Neutralization pond is provided for treatment of regeneration water / waste water in CPP.
  6. Utilization of ETP discharge in the Ball Mill is under process.
  7. STP discharge is presently into the surrounding land meeting the prescribed standards of OSPCB/ CPCB guidelines.
14 Ground water shall be monitored in around the project site through peizometric wells as per CPCB guidelines. Presently we have 24 nos of test wells which are used for peizometric reading of ground water table in our premises.
15 Another gypsum pond with protective liner shall be constructed as per recommendations of NEERI as per CPCB guidelines. New gypsum pond is being designed and finalized as per the guideline of CPCB/EC conditions. Application for Consent To Establish is under process with OSPCB. Construction will start after obtaining the said Consent To Establish.
16 Phospho gypsum shall be sold to cement manufacturers or a granulation plant shall be installed as proposed to utilize Phospho gypsum. The sale figure of Gypsum for last three years is as follows.
2008-09 727655
2009-10 369009
2010-11 500056
Moreover PPL is in the process of installing a Zypmite plant for utilization of gypsum which is in advanced stage of design engineering and expected to be completed within 12-18 months.
17 Spent Catalyst (V2O5) shall be properly stored as per the CPCB guide lines and disposed off to TSDF. Sulfur muck and ETP sludge shall be reused in-house as filler in DAP plant. Spent resin from DM plant shall be sold to authorized agency. Used or spent oil shall be disposed off to authorized reprocessor. Spent catalyst are being stored inside a building with proper flooring and roof . Recently we have obtained the authorization for disposal of Hazardous Waste from SPCB , Odisha .The authorized agency has already been identified and other formalities are under process for disposal of spent catalyst to the said vendor.
Used oil is being disposed off to the authorized reprocessor through our Store department.
Regarding spent resin, we are in the process of interacting various parties concerned for its disposal.
18 As proposed green belt shall be developed in 854 acres (37%) out of 2282.4 acres. 854 Acres of land is already covered / developed under plantation. It is being maintained.
19 Action plan prepared for the complete remediation of the site shall be implemented in consultation with NEERI within 5 years of the issue of this environment clearance and six monthly report submitted to the Ministry and its Regional Office at Bhubaneswar. We have appointed NEERI to prepare an action plan for complete remediation of the site. Copy of agreement with NEERI is attached as Annexure-2 .
We shall be submitting six monthly report to the MoEF along with Half yearly compliance report from 1st December -2011.
20 All recommendation mentioned in the risk assessment report shall be implemented in a time bound manner and an action plan shall be prepared and submitted to the Ministry and its Regional Office at Bhubaneswar. Preparation of action plan is under process and will be submitted by 1st week of September -2011
21 Risk analysis shall be done again after one year and report submitted to the Ministry and its Regional Office at Bhubaneswar. Efforts shall also be made to reduce risk mentioned in the risk assessment report. Yes, we shall be carrying out the study after one year and effort shall also be made to reduce the risk after getting risk assessment report.
22 The ammonia unloading arms in the jetty shall be provide with “ Quick release couplings” for automatic disconnection of ships from unloading arm during unloading in case of bad weather. Already provided in the Jetty area.
23 Total quantity of ammonia storage in the plant shall not exceed 40,000Tons at a time. Accepted
24 The company shall undertake adequate protection measures for handling of ammonia vapor in case of plant upset condition. Safety valve exhaust and drains shall be connected to flare and vent stack. During transfer of materials spillage shall be avoided and garland drains shall be constructed to avoid mixing of accidental spillage with domestic waste and storm drains. Ammonia flare system is in process.
25 The company shall make the arrangement for protection of possible fire hazards as per OISD 117 during manufacturing process in material handling. Please refer Annexure-3 as attached.
26 Occupational health surveillance of the workers shall be carried out on a regular basis and records shall be maintained as per the Factories Act. Please refer Annexure-4 as attached
27 All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for fertilizer industries shall be implemented. We are implementing all recommendations as per CREP guidelines applicable to our plant.
28 Provision shall be made for the housing of construction labor within the site with all necessary infrastructure and facilities such as fuel for cooking , mobile toilets, mobile STP ,Safe drinking water , medical health care ,crèche etc. The housing may be in the form of temporary structures to be removed after the completion of the project. Providing required facilities through respective contractors
B. GENERAL CONDITIONS:
 Sl No  Conditions  Compliance status
1 The project authority shall strictly adhere to the stipulations of the Orissa Pollution Control Board (OPCB) / State Government or any statutory body. We are strictly adhering all stipulation of statutory bodies relevant to our plant.
2 No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. In case of deviations or alteration in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any. We shall not go for any expansion without prior approval of the Ministry.
3 The gaseous emissions (SO2, HCl, NOx, NH3, fertilizer dust) and particulate matter from various process units shall conform to the standards prescribed by the concerned authorities from time to time, Emission data shall be periodically monitored and reports submitted to Ministry’s Regional office at Bhubaneswar, CPCB and OPCB. We are regularly submitting the reports to the SPCB, Odisha and from 1st December, 2011 we shall be submitting the reports to the regional office of MoEF, Bhubaneswar.
4 All the waste waters generated from the various processes shall be recycled/reused in the plant and zero discharge shall be maintained. The domestic waste water shall be treated in septic tanks and treated waste shall be used for irrigation in the green belt All the waste water are treated / recycled / reused as mentioned above under various column of the special conditions.
5 At no time the emissions shall exceed the prescribed limits. In the event of failure of any pollution control system adopted by the unit, the unit shall be immediately put out of operation and shall not be restarted until the desired efficiency has been achieved. We take maximum care not to exceed the emission limit as prescribed. However in case it goes beyond the limit we shall definitely close the process and intimate the authority.
6 The locations of ambient air quality monitoring stations shall be reviewed in consultation with the OPCB and additional stations shall be installed, if required, in the down wind direction as well as where maximum ground level concentrations are anticipated. We have already reviewed those existing locations in consultation with the SPCB officials and continuing the monitoring at those points.
7 Dedicated scrubbers and stacks of appropriate height as per the Central Pollution Control Board guidelines shall be provided to control the emissions from various vents. The scrubbed water shall be sent to ETP for further treatment. Scrubber and adequately high stacks are provided as per CPCB guidelines for control of emissions. All scrubbed water is taken to either ETP or being reused in the process.
8 All the storage tanks will be under negative pressure to avoid any leakage. Breather valves, N2 Blanketing and secondary condensers with brine chilling system shall be provided for all the storage tanks to minimize vapor losses. All liquid raw materials shall be stored in Storage Tanks and drums. Tanks are operated and maintained as per design conditions and parameters as provided by the manufacturer.
9 The company shall undertake following Waste Minimization measures :
  • Metering and control of quantities of active ingredients to minimize waste.
  • Reuse of by products from the process as raw materials or as raw material substitute in other processes.
  • Use of automated filling to minimize spillage.
  • Use of closed feed system into batch reactors.
  • Venting equipment through vapor recovery system
  • Use of high pressure hoses for equipment cleaning to reduce waste water generation.
 All the solid wastes generated from the process are being taken in the DAP as a filler except spent catalyst, gypsum and spent resin. All these materials are quantified.
Waste Material taken as filler are ;
  1. Sulphur Muck
  2. Storm water drain sludge
  3. ETP sludge
Other conditions are also in place to minimize the waste.
10 Fugitive emissions in work zone environment, product and raw material storage area shall be regularly monitored. The emissions shall conform to the limits imposed by the State Pollution Control Boards/ Central Pollution Control Board. Work Zone monitoring will be started from December-2011.
11 The project authorities shall strictly comply with the rules and guidelines under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008 as amended time to time. We are abiding by all the rules as mentioned under Manufacture. Storage and Import of Hazardous Chemicals Rules, 1989 and Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008 as amended time to time.
12 The overall noise levels in and around the plant area shall be kept well within the standards by noise control measures including acoustic hoods , silencers, enclosures etc on all sources of noise generation. The ambient noise level shall conform to the standards prescribed under Environment (Protection) Act , 1986 Rules,1989 viz. 75dBA(day time) and 70 dBA( night time). Ambient noise levels are being measured in 8 locations. Stationary noise levels are being monitored at different locations of the plant.
13 The company shall develop rain water harvesting structures to harvest the run off water for recharge of ground water. The average ground water table in the project area is 2 to 3 meters below ground level. During rainy seasons almost all open area are submerged. To protect the area from water contamination due to PPL during rainy season, the following steps are under taken.
  1. All contaminated areas in the plant premises are segregated.
  2. Precipitated water over contaminated areas is diverted to ETP through effluent drain for treatment.
  3. Other non contaminated area water is discharged to river through storm water drain.
  4. Storm water drain water is tested for pH, fluoride and phosphate during rainy season before being discharged to the river.
  5. Storm water drain is regularly cleaned before rainy season for free flow of storm water.
The harvesting or recharging of the rain water may not be a feasible scheme in this project area because of high level of water table. However there are number of open ponds inside PPL Township that naturally receive surface runoff of the township area during rainy season and recharge the ground water.
14 The company shall undertake eco developmental measures including community welfare measures in the project area for the overall improvement of the environment. The eco development plan should be submitted to the SPCB within three months of receipt of this letter for approval. We are preparing Eco Development Plan and will be completed by September-2011. The same will be submitted at SPCB in October,2011
15 A separate Environment management cell equipped with full fledged laboratory facilities shall be set up to carry out the Environmental Management and monitoring functions. Environment management cell is already in place. It carries out all relevant Environmental Management and monitoring functions.
16 As proposed, Rs 25.02 Crores and Rs 1.24 Crores shall be ear marked towards capital cost and recurring cost / annum for pollution control measures to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State government along with the implementation schedule for all the conditions therein. The funds so provided shall not be diverted for any other purpose. No funds will be diverted. We shall be submitting the expenditure report by 1st December-2011
17 The implementation of the project vis-à-vis environmental action plans shall be monitored by the concerned Regional Office of the Ministry / OPCB/CPCB. A six monthly compliance status report shall be submitted to monitoring agencies and shall be posted on the website of the company. We shall follow the instruction.
18 A copy of the clearance letter shall be sent by the proponent to the Panchayat, Zila Parishad/ Municipal Corporation, Urban local Body and the local NGO, if any from whom suggestions / representations, if any were received while processing the proposal. Reports are already sent to the concerned agencies. Please refer Annexure-5
19 The project proponent shall also submit six monthly reports on the status of compliance of the stipulated EC conditions including results of monitored data (both in hard copies as well as by e mail) to the respective Regional Office of MoEF, the respective zonal office of CPCB and the Orissa Pollution Control Board. We shall follow the instruction.
20 The environmental Statement for each financial year ending 31st March in Form-V as is mandated shall be submitted to the concerned State Pollution Control Board as prescribed under the Environment (Protection) Rules, 1986 as amended subsequently shall also be put on the website of the company along with the status of compliance of environmental clearance conditions and shall also be sent to the respective Regional offices of MoEF by e-mail. Environmental Statement will be posted in PPL website from September 2011 after submitting the same at SPCB, Odisha
21 The project proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the OPCB/Committee and may also be seen at Website of the Ministry at http:/env for. nic. in. This shall be advertised within seven days from the date of issue of the clearance letter at least in two local news papers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the concerned Regional office of the Ministry. Published in odia News paper (Samaj) and English daily (New Indian Express) dtd. 09.10.10.
Please refer Annexure-6.
22 The project authority shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of start of the project. Please refer Annexure-7
 
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