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Health, Safety & Environment

FORM - V

Environmental Statement Report for the financial year ending on 31st March 2021

Part - A

(i) Name and address of the owner/ occupier of the Industry, operation or process K. PRABHAKAR RAO,
DIRECTOR-WORKS,
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 4,29,000 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   07.09.2020

Part - B

Water and Raw Material Consumption:

Water consumption M3/day
Process/Cooling 7901
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 5.49   5.96
2 Diammonium Phosphate  Multigrade

  NP 18:46

  NP 20:20

 

0.210

0.210

 

0.220

0.220

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 Nil 483.977 SCM/MT
1b   Naphtha   Urea 0.388 MT/MT 0.389 MT/MT
2a   Furnace oil Steam Generation   0.044 MT/MT 0.0435 MT/MT
2b   Natural gas Steam Generation   Nil 29.95 SCM/MT
3   Imported Ammonia   Urea 0.039 MT/MT 0.034 MT/MT
4 Ammonia   Diammonium
  Phosphate
  Multigrade
 
      NP 18:46 0.214 MT/MT 0.215 MT/MT
      NP 20:20 0.227 MT/MT 0.228 MT/MT
5   Phosphoric Acid as P2O5   Diammonium
  Phosphate
  Multigrade
 
      NP 18:46 0.442 MT/MT 0.451 MT/MT
      NP 20:20 0.182 MT/MT 0.194 MT/MT
6   MAP   Diammonium
  Phosphate
  Multigrade
 
      NP 18:46 0.050 MT/MT 0.036 MT/MT
      NP 20:20 0.050 MT/MT 0.029 MT/MT
7   Sulphur   Sulphuric Acid 0.332 MT/MT 0.332 MT/MT
8a   Furnace oil   Power

  (For Captive
  consumption)

 

221.97 g/kWh

222.59 g/kWh
8b   Natural Gas   Power

  (For Captive
  consumption)

 

Nil

0.248 SCM/kWh
9 Naphthalene Sulphonated   0.207 MT/MT 0.173 MT/MT
10 Formaldehyde Napthalene 0.148 MT/MT 0.123 MT/MT
11 Caustic Soda Formaldehyde 0.084 MT/MT 0.071 MT/MT
12 Sulphuric Acid   0.156 MT/MT 0.131 MT/MT
         

Part - C

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)
15.4 <5 -12 Stack height is as stipulated by KSPCB
2. Boiler Stack (Fuel changeover from Furnace oil to Natural gas from December 2020) 203 <5 - 382 -do-
3. Raw Naphtha Heater (Not online from December 2020) 0.5 8 - 10 -do-
4. Process Air Heater (Fuel changeover from Naphtha to Natural gas from December 2020) 1.2 <5 - 9 -do-
5. Naphtha Vaporiser (Not online from December 2020) 0.8 7 - 9 -do-
6a. Process NG heater(Online from December 2020) Negligible <5 -do-
6b. Captive Power Plant (Fuel changeover from Furnace oil to Natural gas from December 2020) 1809 <5 - 526 -do-
7 Sulphuric Acid Plant stack 84.5 450-596 -do-
II. Particulate Matter
1. Primary Reformer Stack 58.3 10 - 29 Well below the prescribed standard
2. Boiler Stack 20.0 14 - 29 -do-
3. Raw Naphtha Heater Negligible Negligible -do-
4. Process Air Heater Negligible Negligible -do-
5. Naphtha Vaporiser Negligible Negligible -do-
6. Urea Prill Tower 803 60 - 85 -do-
7. DAP Stack 341 60 - 88 -do-
III. Fluorine
1. DAP Stack 8.0 1.1 - 2.0 -do-
IV Acid Mist
1 Sulphuric Acid Plant stack 4.4 24 - 28 -do-

Part - D

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 (2019-20) During the current financial year (2020-21)
(a) From Process:
1) Used oil (Waste process No.5.1)
30.0 MT(Generated)
30.0 MT (Sold)
37.25 MT(Generated)
37.25 MT (Sold)
  2) Waste oil (Waste process No.5.2) 432.55 MT (Generated)
432.55 MT (Sold)
300.77 MT (Generated)
300.77 MT (Sold)
  3) Spent Catalyst (Waste process No.18.1) Nil (Generated)
Nil (Sold)
23.19 (Generated)
23.19 (Sold)
  4) Discarded containers / barrels (Waste process No.33.3) 887 No. (Generated)
887 No. (Sold)
210 No. (Generated)
145 No. (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)
(b) From Pollution Control Facilities: Nil Nil

Part - E

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

Part - F

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.

Part - G

Impact of the pollution abatement measures on conservation of natural resources and on the cost of production.
The Ecological studies carried out at Arabian Sea Water near Thaneerbhavi indicate that the ecological condition at sea both chemically and biologically is undisturbed.

Urea Hydrolyser stripper which has been specifically installed for pollution control has the following beneficial effects

  • Recovery of Ammonia and Urea from the effluent streams leads to saving to the tune of Rs.115 per MT of Urea.
  • Utilisation of urea hydrolyser stripper outlet water for cooling tower make up leads to saving of water costing about Rs.56 per MT of Urea.

Part - H

Additional measures/investment proposal for environmental protection including abatement of pollution, prevention of pollution.

Additional investment proposed in the Budget 2021-2022 is Rs. 133 lakhs

Part - I

Any other particulars for improving the quality of the environment.

  • Introduction of Natural Gas as feed and fuel in Captive power plant and Ammonia plant has reduced SOx emission below detection limit of 5mg/NM3
  • As a part of commitment for preservation of environment and ecology, MCF has installed wastewater treatment and recovery plants with latest technologies consists of Lamella clarifier, Ultra-filtration and Reverse Osmosis (RO) during 2010 by investing about Rs.700 lakhs for treating the wastewater generated from the process plants. MCF has also upgraded the sewage treatment plant by adapting latest Membrane Bio Reactor (MBR) technology. From this wastewater recovery plants, there is a recovery of about 1000 kilolitres of water which is about 10 % of our daily consumption. After the implementation of these wastewater treatment plants MCF has achieved the target of zero wastewater discharge and there is no wastewater discharge from MCF.
    1. Back wash water of sand filter and activated carbon filter from water treatment plant and cooling tower side stream filter containing high suspended solids is treated by using Lamella Clarifier technology. The treated water free from suspended solids is reused in cooling tower as makeup water.
    2. Water treatment plant resin regeneration and cooling tower blow down effluent streams containing high dissolved solids are treated by Reverse Osmosis technology. This effluent is passed through clarifier, pressure filters and Ultra Filtration (UF) units to remove suspended solids and colloidal particles and then it is treated in Reverse Osmosis (RO) units to remove dissolved solids. Treated wastewater is reused in the process.
    3. Treatment of Sewage effluent: Till end of March 2010 the extended activated sludge system with extended aeration and high mixed liquor suspended solids was adopted for treatment of sewage effluent and the treated sewage was discharged to the green belt for watering purpose. With the aim of reusing the treated sewage effluent, sewage effluent treatment system has been upgraded by adapting Membrane Bio Reactor (MBR) Technology during 2010.The treated domestic effluent of about 240 KL per day is reused in the process.
  • Separate Environmental Laboratory with all facility to carry out various analysis of environmental samples was setup in June-2012. The Environmental Laboratory has been accredited in accordance with the ISO/IEC 17025:2017 standard.
  • “E-waste Collection Facility” has been provided inside factory and also at MCF Township for collection and disposal of E-waste generated at homes in a scientific manner.
  • LED lighting assembly is installed in various places inside factory premises for conservation of energy.
  • Cooling water treatment system has been changed over to a non chromate system in the year 1991.
  • The company has planted about 63,000 trees like Teak, Mangium, Eucalyptus, Subabul, Acacia etc., developed in our green belt area. The area covered by the green belt is about 64 acres. About 2000 additional saplings were planted during 2020-21. It is planned to plant about 2000 additional saplings during 2021-22 also.
  • Environmental Management System (EMS) in line with ISO14001:2015 is implemented and certified by M/s Det Norske Veritas, Bangalore, which is valid up to 16.08.2023.
  • Installed low NOx burners and excess air control devices in primary reformer of ammonia plant to improve the burner efficiency.
  • Changed over urea plant start up passivation system from high pressure CO2 to low pressure steam passivation for noise reduction and for conserving raw materials.
  • Elimination of chlorine dosing to cooling tower by installing Chlorine dioxide generation unit, hence preventing hazard.
  • Installed heat pumps to recover condensate from various areas to save steam and energy.
  • Synthesis gas recovery system is installed in synthesis gas compressors to recover synthesis gas from the seal vent gas.
  • Provided acoustic treatment to the entire DG house to control the noise pollution.
  • Acoustic enclosure has been provided to all the AMF emergency generators installed.
  • Installed modified prill bucket in urea plant to mitigate the emission of particulates.
  • Disposal of bio-medical waste generated at the occupational health centre in common biomedical waste disposal facility.
  • Meteorological station comprising facilities to monitor rainfall, maximum and minimum temperature, relative humidity, barometric pressure, wind direction and velocity has been established.
  • Conducting public awareness programmes in the neighbourhood for public in environmental and safety aspects.
  • ‘5-S’ system, a Japanese tool to improve housekeeping, and upkeep of plants and offices is implemented.
  • Implemented the schemes for harvesting roof water at our township and recharge the bore wells. Total roof area covered is about 3500 m2 and estimated water harvested is 13,300 m3/year.
  • Installed 1500 L capacity “Solar water heater” with 16 collectors for our Industrial canteen and 4 No. of solar street lights at our factory and 4 No. of solar lights at our township.
  • Installed Continuous Ambient Air Quality Monitoring Station (CAAQMS) inside the factory premises to monitor Ambient Air Quality continuously and LED display board was installed at the Main gate facing the highway for the public.
  • Installed Economiser and low NOx burner in our Auxiliary boiler during revamp which improve the fuel efficiency.
  • Installed Hydraulic power recovery turbine (HPRT) in our CO2 separation unit in our Ammonia plant which recovers pressure energy from high pressure solution during let down and converts to mechanical energy which is used to drive the pump.
  • Continuous online monitoring system for liquid effluent is installed in our Wastewater Recovery Unit for monitoring of pH, Ammoniacal Nitrogen and Flow. Continuous online monitoring systems for SPM and Ammonia are installed in Urea plant prill tower fan ducts and SPM, Ammonia and Fluorine online analysers are installed in DAP plant stack for continuous monitoring. Continuous online monitoring systems for NOx are installed in Captive power plant boiler stacks, Ammonia plant boiler stacks and reformer stack. Values from the analysers are hooked up to Central Pollution Control Board server.
  • We have installed biogas plant to generate biogas from the leftovers from the kitchen. Biogas generated are utilized in Kitchen for preparing food.