ENVIRONMENTAL IMPACT ASSESSMENT REPORT FOR PROPYLENE DERIVATIVE PETROCHEMICAL PROJECT OF BPCL AT KOCHI, KERALA
FOR M/s. BHARAT PETROLEUM CORPORATION LIMITED
REPORT NO. A419-EI-1741-1401
January 2015 Final Report for EC This report is prepared for M/s. BPCL and it is for use by M/s. BPCL or their representatives/organizations only. The matter contained in the report is confidential.
ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPYLENE DERIVATIVE PETROCHEMICAL PROJECT AT KOCHI, KERALA FOR BPCL-KR
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INDEX EXECUTIVE SUMMARY 1.0
INTRODUCTION
1.1
NEED FOR PROPYLENE DERIVATIVES PETROCHEMICAL PROJECT………..…... .2
1.2
SCOPE OF THE EIA STUDY………………………………………………………………....3
1.3
FRAME WORK OF ASSESSMENT…………………………………………………………. 4
1.4
METHODOLOGY FOR ENVIRONMENTAL IMPACT ASSESSMENT…………………. 4
1.4.1
PROJECT SETTING AND DESCRIPTION……………………..………………………….. 4
1.4.2
IDENTIFICATION OF IMPACTS…………………………………..……………………….... 5
1.4.3
BASELINE DATA COLLECTION…………….………………………………………..……...5
1.4.4
ENVIRONMENTAL IMPACT PREDICTION & EVALUATION…………………….……… 5
1.4.5
ENVIRONMENTAL MANAGEMENT PLAN (EMP) ……………………………….…….... .5
1.5 1.6
CONTENTS OF EIA REPORT …………………………………………………………. 6 PROJECT PROPONENT……………………………………………………………….. 7
2.0
PROJECT PROFILE
2.0
INTRODUCTION……………………………………………………………………….……....9
2.1
PROJECT LOCATION…………………………………………………………………….… ..9
2.2
PROJECT CONFIGURATION…………………………………………………………….... 13
2.2.1
RAW MATERIALS…………………………………………………………………………….15
2.3
PROCESS DESCRIPTION………………………………………….……………………….17
2.3.1
ACRYLIC ACID………………………………………………………………………………..17
2.3.2
ACRYLATES…………………………………………………………………………………..18
2.3.3
OXO PROCESS………………………………………………………………………………19
2.4
RAW MATERIAL / PRODUCT STORAGE.................................................................... 22
2.4.1
LOGISTICS…………………………………………………………………………………....22
2.5
UTILITIES CONSUMPTION…………………………………………………………………23
2.5.2
WATER REQUIREMENT...................……………………………………………………...23
2.5.3
POWER CONSUMPTION..................……………………………………………………...24
2.5.4
FUEL REQUIREMENT.......................……………………………………………………...25
2.5.5
COOLING WATER.............................……………………………………………………...25
2.6
EMISSIONS FROM PROPOSED UNITS…………………………………………….…….25
2.6.1
AIR ENVIRONMENT……………….………………………………………………….……..25
2.6.2
WATER ENVIRONMENT……………………………………………………………..….….26
2.6.3
SOLID AND HAZARDOUS WASTE MANAGEMENT ………..…..………….…….…….28
2.6.4
NOISE …………..………………..…………………………………………..………………..29
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2.7 ENVIRONMENT MEASURES………………………………………………………………..29 2.7.1
PROPOSED AIR POLLUTION CONTROL SYSTEM …………………………...……..29
2.7.2
WATER POLLUTION MANAGEMENT SYSTEM ...…………………………………….31
2.7.3
NOISE POLLUTION MANAGEMENT SYSTEM ...………………….…………………..31
2.7.4
LAND POLLUTION MANAGEMENT SYSTEM ...…………………….………………….31
3.0
EXISTING ENVIRONMENTAL STATUS
3.0
DESCRIPTION OF ENVIRONMENT……………………………………………………..33
3.1
AIR ENVIRONMENT……………………………………………………………………......33
3.1.1
MICROMETEOROLOGICAL DATA …………..………..…………………………………33
3.1.1.1 HISTORICAL DATA……………………………………………………………………..….33 3.1.1.2 METEROLOGY- DATA GENERATED AT PLANT SITE…………………………… …33 3.1.2
SELECTION OF AAQ STATION………………………………………..………..……..35
3.1.3
EXISTING AAQ STATUS…………………………………………………………….........36
3.1.4
RESULTS AND DISCUSSION…………………………………………………….….…..38
3.1.5
AMBIENT AIR QUALITY MONITORING BY BPCL KR…………………….………......46
3.2
NOISE ENVIRONMENT………. ………………………………………………………..49
3.2.1
NOISE LEVELS ……………………………………………………………………….……50
3.2.2
METHODOLOGY OF NOISE MEASUREMENT……………………………….……….51
3.2.3
DATA ANALYSIS…………………………………………………………………….……..52
3.2.4
TRAFFIC………………………………………………………………………….………...64
3.3
WATER ENVIRONMENT………………………………………………………………….87
3.3.1
SAMPLE COLLECTION AND ANALYSIS………………………………………………..88
3.3.2
DATA ANALYSIS……………………………………………………………………….....92
3.3.3
CONCLUSION...............................................................................................................99
3.4
LAND ENVIRONMENT……….…………………………………………………………..100
3.4.1
METHODOLOGY OF SAMPLE COLLECTION AND ANALYSIS…………………...100
3.4.2
SOIL DATA ANALYSIS…………………………………………………………..…..…..102
3.5
ECOLOGY…………………………………………………………………………………106
3.5.1
OBJECTIVE OF ECOLOGICAL STUDY.....................................................................108
3.5.2
METHODOLOGY ADOPTED FOR SURVEY.............................................................108
3.5.3
HABITAT WISE REPRESENTATION........................................................................123
3.6
SOCIO ECONOMIC ENVIRONMENT………………………………………………….133
3.6.1
SOCIO ECONOMIC STRUCTURE……………………………….…………..………133
3.6.2
OCCUPATIONAL STRUCTURE………………………………………………………135
3.6.3
AMENITIES………………………………………………………………………………138
3.6.4
SITE SPECIFIC STUDIES………………………………………………………………..141
3.6.4.1 POPULATION DEMOGRAPHIC DETAILS…………………………………………….142 Template No. 5-0000-0001-T2 Rev. 1
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3.6.4.2
INDUSTRIES……………………………………………………………………………….142
3.6.4.3
DISEASES IN THE AREA………………………………………..………………..……....142
4.0
PREDICTION OF IMPACTS
4.0
IMPACT ASSESSMENT……………………………………………………………………..144
4.1
METHODOLOGY….……………………………………………………………………….…144
4.2
IDENTIFICATION OF ENVIRONMENTAL IMPACTS……………………………….…….147
4.3
AIR ENVIRONMENT……………………………………………………………………... …148
4.3.1
CONSTRUCTION PHASE…………………………………………………………………...148
4.3.2
OPERATION PHASE…………………………………………………………………………150
4.4
WATER ENVIRONMENT…………………………………………………………………….153
4.4.1
CONSTRUCTION PHASE…………………………………………………………………153
4.5
NOISE ENVIRONMENT……………………………………………………….................. 156
4.5.1
CONSTRUCTION PHASE……………………………………………………………………156
4.5.2
OPERATION PHASE…………………………………………………………………………157
4.6
LAND ENVIRONMENT……………………………………….…….....................................158
4.6.1
CONSTRUCTION PHASE……………………………………………………………….......158
4.6.2
OPERATION PHASE…………………………………………………………………………160
4.7
BIOLOGICAL ENVIRONMENT………………………………………………………………160
4.7.1
CONSTRUCTION PHASE……………………………………………………………………160
4.7.2
OPERATION PHASE…………………………………………………………………………161
4.8
SOCIO ECONOMIC ENVIRONMENT………………………………………………………162
4.8.1
CONSTRUCTION PHASE……………………………………………………………………162
4.8.1.1 EMPLOYEMENT GENERATION…………………………………………………………....162 4.8.1.2 EFFECT ON TRANSPORT……………………………………………………………….....162 4.8.1.3 EFFECT ON OTHER LOCAL INFRASTRUCTURE……………………………………….163 4.8.2
OPERATIONAL PHASE……………………………………………………………………...164
4.9
SUMMARY OF IMPACTS…………………………………………………………………….165
5.0
ENVIRONMENT MONITORING PROGRAM
5.1
INTRODUCTION………………………………………………………………………..……..167
5.2
OBJECTIVES OF MONITORING……………………………………………………….…...167
5.3
ENVIRONMENT MONITORING PROGRAM………………………………………………167
6.0
ADDITIONAL STUDIES
6.1
PUBLIC CONSULTATION…………………………………………………………………..170
6.2
RISK ASSESSMENT ……..…………………………………………………………………175
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7.0
PROJECT BENEFITS
7.1
SUPPLY CHAIN……………………………………………………...……………...…….177
7.2
INTEGRATED AND SUSTAINABLE DEVELOPMENT……………………..…………177
7.3
SOCIO-ECONOMIC DEVELOPMENT………………………………………………….177
8.0
ENVIRONMENTAL MANAGEMENT PLAN
8.1
ENVIRONMENT MANAGEMENT…………………………………………………….....180
8.2
ENVIRONMENTAL MANAGEMENT PLAN……………………..……………….. .......180
8.2.1
AIR ENVIRONMENT…………………………..………………..………………………...180
8.2.2
WATER ENVIRONMENT…………….……………………………..…….……………...180
8.2.3
LAND ENVIRONMENT……………………….………………..…………….…………...181
8.2.4
NOISE ENVIRONMENT……………………………………………………….…............181
8.2.5
BIOLOGICAL ENVIRONMENT……………………………………………..…….….......182
8.2.6
SOCIO ECONOMIC ENVIRONMENT……………………………………………......,…182
8.3
ENVIRONMENTAL MONITORING PROGRAM……………………………..….,,,........182
8.3.1
MEASURES FOR IMPROVEMENT OF BIOLOGICAL ENVIRONMENT..………......183
8.3.2
PHASE WISE GREENBELT DEVELOPMENT PLAN……………………..………......183
8.3.3
SPECIES SELECTION……………………………………………………………………183
8.3.4
PHASE WISE GREENBELT DEVELOPMENT PLAN………………………………….185
8.4
ENVIRONMENT CELL…………………..…………………………………..……… .......186
8.5
IMPLEMENTATION OF ENVIRONMENTAL MANAGEMENT PLAN…….... …... .....186
8.6
BUDGET OF ENVIRONMENT MANAGEMENT PLAN …………………………….....186
9.0
SUMMARY & CONCLUSION
9.1
SUMMARY…………………………………….…………………………………………….189
9.2
CONCLUSIONS…………………………………………………………………………….189
9.3
MANAGEMENT OF RELEASES OF POLLUTANTS…………………………………...189
9.4
RISK ASSESSMENT……………………………………………………………………….189
9.5
CORPORATE SOCIAL RESPONSIBILITY OF BPCL…………………………………..189
9.6
REMARKS…………………………………………………………………………………..190
10.0
CONSULTANT DETAILS
10.1
GENERAL INFORMATION………………………………………………………………..192
10.2
ESTABALISHMENT………………………………………………………………………..192
10.3
EIL’S VISION………………………………………………………………………………..192
10.4
EIL’S MISSION……………………………………………………………………………..193
10.5
CORE VALUES OF EIL………………………………...…………………………………193
10.6
QUALITY POLICY OF EIL………………………………………...………………………193
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10.7
HSE POLICY OF EIL…………………………………………...………………………….193
10.8
ENVIRONMENTAL POLICY OF EIL………………………………………..……………193
10.9
RISK MANAGEMENT POLICY OF EIL……………………………………………….…194
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LIST OF FIGURES FIG.NO
DESCRIPTION
PAGE NO.
2.1
PROJECT LOCATION
9
2.2
PROJECT LOCATION AND ITS BOUNDARIES
10
2.3
10 KM RADIUS OF THE PROPOSED PROJECT
12
2.4
OVERALL PLOT PLAN OF PDPP
14
2.5
BLOCK FLOW DIAGRAM: INTEGRATION WITH REFINERY
16
2.6
SYNERGY BETWEEN IREP & PDPP
23
2.7
WATER BALANCE
24
2.8
SCHEMATIC DIAGRAM FOR INCINERATION FACILITY
30
3.1.1
PRIMARY METEOROLOGICAL DATA –WIND ROSES
35
3.1.2
MAP SHOWING AMBIENT AIR SAMPLING LOCATIONS
36
3.1.3
MEASURING INSTRUMENTS(AIR)
38
3.1.4
AAQ OF PARTICULATE MATTER (PM10 & PM2.5)
45
3.1.5
AAQ OF GASEOUS CONCENTRATION (SO2, NOX & O3)
46
3.2.1
MEASURING INSTRUMENT(NOISE)
49
3.2.2
MAP SHOWING NOISE SAMPLING LOCATIONS
50
3.2.3
REPRESENTATION OF AVERAGE TRAFFIC DATA
87
3.3.1
91
3.4.1
MAP SHOWING GROUND & SURFACE WATER SAMPLING LOCATIONS MAP SHOWING SOIL SAMPLING LOCATIONS
101
3.4.2
SOIL TEXTURE DIAGRAM OF THE STUDY AREA
102
3.5.1
107
3.5.4
THICK GREEN COVER ( MIXED PLANTATION WITH ORCHARDS) AROUND BPCL REFINERY AGRICULTURAL FIELDS SURROUNDING 10 KM RADIUS OF STUDY AREA HABIT WISE REPRESENTATION OF PLANTS FROM THE STUDY AREA FAUNA PLATE
3.5.5
FLORA AND LANDSCAPE PHOTOGRAPHS
132
3.6.1
POPULATION COMPOSITION
134
3.6.2
OCCUPATIONAL STATUS
136
3.6.3
LITERACY LEVELS
137
10.1
EIL ACCREDITION BY NABET
195
3.5.2 3.5.3
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LIST OF TABLES S.NO
DESCRIPTION
1.1
PRODUCTS FROM PDPP
PAGE NO. 2
1.2
DEMAND OF PRODUCTS
3
2.1
ENVIRONMENTAL SETTING OF THE PROJECT
10
2.2
LIST OF PRODUCTS AND PRODUCTION CAPACITY
13
2.3A
ADMINISTRATIVE DISTRIBUTION OF LAND
15
2.3B
LAND USE BREAKUP OF PLOT
15
2.4
UTILITY INTEGRATION WITH REFINERY
16
2.5
DETAILS OF PRODUCT STORAGE
22
2.6
PDPP PRODUCT MOVEMENT MODES
22
2.7
BREAKUP OF POWER REQUIREMENT OF PDPP
24
2.8
FUEL CONSUMPTION
25
2.9
DETAILS OF AIR EMISSIONS
26
2.10
EFFLUENT SUMMARY
27
2.11
QUALITY OF SANITARY EFFLUENT
28
2.12
HANDLING OF SOLID WASTE
28
2.13
CATALYST SUMMARY OF PDPP
29
2.14
INDIAN STANDARD FOR INCINERATION
30
2.15
QUALITY OF DISPOASAL OF TREATED EFFLUENT FROM IREP
31
3.1.1
SUMMARISED PRIMARY METEOROLOGICAL DATA
34
3.1.2
AMBIENT AIR QUALITY – METHODOLOGY
37
3.1.3.
NATIONAL AMBIENT AIR QUALITY STANDARDS
38
3.1.4
AMBIENT AIR QUALITY MONITORING RESULTS : PM10
41
3.1.5
AMBIENT AIR QUALITY MONITORING RESULTS : PM2.5
42
3.1.6
AMBIENT AIR QUALITY MONITORING RESULTS : SO2
42
3.1.7
AMBIENT AIR QUALITY MONITORING RESULTS : NOX
43
3.1.8
AMBIENT AIR QUALITY MONITORING RESULTS : O3
43
3.1.9
AMBIENT AIR QUALITY MONITORING RESULTS : NH3
44
3.1.10
AMBIENT AIR QUALITY MONITORING RESULTS : CO
44
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3.1.11
AMBIENT AIR QUALITY MONITORING RESULTS : METHANE HC
44
3.1.12
AMBIENT AIR QUALITY MONITORING RESULTS : BENZENE
45
3.1.13
AMBIENT AIR QUALITY MONITORING RESULTS : TOLUENE
45
3.1.14
AMBIENT AIR QUALITY MONITORING RESULTS
47
3.2.1
HOURLY NOISE DATA: SAMPLING PERIOD: 03RD TO 08TH MARCH, 2013
53
3.2.2
HOURLY NOISE DATA: SAMPLING PERIOD: 14TH TO 17TH MARCH, 2013 (2ND QUARTER) HOURLY NOISE DATA: SAMPLING PERIOD: 21ST TO 25TH MARCH, 2013 (3RD QUARTER) HOURLY NOISE DATA: SAMPLING PERIOD: 21ST TO 25TH APRIL, 2013 HOURLY NOISE DATA: SAMPLING PERIOD: 26H TO 30H APRIL, 2013
54
3.2.3 3.2.4 3.2.5 3.2.6
HOURLY NOISE DATA: SAMPLING PERIOD: 01ST TO 05TH MAY, 2013 3.2.7 HOURLY NOISE DATA: SAMPLING PERIOD: 08TH TO 11TH MAY, 2013 3.2.8 HOURLY NOISE DATA:SAMPLING PERIOD: 13TH TO 21ST MAY, 2013 3.2.9 HOURLY NOISE DATA: SAMPLING PERIOD: 20TH TO 28TH MAY, 2013 3.2.10 HOURLY NOISE DATA: SAMPLING PERIOD: 3RD TO 12TH JUNE, 2013 3.2.11 HOURLY NOISE DATA : SAMPLING PERIOD: 17TH TO 26TH JUNE, 2013 3.2.12- TRAFFIC DATA (MARCH- JUNE) 3.2.22
55 56 57 58 59 60 61 62 63 65 86
3.2.23
AVERAGE TRAFFIC DATA (MARCH-JUNE)
87
3.3.1
PARAMETERS & METHODOLOGIES ADOPTED IN ASSESSING QUALITY OF WATER WATER QUALITY - PHYSIO-CHEMICAL ANALYSIS OF GROUND WATER (MARCH-MAY 2013) WATER QUALITY - PHYSIO-CHEMICAL ANALYSIS OF SURFACE WATER (MARCH-MAY 2013) ENVIRONMENTAL STANDARDS WATER QUALITY CRITERIA
89
3.3.2 3.3.4 3.3.53.3.7 3.3.8
92 94 95 97 99
3.4.13.4.3 3.4.4
PHYSIOCHEMICAL PARAMETERS OF THE SOIL
103105 106
3.5.1
112
3.5.2
DISTRIBUTION OF PLANTS IN THE STUDY AREA AND ITS SURROUNDING FRUIT YIELDING PLANTS FROM THE STUDY AREA
3.5.3
LIST OF BIRDS DOCUMENTED DURING THE STUDY PERIOD
125
3.5.4
LIST OF BUTTERFLIES IN AND AROUND THE STUDY AREA
128
3.5.5
FAMILY WISE DISTRIBUTION OF BUTTERFLIES IN THE STUDY AREA
129
CONCENTRATION LEVELS FOR SOIL
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3.5.6
LIST OF AMPHIBIANS RECORDED IN THE STUDY AREA
129
3.5.7
MAMMALS RECORDED IN THE STUDY AREA
130
3.6.1
POPULATION COMPOSITION
133
3.6.2
OCCUPATIONAL STRUCTURE
136
3.6.3
LITERACY LEVELS
137
3.6.4
AMENITIES (EDUCATIONAL FACILITIES)
138
3.6.5
AMENITIES MEDICAL FACILITIES
139
3.6.6
140
3.6.7
AMENITIES (WATER, POST & TELEGRAPH, COMMUNICATION, BANKING AND ELECTRICITY) AMENITIES (FOREST AND IRRIGATION LAND USE)
3.6.8
POPULATION DEMOGRAPHIC DISTRIBUTION
142
3.6.9
LIST OF INDUSTRIES
142
4.1
MATRIX FOR EVALUATING SPATIAL CRITERIA
145
4.2
MATRIX FOR EVALUATING TEMPORAL CRITERIA
146
4.3
MATRIX FOR EVALUATING SIGNIFICANCE
147
4.4
IMPACT IDENTIFICATION MATRIX
148
4.5
IMPACT OF AIR EMISSIONS (CONSTRUCTION PHASE)
150
4.6
SO2 AND NOX EMISSION DATA
151
4.7
PREDICTED VALUES OF GLC FOR SO2
151
4.8
PREDICTED VALUES OF GLC FOR NOX
152
4.9
IMPACT OF AIR EMISSIONS (OPERATION PHASE)
152
4.10
IMPACT OF WATER CONSUMPTION (CONSTRUCTION PHASE)
153
4.11
IMPACT OF EFFLUENT GENERATION (CONSTRUCTION PHASE)
154
4.12
IMPACT OF WATER CONSUMPTION (OPERATION PHASE)
155
4.13
IMPACT OF EFFLUENT GENERATION (OPERATION PHASE)
155
4.14
SOUND PRESSURE LEVELS OF CONSTRUCTION MACHINERY
156
4.15
IMPACT ON AMBIENT NOISE (CONSTRUCTION PHASE)
157
4.16
IMPACT ON AMBIENT NOISE (OPERATION PHASE)
157
4.17
IMPACT ON LAND USE & TOPOGRAPHY (CONSTRUCTION PHASE)
159
4.18
IMPACT ON SOIL QUALITY (CONSTRUCTION PHASE)
159
4.19
IMPACT ON SOIL QUALITY (OPERATION PHASE)
160
4.20
IMPACT ON BIOLOGICAL ENVIRONMENT (CONSTRUCTION PHASE)
161
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4.21
IMPACT ON BIOLOGICAL ENVIRONMENT (OPERATION PHASE)
161
4.22
163
5.2
IMPACT ON SOCIO-ECONOMIC ENVIRONMENT (CONSTRUCTION PHASE) IMPACT ON SOCIO-ECONOMIC ENVIRONMENT (OPERATION PHASE) SUMMARY OF IMPACT EVALUATION IN TERMS OF SIGNIFICANCE VALUE ENVIRONMENTAL MONITORING PROGRAM (CONSTRUCTION PHASE) ENVIRONMENTAL MONITORING PROGRAM (OPERATION PHASE)
6.1
PUBLIC HEARING ISSUES
170
8.1
LIST OF TREE SPEICIES SUGGESTED FOR GREENBELT DEVELOPMENT PROPOSED CAPITAL INVESTEMENT FOR POLLUTION CONTROL MEASURES PROPOSED RECURRING COST FOR POLLUTION CONTROL MEASURES
184
4.23 4.24 5.1
8.2 8.3
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LIST OF ANNEXURES ANNEXURE I: ANNEXURE II: ANNEXURE III: ANNEXURE IV: ANNEXURE V: ANNEXURE VI: ANNEXURE VII: ANNEXURE VIII: ANNEXURE IX: ANNEXURE IXA: ANNEXURE X: ANNEXURE XI:
COPY OF TOR APPROVED TOR COMPLIANCE STATEMENT COPY OF LETTER FOR APPROVAL OF CHANGE OF NAME REMOTE SENSING MAP OF ROAD NETWORK REMOTE SENSING MAP OF WATER BODIES GENERAL ARRANGEMENT OF RAIN WATER PITS. REMOTE SENSING MAP OF LAND USE DRAINAGE MAP MATERIAL SAFETY DATASHEET DETAILS OF OCCUPATIONAL HEALTH PROGRAM. QUALITY ENVIRONMENT HEALTH & SAFETY POLICY ORGANIZATIONAL STRUCTURE FOR ENVIRONMENT MANAGEMENT AND ORGANOGRAM FOR DMP ANNEXURE XII: NOTE ON COMPLIANCE TO THE RECOMMENDATIONS MENTIONED IN THE CREP GUIDELINES ANNEXURE XIII: REMOTE SENSING MAP FOR GEOMORPHOLOGY ANNEXURE XIV: DETAILS OF AIR MODELLING ANNEXURE XV: AUTHORISATION LETTER FOR WATER INTAKE ANNEXURE XVI: PROCEEDINGS OF PUBLIC HEARING ANNEXURE XVII: RAPID RISK ANALYSIS STUDY ANNEXURE XVIII: SOCIAL DEVELOPMENT ACTIVITIES BY BPCL KR ANNEXURE XIX: SLUDGE DISPOSAL AGREEMENT ANNEXURE XX: CERTIFIED MONITORING/COMPLIANCE REPORT
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EXECUTIVE SUMMARY ENVIRONMENTAL IMPACT ASSESSMENT REPORT FOR PROPYLENE DERIVATIVE PETROCHEMICAL PROJECT AT KOCHI, KERALA
FOR M/s. BHARAT PETROLEUM CORPORATION LIMITED
JANUARY 2015 Final report for EC
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1.0
Executive Summary The Executive Summary covers the following chapters in brief: 1. Project Description 2. Anticipated Environmental Impacts and Mitigation measures 3. Project Benefits 4. Environment Management Plan
1.1
Project Description Kochi Refinery, a unit of Bharat Petroleum Corporation Limited (BPCL-KR), is a 9.5 MMTPA Refinery located at Ambalamugal in Ernakulam District (Kerala), India.
The
Refinery was commissioned in 1966 with crude oil processing capacity of 2.5 Million Metric Tons Per Annum (MMTPA). Through progressive revamps and addition of process units, the refining capacity has been augmented to present level of 9.5 MMTPA.BPCL-KR is implementing Integrated Refinery Expansion Project (IREP) to enhance the refining capacity to 15.5 MMTPA, that will produce 500 KTPA polymer grade Propylene. A major foray into petrochemicals is proposed at BPCL-KR, based upon feed-stock Propylene that would be available from Petrochemical Fluid Catalytic Cracking Unit (Petro FCCU) that is being set up as part of the Integrated Refinery Expansion Project (IREP). The Petrochemical Fluid Catalytic Cracking Unit (Petro FCCU) with a capacity to process 2.2 MMTPA of Vacuum Gas Oil (VGO) would produce 500 KTPA of Polymer Grade Propylene (PGP) of which 250 KTPA is proposed to be utilized for the production of value added petrochemicals. The requirement of industrial gases such as Hydrogen, Synthesis gas, Nitrogen & Oxygen shall be sourced from the Build Own Operate (BOO) facility, being set up as part of IREP project within BPCL-KR premises. Initially the Propylene Derivatives Petrochemical Project (PDPP) was planned with LG Chem, South Korea as a joint venture (JV). Project proposal for issue of Terms of Reference (TOR) for EIA was considered in the 6th reconstituted Expert Appraisal Committee (EAC) (Industry) meeting held during 5th March 2013. The Committee discussed the project details, utility requirements and the presentation by the project proponent/EIA Consultant (Engineers India Limited). After detailed deliberations, the Expert Appraisal Committee prescribed Terms of Reference (TOR) dated 30th April 2013 for preparation of EIA/EMP. After LG Chem’s decision not to proceed with the proposed Joint Venture PDPP, BPCL intends to proceed with project on its own. The same was informed to MoEF and approval
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was obtained from MoEF dated 23rd July 2014 for change in name, after LG Chem's exit from the project. Further, it was informed by MoEF that all other conditions and validity of TOR remain unchanged. PDPP complex will be set up close to the refinery in order to achieve integration of feedstock supply, utilities, offsites and other facilities. PDPP will manufacture niche petrochemical products such as Acrylic acid, Oxo-alcohols and Acrylates. The Project is expected to achieve mechanical completion in the first quarter of 2018. The Refinery/Petrochemical Complex will become a pacesetter in safety, environmental compliance, reliability, energy efficiency and operating cost. Based on the scope of work, guidelines generally followed for EIA studies and past experience of EIL on such industrial projects, a corridor encompassing of area within 10 km radius of proposed project location is considered as spatial frame for the impact assessment. Temporal frame of assessment has been chosen to reflect the impacts in two distinct phases of the project as: Construction phase Operation Phase M/s Pragathi Labs (P) Labs, Hyderabad, an approved agency by MOEF, had been entrusted to collect environmental baseline data in terms of various parameters for pre monsoon season starting from March 2013 to June 2013. 1.2
Proposed Process Configuration of PDPP The proposed PDPP complex consists of three major process units Acrylic acid, Oxoalcohol and Acrylates. About 329 KTPA of products will be manufactured from 250 KTPA of Propylene feed stock, in the PDPP complex. Matching Utilities and Off-site facilities are also envisaged as part of the project. The land required for the project is approximately 132 acres (118 acres towards Plant facilities and green belt development for presently envisaged products and 14 acres for related future products) Land acquisition activities have been completed. The Estimated Cost of the Project is approximately Rs.4588 Crore. This
includes
cost
towards
environmental
management
and
Corporate
Social
Responsibility. Major process units, products manufactured from PDPP and its applications are shown in Table A below.
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Table A. Details of products Process Unit Acrylic Acid Unit Acrylates Unit Oxoalcohol Unit
Product
Quantity (KTPA) Acrylic 47
Ester Grade Acid (EAA) Butyl Acrylate 2-Ethyl Hexyl Acrylate N-Butanol 2 Ethyl-Hexanol Iso-Butanol Total
180 10 38 47 7 329
Product Glacial Acrylic Acid (future) Super Absorbent Polymer (future)
Uses / Industry Water treatment chemicals, Detergents Paints & Inks, Adhesives, Textiles, Resins Plasticizers, Di-Octyl Phthalate, Detergents, Paints and Inks
Uses / Industry Water treatment chemicals, Detergent, SAP Production Diaper / Female sanitary products/Irrigation
Acrylic Acid: By oxidation process, Propylene is vaporized and converted directly to Acrylic Acid through two step continuous oxidation reaction with air (oxygen) in the reactors, over a catalyst bed. This is followed by solvent extraction and purifications steps to produce Ester grade Acrylic acid. Oxo-alcohol: The Oxo- alcohol process unit produces, 3 different alcohols, 2-Ethyl Hexanol, normal Butanol and Iso Butanol, Propylene is reacted with synthesis gas , in the presence of catalyst to produce N/I- Butyraldehydes. N-Butyraldehyde is further processed to produce N-Butanol and 2-Ethyl Hexanol. I- Butyraldehyde is converted to I-Butanol. Acrylate Esters: Acrylate Esters are produced by esterification of Ester grade acrylic acid (EAA) and alcohols ( n-Butanol and 2-Ethyl Hexanol). Butyl Acrylate (BA) is produced from liquid-phase continuous esterification of EAA and n-Butanol using a catalyst. 2-Ethyl Hexyl Acrylate (2-EHA) is produced by liquid-phase continuous esterification of EAA and 2-Ethyl Hexanol (2-EH) using a catalyst. Utilities: Total requirement of fuel within the process units would be met mostly by LPG/ LNG and partly by internal generation. Emissions have been worked out with low sulphur fuel oil combination firing. All the incinerators shall be designed for dual firing. Approximately 25 MW of power is required for the PDPP facilities and will be sourced from the refinery. Net quantity of treated raw water that will be sourced from BPCL-KR is 391 m3/hr. Effluent generated from PDPP will be routed to effluent treatment plant of BPCL-KR for treatment and final disposal. 2.0
Anticipated Environmental Impacts & Mitigation measures The various activities involved in both construction and operation of proposed project are identified first, and then its likely impacts are identified. The environmental impacts associated with the proposed project on various environmental components such as air,
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water, noise, soil, flora, fauna, land, socioeconomic, etc. has been identified using Impact Identification Matrix (Table B). Table B. Impact Identification Matrix
Flora
Fauna
Livelihood & occupation
*
*
*
*
*
Infrastructure
Land (land use, topography & drainage, soil)
CONSTRUCTION PHASE Site clearing (Demolition works & clearing of * vegetation) Burning of waste, refuse * Civil works such as earth moving and building of * structures Heavy equipment operations Disposal of construction * wastes Generation/disposal of sewerage Transportation of materials * OPERATION AND MAINTENANCE PHASE Feedstock and product * handling and storage Process units, utilities and * offsites Waste management- liquid * and solid waste/Incineration Transportation of products *
Socioeconomic
Ambient noise
Biological
Ground / surface water (quantity / quality)
Activities
Ambient air quality
Physical
* *
*
*
* * * *
* * *
The impact assessment has been carried out with respect to various environmental components, taking into account, the existing status of environment and the changes likely to occur due to the project activities. 2.1
Impact Assessment and Mitigation Measures Air Environment- Construction Phase Impacts (Significance - Low) Dust will be generated from earth-moving, grading, pipeline laying and civil works, and movement of vehicles on unpaved roads. PM, CO, NOX, & SO2 will be generated from operation of diesel sets and diesel engines of machineries and vehicles.
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Mitigation Measures Preventive maintenance of vehicles and equipment. Vehicles with valid Pollution under Control certificates to be used. Unnecessary engine operations to be minimized. Implementing dust control activities such as water sprinkling on unpaved sites. Controlled vehicle speed on site Vehicle to be covered during transportation of material Providing dust collection equipment at all possible points Operation Phase Impacts (Significance - Medium) SOX, NOX, PM and CO emission from waste incinerator. PM, CO, NOX, generation from vehicles movement Mitigation Measures Operation phase (Impact significance: Medium) Developing peripheral green belt. Ensuring preventive maintenance of equipment. Monitoring of air polluting concentrations Water Environment - Construction Phase Impacts (Significance: Water consumption – Low, Effluent generation - Low) Raw water required for construction & drinking purpose will be sourced from existing refinery sources. Generation of sanitary sewage. Mitigation Measures During construction phase, used construction water is the only effluent generated due to construction activities and most of the effluent generated will be so small that it will either get percolated to ground or get evaporated. Monitoring water usage at construction camps to prevent wastage. The Sewage Treatment Plant (STP) at construction camps/ sites and the proposed facilities are properly designed to handle peak waste water load and properly maintained. Supply of temporary/ portable toilets for construction staff. Operation Phase Impacts (Significance: Water consumption – Low, Effluent generation - Low) Water requirement shall be met from BPCL Kochi Refinery for which authorization has already been obtained by BPCL-KR.
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Approximately 35 m3/hr of waste water will be generated from the proposed facilities. The same shall be routed to BPCL Refinery ETP for treatment and disposal. Mitigation Measures Tracking of consumption and installing water meter from BPCL Refinery. Installation of rainwater harvesting structures to collect and use rainwater, thereby reducing abstraction. Noise Environment - Construction Phase Impacts (Significance - Low) Noise generation due to operation of heavy equipment and machinery, operation of DG sets and movement of heavy vehicles. Mitigation Measures Preventive maintenance of equipment and vehicles Unnecessary engine operations to be minimized(e.g. equipment with intermitted use switched off when not working) DG sets to be provided with acoustic enclosures and exhaust mufflers Operation Phase Impacts (Significance - Medium) Noise generation due to operation of pumps & compressors etc. Mitigation Measures Avoiding continuous (more than 8 hrs) exposure of workers to high noise areas. Provision of ear muffs at the high noise areas. Ensuring preventive maintenance of equipment. Land Environment - Construction Phase Impacts (Significance: Land-use & topography – Low, Soil quality - Low) There is a potential for impact on soil quality due to spills, leaks of fuel and disposal of construction waste materials. Mitigation Measures Restricting all construction activities to the maximum possible extent inside the project boundary. The top soil stock pile is not contaminated with any type of spills. Any material resulting from clearing and grading should not be deposited on approach roads, streams or ditches, which may hinder the passage and/or natural water drainage. Restoration of construction camp sites before abandonment.
VII
After final site grading is complete, ensuring that the excess excavated material is not dumped indiscriminately but used for filling low lying areas construction by locals. Developing project specific waste management plan Developing and maintaining dedicated waste storage areas Operation Phase Impacts (Significance: Soil Quality - Low ) There is a potential for impact on soil quality due to handling and storage of hazardous waste and chemicals (e.g. waste oil, oil contaminated filters). Mitigation Measures Developing and maintaining dedicated waste storage areas. Disposing hazardous wastes to authorized vendors as per legal requirements. Biological Environment - Construction Phase Impacts (Significance –Medium) Road kills of animals due to movement of project-related vehicles. Obstruction of natural pathways and water holes of animals. Cutting of trees for clearing site for project development and firewood requirements by construction workers. Mitigation Measures Avoid cutting of tress wherever possible, especially the endangered species observed in the study area. Exploring opportunities for conservation of endangered species. Closing of trenches as soon as possible of construction. Prevent littering of work sites with wastes, especially plastic and hazardous waste, if any. Operation Phase Impacts (Significance – low) Road kills of animals due to movement of project-related vehicles. Mitigation Measures Maintain the greenbelt already developed Plant additional trees during operation phase Socio-Economic Environment - Construction Phase Impacts (Significance –Low) Disturbance and road safety issues to local community due to movement of project-related vehicles and heavy machineries. Sharing of local resources and infrastructure by the migrant workforce
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Disputes between locals and migrant workforce affecting societal harmony. Local employment and business generation (positive impact). Mitigation Measures Training contractors on company safety policy requirements and monitoring speed and route of project-related vehicles within the project area. Determining the safe, legal load limits of all bridges and roads that will be used by heavy vehicles and machinery. Upgrading local roads, wherever required, to ensure ease of project activity and community safety Consolidating deliveries of materials and personnel to project sites, whenever feasible, to minimize flow of traffic Minimizing interruption of access to community use of public infrastructure Providing prior notice to affected parties when their access will be blocked, even temporarily. Monitoring construction camp safety and hygiene Preventing use of drugs and alcohol in project-sites Preventing possession of firearms by project-personnel, except those responsible for security Project-related waste and wastewater is disposed in a responsible manner Operation Phase Impacts (Significance –Low) Additional load on traffic due to transport of both personnel and material. Employment Generation of around 180 people during operational phase. Mitigation Measures Extending reach of CSR programs to new project areas. Monitoring speed and route of project-related vehicles within the project area. 3.0
Project Benefits No local production source except for Oxo alcohol. The identified products are predominantly imported into India. Strong demand: Huge potential in India has been established through an independent market survey. Additionally, availability of local source of feedstock is expected to provide tremendous opportunity for growth in downstream industries, which is expected to further boost the employment potential. Generate direct / indirect employment and better economic status of the community due to better earnings. Synergy with Kochi Refinery/BOO (being set up as part of IREP) has been envisaged for feedstock supply, utilities, offsite and other support facilities.
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Tax Incentives: Government of Kerala (GoK) has provided exemption of Works Contract Tax (WCT) and deferment of Central Sales Tax (CST), Kerala Government Sales Tax (KGST), Value Added Tax (VAT) for IREP and PDPP promoted by BPCL. 4.0
ENVIRONMENTAL MANAGEMENT PLAN Environmental Management Plan (EMP) is planning and implementation of various pollution abatement measures for any proposed project. The EMP lists out all these measures for planning phase, construction phase and operational phase of the plant. Propylene Derivative Petrochemical Project shall be designed taking into account all the legislations/rules and as per the directives of Environmental Clearance documents. The control of Environmental pollution during construction phase even though for a shorter period is of vital importance. The required mitigation measures with complete details have been considered in order to develop effective mitigation measures. The environmental management plan during the operational phase of the plant shall therefore be directed towards the following: Ensuring the operation of various process units as per specified operating guidelines/operating manuals. Strict adherence to maintenance schedule for various machinery/equipment. Good Housekeeping practices. Post project environmental monitoring.
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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPYLENE DERIVATIVE PETROCHEMICAL PROJECT OF BPCL AT KOCHI, KERALA
Document No. A419-EI-1741-1401 Page 1
APPROVED TERMS OF REFERENCE COMPLIANCE STATEMENT
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A separate chapter on status of Not applicable as this is a Grass-root project. compliance of Environmental Conditions granted by State/Centre to be provided. As per circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA/EMP report. Executive summary of the project The same is attached with EIA Report. Justification of the project. Need for petrochemical products & its demand along with justification for setting up a new project is provided in section-1.1 of chapter-1. Promoters and their back ground. Bharat Petroleum Corporation Limited (BPCL) a Navratna company under the ministry of Petroleum & Natural Gas is having a total refining capacity of 30.5 MMTPA. It has been ranked 229th in the Fortune Global 500 companies. It is having presence in Refining, Oil & Gas Exploration and Marketing of Petroleum Products. Regulatory framework. A framework of assessment considered for the study is given in section-1.3 of chapter-1 Environment clearance for the existing Not applicable as this is a Grass-root project. unit issued by the Ministry, Consent to Operate and Authorization accorded by the KSPCB. Data for the stack emissions, fugitive The emissions in terms of air, wastewater, solid emissions; water requirement and water & hazardous wastes are estimated to be balance chart; wastewater generation, generated from proposed project is given in treated effluent quality, re-utilization and section 2.6 of chapter-2. disposal of solid/hazardous waste for the existing unit. Project location and plant layout. Pictorial view of the proposed location and overall plot plan is indicated in Section 2.1 (Fig 2.1, Fig 2.2, Fig 2.3 & fig 2.4) of chapter-2. Infrastructure facilities including power Details are provided in section-2.5 of chapter-2 sources. Total cost of the project along with total The estimated total cost of the project is capital cost and recurring cost/annum for approximately environmental pollution control measures. Rs. 4588 Crore. The total cost of projects includes the cost for pollution control measures. Proposed Capital Investment for Pollution Control Measures: Rs. 200.0 Crore. Proposed Recurring Cost for Pollution Control Measures: Rs. 4 Crore.
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Details of the same are given in table 8.2 and table 8.3 of chapter 8. Project site location along with site map of Details provided in Section 2.1 of chapter-2.
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10 km area and site details providing various industries, surface water bodies, forests etc. Present land use based on satellite Land use remote sensing map prepared by imagery for the study area of 10 km M/s. Kerala state remote sensing & radius. Environment centre is attached as Annexure VII. Details of land availability for the project along with supporting document. Location of National Park/Wild life sanctuary/ Reserve forest within 10 km radius of the project. Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests. Details of the total land and break-up of the land use for green belt and other uses. List of products along with the production capacities. Detailed list of raw material required and source, mode of storage. Manufacturing process details along with the chemical reactions and process flow chart. Action plan for the transportation of raw material and products Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary. Ambient air quality monitoring at 6 locations within the study area of 5 km, aerial coverage from project site as per NAAQES notified on 16 September, 2009. Location of one AAQMS in downwind direction. One season site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, SO2, NOx, CO, VOCs including HC (methane and non methane) shall be collected .The monitoring stations shall take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring shall also be included.
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The total land required for the project is acquired and the survey numbers are provided in table 2.3.A of chapter 2. There is no National Park/Wild life sanctuary/ reserve forest located within the study area of 10km radius Not applicable - since there is no reserve forest within 10 km radius of the project location Details provided in table 2.3.A and 2.3.B of chapter 2. Updated details provided in table 2.2 of chapter- 2. Details provided in section 2.2.1 & 2.4 of chapter-2. Details provided in section 2.3 of chapter-2. Details provided in section 2.4 of chapter-2. All micro-meteorological details are provided in section 3.1.1 of chapter-3 Details are given in section-3.1.2 in chapter-3
Details are given in section- 3.1.1, 3.2 and 3.3 in chapter-3.
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Statement Air pollution control measures proposed for the effective control of gaseous/process emissions within permissible limits. Name of all the solvents to be used in the process and details of solvent recovery system. Design details of ETP, incinerator, if any along with boiler, scrubbers/bag filters etc
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Status Details provided in section 8.2 of chapter-8.
Details are provided in section 2.3.1 of Chapter 2. Two numbers Incinerators are considered in the PDPP complex. Design details will be finalized after detail engineering as per licensor inputs.
Effluent will be routed to IREP ETP for treatment and disposal. Design capacity of IREP ETP is 700 m3/hr which includes 35 m3/hr of effluent from PDPP. Disposal quality from IREP ETP is mentioned in table 2.15 of chapter 2. Details of water and air pollution and its Details are provided in section 4.3 and section mitigation plan. 4.4 of chapter-4. Action plan to control ambient air quality Details are provided in section 8.2.1 of as per NAAQS Standards notified by the chapter-8. Ministry on 16th September, 2009. An action plan prepared by SPCB to Not applicable as this is a Grass-root project. control and monitor secondary fugitive emissions from all the sources. Determination of atmospheric inversion The air quality modeling was done and it is level at the project site and assessment of seen that the maximum GLC’s are found to be ground level concentration of pollutants contained within the complex. Details provided from the stack emission based on site in Annexure XVI. specific meteorological features. Air quality modeling for proposed plant. Permission from competent Authority for Water required for PDPP is met from the the drawl of water. allocated quantity of BPCL refinery. A copy of approval is attached as Annexure XV. Water balance chart for existing and expansion project including quantity of effluent generated recycled and reused Water balance for PDPP is provided in section 2.5.2 and figure 2.7 of chapter-2. and effluent discharge. Attempt to be made for reduction for Various operational control measures will be usage of water. implemented in terms of HSE audit (surveillance & main) as per the HSE Policy. Cooling tower blow-down is sent to IREP RODM plant for recovery and recycle. Waste water is sent to IREP ETP for final treatment. Condensate from PDPP is sent to IREP for recovery. Complete scheme of effluent treatment. Effluent is routed to IREP ETP for treatment Characteristics of untreated and treated and disposal to meet the environment effluent to meet the standard. standards GSR 186(E) dated 18th March 2008. Zero discharge effluent concepts to be Zero effluent discharge concept has been
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Statement
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Status
adopted
adopted and no effluent is discharged outside. Effluent generated from PDPP is routed to IREP ETP for treatment and treated water is reused within refinery/recycled to PDPP.
Ground water quality monitoring minimum at 6 locations shall be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic). The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste.
Details are provided in section-3.3.1 and section 3.3.2 of chapter-3.
Details are chapter-2
provided
in
section-2.6.3
of
Action plan for the disposal of fly ash Not applicable generated from boiler shall be included. 36
Precautions to be taken during storage Details of chemical storage are provided in and transportation of hazardous section 2.4 of chapter 2. The same shall be chemicals shall be clearly mentioned and handled as per guidelines mentioned in MSDS. incorporated.
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Material Safety Data Sheet for all the Chemicals are being used/will be used. CAS No./RTECS No./DOT/UN etc to be mentioned against each chemicals Authorization/Membership for the disposal of solid/hazardous waste in TSDF
All details are attached as Annexure-IX.
Risk assessment for storage for chemicals/ solvent. Action plan for handling and safety system. An action plan to develop green belt in 33 % area.
Details are provided in Risk Assessment Study (attached as Annexure-XVII).
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Solid waste generated will be disposed through authorized agency. Permission to dispose solid waste is attached as Annexure XIX.
Details are provided in section 8.3.1 of chapter8.
Layout plan for green belt shall be provided 41
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Layout plan is attached in chapter 2 under figure 2.4 Action plan for rainwater harvesting The layout prepared includes rain water measures at plant site shall be included to harvesting pits. The same is provided in harvest rainwater from the roof tops and Annexure VI (GA of rainwater harvesting pit). storm water drains to recharge the ground water. Details of occupational health program. i) To which chemicals, workers are (i) All chemicals area handled through conduits exposed directly or indirectly. / pipes / vessels. No direct or indirect exposure is envisaged. ii) Whether these chemicals are within
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Threshold Limit Values (TLV)/ Limit Values (TLV).Details of chemicals in Permissible Exposure Levels as per terms of TLVs are given in MSDS are attached ACGIH recommendation. in IX. iii) What measures company have taken (iii) All measures as listed in specific MSDS will to keep these chemicals within PEL/TLV. be managed / executed during operation phase. The same shall be verified / audited / examined for gaps as per the protocol of existing QEHS management. iv) How the workers are evaluated (iv) During the pre-employment as well as concerning their exposure to chemicals during the periodic medical examination, the during pre-placement and periodical blood routine and urine routine examinations of medical monitoring. the employees are done. In addition, Urine phenol estimation of employees working in the existing ARU plant, and all employees who are liable to be exposed to benzene is also done.
v) What are onsite and offsite emergency (v) There exists company’s onsite & offsite plan during chemical disaster. emergency management plan. The organogram of the same is indicated in Annexure XI. Details of this document will be circulated and kept as per approved communication policy. vi) Liver function tests (LFT) during pre- (vi) An occupational laboratory under the placement and periodical examination supervision of doctor within the existing refinery will be extended for carrying out periodical examination. LFT is not being done during the Pre-employment or Periodic medical examinations. Details are provided in annexure (Occupational Health Program)
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Details of occupational health surveillance Details are provided in annexure programme. (Occupational Health Program)
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A
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Socio-economic development activities As per HSE management practice an shall be in place environmental cell consisting of corporate social management team will be developed. This team will monitor various socio economical development activities and formulate needful action plan. Note on compliance to the The same is attached as Annexure XII recommendations mentioned in the CREP guidelines. Detailed Environment management Plan Details are provided in chapter-8. (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound
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Statement implementation plan for mitigation measure shall be provided EMP shall include the concept of wasteminimization, recycle / reuse / recover techniques, energy conservation, and natural resource conservation. Total capital cost and recurring cost/annum for environmental pollution control measures
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Status
Details are given in chapter-8.
The estimated total cost of the project is approximately Rs. 4588 Crore. The total cost of projects includes the cost for pollution control measures. Proposed Capital Investment for Pollution Control Measures: Rs. 200 Crore. Proposed Recurring Cost for Pollution Control Measures: Rs. 4 Crore.
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Corporate Responsibility
Environmental
Details of the same are given in table 8.2 and table 8.3 of chapter 8.
(a) Does the company have a well laid Yes, Quality, Environment, Health & Safety down Environment Policy approved by Policy (QEHS) and of BPCL have been its Board of Directors? If so, it may be attached as Annexure X detailed in the EIA report. (b) Does the Environmental Policy Yes, QEHS Policy is attached as Annexure X. prescribe for standard operating process/procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in Organizational structure for Environment the EIA report. Management and Organogram for Emergency response & Disaster Management Plan are (c) What is the hierarchical system or attached as Annexure XI Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. (d) Does the company have a system of Yes, QEHS Policy is attached as Annexure X reporting of non compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report 50
Public hearing issues raised and A compliance statement on issues raised commitments made by the project during public hearing is attached as Annexureproponent on the same should be XVI.
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Statement
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included separately in EIA/EMP Report in the form of tabular chart. Any litigation pending against the project NIL and/or any direction/order passed by any Court of Law against the project, if so, details thereof.
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CHAPTER – 1 INTRODUCTION
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INTRODUCTION BPCL intends to establish a Propylene Derivatives Petrochemical Project (PDPP) at Kochi, India, to manufacture niche Petrochemicals products such as Acrylic acid, Oxo-alcohols and Acrylates. Polymer Grade Propylene (PGP) shall be supplied by BPCL Kochi Refinery after implementation of the Integrated Refinery Expansion Project (IREP) at Kochi, Kerala, India. The Project is expected to achieve mechanical completion in the first quarter of 2018. BPCL entrusted the task of preparation of Environmental Impact Assessment (EIA) and Risk Analysis/Assessment (RRA) studies to M/s Engineers India Limited (EIL) for obtaining Environmental Clearance. The details of such assessment studies are given in chapters 3 to 5. EIL is an accredited consultant for carrying out EIA studies by Quality Council of India in petrochemical industry.
1.1
NEED FOR PROPYLENE DERIVATIVES PETROCHEMICAL PROJECT The proposed Petrochemical Project is the first project of its kind in India producing niche chemicals such as Acrylic acid, Oxo-alcohols, and Acrylates. Worldwide, the major players that manufacture these niche petrochemicals are BASF, Dow Chemical, Arkema, Nippon Shokubai, StoHaas and LG Chem. These 6 manufacturers account for over 70% of the world capacity. Propylene is a versatile feedstock that is used in the manufacture of these niche petrochemicals. Earlier project established in India that produces Oxo alcohol is Andhra Petrochemicals, Vishakhapatnam. Now, BPCL has embarked upon a major project for capacity expansion of its Kochi Refinery from 9.5 to 15.5 MMTPA (Million Metric Tons per Annum), named as Integrated Refinery Expansion Project (IREP). The proposed IREP facilities include a Petro-FCCU from which about 500 kTPA (kilo ton per annum) polymer grade Propylene would be available. Therefore BPCL intends to establish a Propylene Derivatives Complex at Kochi, India that shall consume approximately 250 kTPA of polymer grade Propylene, derived from IREP to manufacture niche Petrochemical products. The finished products from the Petrochemical complex are utilized by a large number of domestic and industrial manufacturers of commodities such as, paints and other products. Among Acrylic Esters, the products in the order of greatest demand are Butyl Acrylate (BA) and 2-Ethyl Hexyl Acrylate (2-EHA). Ester grade Acrylic Acid is used in Detergents, water treatment, pulp and paper, textiles & surface coatings. The next largest market for Ester grade Acrylic Acid (EAA) is Super Absorbent Polymers (SAP). SAP is a cross linked poly acrylic acid salt that can absorb 100~1000 times its own weight in water. Future provision in terms of plot area is being provided in the PDPP complex to manufacture Glacial Acrylic Acid (GAA) an intermediate produced by processing EAA required to produce SAP. Products from PDPP and its uses are described in table 1.1.
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Table 1.1 Products from PDPP Product
Uses / Industry
Acrylates (BA & 2-EHA) N-Butanol/ 2 Ethyl Hexanol/ Iso Butanol Ester Grade Acrylic Acid Glacial Acrylic Acid & Absorbent Polymer (future)
Super
Paints & Inks, Adhesives, Textiles, Resins Plasticizers, Di-Octyl Phthalate, Detergents, Paints and Inks Water treatment chemicals, Detergent, pulp and paper, surface coatings Diaper / Female sanitary products/Irrigation
Market Demand in India (kTPA) The market study indicates excellent growth potential for niche chemicals such as Acrylic acid in the Indian market scenario. BPCL has excellent opportunity to overcome the supply shortfall that is predicted, based on the assumption that no new capacities are being added in the period up to the year 2018. The same is depicted below in table 1.2. Table 1.2 Demand of products 2018
2019
2020
2021
2022
2023
2024
2025
kTPA
kTPA
kTPA
kTPA
kTPA
kTPA
kTPA
kTPA
kTPA
47
30
31
33
34
35
36
39
107
180
158
170
179
187
195
207
223
241
10
8
9
9
10
10
11
12
13
N-Butanol
38
58
60
61
63
64
66
69
92
2 Ethyl Hexanol
47
94
99
102
105
109
113
119
126
Iso Butanol
7
36
37
38
39
39
40
42
44
Product Acrylic Acid Butyl Acrylate 2-Ethyl Hexyl Acrylate
PDPP Capacity
Shown below is a summary of basic product delivery schemes planned Area Domestic Export 1.2
Region All India Overseas Market
Mode of Transport Road Transport Sea
SCOPE OF THE EIA STUDY Project proposal for issue of Terms of Reference (TOR) for EIA was considered in the 6th reconstituted Expert Appraisal Committee (EAC) (Industry) meeting held during 5th March 2013. The Committee discussed the project details, utility requirements and the presentation by the project proponent/EIL. After detailed deliberations, the Expert Appraisal Committee prescribed Terms of Reference (TOR) for preparation of EIA/EMP. A copy of TOR is attached as Annexure –I. The EIA report is prepared in accordance with the approved TOR and a compliance statement is given in Annexure-II.
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Initially the project was planned with LG Chem as a joint venture (JV). Later LG Chem had withdrawn from JV and it has been decided that BPCL will proceed with the project on its own. The same was informed to MoEF and approval was obtained from MoEF for change in name, after LG Chem's exit from the project. Further, it was informed by MoEF that, all other conditions and validity of TOR remain unchanged. A copy of letter for approval of change in name is attached as Annexure III. The objectives of prescribed TOR for preparation of EIA study are as follows: To establish environmental setting of the project in terms of site details, project description, products/chemicals its storage, safety measures and precautions taken during storage and transportation, pollution control devices/measures, emission summary, hazardous waste/chemicals management etc. Establish existing environmental status for the period of 3 months (except monsoon season) for meteorology, air quality, water quality, noise, soil, ecology and Socioeconomic aspects. Prediction and evaluation of the environmental impacts that may result from project development. Outline the Environmental Management Plan (EMP) to mitigate the negative impacts, if any. Risk assessment for storage for chemicals/solvents. Action plan for handling & safety system. 1.3
FRAME WORK OF ASSESSMENT Based on the scope of work, guidelines generally followed for EIA studies and past experience of EIL on such industrial projects, a corridor encompassing of area within 10 km radius of proposed project location is considered as spatial frame for the impact assessment. Temporal frame of assessment has been chosen to reflect the impacts in two distinct phases of the project as: a) b)
Construction phase Operation Phase
Time frame and the type of impacts will be different for these phases of the project. 1.4
METHODOLOGY FOR ENVIRONMENTAL IMPACT ASSESSMENT The methodology adopted for carrying out the Environmental Impact Assessment for the proposed project has been based on the Guidelines issued by Ministry of Environment and Forests (MoEF) and EIL's past experience of similar jobs. An effective environmental assessment calls for establishing sufficient background data on various environmental components through reconnaissance survey, sampling and available literature survey etc. The methodology adopted in preparing this EIA report is outlined in the following sections:
1.4.1 PROJECT SETTING AND DESCRIPTION In this section, project site details, process description and other facilities are defined. The description also gives details of effluents (gaseous/liquid/solid/noise) and its generation Template No. 5-0000-0001-T2 Rev. 1
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sources. Coverage on environmental setting of the proposed Petrochemical complex in terms of site details, project description, products/chemicals and its storage and transportation facilities, pollution control measures, emission summary are described. This gives an overview of the proposed Petrochemical project development and management. 1.4.2 IDENTIFICATION OF IMPACTS In order to identify the impacts comprehensively, all the activities associated with the proposed project during the construction as well as operational phase are identified and listed. 1.4.3 BASELINE DATA COLLECTION Existing status of pollution in the study area have been established. M/s. Pragathi Labs Private Limited, Hyderabad, was engaged for establishing status of air, water, noise, and land. Ecology & biodiversity and socioeconomic component of environment are studied by inhouse accredited Functional Area Experts (FAEs). Existing environmental data for this Project was collected during the period of March 2013 to June 2013. Data thus collected has been utilized here for prediction and assessment of impacts quantitatively/qualitatively of various environmental parameters. 1.4.4 ENVIRONMENTAL IMPACT PREDICTION & EVALUATION In this part of the report, evaluation of pollution caused due to various emissions (Gaseous, Liquid, Solid, Noise) from the proposed activities is detailed. These identified impacts are assessed for arriving significance value in terms of high/ medium/low. In order to assess the overall significance, impacts are scrutinised in terms of its spatial, temporal, vulnerability & Intensity. Each of these parameters separately scaled and the same are summed up through a matrix form. 1.4.5 ENVIRONMENTAL MANAGEMENT PLAN (EMP) In order to mitigate or minimise the negative impacts of the proposed project, an effective EMP is called for. Therefore, in the final part of the report the planning and implementation of various pollution abatement strategies including the proposed monitoring/surveillance network has been described. Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure is formulated. 1.5 CONTENTS OF THE EIA REPORT The report has been divided into the following chapters: Chapter-1: Introduction This chapter provides the brief description and objectives of the project, scope of the study, need for propylene derivatives petrochemical project. Chapter-2: Project Description This chapter presents the details of the proposed project with description of the resources required and emissions, waste and wastewater anticipated to be generated. Template No. 5-0000-0001-T2 Rev. 1
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Chapter-3: Description of Environment This chapter describes the existing baseline status of environment components collected in a pre-defined study area based on primary and secondary data collection. Chapter-4: Anticipated environment impacts and mitigation measures This chapter describes the potential impacts of the proposed project and evaluates their significance based on parameters such as Intensity (I), Spatial extension (Sp), Temporal duration (T) and Environmental Vulnerability (V). Wherever applicable, mathematical models were used to quantify the intensity and spatial extension of the impacts. Impact avoidance and mitigation measures are delineated. Chapter-5: Environment monitoring programme This chapter describes the details of the monitoring schedule to be implemented for checking the effectiveness of mitigation measures. It covers the parameters, frequency and location of monitoring. If existing monitoring schedule is sufficient to cover the proposed development, the same has been clearly mentioned. Chapter-6: Additional Studies This chapter assesses the issues related to public consultation and the potential risks involved in the construction and operation of proposed facilities. This chapter also includes Rapid Risk Analysis (RRA). Chapter-7: Project Benefits This chapter presents the details of direct and indirect benefits due to proposed project. Chapter-8: Environment Management Plan This chapter describes the organizational structure and resources planned for implementing the mitigation measures and monitoring schedule. Chapter-9: Summary and Conclusions This chapter summarizes the potential positive and negative environmental impacts of the project. Chapter-10: Disclosure of Consultants This chapter contains the list of various experts engaged in preparing the EIA report along with brief introduction of the consultancy to which they belong.
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PROJECT PROPONENT ADDRESS OF THE PROJECT PROPONENT The correspondence address of the project proponent is: Mr. George Paul Dy. General Manager (Project-JV) BPCL- Kochi refinery Post Bag 2 Kundannur, Maradu- 682304 E-mail:
[email protected] Tel: 0484-2823802 Fax: 0484-2706408 PARTICULARS OF EIA CONSULTANT: The EIA consultant is Engineers India Limited. The complete address for correspondence is given below. Mr. J K Joshi Head, Environment Division Engineers India Limited Research & Development Complex, Sector-16, On NH-8 Gurgaon – 122001, Haryana Email:
[email protected] Telephone number: 0124-3803509 Fax number: 0124-2391413 Website: www.engineersindia.com
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CHAPTER – 2 PROJECT DESCRIPTION
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INTRODUCTION This chapter describes the details of proposed project configuration, process description, environmental setting of the project, utilities, waste and waste water generation etc.
2.1
PROJECT LOCATION Propylene Derivatives Petrochemical Project (PDPP) is located at Ambalamugal, Puthencruz/Thiruvaniyoor Village, Ernakulam District, Kerala. The project site is located at 4 km from NH-49, 5-km from Thripunithura railway station and 15 km from Ernakulam Major Railway station. Also the project site falls at Seismic Zone – III (as per IS-1893, Part III: 2002). Project location is shown in Figures 2.1 & 2.2.
PROJECT LOCATION
Figure 2.1: Project Location
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Figure 2.2: Project Location and its Boundaries A summary of environmental setting of the project is given in Table 2.1. Table 2.1: Environmental setting of the project.
Sr. No.
Particulars
Details
1
Plant Location
Ambalamugal, Ernakulam District, Kerala
2
Plant site co-ordinates
Latitude : 9057’36” N to 9058’57” N Longitude: 76021’56” E to 76024’12”E
3
Climatic Conditions (IMD, Kochi )
a)
Temperature Maximum Minimum Annual Rainfall Relative Humidity Predominant wind directions
b) c) d) 4 a) b) c)
Climatic conditions at Site Temperature Relative humidity Predominant wind directions
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33.0 oC (May) 21.10C (December) 3200 mm Maximum-89.0 % ; Minimum-66.0% Annual: 08.30:E 17.30: W From March –May 2013 Maximum: 35.8 oC ; Minimum: 21 oC Maximum:99% ; Minimum: 41% WNW and NW Copyrights EIL – All rights reserved
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5
Plant site Elevation above MSL
2 m to 32 m above MSL
6
Plant site Topography
Generally plain
7
Present Land use at the site
Industrial
8
Nearest Highway
NH-49 (4.0 km)
9
Nearest Railway station
Thripunithura (5.0 Km, NE)
10
Nearest Airport
Kochi (23 km, NW)
11
Nearest major water bodies
Chitrapuzha River (1.0 km, SW )
12
Nearest town/City
Thripunithura, (5.0 Km, NE)
13
Archaeologically important places
Hill Palace Museum at Thripunithura
14
Protected areas as per Wildlife Protection Act,1972 (Tiger reserve, Elephant reserve, Biospheres, National parks, Wildlife sanctuaries, community reserves and conservation reserves)
None in 10 km radius as per Wildlife Protection Act 1972
15
Seismicity
Seismic Zone-III as per IS 1893 (Part I): 2002
16
Defence Installations
None in 10-km radius area
Map showing study area encompassing 10 km radius of the proposed project is shown in figure 2.3. The 10 km study circle around the PDPP site comprises parts of Paravur and Kanayannur talukas in Ernakulam District. Ernakulam, Fort Cochin, Willingdon Island on the east and Puthencruz, Vadayabadi, Kolancheri on the west are the major boundaries of the proposed site. Cochin port, one of the major ports in the country is situated on Willingdon Island. Some of the major towns and villages within the study area are Nettur Eroor, kolancheri, Nalakkam, Karimukal, Chottanikkara, Brahmapuram, Irumpanam, Hill Palace, Puthencruz, Vytilla, Maradu etc. Several rivers discharge large quantities of fresh water and sediments into the backwaters. The most important river is Periyar with other smaller rivers being Muvattupuzha, Karunnanur, Mennachil, Chalakudy and Pamba. A unique feature of the area is the fishing using Chinese Fishing nets. As regards the road network in the study area, Cochin is connected to other states through National Highways (NH) No.47, 17 and 49. This NH 47 runs inland from Kanyakumari and joins at Salem. The NH 47 also connects at Trichur with NH 17, which runs northwards along Template No. 5-0000-0001-T2 Rev. 1
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the coast to Mumbai. A remote sensing map for Road network details is attached as Annexure IV.
Figure 2.3: 10 km radius of the proposed project
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Cochin has direct access in broad-gauge to the southern and national rail network including the recent Konkan Rail line facilitating connections to all major industrial towns and population centers.. The nearest railway station is located at Tripunithura at about 4 km in the eastern direction from the project site. Other major railway stations within the vicinity of the PDPP complex are Ernakulam Junction and Ernakulam Town and there is railway siding at Irumpanam. 2.2
PROJECT CONFIGURATION About 329 KTPA of products will be manufactured from Propylene Derivative Petrochemical Project (PDPP) Complex. List of Products manufactured from PDPP and its applications are provided in table no. 2.2. Table 2.2 List of Products Product Ester Grade Acrylic Acid (EAA)
Quantity (KTPA) 47
Butyl Acrylate
180
2-Ethyl Hexyl Acrylate
10
N-Butanol
38
2 Ethyl-Hexanol
47
Iso-Butanol
7
Total
Uses / Industry Water treatment chemicals, Detergents, pulp and paper, surface coatings Paints & Inks, Adhesives, Textiles, Resins Plasticiszers, Di-Octyl Phthalate, Detergents, Paints and Inks
329 Product
Uses / Industry
Glacial Acrylic Acid (future)
Water treatment chemicals, Detergent
Super Absorbent Polymer (future)
Diaper / Female sanitary products / Irrigation
Facilities within the complex other than process units include intermediate and finished product storages, interconnecting pipelines between refinery and PDPP, compressed air system, chilled water system for Acrylic Acid unit and Acrylate unit, Cooling water system, flare system (HP & LP), fire station, fire water storage & fire fighting systems, incinerators for safe disposal of process waste gas/liquid streams, warehouses for storage of chemicals & catalysts, , Product dispatch facilities, maintenance shop and warehouse, DCS control room, laboratory administration building, Sewage treatment plant, construction facilities etc. Power, Steam, Raw Water, DM water & Boiler Feed water are proposed to be sourced from the refinery. Construction activities are anticipated to take place over a period of at least three years. Commissioning and production ramp-up will be as follows: 80% in first year of operation 90% in second year of operation 100% in third year of operation Overall plot plan showing the process facilitates required for manufacturing the above products is given in figure 2.4.
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Figure 2.4 Overall Plot Plan of PDPP Template No. 5-0000-0001-T1 Rev. 1
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Total area required for the proposed propylene derive petrochemical project shall be 132.24 Acres. Out of which 40 Acres shall be used for green belt development. A detail of administrative distribution of total plot is given in table 2.3.A and breakup of the total plot in terms of its usage is given in table 2.3.B. Table 2.3.A: Administrative distribution of land Sl. No.
Village
Block No.
Survey Nos.
Area (in acres) 75.32
56.92
1
Puthencruz
39
167,168,174,176,177, 185,186,187,188,189, 190,191,192,193,194, 195,196,197,209,210,211
2
Thiruvaniyoor
40
2,3, 4,5,7,8,9,11, 62,63,64,65 Total
132.24
TABLE 2.3.B: Land-use breakup of plot S. No
Description
Area (in acres)
1.0
Plant facilities including Storage & Loading
78.2
2.0
Green Belt Development
40.0
3.0
Future facilities
14.04 Total Plant area Required
132.24
2.2.1 Raw materials Raw materials required for Propylene Derivative Petrochemical Project are Propylene Synthesis gas (CO + Hydrogen : 99 % (min); H2/CO : 0.99) Hydrogen (H2) Source of raw materials About 250 KTPA of polymer grade Propylene will be the feed for Propylene Derivative Petrochemical Project (PDPP). This would be available from Integrated Refinery Expansion Project (IREP) of BPCL-KR. Raw materials Hydrogen and Synthesis gas and utilities such as Nitrogen & Oxygen will be sourced from the Build Own and Operate (BOO) facility that is being set up as a part of IREP. As the PDPP Project site is located just opposite to the Kochi Refinery, no storage of raw material is envisaged inside PDPP Complex. Utilities integration with Refinery is shown in table 2.4.
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Table 2.4 Utilities integration with Refinery S. No Utility 1 DM Water 2 Treated Raw water 3 Power 4 Boiler Feed water (BFW) 5 Condensate 6 Nitrogen, Syn gas, Oxygen, Hydrogen 7 Fuel (Vaporized LPG) 8 Cooling tower blow down 9 Waste water 10 Fire water make up 11 Recycle water from IREP ETP* *after reverse osmosis treatment
Source / Destination From BPCL-KR From BPCL-KR From BPCL-KR From BPCL-KR To BPCL-KR From BPCL-KR (BOO Plant) From BPCL-KR To BPCL-KR To BPCL-KR From BPCL-KR From BPCL-KR
The complex is located close to the refinery to facilitate good integration for feedstock, utilities and offsite facilities.
Block Flow Diagram- Integration with Refinery EAA
ACRYLIC ACID 47 KTPA
PG PROPYLENE
ACRYLIC ACID UNIT (160 KTPA)
250 KTPA FROM: BPCL-KR AIR
BA 180 KTPA
GAA SAP (FUTURE UNIT) (FUTURE UNIT) EAA 113 KTPA
OXYGEN 800 NM3/ANNUM FROM: BOO-KR SYN GAS 99833 TPA FROM: BOO-KR
OXO ALCOHOL UNIT (212 KTPA)
N-BuOH: 112 KTPA
2-EHA 10 KTPA N-BUTANOL 38 KTPA
ACRYLATE UNIT (190 KTPA)
I-BUTANOL
7 KTPA
2-EH: 8 KTPA
2-EH
47 KTPA
N-BuOH / I-BuOH / 2-EH
EFFLUENT
HYDROGEN
TO: IREP-ETP
6584 TPA FROM: BOO-KR
OFFSITES
UTILITIES (Power ,HP STEAM, DMW, BFW, TRW, N2, Fuel, FW Make up)
UTILITIES
CHILLED WATER SYSTEM PDPP ISBL
BLOWDOWN TO: BPCL-KR CONDENSATE TO: BPCL-KR
Note: The Feed / Utility quantities indicated are tentative and subject to minor change post receipt of design package from Licensor
Figure No. 2.5 Block Flow diagram for Integration with refinery Template No. 5-0000-0001-T2 Rev. 1
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PROCESS DESCRIPTION The Processes involved in manufacture of each product are described in following sections.
2.3.1
Acrylic Acid (AA) Acrylic Acid is produced by a two stage reactor system. The first stage reactor oxidizes propylene with air to produce Acrolein. The second stage reactor oxidizes the Acrolein to Acrylic acid. Both reactions are exothermic. The heat of reaction is used to produce steam.
The series of steps required to produce Ester Grade Acrylic Acid is as follows Crude Acrylic Acid Section The Acrylic Acid produced in the reactors is recovered from the reactor product gas stream as an aqueous solution. The Crude Acrylic acid is sent to the Ester Grade Acrylic Acid (EAA) section for purification. The off gas generated by the process is sent to the incinerator. Acrylic Acid Reactor Section The heart of the reactor section consists of two tubular, fixed bed reactors, which are operated in series. The tubes are filled with catalyst effecting the desired oxidation reaction. From outside, the reactor tubes are cooled by circulating molten salt system. Salt bath temperature is controlled by heat exchangers, which generate steam. There is heater provision to maintain the temperature of the molten salt system when the unit is under temporary shutdown. The reactor feeds are propylene, air, steam and recycle gas. The steam and recycle off gas feeds are needed to help control reactor hotspot temperatures and provide a feed mixture, which is not flammable. The reactor feed mixture is too low in oxygen to be flammable during normal operation. The cooled reactor product gas stream is sent to the Acrylic Acid recovery section Acrylic Acid Recovery Section Quench Acrylic Acid is recovered from the reactor product gas as an aqueous solution in the quench tower. The reactor product gas enters the top of the quench tower and is quenched with a spray of liquid from offgas treater. This liquid is mainly water, Acrylic Acid and Acetic Acid. The aqueous Acrylic Acid solution is cooled in the quench tower bottoms cooler and sent to the extractor feed surge tank. Template No. 5-0000-0001-T2 Rev. 1
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Acrylic Acid Extraction and Solvent Recovery Solvent extraction is used to separate most of the water from the aqueous Acrylic Acid solution. The extraction solvent is a mixture of two different organic solvents. Iso Propyl Acetate (IPAC) rejects water while Cyclo-hexane extracts most of the Acrylic Acid. The raffinate (residual water phase) from the extractor bottom is sent to the raffinate stripper for recovery of solvents before the waste water is disposed. Solvent Separator The extract from the extractor is preheated in the solvent separator pre-heater and sent to the solvent separator. In the solvent separator, nearly all of the Cyclohexane and some of the IPAC are distilled off as the overhead stream. The overhead vapour stream is condensed in the internal thermoplate solvent separator condenser and collected in a condensate pan. The condensate is sent to the solvent separator decanter, where an internal baffle separates the organic and water phases. The solvent separator reflux pump returns a portion of the decanter organic phase to the top of the column as reflux, recycles a small amount to the inlet of the condenser, and sends the remainder to the Cyclohexane rich solvent storage tank. The decanter water phase is sent to the raffinate stripper via the solvent separator decanter water pump. The solvent separator operates under vacuum provided by the ejector system. Vapours in the vent gas from the solvent separator condenser are condensed in the internal thermoplate solvent separator vent condenser, which is cooled with refrigerated water from the Common Facility. The solvents are recycled back to the process from the storage tanks. Crude Acrylic Acid is separated from the extraction solvents by distillation. Acrylic acid is a heat sensitive product, which can dimerise and polymerise. Dimerisation results in loss of product and polymerization can cause fouling of equipment. Acrylic acid recovery and purification deals with prevention of undesirable reactions though the use of vacuum distillations, special distillation trays, and injection of polymerization inhibitors. Crude Acrylic Acid Ancillaries Inhibitor System: The recovery section includes facilities for preparation of Hydroquinine (HQ) inhibitor solutions in water and IPAC. The quantities of solid HQ required are transferred manually (unloading of inhibitor bags) into the mixing vessels. Inhibitor system is also provided for acrylic acid storage tanks in order to prevent polymerization. Vacuum System: A steam ejector vacuum system is required to maintain the required operating pressures for AA recovery distillation. Ester Grade Acrylic Acid Purification : Final purification from Crude Acrylic Acid (EAA) to Ester Grade Acrylic Acid (EAA) is achieved by vacuum distillation. The produced EAA is pumped to the following destinations: EAA export tank (O.S.B.L) for intermediate storage Inhibitor storage vessels 2.3.2
Acrylates This consist of one unit each producing Butyl Acrylate (BA) and 2- Ethyl Hexyl Acrylate (2EHA).
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Butyl Acrylate (BA) Fresh feed Acrylic Acid, Alcohol and a small amount of catalyst, are introduced into a series of two reactors known as 1st Esterification Reactor and 2nd Esterification Reactor. Water produced from the reaction is distilled and removed from the top of the Dehydrator. Reactor effluent containing both the product and catalyst is fed to the Catalyst Extraction Column to recover catalyst. The raffinate is fed from the top of the column to the washing column for separation of small amounts of acrylic acid and catalyst using water. The bottom stream is fed to the Alcohol Recovery Column where alcohol in the water is recovered from the top
The bottom stream from the Alcohol Topping Column is then fed to the Ester Purification Column where ester is distilled and recovered from the top of the column as product. The bottom stream is fed to the Heavy end Decomposer to recover Acrylate from heavy byproducts. 2-Ethyl Hexyl Acrylate (2-EHA) Fresh feed Acrylic Acid, excess molar ration of 2-Ethylhexanol to Acrylic Acid and small amount of catalyst are introduced into a series of two reactors known as 1st esterification reactor and 2nd esterification reactor successively. Water produced by the reaction is distilled with azeotropic solvent and removed from the top of the Dehydrator. Effluent containing both product and catalyst is fed to Catalyst extraction column to recover catalyst.
The raffinate is withdrawn from the top of the column and fed to washing column for the separation of small amounts of catalyst using water. The bottom stream from the column is discharged to the Waste water tank. The top stream is fed to the alcohol topping column where the unreacted 2-Ethyhexanol contained is recovered from the top of the column. The bottom stream is then fed to the Ester purification column where 2-EHA is distilled and recovered from the top of the column as product 2-EHA. 2.3.3
Oxo Process Propylene and Synthesis gas (CO + H2) are reacted to form Butyraldehyde. The reactions are carried out in reactors which contain proprietary rhodium catalyst ligand solution. Under the operating conditions selected, these reactions occur approximately in the ratio N-Butyraldehyde to Isobutyraldehyde in the range 10:1 to 30:1 depending on the ligand employed for the process. However, smaller amounts of the branched chain IsoButyraldehyde, Propane and various self-condensation products of the Aldehyde are also formed.
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The reactions are carried out in the liquid phase in two stirred tank reactors in series which contain the rhodium catalyst in the presence of a ligand. These catalysts are dissolved in a solution which is a mixture of reactants, products and by products, the latter being largely the heavier components formed from a series of chemical reactions starting with the selfcondensation of Butyraldehyde. Both Propylene and Synthesis gas are fed to the unit after a purification process to remove any impurities and contaminants that may affect catalyst activity. Propylene, Synthesis gas is fed to the OXO reactors are converted to N/I-Butyraldehyde. The reactor solution flows to the vaporizer where the product aldehyde is vaporised and separated from the catalyst solution in the vaporizer catchpot. Any entrained catalyst solution is recovered by the internals installed within the drum. The Aldehyde passes to the Condenser and the concentrated catalyst solution is cooled by the Cooler. The catalyst solution is then pumped to the Catalyst Conditioning Unit and then returned to the Oxo reactor completing the liquid recycles. The aldehyde from the vaporizer catch-pot is cooled and condensed in the Condenser and passes to the Condensate Drum where the vapor and liquid are separated. The Butyraldehyde is pumped to the stabilser. The vent is compressed by the vaporizer Vent Compressor and is cooled to condense the Butyraldehyde which flows to the vaporiser Vent Condensate Drum and the vapours are vented to the fuel gas header. The fuel gas generated has heating value and can be used for heating other process streams in the plant. The Aldehyde solution is further subjected to a stabilisation and Isomer separation process that produces n/i Butyraldehyde. n-Butyyraldehyde is sent to intermediate storage for the production of n-Butanol and 2-Ethyl Hexanol. The Butanol unit is designed to produce normal Butanol (n- BuOH) and iso Butanol (iBuOH). A) Alcohol Process (n-BuOH & i-BuOH) The Butanol unit contains the following sections: Vapour Phase Hydrogenation. Refining System
Normal Butanol and iso-Butanol are produced directly from mixed Butyraldehyde by hydrogenation. The downstream refining train consists of a series of distillation columns that produces n-Butanol and i-Butanol which are routed to storage. B) 2-Ethylhexanol (2-EH) The 2-EH Unit contains the following sections: Template No. 5-0000-0001-T2 Rev. 1
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Aldolisation. Ethyl-3-Propyl Acrolein (EPA) Hydrogenation. Refining System. Water Stripper and Vacuum System.
EPA is formed by the Aldolisation of n-Butyraldehyde to Butyraldol and then dehydration of the Butyraldol to 2-Ethyl-3-Propyl Acrolein (EPA) under the presence of an aqueous catalyst. n-Butyraldehyde feed is fed to the Aldol reactor. The product, unreacted reactants and from the aldol reactor pass forward to the high performance pipe reactor (HPPR). The reaction products are cooled and then decanted to remove the aqueous phase in the decanter. The major portion of aqueous phase leaving for the decanter is recycled to the reactor and a small is passed to a water treatment facility. The cooled product, EPA is purified in distillated tower. Slippage of unreacted n-BAL being taken as an overhead product is recycled to the reactor. High boils byproducts being taken as a bottom products are passed to a liquid fuel tank. Purified EPA being taken as a side cut product is fed directly to hydrogenation reactor where it is hydrogenation to form crude 2- Ethylhexanol product. The hydrogenation reactor feed, EPA is liquid phase. EPA and hydrogen are fed to the reactor. The liquid reactants pass downwards through reactor with hydrogenation catalyst. The hydrogenation reaction is exothermic; the heat cooled down by recycle of cooled product 2- Ethylhexanol. The 2-Ethyl Hexanol (2 EH) product is cooled and then separated from the recycle hydrogen gas in the catch-pot, and degassed. The recycle gas leaving the catch-pot and flash hydrogen are compressed and recycled to the hydrogenation reactor. The crude 2-Ethyl Hexanol is distilled to remove low boils components and high boils under vacuum to remove the lights which are unreacted organics, water and dissolved gases. The low boils are removed the overhead after condensation. The high boils are removed from the bottom of tower. The final product 2-Ethylhexanol is produced from the side of tower, and via the cooler to storage in the 2-EH Test Tank. Aqueous effluents from the Oxo Unit, BuOH Refining, 2-EH refining and Aldolisation sections, and the condensate from the vacuum package are routed to the water stripper section. Here the organic content is recovered for use as fuel and the stripped water passes to the battery limit for OSBL effluent treatment.
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2.4
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Raw material / Product storage Polymer grade Propylene, the raw material is stored in bullets located within BPCL-KR. Therefore no storage has been envisaged inside the PDPP Complex. Offsite storage facilities are designed to store and transfer feed, finished products. The list of offsite storage tanks, capacity of each tank and number of tanks are mentioned in table 2.5 below and the same is shown in overall plot plan. Table 2.5 Details of product storage Products
Capacity (Metric Tonne)
Quantity (Nos.)
Total Capacity (Metric Tonne)
AA
1000
2
2000
BA
4000
2
8000
2-EHA
1500
2
3000
2-EH
1500
2
3000
N-BuOH
1500
2
3000
i-BuOH
250
2
500
Apart from the above storage facilities as per requirement will be provided for Product rundown, intermediates, solvents and chemicals. 2.4.1
Logistics Below mentioned products shall be produced from PDDP Complex. These are targeted to be sold mainly in the domestic market. A small quantity of products is proposed to be exported to SEA, Western Europe, Middle East and Africa after the domestic demand is satisfied. The modes and routes of transfer of products are shown in Table 2.6. Table 2.6: PDPP Product Movement Modes Products
Quantity In KTPA
Type of vehicle required for road transport
EAA (Ester grade Acrylic acid)
47
Drums in trucks
BA (Butyl Acrylate)
180
Bulk Tankers / Drums in trucks
EHA (2- Ethyl Hexyl Acrylate)
10
Bulk Tankers / Drums in trucks
N- Butanol
38
Bulk Tankers / Drums in trucks
I- Butanol
7
Bulk Tankers / Drums in trucks
2-EH (2-Ethyl Hexanol)
47
Bulk Tankers / Drums in trucks
The above mentioned products shall be dispatched in Trucks / Tankers to domestic markets. Transport to overseas market shall be via Ship. Template No. 5-0000-0001-T2 Rev. 1
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UTILITIES CONSUMPTION A Build Own Operate (BOO) facility is being set up as a part of IREP, close to the refinery for supply of raw materials such as feed, utilities, off site facilities etc. The PDPP shall also source its requirement of Hydrogen, Nitrogen, Synthesis gas and Oxygen from the BOO plant. Hence considerable synergy exists between the PDPP project and BPCL-KR.
2.5.1
Synergy between IREP & PDPP o
Supply of feedstock, treated raw water, DM water and power from BPCL-KR.
o
Supply of Synthesis gas, Hydrogen, Nitrogen and Oxygen from Build Own & Operate (BOO) plant being set up by third party within the premises of BPCL-KR.
o
Reprocessing of blow down streams from PDPP in RO plant / Condensate Polishing Unit (CPU) of BPCL-KR’s IREP Project.
o
Final treatment of Waste Water from PDPP in BPCL-KR ETP.
This is illustrated in figure 2.6.
Figure 2.6: Synergy between IREP & PDPP 2.5.2
Water requirement Fresh water requirement for the proposed Propylene Derivative Petrochemical Project is 391 m3/hr (net quantity). This is met from BPCL Kochi Refinery for which authorization has already been obtained by BPCL-KR. Source of water for BPCL-KR is from Periyar River. BPCL - KR has consent from the Govt of Kerala for drawing water from Periyar River up to 3083.3 m3/hr. The projected demand for PDPP complex along with BPCL-KR existing consumption and IREP requirement is within the allocated quantity. Raw water will be used for various purposes such as, make up for cooling water, DM water /Boiler Feed
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Water (BFW) supply from refinery, drinking water. The water balance for PDPP is depicted in figure-2.7.
Figure 2.7: Water balance Normal fire water make-up requirement is 5-10 m3/hr. Fire water requirement shall met from available fire water network at BPCL-KR. 2.5.3
Power Consumption: Approximately 25 MW of power is required for the proposed PDPP as mentioned in Table2.7. The total power requirement shall be met from the Captive power plants of Refinery. Table 2.7: Breakup of power requirement of PDPP Consumer
Normal consumption (MW)
Process Units
14
Utility and Offsite Total
10.6 24.6
Backup power for PDPP complex shall be met from electrical grid which is part of the refinery. Thus no separate power facilities have been envisaged for PDPP.
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2.5.4
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Fuel Requirement The fuel requirements for proposed complex are given in Table 2.8. Table 2.8 Fuel Consumption
PDPP COMPLEX FUEL DEMAND Vaporized LPG for PDPP complex
Unit Kg/hr
Consumption 1213
Note: LNG is proposed to be used as an alternate fuel. The figure indicated above is the net Fuel
consumption after considering internal generation of gas/liquid fuel streams from the process. Emissions have been worked out with low sulphur fuel oil combination firing.
2.5.5
Cooling Water System: Cooling water requirement for all the new facilities in the PDPP complex will be entirely met through new re-circulating cooling water system operating with treated raw water as makeup. The make-up water for the cooling water system shall be pumped from the raw water system of BPCL (KR) complex by cooling water make up pumps. PDPP complex cooling tower blow down shall be routed to BPCL-KR.
2.6
EMISSIONS FROM PROPOSED UNITS The emissions in terms of air, wastewater, solid & hazardous wastes are estimated to be generated from proposed project is given in succeeding sections.
2.6.1
Air Environment Two stacks are envisaged from process units for release of emissions. Off gases and other waste gases generated from the process units are routed to waste incineration unit for treatment. Air emissions released from the same is tabulated in below table 2.9.
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Table 2.9 Details of air emissions Acrylic Acid Process Off Gas
Flow Rate
Gas Composition
84 tons/hr
Relief from Oxidation Reactor
As per design
Molecular wt - 27.7 wt % Nitrogen – 83.28 % Oxygen – 4.77 % Argon – 1.41 % CO – 0.96 % CO2 – 2.78 % C2 ,C3 – 0.39 % Organics including Acrolein , Acetic acid etc – 0.39 % Water – 6 %
Acrylates Process Effluent gas 53000nm3/hr
Oxo Alcohol Process Vacuum 2.0 Nm3/hr Package (Nor) Vent 3.0 Nm3/hr Tank Vent Gas LP OFF Gases High pressure off gas
4000 Nm3/hr
Suggested Treatment Methods Waste Incineration Unit
Max Stack Emission to Atmosphere SOX ≤ 200 mg/Nm3 NOX ≤ 100 mg/Nm3 HCL ≤ 50 mg/Nm3 CO ≤ 100 mg/Nm3 Cl2 ≤ 5 mg/Nm3 Organics ≤ 20mg/Nm3
Routed to flare
Emergency
Waste SOX ≤ Incineration 200mg/Nm3 Unit NOX ≤ 400mg/Nm3 CO ≤ 100mg/Nm3 Particulate ≤ 50mg/Nm3 Saturated with organics ,mainly 2EH
Waste Incineration Unit
Routed to flare
Emergency only
VOC Emissions VOC shall be emitted from Fugitive Emission, Vent Gas of Product storage tank & Loading Area of Acrylic Acid, Butyl Acrylate, 2-Ethyl Hexyl Acrylate, N-butanol, Iso Butanol & Vent Gas of SAP (future) Process. VOC emissions shall be suitably addressed in the detailed engineering stage. 2.6.2
Water Environment About 35 m3/hr of effluent is generated from PDPP which is routed to IREP ETP for treatment and recycle. IREP ETP is having provision for treating 50 m3/hr of waste water generated from PDPP. The summary of effluent generated from PDPP is shown in below table 2.10.
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Table 2.10 Effluent summary Acrylic Acid Process
Flow rate
Quality
Waste water
16.4 tons/hr
Liquid Organic waste
0.24 tons/hr
Water: 92.59% Acetic Acid: 4.17% Formaldehyde: 1.89% COD: 83wtppm Polymer: 39.22% Dimer Acrylic Acid:23.55% Hydroquinone: 25.17% Phenothiazine: 5.30% MEHQ: 3.15%
Acrylates Process Waste water 16.0 tons/hr
Oxo Alcohol Process Waste water 2.35 m3/hr (nor.) 3.0 m3/hr(max) Aldol effluent
0.3 m3 /hr (nor) 0.6 m3/hr (max)
Suggested treatment methods Incineration
Final quality COD : 125 ppm
Incineration
COD ≤ 125wtppm Oil ≤ 50wtppm Temperature ≤ 50°C Cu : 1 ppm
Either incineration or routing to IREP ETP as per licenser advise
COD : 500 ppmw BOD : 100 ppm mg/l Total Phosphate : 0.1 mol/l (max.) Org. Sodium Salt : 50 ppmw (max.) COD : 80,000 mg/l (max) BOD : 50,000 mg/l (max) NaOH : 0.5 wt% Na Butyrate : 5 wt% C8 Heavies : 1 wt%
Either incineration or routing to IREP ETP as per licenser advise Waste Incineration Unit
The liquid effluent shall be routed to IREP ETP for treatment and shall meet all standards specified by MoEF. Effluent with higher COD will be routed to waste incineration unit. Contaminated Rain water: Actual quantity and quality of Contaminated Rain Water (CRW) will depend on the intensity of the rain on particular day. About 1000 m3/day of CRW is estimated from PDPP plot area. First 15 minutes of accumulated contaminated rain water (CRW) from the PDPP complex shall be routed to an oil water separator and will be reused. Blow-down: CT blow down is being sent from PDPP to IREP RODM Plant and shall be considered under combined flow for handling / treatment / recovery. No treatment is envisaged in PDPP.
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Sanitary Effluent: Sanitary waste from the Petrochemical complex shall be routed to a sanitary effluent treatment package unit. The package unit shall consist of physical removal of suspended solids and biological treatment for the removal of BOD and COD. This step will be complemented by filtration and adsorption followed by chlorine disinfections before discharging to green belt. Following shall be the design conditions for Sanitary Effluent Streams: Design Flow of STP: 5 m3/hr Table No. 2.11 Quality of Sanitary effluent Parameter BOD COD TSS
Concentration 200 400 200
All units are in mg/l. Sanitary effluent shall be treated to meet total suspended solids < 100 mg/l and BOD3 days, 270C < 100 mg/l. 2.6.3
SOLID AND HAZARDOUS WASTE MANAGEMENT The solid waste generated in the PDPP complex is described in table 2.12. Some quantities of solid waste are expected to be generated during the construction phase. These wastes shall be disposed as per statutory requirements. Solid waste generated will be disposed by Landfill / incineration methods that will comply with all statutory requirements. Table-2.12 - Handling of Solid waste Acrylic Acid Process Polymer residue : 3 kg/hr Spent catalyst: 130 m3 in 40 months Acrylates Process Heavy ends Oxo Alcohol Process Spent Catalyst
Suggested treatment methods Third party vendor for disposal Shipped back to vendor for precious metal recovery Used as fuel in the process Secure landfill or shipped back to vendor for metal recovery
Details of spent catalysts generated from PDPP are given in below table 2.13.
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Table 2.13 Catalyst Summary for PDPP Quantity (m3)
Replacement
Oxidation Catalyst Initial Charge (Proprietary)
Catalyst-1 : 65.4 Catalyst-2 : 65.4
40 months
Spent Catalyst shipped back to the vendor for reprocessing
Feed Purification adsorbent -1 Feed Purification adsorbent -2
48.4
36 months
Disposal to landfill
8.9
36 months
Recovery of precious metal/landfill
Feed Deoxidation Catalyst
2.3
36 months
Recovery of precious metal/landfill
Oxo reactor
16 kg
24 months
3.6 kg/annum make up
Proprietary Catalyst
585 kg
Catalyst Name
Hydrogenation Catalyst 2.6.4
106.5 ton
Remarks
2.64 ton/annum make up 24 months
Recovery of precious metal
Noise Emission The overall noise levels in and around the proposed petrochemical complex shall be kept well within the standards by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels conform to the standards prescribed under Environmental (Protection) Act, 1986 Rules, and 1989.
2.7
Environment Measures
2.7.1
Proposed Air Pollution Control Measures In order to minimize the impact of the proposed project on the environment, due attention is given for implementing effective pollution control measures. Emissions from the PDPP complex will be as per statutory norms. The PDPP complex will be designed in such a way that the total emission from the facility will meet all the applicable standards / stipulations. To control fugitive emissions following measures will be taken: Minimum number of flanges, valves etc. High grade gasket materials. Usage of state-of-art low leakage valves preferably with bellow seals. Usage of pumps with mechanical seals. Provisions of double seal in some storage tanks. Provision of seals in the drains and manholes. The emissions of SO2, NOx, SPM and CO, from the incinerators, shall be monitored as per statutory regulations. On-line emission analyzers shall be installed on all stacks. Control measures provided for each source of air emission is described in the following sections.
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Waste gas / Waste Oil: The following waste streams from Acrylic Acid plant are burnt in the Waste Incineration Unit: Gaseous waste consisting of off-gas and plant vent streams Liquid organic waste stream and waste water with high COD content The waste Incinerator unit consists of Combustion chamber, burners, Steam boiler and super-heater, including off-gas stack. The organic waste stream as well as the organic content in the off-gas stream contributes to the heat balance. The waste streams are routed to the burner together with the required support fuel (Fuel oil/Vaporized LPG) and the incineration air. The incineration temperature reached inside the incineration chamber and the belonging retention time is sufficient to achieve a conversion of all compounds to be burned that will comply with emission regulations as per table 2.14. The hot flue gas from the combustion chamber can be utilized to generate steam, as well pre-heating boiler feed water. A Schematic diagram for incineration facility is shown in Figure 2.8.
Figure 2.8 Schematic diagram for incineration facility Gaseous and Liquid waste streams from Acrylates and Oxo-alcohol unit shall also be incinerated and the emissions will comply with the stipulated regulations. Table 2.14 Indian standard for Incineration Pollutant PM SO2 NOX CO
Standard (mg/Nm3) 50 200 400 100
Note: All monitored values shall be corrected to 11% oxygen on dry basis. The CO2 concentration in tail gas shall not be less than 7%. Developing Green Belt: As Green cover acts as a natural sink to pollutants, 40 acres of land have been allotted for developing the Green belt around the project site. Template No. 5-0000-0001-T2 Rev. 1
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2.7.2
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Water Pollution Management System Quality of water disposed from IREP ETP is given in table no. 2.15 Table No. 2.15: Quality of disposal of treated effluent from IREP
2.7.3
Sl. No. 1 2 3 4 5 6 7 8 9 10
Temperature pH Oil & Grease, mg/l BOD3 days, 27 deg C, mg/l COD, mg/l Total Suspended Solids (TSS), mg/l Sulphides, mg/l Phenol, mg/l Ammonia as N, mg/L TKN, mg/L
11
Total Dissolved Solids, mg/l
Parameters
Value Ambient 6.0 – 8.5 5 15 125 20 0.5 0.35 15 40 ~5000 (Normal) /~7000 (Design)
Noise Pollution Management System Noise Abatement Measures in Plant Area: The overall noise levels in and around the proposed petrochemical complex shall be kept well within the standards by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels conform to the standards prescribed under Environmental (Protection) Act, 1986 Rules, and 1989.
2.7.4
Land Pollution Management System For the protection of the land environment, BPCL will adopt environmentally sound solid waste management practices based on the philosophy of minimization of generation of solid waste and safe disposal of residual waste. Groundwater monitoring: The quality of ground water shall be periodically monitored to ensure that there is no adverse impact of complex operations on the groundwater quality.
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CHAPTER-3 EXISTING ENVIRONMENTAL STATUS
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3.0
DESCRIPTION OF ENVIRONMENT
3.1
AIR ENVIRONMENT
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The monitoring network for the air quality surveillance program is based on the following considerations. Meteorological conditions on synoptic scale Topography of the study area Representation of regional background levels Representation of plant site Representation of cross sectional distribution in the downward direction Influence of the existing sources if any, are to be kept at minimum Inclusion of major distinct villages to collect the baseline status 3.1.1
Micrometeorological Data Micro-meteorological data within the project area during the air quality survey period is an indispensable part of air pollution study. The meteorological data recorded during survey period is very useful for proper interpretation of the baseline information as well as for input to predictive models for air quality impacts.
Meteorological data
Primary data: Hourly data collected at site using AWS (3 months) Parameters like Wind speed, wind direction, Temperature, Humidity and Rainfall collected and computed to hourly results using Automatic Weather Station for 90 days near to the project site installed at >10 m height. Secondary data Available last 1 year (IMD Thiruvananthapuram) (Temperature, Humidity, Rainfall, wind direction and speed)
3.1.1.1 Historical Data Historical data on meteorological parameters also plays an important role in identifying the general meteorological status of the region. Site specific data can be compared with historical data in order to identify changes which may have taken place due to the various developments in the area. Meteorological Data from IMD: As per the historical data (IMD), collected for one year at Naval Air station at Kochi (April 2012 to March 2013), the maximum mean wind speed (12.3 km/hr) was recorded in the month of May where the minimum mean wind speed (7.8 km/hr) in the month of June. 3.1.1.2 Meteorology – Data generated at plant site Meteorology of the study zones plays an important role in the study of air pollution. Micrometeorological conditions at the proposed project site regulate the dispersion and dilution of air pollutants in the atmosphere. For this purpose an automatic weather station (Watch Dog 2000 series USA) was installed near the plant site for three months (March May 2013) and recorded hourly observations for the parameters like Maximum and
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Minimum Temperatures (ºC), Relative Humidity (%), Wind Speed (km/hr), Wind direction, Solar radiation (Watt/m2) and Rainfall (mm). The hourly-recorded observations (wind velocity and wind directions) during 4 weeks study period are used in computing percentage frequencies (0-7 morning, 8-15 noon, 16-23 evening & 0-23 hrs) and are depicted in the form of „wind roses‟ in Fig 3.1.1. The predominant wind direction is WNW followed by NW with an average wind speed 9.4 kmph. Maximum and minimum temperature is 39.9 OC and 21 OC during the study period is given in Table 3.1.1. Table 3.1.1 Summarised Primary Meteorological data (Period: March – May 2013)
Month
March April May
Wind Speed
Relative Humidity (%)
Temperature (0C)
(Kmph) Mean Max. Min. Mean Max. Min. Avg.
9.3 9.1 9.7
28.7 32.4 21.0 29.6 35.8 23.3 31.1 34.2 22.0
0-7 Hours
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69 58 64
84 99 99
Solar Radiation Watt/m2
Rain fall (mm)
56 41 45
No. of rainy days
10 9 10
24-hours Total Mean Highest
12 47 17
30.6 91.5 76.9
223 227 246
Max.
967 963 1029
8-15 Hours
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16-23 Hours
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0-23 Hours
Fig 3.1.1 Primary Meteorological data –Wind Roses Period: March - May 2013 3.1.2
Selection of AAQ stations A network of Twelve (12) ambient air-sampling locations has been selected for assessment of the existing status of air environment within the study zone (Fig 3.1.2). The heights of the sampling locations were kept between 4 to 6 m in all the locations. After reconnaissance of the area and observing the topographical features and review of the available meteorological data and local conditions the sampling sites were chosen which will be the representative of the local areas under study.
Code
Locations
A1 A2 A3 A4 A5 A6
Irumpanam CISF Quarters Eroor Bramahapuram Puthencruz Karimukal
Distance Direction (KM) w.r.t Project --W 0.3 W 0.6 WNW 0.9 N 1 E 1.4 ENE
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Code
Locations
A7 A8 A9 A10 A11 A12
Chottanikkara Maradu Vytilla Nettur Nalakkam Kolancheri
Distance Direction (KM) w.r.t Project 2.3 SE 5.6 SW 5.0 WSW 7.5 SW 7.2 NW 8.5 E
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Fig 3.1.2 Map showing Ambient Air sampling Locations 3.1.3
Existing AAQ status Pollutants like PM10, PM2.5, SO2, NOx, CO, O3, NH4, C6H6, HC and Non Methane Hydrocarbons were selected and analyzed. The methodology of sampling and analysis in detail are given in the following tables.
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Parameters sampling duration Attribute AAQ
Parameter PM10,PM 2.5 , SO2, NOx, CO, O3, NH4, C6H6, HC & Non Methane Hydrocarbons
Frequency of Monitoring 24 hr sampling for PM10, PM2.5, SO2, NOx, HC & Non methane Hydrocarbons. 8 hr sampling for O3 & CO. Sampling height varies between 3-6 m above ground level.
Gases
Variables
Dust
Table 3.1.2: Ambient Air Quality - Methodology
PM10
Pollutant Particulate Matter
Method of analysis Gravimetric (Fine Dust Sampler)
PM2.5
Particulate Matter
Gravimetric (Fine Dust Sampler)
SO2
Sulfur Dioxide
NOx
Nitrous Oxides
O3 CO NH4 C6H6 HC NHC
Ozone Carbon monoxide Ammonia Benzene Methane Hydrocarbons Non methane Hydrocarbons
Improved West and Geake Method Jacob & Hochheisser Modified Na Arsenate Spectrophotometric Method Gas Chromatography Indo Phenol Blue Method Gas Chromatography Gas Chromatography Gas Chromatography
Installation Install at a place where representative results anticipated of the area and away from local activities. At least 15 m distance from local sources Sampling height: 4-6 m (free from obstructions).
Rota meter flow: 0.2 LPM Impinger: Capacity 35 ml, 22 cm in length and 2.6 cm wide, impinging end of the tube 1 mm bore size. Manometer: Average >1.1 cu.m/minute Sampling duration 24 hr sampling for SPM, PM10, PM2.5, SO2, NOx, HC & Non methane Hydrocarbons. 8 hr sampling for O3, CO. During 3 month season monitoring period each week 2 samples will be collected at each site during 12 week survey period. Samples will be collected in such a way that all days in a week (Monday to Saturday) will be covered.
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Fig 3.1.3 Measuring instruments 3.1.4 Results and Discussion The AAQ survey has been carried out at 12 locations within the study zone. Measurement of the actual, PM10, PM2.5, SO2, NOx, CO, O3, NH4, C6H6, HC and Non Methane Hydrocarbons levels help to understand the existing environmental scenario. The results of SO2, NOx, SPM and PM10 & Ozone, Benzene & Ammonia are expressed in g/m3, CO expressed in mg/m3, where as the results of HC is expressed in ppm. Various statistical parameters like standard deviation, geometric mean, minimum, maximum concentrations and different percentiles have been computed from the data generated during sampling in all sampling stations (Tables 3.1.3 to 3.1.11). Table 3.1.3 National Ambient Air Quality Standards Sl. No.
1.0
Pollutant
Sulphur Dioxide (SO2)
Time Weighted Average Annual Average* 24 hours**
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Concentration in Ambient Air Industrial, Methods of Ecologically Residential, measurement Sensitive Rural & other Area areas 50 µg/m3 20 µg/m3 -Improved West and Gaeke 80 µg/m3 80 µg/m3 -Ultraviolet Fluorescence
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2.0
3.0 4.0
5.0
6.0
Oxides of Nitrogen as NO2 Particulate Matter , Size
