Environmental Statement Report for the financial year ending on 31st March 2023.
(i) | Name and address of the owner/ occupier of the Industry, operation or process | S. GIRISH CHIEF MANUFACTURING OFFICER MANGALORE CHEMICALS & FERTILIZERS LTD., PANAMBUR, MANGALURU - 575 010. |
|
(ii) | Industry Category Primary (STC Code) Secondary (SIC Code) |
Primary | |
(iii) | Production Capacity | Product | Consented capacity |
Urea | 4,71,000 MT/Annum | ||
Ammonium Bicarbonate |
24,750 MT/Annum | ||
Diammonium Phosphate (Multigrade) |
4,01,500 MT/Annum | ||
Sulphuric Acid | 1,46,000 MT/Annum | ||
Sulphonated Napthalene Formaldehyde | 85,000 MT/Annum | ||
Speciality Mixtures of Plant Nutrients | 2,21,000 MT/Annum | ||
(iv) | Year of establishment | Urea | 1976 |
Ammonium Bicarbonate |
1982 | ||
Diammonium Phosphate/NP (Multigrade) |
1987 | ||
Sulphuric Acid | 2006 | ||
Sulphonated Napthalene Formaldehyde | 2010 | ||
Speciality Mixtures of Plant Nutrients | 2011 | ||
(v) | Date of the last environmental statement submitted | 16.08.2022 |
Water and Raw Material Consumption:
Water consumption M3/day | |||||
---|---|---|---|---|---|
Process/Cooling | 6910 | ||||
Domestic | 291 | ||||
Name of Products | Process water consumption per unit of product output | ||||
During the previous financial year (M3/T) | During the current financial year (M3/T) | ||||
1 | Urea | 6.04 | 6.99 | ||
2 | Diammonium Phosphate
Multigrade
NP 18:46 NP 20:20 | 0.222 0.222 |
0.212 0.212 |
||
3 | Ammonium Bicarbonate | Nil | Nil |
(ii) Raw Material consumption:
Sl. No. | Name of Raw Material | Name of product | Consumption of Raw Materials per unit of output | |
---|---|---|---|---|
During the previous financial year | During the current financial year | |||
1a | Natural gas Feed | Urea | 524.631 SCM/MT | 489.1 SCM/MT |
1b | Naphtha | Urea | - | - |
2a | Furnace oil Steam Generation | |||
2b | Natural gas Steam Generation | 32.32 SCM/MT | 57.7 SCM/MT | |
3 | Imported Ammonia | Urea | 0.00098 MT/MT | |
4 | Ammonia | Diammonium Phosphate Multigrade |
||
NP 18:46 | 0.219 MT/MT | 0.219 MT/MT | ||
NP 20:20 | 0.209 MT/MT | 0.212 MT/MT | ||
5 | Phosphoric Acid as P2O5 | Diammonium Phosphate Multigrade |
||
NP 18:46 | 0.470 MT/MT | 0.470 MT/MT | ||
NP 20:20 | 0.208 MT/MT | 0.208 MT/MT | ||
6 | MAP | Diammonium Phosphate Multigrade |
||
NP 18:46 | ||||
NP 20:20 | ||||
7 | Ammonium Sulphate | Diammonium Phosphate Multigrade |
||
NP 18:46 | ||||
NP 20:20 | 0.075 MT/MT | 0.073 MT/MT | ||
8 | Sulphur | Sulphuric Acid | 0.332 MT/MT | 0.332 MT/MT |
9a | Furnace oil | Power
(For Captive |
||
10b | Natural Gas | Power
(For Captive |
0.261 SCM/kW |
0.253 SCM/kW |
11 | Naphthalene |
Sulphonated Napthalene Formaldehyde |
0.175 MT/MT | 0.175 MT/MT |
12 | Formaldehyde | 0.125 MT/MT | 0.125 MT/MT | |
13 | Caustic Soda | 0.077 MT/MT | 0.076 MT/MT | |
14 | Sulphuric Acid | 0.131 MT/MT | 0.132 MT/MT | |
Pollution discharged to Environment/unit of output
(Parameters as specified in the consent issued)
Pollutants | Quantity of pollutants discharged (mass/day) Kg/Day | Concentration of pollutants in discharges (mass/volume) mg/l | Percentage of variation from prescribed standards with reasons. | |
---|---|---|---|---|
A. WATER | ||||
1 | Ammoniacal Nitrogen as N | No Effluent Discharge. Effluent is treated and reused. | ||
2 | Total Kjeldahl Nitrogen as N | |||
3 | Free Ammonia as NH3 | |||
4 | Urea as NH2CONH2 | |||
5 | Total suspended solids | |||
6 | BOD for 3 days at 27oC | |||
7 | COD | |||
8 | pH | |||
9 | Temperature oC | |||
10 | Colour and odour | |||
11 | Oils and grease | |||
12 | Total Residual chlorine as Cl | |||
13 | Hexavalent Chromium as Cr+6 | |||
14 | Total Chromium as Cr | |||
15 | Copper as Cu | |||
16 | Zinc as Zn | |||
17 | Nickel as Ni | |||
18 | Sulphides as S | |||
19 | Vanadium as V | |||
20 | Iron as Fe | |||
21 | Nitrate Nitrogen as N |
Pollutants | Quantity of pollutants discharged (mass/day) | Concentration of pollutants in discharges (mass/volume) | Percentage of variation from prescribed standards with reasons. | |
---|---|---|---|---|
B. AIR | ||||
I. | Sulphur Dioxide | Kg/day | mg/NM3 | |
1. | Primary Reformer Stack (Feed changeover from Naphtha to Natural gas from December 2020) |
Negligible | <5 | Stack height is as stipulated by KSPCB |
2. | Boiler Stack (Fuel changeover from Furnace oil to Natural gas from December 2020) | Negligible | <5 | -do- |
3. | Process Air Heater (Fuel changeover from Naphtha to Natural gas from December 2020) | Negligible | <5 | -do- |
4. | Process NG heater (Online from December 2020) | Negligible | <5 | -do- |
5. | Captive Power Plant (Fuel changeover from Furnace oil to Natural gas from December 2020) | Negligible | <5 | -do- |
6 | Sulphuric Acid Plant stack | 110 | 413-773 | -do- |
II. | Particulate Matter | |||
1. | Primary Reformer Stack | 35 | 10 - 12 | Well below the prescribed standard |
2. | Boiler Stack | 8.6 | 10 - 12 | -do- |
3. | Process Air Heater | Negligible | Negligible | -do- |
4. | Process NG Heater | Negligible | Negligible | -do- |
5. | Urea Prill Tower | 802 | 65 - 80 | -do- |
6. | DAP Stack | 349 | 78 - 89 | -do- |
III. | Fluorine | |||
1. | DAP Stack | 4.4 | 0.6- 1.3 | -do- |
IV | Acid Mist | |||
1 | Sulphuric Acid Plant stack | 4.3 | 22 - 26 | -do- |
HAZARDOUS WASTES
(As specified under Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016)
Hazardous Wastes | Total quantity (Te) | ||
---|---|---|---|
During the previous financial year (2021-22) | During the current financial year (2022-23) | ||
(a) | From Process:
1) Used oil (Waste process No.5.1) |
18.602 MT (Generated) 18.602 MT (Sold) |
14.162 MT(Generated) 14.162 MT (Sold) |
2) Waste oil (Waste process No.5.2) | 111.88 MT (Generated) 111.88 MT (Sold) |
91.126 MT (Generated) 91.126 MT (Sold) |
|
3) Spent Catalyst (Waste process No.18.1) | 23.0 MT (Generated) 23.0 MT (Sold) |
Nil(Generated) Nil(Sold) |
|
4) Discarded containers / barrels (Waste process No.33.3) | 1457 No.s (Generated + previous year balance) 1457 No.s (Sold) |
499 No.s (Generated) 499 No.s (Sold) |
|
5) Spent carbon (Waste process No.18.2) | Nil (Generated) Nil (Sold) |
Nil (Generated) Nil (Sold) |
|
6) Spent Vanadium Catalyst (Waste process No.17.2) | Nil (Generated) Nil (Sold) |
Nil (Generated) Nil (Sold) |
|
7) Metal & Metal bearing wastes. (Waste process No.B1) | 357.87 MT (Generated) 357.87 MT (Sold) |
495.84 MT (Generated) 495.84 MT (Sold) |
|
(b) | From Pollution Control Facilities: | Nil | Nil |
SOLID WASTES
Solid Waste | Total Quantity | ||
---|---|---|---|
During the previous financial year | During the current financial year | ||
a) From Process | No solid waste is generated from Process and Pollution Control facilities | ||
b) Pollution Control Facility | |||
c) Quantity Recycled or reutilised within the unit |
Please specify the characteristics (in terms of concentration and quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes.
Spent Catalyst
Catalysts are used in different sections of Ammonia plant. Its life is usually 2-10 years and is different for each catalyst. When the catalysts lose their activity, they are discharged during shut downs. After discharging spent catalysts are filled in drums and stored in a shed in secured manner protected from sun and rain.
Spent catalysts are sold to outside agencies for reprocessing and recovery of metals. The agency should possess certification of registration from Central Pollution Control Board/ Karnataka State Pollution Control Board. If reprocessors are not available it will be disposed as per the directives of KSPCB
Spent Carbon
Spent Activated Carbon is generated from the Demineralisation Plant. After discharging, spent activated carbon are filled in drums and stored in a shed and disposed as per the directives of KSPCB.
Used oil
Used oil/oil emulsions originating from compressors, pumps and other machinery are collected in oil pits and sent to oil separator. From the oil separator oil is skimmed by mechanical oil skimmers and collected in drums. Similarly used oil is generated in the DG sets at Captive Power Plant. This is also collected in drums. After filling in the barrels they are temporarily stored in a yard provided with pavement, curb walls and water oil separator.
This Used oil is then sold to outside agencies having adequate facility for refining and disposal of hazardous waste. The agency should possess certification of registration from Central Pollution Control Board/ Karnataka State Pollution Control Board.
Discarded containers / barrels used for hazardous wastes & chemicals
Stored in a shed and sold to KSPCB Authorised Handlers.
Sulphur Cake
Sulphur Cake collected from filter in Sulphuric acid plant is used in the DAP plant as filler material.
Metal & Metal bearing wastes
Stored in a shed and sold to KSPCB Authorised Handlers.
Impact of the pollution abatement measures on conservation of natural resources and on the cost of production.
Additional measures/investment proposal for environmental protection including abatement of pollution, prevention of pollution.
Additional investment proposed in the Budget 2023-2024 is Rs. 100 lakhs
Any other particulars for improving the quality of the environment.