Sponsor :

Reliance Jamnagar Infrastructure Limited

Consolidated EIA document with Clarifications & Additional

information Provided to the MoEF, New Delhi

October 2009
 Contents
Index No. Title Page No.

Executive Summary (I- XVIII)

List of Plates viii

List of Figures ix
List of Tables xii
List of Annexure xvi
1.0 Introduction
1.1 Preamble 1.1
1.2 Project Setting 1.3
1.2.1 Existing industrial Estate in Jamnagar District 1.4
1.2.2 Common facilities for the SEZ 1.10
1.2.2.1 Captive Power Plant (CPP) 1.10
1.2.2.2 Desalination Plant 1.10
1.2.2.3 Central Effluent Treatment Plant 1.11
1.2.2.4 Common Incinerator Facility 1.11
1.2.2.5 Common Secured Landfill Facility 1.11
1.2.3 Project Cost and Schedule 1.12
1.3 Stage of EIA 1.12
1.4 Scope of EIA 1.12
1.5 Objectives 1.13
1.6 Study Area 1.14
1. 7 Approaches and Methodology 1.14
1.7.1 Establishing Baseline Environmental Status 1.14
1.7.1.1 Physical Resources 1.14
1.7.1.2 Ecological Resources 1.17
1.7.1.3 Economic Development 1.18
1.7.2 Anticipated Environmental Impacts 1.19
1.7.3 Environmental Management Plan 1.19
1.8 Contents of the Report 1.20
1.9 Environmental Clearance Process 1.21

2.0 Description of the Project

2.1 Indian SEZ Policy 2.1
2.1.1 Some of the Key benefits of an SEZ are as follows: 2.1
2.1.2 SEZs and Labour Laws 2.2
2.1.3 Emerging Domestic SEZ's in Gujarat 2.3
2.1.4 Gujarat State SEZ Policy 2.3
2.2 The National Economy 2.5

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Index No. Title Page No.

2.3 The State Economy 2.7

2.3.1 Economic Growth of Gujarat 2.8
2.3.2 Sectoral growth 2.8
2.3.3 Industrial Development in Gujarat 2.8

2.4 Location & Connectivity 2.10

2.4.1 Scale (Size - Scalability) 2.11

2.4.2 Port Operations 2.11
2.5 Regional Attributes of Jamnagar 2.12
2.6 The Development Plan 2.12
2.6.1 Targeted Industrial Components 2.13
2.6.2 The Housing 2.15
2.6.3 Building Social Health 2.16
2.7 Infrastructure Facilities 2.16
2.7.1 Water Supply 2.16
2.7.1.1 Sources of Supply: 2.17
2.7.2 Power 2.19

3.0 Process Description

3.1 Introduction 3.1

3.2 C1 based Units 3.3
3.2.1 Integrated Gasification Combined Cycle(Petcoke Gasification) 3.3
3.2.2 Methanol 3.7
3.2.3 Acetic Acid 3.7
3.2.4 Vinyl Acetate Monomer 3.9
3.2.5 Poly Vinyl Acetate 3.10
3.2.6 Poly Vinyl Alcohol 3.11
3.3 C2 Based Units 3.12
3.3.1 Multifeed Steam Cracker 3.12
3.3.2 Monoethylene glycol (MEG)/Diethylene Glycol (DEG) and
Triethylene Glycol (TEG) 3.16
3.3.3 Polyethylene (LDPE/LLDPE) 3.17
3.4 C3 Based Units 3.18
3.4.1 Acrylic acid 3.18
3.4.2 Super Absorbent Polymer (SAP) 3.19
3.4.3 2-Ethyl Hexanol 3.20
3.4.4 n-butyraldehyde 3.22
3.4.5 n-Butyl Acrylate 3.23

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 Index No. Title Page No.
3.4.6 n-Butanol 3.24
3.4.7 Propylene Oxide 3.25
3.4.8 Hydrogen Peroxide (H2O2) 3.28
3.4.9 Polypropylene (PP) 3.31
3.5 C4/C5 Based Units 3.31
3.5.1 Butyl /Halo Butyl Rubber 3.31
3.5.2 E-SBR Project 3.34
3.5.3 Maleic anhydride 3.35
3.6 C6/C7/C8 based Units 3.36
3.6.1 Mono Nitro Benzene 3.36
3.6.2 Aniline 3.37
3.6.3 Methylene Di Aniline 3.38
3.6.4 Phosgene 3.39
3.6.5 Methylene Diphenyl Diisocyanate 3.40
3.6.6 Styrene 3.41
3.6.7 Paraxylene and Orthoxylene 3.43
3.6.8 Purified terepthalic acid (PTA) 3.44
3.6.9 Polyester/ Polyethylene Tere-phthalate (PET) 3.45
3.6.10 PSF - Process Description 3.47
3.6.11 Staple Fibre Production 3.49
3.6.12 Downstream Process 3.51
3.6.13 POY Process 3.54
3.7 Carbon Black 3.55
3.8 Lube Oil Cum Refinery Complex 3.56
3.9 Captive Power Plant 3.58

3.10 Desal Plant 3.59

3.11 JERP Refinery 3.62

3.12 Product, Process and Utility Integration 3.64

4.0 Baseline Environmental Status

4.1 Air Environment 4.2

4.1.1
Design of Network for Ambient Air Quality
Monitoring Locations 4.2
4.1.2 Reconnaissance 4.2
4.1.3 Ambient Air Quality Monitoring 4.3
4.1.4 Instruments used for Analysis 4.3
4.1.5 Micrometeorology 4.4

4.1.5.1 Mixing Height/Inversion Study 4.4

4.1.6 Existing Ambient Air Quality Status 4.5

4.1.7 Ambient Air Quality Concentrations vis-à-vis
Stipulated Standards 4.8

_____________________________________________________________________

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Index No. Title Page No.

4.2 Noise Environment 4.41

4.2.1 Reconnaissance 4.41
4.2.2 Background Noise 4.41
4.2.2.1 Noise Levels in Residential and Commercial Areas 4.42
4.2.2.2 Noise Levels in Industrial Areas 4.42
4.2.2.3 Noise Levels in Silence Zone 4.42
4.2.3 Traffic Study 4.43

4.3 Water Environment 4.47

4.3.1 Reconnaissance 4.47
4.3.2 Baseline Data 4.47
4.3.2.1 Surface Water Resources 4.47
4.3.2.2 Methodology for Water Quality Assessment 4.48
4.3.2.3 Surface Water Quality 4.48
4.3.2.4 Groundwater Resources 4.49
4.3.2.5 Ground Water Quality 4.50
4.3.3 Bacteriological Characteristics 4.50
4.3.4 Biological Characteristics 4.50

4.4 Land Environment 4.64

4.4.1 Reconnaissance 4.64
4.4.2 Geology at Project Site 4.64
4.4.3 Baseline Status 4.65
4.4.3.1 Physical Characteristics of Soil 4.65
4.4.3.2 Chemical Characteristics 4.65
4.4.4 Soil Microbiology 4.67
4.4.5 Landuse Pattern 4.67
4.4.6 Remote Sensing Studies for Land use Analysis 4.67

4.5 Biological Environment 4.93

4.5.1 Introduction 4.93
4.5.2 Study Area 4.94
4.5.3 Survey Methodology 4.94
4.5.4 Vegetation Biodiversity in Study Area 4.95

_____________________________________________________________________

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 Index No. Title Page No.
4.5.5 Floristic Structure and Composition 4.96
4.5.5.1 Floristic Characteristic within 15 km
radius from the Proposed Project Site 4.96
4.5.5.2 Floristic Characteristic within 15-25 km
radius from the Proposed Project Site 4.97
4.5.6 Medicinal Plants in Study Area 4.98
4.5.7 Social Forestry 4.98
4.5.8 Reserved Forest 4.99
4.5.9 Threatened Plant Species 4.99
4.5.10 Agriculture 4.99
4.5.10.1 Agroclimatic Condition of Study Area 4.100
4.5.11 Assessment of Wildlife and Avifauna 4.100

4.5.11.1 Faunal Diversity 4.100

4.5.11.2 Avifauna 4.100
4.5.11.3 Rare, Endangered and Vulnerable Faunal Species 4.101

4.5.12 Fishery 4.101

4.6 Socio-Economic Environment 4.123

4.6.1 Reconnaissance 4.123
4.6.2 Baseline Status 4.123

4.6.2.1 Demographic Structure 4.124

4.6.2.2 Infrastructure Resource Base 4.124
4.6.2.3 Economic Attributes 4.125
4.6.2.4 Health Status 4.126
4.6.2.5 Cultural and Aesthetic Attributes 4.126

4.6.3 Socio-economic Survey 4.126

4.6.4 Awareness and Opinion of the People about the Project 4.128
4.6.5 Quality of Life 4.128

5.0 Identification and Prediction of Environmental Impacts

5.1 Impacts During Construction Phase 5.3

5.1.1 Air Environment 5.4
5.1.2 Noise Environment 5.5
5.1.3 Water Environment 5.5
5.1.4 Land Environment 5.6
5.1.5 Biological Environment 5.6
5.1.6 Socio-economic Environment 5.7
5.1.7 Impacts on Health & Safety 5.7

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Index No. Title Page No.

5.2 Impacts during Operation Phase 5.11

5.2.1 Air Environment 5.11
5.2.1.1 Air Pollutant Emissions 5.11
5.2.1.2 Micro-Meteorology 5.12
5.2.1.3 Air Quality Modeling 5.12

5.2.2 Noise Environment 5.28

5.2.2.1 Impacts due to Stationary Noise Source 5.28

5.2.3 Water Environment 5.32

5.2.3.1 Water requirement 5.32
5.2.4 Land Environment 5.34
5.2.4.1 Land use Pattern 5.34
5.2.5 Biological Environment 5.34
5.2.6 Socio-economic Environment 5.34

5.3 Pollution Load 5.39

5.4 Public Consulation Summary 5.39

6.0 Environmental Management Plan

6.1 EMP during Construction Phase 6.3

6.1.1 Site Preparation 6.3
6.1.2 Air Environment 6.3
6.1.3 Noise Environment 6.5
6.1.4 Water Environment 6.5
6.1.5 Land Environment 6.7
6.1.6 Biological Environment 6.8
6.1.7 Socio-economic Environment 6.9
6.1.8 Energy and Water Use 6.10

6.2 Environmental Management Plan during Operational Phase 6.10

6.2.1 Air Environment 6.11
6.2.2 Noise Environment 6.16
6.2.3 Water Environment 6.17

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Index No. Title Page No.

6.2.3.1 Sewerage Management Plan 6.18

6.2.3.2 Drainage 6.19
6.2.3.3 Wastewater treatment plant 6.20
6.2.4 Land Environment 6.23
6.2.4.1 Hazardous /Solid Waste Management 6.24
6.2.4.2 Common Incinerator Facility 6.28
6.2.4.3 Common Secured Landfill Facility 6.31
6.2.5 Biological Environment 6.38
6.2.5.1 Preparation of greenbelt plan keeping in
view the selected plant species 6.39
6.2.5.2 Guidelines for plantation 6.39
6.2.6 Socio-economic Environment 6.40
6.2.7 Health and Safety 6.40
6.2.8 A note on Occupational and surveillance and safety measures 6.41
6.3 Capital/ Recurring Expenditure on Environmental Management 6.41
6.4 Proposed Environment Monitoring 6.41

7.0 Rehabilitation and Resettlement Plan

7.1 Socio Economic Survey 7.1
7.1.1 Demographic Profile of Project affected People 7.1
7.1.2 Recommendations from National
Rehabilitation and Resettlement Plan 7.4
7.2 Recommendations 7.6
7.3 R&R Programme Monitoring and Reporting Procedure 7.7

vii
 List of Plates

Plate No. Title Page No.

Plate I False Colour Composite of Study area around Proposed 4.74

SEZ Site at Jamnagar

Plate II Land use / Land Cover Status around 25 km of the 4.75

proposed SEZ

4.5.1 A View of Thorny Vegetation near the Tebhada Reserve 4.104

Forest

4.5.2 A View of Mangrove Vegetation near Vadinar Village salt pan 4.104

4.5.3 A View of forest observed near the Sansora Reserve Forest 4.105

4.5.4 Reef Heron observed near the Vadinar Jetty 4.105

_______________________________________________________________________

viii
 List of Figures

Figure No. Title Page No.

1.1 Location of SEZ at Jamnagar 1.23

1.2 Location of SEZ Area 1.24

1.3 Overall Plot Plan of Proposed SEZ 1.25

1.4 Study Area around the Proposed SEZ 1.26

2.1 Existing and Proposed SEZ’s in India 2.21

2.2 Water Balance for SEZ (All figures in m3/hr) 2.22

3.1 Proposed Units of SEZ 3.67

3.2 Process Flow Diagram for IGCC Unit 3.68

3.3 Process Flow Diagrams for the Production of Methanol by the 3.69
Copper Catalyzed Intermediate Pressure Process

3.4 Process Flow Diagram for Acetic Acid 3.70

3.5 Process Flow diagram for Vinyl Acetate Monomer by the

Vapor Process 3.71

3.6 Process Flow Diagram for Poly Vinyl Acetate 3.72

3.7 Process Flow Diagram For The Production Of Poly Vinyl

Alcohol By Solution Polymerization 3.73

3.8 Block Flow Diagram for Multifeed Steam Cracker 3.74

3.9 Propane Dehyfrogenation in cracker complex 3.75

3.10 Block Diagram for Mono Ethylene Glycol 3.76

3.11 Block Flow Diagram of PE (I & II) Process 3.77

3.12 Process Flow Diagram for Crude Acrylic Acid Production

Process 3.78

3.13 Process Flow Diagram for Production of SAP 3.79

3.14 Process Flow Diagram for 2-EthylHexanol 3.80

3.15 Process Flow Diagram for n-butyraldehyde 3.81

_______________________________________________________________________

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Figure No. Title Page No.

3.16 Process Flow Diagram for n-Butyl Acrylate 3.82

3.17 Process Flow Diagram for n-Butanol 3.83

3.18 Propylene Derivatives- Cumene process 3.84

3.19 Propylene Derivatives – Phenol process 3.84

3.20 The Anthraquinone Process for H2O2 Manufacture 3.85

3.21 Block Flow Diagram of Poly Propylene (PP) 3.86

3.22 Process Flow Diagram of ESBR 3.87

3.23 Process Flow Diagram of Maleic Anhydride 3.88

3.24 Schematic of Mono Nitro Benzene Process 3.89

3.25 Process Flow Diagram for Aniline 3.90

3.26 Block Diagram For MDA Production Process 3.91

3.27 A Process Flow Diagram : Phosgene Manufacture 3.92

3.27 B Process Flow Diagram for Scrubbing of Remaining Gases 3.92

3.28 Schematic of Polymeric Methylene Dianiline Phosgenation

Process 3.93

3.29 Process Flow Diagram of Styrene 3.94

3.30 Block Diagram for Aromatics 3.95

3.31 Block Flow Diagram for Production of PTA 3.96

3.32 1000 KTA Bottle Grade PET: Continuous Polymerisation

Section (CP) 3.97

3.33 Block Diagram for production and Packing of Bottle Grade PET 3.98

3.34 Block Flow Diagram For POY / FDY / DTY Production 3.99

3.35 Block Diagram of the Carbon Black Manufacturing Process 3.100

3.36 Block Diagram of Captive Power Plant 3.102

3.37 Process Flow of Desal Plant 3.103

3.38 Overall Integration of petroleum and petrochemical complex 3.104

3.39 Overall Energy Integration 3.105

3.40 Overall water balance Integration 3.106

x
 4.1.1 Sampling Location for Ambient Air Quality Monitoring 4.9

4.1.2 Windrose diagram during Winter Season 4.10

4.2.1 Sampling Location for Noise Monitoring 4.44

4.3.1 Sampling Locations for Water Quality Monitoring

(Surface and Ground Water) 4.53

Figure No. Title Page No.

4.4.1 Location Identified for Soil Sampling 4.71

4.4.2 Texture Diagram for Soil Samples 4.72

4.4.3 Pie Chart Showing the Land use Pattern in the Study Area 4.73

4.5.1 Location Identified for Biological Survey 4.103

4.6.1 Socio-economic in the study area 4.131

4.6.2 Employment pattern in the study area 4.132

5.1 Estimated GLCs of SO2 due to Proposed SEZ in Winter Season 5.15

5.2 Estimated GLCs of NOx due to Proposed SEZ in Winter Season 5.16

5.3 Predicted Noise Contours due to Proposed Units at SEZ 5.30

5.4 Water Balance Diagram 5.33

6.1 Schematic Flow Diagram of Proposed Central Effluent 6.43

Treatment Plant in SEZ

6.2 Schematic Profile of an FML Plus Composite Double 6.44

Liner System for a Landfill

6.3 Schematic of an FML plus Composite Double-liner System 6.45

for a Landfill

6.4 Block Flow Diagram of MEG pretreatment 6.46

xi
 List of Tables
Table No. Title Page No.

1.1 Feasibility Analysis For The Location of SEZ 1.27

1.2 List of Units Proposed for SEZ Project 1.30

1.3 Recommended Methods of Monitoring & Analysis for

Criteria Parameters and Pollutants 1.34

2.1 Existing & Proposed Special Economic Zones in India 2.23

3.1 Proposed Storage tanks – SEZ 3.107

3.2 Proposed Solid Storage Tanks – SEZ 3.109

3.3 Proposed Storage Tanks for the Liquid Products 3.109

3.4 Proposed Storage Tanks for Safe Stock 3.110

4.1.1 Environmental Attributes & Frequency of Monitoring 4.11

4.1.2 Details of Ambient Air Quality Monitoring Locations 4.12

4.1.3 Instruments Used for Analysis 4.13

4.1.4 Techniques Used for Ambient Air Quality Monitoring 4.14

4.1.5 Ambient Air Quality Status (Winter Season) 4.15

4.1.6 Ambient Air Quality Status (Winter Season) 4.17

4.1.7 Cumulative Percentile of SPM (Winter Season) 4.19

4.1.8 Cumulative Percentile of RSPM (Winter Season) 4.20

4.1.9 Cumulative Percentile of SO2 (Winter Season) 4.21

4.1.10 Cumulative Percentile of NOx (Winter Season) 4.22

4.1.11 Cumulative Percentile of NH3 (Winter Season) 4.23

4.1.12 Concentrations of Non-methane Hydrocarbons and

Carbon Monoxide (Winter Season) 4.24

4.1.13 Comparison of Ambient Air Quality Levels with Stipulated

Standards 4.25

4.2.1 Background Noise Levels in the Study Area 4.45

4.3.1 Sampling Locations for Water Quality 4.54

___________________________________________________________________

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 Table No. Title Page No.

4.3.2 Standard Operating Procedure for Water and

Wastewater Sampling & Analysis 4.55
4.3.3 Analytical Techniques and Test Detectable Limits for
Water and Wastewater Sampling and Analysis 4.56
4.3.4 Water Quality - Physical Parameters 4.57

4.3.5 Water Quality - Inorganic Parameters 4.58

4.3.6 Water Quality - Nutrient, Demand and Organic Parameters 4.59

4.3.7 Water Quality - Heavy Metals 4.60

4.3.8 Water Quality - Bacteriological Parameters 4.61

4.3.9 Water Quality – Biological Parameters (Phytoplankton) 4.62

4.3.10 Biological Parameter – Zooplankton 4.63

4.4.1 Soil Sampling Locations 4.76

4.4.2 Soil Texture in Study Area 4.77

4.4.3 Physical Characteristics of Soil 4.78

4.4.4 Chemical Characteristics of Soil Extract 4.79

4.4.5 Cation Exchange Capacity of Soil 4.80

4.4.6 Relationship of CEC with Adsorptivity 4.81

4.4.7 Relationship of CEC with Productivity 4.81

4.4.8 Fertility Status of Soils in the Study Area 4.82

4.4.9 Soil Quality - Heavy Metals 4.83

4.4.10 Microbiological Characteristics of Soil 4.84

4.4.11 Landuse Pattern in Villages of the study Area 4.85

4.4.12 Landuse/Land Cover Classification System 4.91

4.4.13 Inventory of Landuse /Landcover (25 km) 4.92

4.5.1 Sampling Locations for Biological Environment Survey in

the Study Area 4.106

4.5.2 Common Plant Species Present in Jamnagar Dist 4.107

_______________________________________________________________________

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Table No. Title Page No.

4.5.3 Medicinal Plants in Jamnagar District and their Medicinal Value 4.112

4.5.4 Simpson’s Diversity Index (SDI) of Flora in the Study Area 4.115

4.5.5 List of Agricultural Crops in Jamnagar District 4.116

4.5.6 List of Fauna found in the Jamnagar District 4.117

4.5.7 Rare, Endangered and Vulnerable Status of Birds

in Jamnagar District 4.120

4.5.8 List of Marine Fish Species 4.121

4.5.9 Different Prawn Species Found in the Gulf of Kutch 4.122

4.6.1 Distance and Direction of the Villages Surveyed 4.133

4.6.2 Demographic Structure in Study Area 4.134

4.6.3 Summary of Demographic Structure 4.139

4.6.4 Infrastructure Resource Base of the Study Area 4.140

4.6.5 Mortality Rate of the Study Area 4.141

4.6.6 Existing Quality of Life in the Study Area 4.142

5.1 Likely Impacts of Construction Phase 5.9

5.2 Likely Impacts of Operational Phase 5.17

5.3 SEZ Units 5.19

5.4 Stack Details for the Refinery, Power Plant and the Petrochemical 5.20
Units

5.5 Meteorological Data for winter season 5.24

5.6 Cumulative Values of GLCs for SO2 and NOx after Superimposing
with the Baseline AAQM Data 5.27

5.7 Noise Impact from Stationary Sources at SEZ at Nearby

Communities 5.31

5.8 Prediction of Qualitative Impacts on Socio-economic

Environment 5.36

5.9 Expected Change in Subjective Quality of Life 5.37

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Table No. Title Page No.

5.10 Expected Change in Cumulative Quality of Life 5.38

5.11 Pollution Load from Units in Petroleum & Petrochemical complex 5.41

5.12 Water requirement and effluent generation from each unit 5.43

6.1 Hazardous Waste Quality and Mode of Disposal 6.47

6.2 List of Plant Species suggested for Green belt 6.50

6.3 Post-project Environmental Monitoring Plan 6.51

6.4 Effluent Characteristics of PFY unit 6.56

xv
 List of Annexure
Annexure Title
No.

I National Ambient Air Quality Standards (NAAQS) (1994)

II Noise Standards

III Damage Risk Criteria of Noise Levels for Hearing Loss,

Occupational Safety & Health Administration (OSHA)

IV Classification of Inland Surface Water (CPCB Standards)

V General Standards for Discharge of Environmental Pollutants-

Effluents (Gazette Notification of MoEF, May 1993)

VI Procedure for Environmental Clearance of the project

VII Pollution Prevention and Abatement Handbook (World Bank

Group) for Petrochemicals Manufacturing, July 1998.

VIII Resettlement & Rehabilitation Plan Instructions of Government of India

(Ministry of Industry) 1988

IX Safe Management of Phosgene

X Salient Futures of Multi feed cracker complex

XI Technical Details of Incinerator

XII A note on Occupational health and Surveillance at Jamnagar Refinery

Complex

XIII Safety Management systems at RIL, Jamnagar Refinery Complex

xvi
 Executive Summary
1.0 Introduction
The enactment of SEZ Act 2005 by the Central Government and the State SEZ
Act and rules notified by the State Government of Gujarat has enthused Reliance
Jamnagar Infrastructure Limited (RJIL) to set up a multi-product Special Economic Zone in
the backward rural area of Jamnagar district of Gujarat with modern integrated
infrastructure. The SEZ will have all the required infrastructure and facilities to ensure
sustainable development of medium and large-scale industries and service activities.

The proposed site is located near the State Highway No 25 on the way from Rajkot
to Okha and is adjacent to the existing refinery complex of Reliance Industries Limited
(RIL). The overall size of the SEZ is approximately 4,545 hectares (11,231 acres).

The latitude and longitude of the center of the proposed SEZ are 22o 20’ 30” North and 69o
53’ 00’’ East.

The various petroleum and petrochemical downstream units which can be set up
in the proposed SEZ are as follows:

C1 Based Units

• Coke Gasification

• Methanol Synthesis

• Acetic Acid

• Vinyl Acetate Monomer

• Polyvinyl Acetate (PVA)

• Polyvinyl Alcohols (PVOH)

C2 Based Units

• Multifeed Cracker Complex

• Ehtylene Oxide Derivatives like Mono Ethylene Glycol (MEG), Di Ethylene

Glycol (DEG) Tri Ethylene Glycol (TEG)

i
 • Polyethylene polymers like Low Density Polyethylene, Linear Low Density
Polyethylene (LLDPE), High Density Polyethylene

C3 Based Units

• Acrylic Acid & derivatives , Super Absorbent Polymer (SAP)

• Acrylates (Methyl, Butyl & 2 Hexyl & Oxy Alcohols)

• Propylene derivatives like Propylene Oxide, Cumene, Phenol

• Propylene Glycols

• Polyols

• Hydrogen Peroxide (H2O2)

• Polypropylene PP (Non woven)

• Polypropylene (PP)

C4/C5 Based Units

• Butyl Rubber , Styrene Butadiene Rubber (SBR) ,

• Poly Butadiene Rubber (PBR)

• Butene 1

• Maleic Anhydride (MA)

• Fumaric Acid

C6/ C7/ C8 Based Units

• Benzene

• Styrene

• Paraxylene (PX), Orthoxylene (OX)

• Putrefied Teraphthalic acid (PTA)

• Polyethylene Tera-phthalate (PET)

• Polyesters Complex Polyester Oriented Yarn (POY)

• Polyester Stable Fibre (PSF)

Carbon Black Feedstock

Lube Oil cum refinery Complex (LOBS)
Captive Power Plant
& Jamnagar Export Refinery Project (JERP) which has already been accorded
Environmental Clearance by the MoEF in 2005 / 2006.

ii
 The Modernization and de-bottle necking of the existing refinery and expansion
refinery (called as Jamnagar Export Refinery) along with their infrastructure had been
accorded the environmental clearance by the ministry in 2005 and amended in 2006. Since
this JERP is being built in the SEZ area, JERP is included in the EIA. However, the
emissions of JERP are included in the analysis of this study.

The common facilities for the proposed SEZ are Captive power plant, Desalination
Plant, Central ETP, Incinerator and a Secured disposal facility. The desalination plant will
be providing 15,000 cu m/hr of water required for the industrial and the residential complex.

The power requirement for the proposed zone would be met through a captive
power plant of 2100 MW capacity to be set up as a part of the SEZ infrastructure.

Government of India have announced a Policy of Special Economic Zones (SEZs)

during March 2005 with a view to augmenting infrastructure facilities for export production.

The Central Government has offered various incentives and facilities both to
developer of SEZ as well as the industrial units coming up on SEZ. All approvals are to be
given by the Development Commissioner for establishment of the unit in SEZ. The
management of the Special Economic Zone will be under the designated Development
Commissioner.

The Development Commissioner will grant all the permissions as Single Point
Clearance from his office. These will include registration of the unit, allocation of land,
permission for construction of building and approval of building plan, power connection,
environmental clearance, water requirement etc.

Transactions within the SEZ shall be exempted from all State taxes including
Sales Tax, VAT, Motor spirit tax, luxury tax and entertainment tax, purchase tax and other
state taxes.

SEZ located in the Jamnagar district the, in close proximity to Arabian Sea. The
other advantages are:

• It is well connected with important state road network (state highway no. 25)
and other important national node via NH- 8A. It is about 30km from
Jamnagar and 340km from Ahmedabad

• A broad gauge railway network connects Reliance SEZ with Jamnagar and
other rail network

• Reliance port at Sikka, being a part of Reliance industries would contribute a

good deal of efficiency in the functioning of the SEZ

iii
 • Airports at Jamnagar are in near proximity to the SEZ site only 25 km.

The Reliance will develop the industry, housing, social infrastructure needed for
their refinery and its allied activities. The SEZ is expected to generate employment for
40,000 people.

A new Residential township is being proposed to house the employees and the
growing influx of immigration due to the new industries coming up in the SEZ unit. The
township will be designed on sectoral basis where each sector will be self-sufficient in
terms of commercial, retail, public/semi-public amenities.

2.0 Key Findings

2.1 Air Environment
The ambient air environment monitoring was done in the year of 2005-06 winter
seasons and the analysis is as follows.

AAQM locations were monitored on 24 hourly average basis as per the guidelines
of CPCB and NAAQS. The conventional and project specific parameters such as
Suspended Particulate Matter (SPM), Respirable Suspended Particulate Matter (RSPM),
Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx), Ammonia (NH3), Carbon Monoxide (CO)
and Non-Methane Hydrocarbons (NMHC) were monitored at AAQM Locations.

The overall 24 hourly wind rose during winter season indicates the predominant
winds from N-E sector. During winter season, 98th percentile values of 24 hourly SPM
concentration ranged between 99.9-396 μg/m3. The arithmetic mean varied between 87-
256 μg/m3. 98th percentile and arithmetic mean of 24 hourly RSPM concentrations varied in
the range of 60.8-175 μg/m3 and 6-114 μg/m3 respectively. The 98th percentile
concentrations of 24 hourly SO2 in winter season varied from
6-31 μg/m3. The arithmetic mean ranges from 4.5-22 μg/m3.The 98th percentile
concentrations of 24 hourly NOx in winter ranged between
10-30 μg/m . The arithmetic mean values varied between 6-20.33 μg/m .The arithmetic
3 3

mean and 98th percentile values of NH3 were observed in the range of 10-192 μg/m3 and
31-274 μg/m3 .CO and NMHC concentrations at all the monitoring locations are observed to
be varying in the range of 263-1139 μg/m3 and BDL – 138 μg/m3.

It was observed that SPM and RSPM concentrations exceeded the stipulated
standards at most of the ambient air quality monitoring locations.

The Industrial Source Complex – Short Term Version 3 (ISCST-3) model has been
developed to simulate the effect of emissions from point sources on air quality. As per the

iv
model, the maximum GLCs of SO2 and NOX from SEZ emission are estimated to be 57
μg/m3 (4.16 km, SSW Direction) and 56 μg/m3 (4.16 km, SSW Direction) respectively in
winter season. The estimated GLCs for SO2 and NOX after superimposing with the
baseline are in the range of 14-60 μg/m3 and 23-51 μg/m3 respectively within the stipulated
standards for the industrial areas.

Subsequently, the ambient air monitoring was done for 2007-2008 winter season.
The analysis as follows.

SPM:

The Ambient Air Quality Monitoring was carried out by NEERI during winter
season (2008) wherein SPM concentration were observed at the border line / more than
the average for the area at 15 places out of 24 locations.

As the Jamnagar SEZ located in a semi arid area with low green cover and very
scanty rainfall in the last two years which are the main contributing factors for getting more
values of Ground Level Concentration of SPM. The very low green cover (only 15%) can be
seen from Landuse/land cover pattern satellite image given in EIA Report

The main contributing factor for the variation in the SPM values can be co-related
with rainfall occurred during that period. The rainfall in 2007-08 season spread is confined
to only 3 days. If the rain is spread over the season then moisture content in the soil
remains for longer period which is helpful to minimize the dust resuspension and
subsequently results in lower SPM value.

More SPM values are observed at Moti Khavadi, Arablus, Mungani, Satalus can
be attributed because of the higher vehicular traffic, poor road conditions, dirt tracks, cattle
movements etc. in the area.

SO2

The average SO2 concentration was observed to be marginally more ( than 30

µg/m3 ) at three locations. However, These SO2 concentration are much less than the
standards of National Ambient Air Quality Standards (NNAQS) for industrial / residential
area.

Cl2

Generally the chloride in the ambient air is found out in the form of sodium chloride
in the aerosol type condition typically near the sea coast due to the wind action. However, it
will be quite difficult to measure by using the standard high volume sampling method. This
is also has been checked in the literature.

v
 As suggested by the honorable members of the committee “the Cl2 concentrations
in the above mentioned range very rarely occur in typical urban pollution.

HCl

As in the case of CL2 the results are very erroneous.

2.2 Noise Environment

The noise levels ranged between 30-70 dBA during daytime and 38-60 dBA during
nighttime. The noise levels in commercial areas varied in the range of 30-60 dBA during
daytime and 43-53 dBA during nighttime.

Noise levels were measured in front of these industries during daytime and
nighttime and observed to varying in the range of 46 – 59 dBA during daytime and
42 – 51 dBA during nighttime.

Noise levels were also monitored in schools, hospitals and temples in the study
area. The noise levels varied from 47-55 dBA during daytime and 38-53 dBA during night
time.

The noise levels are observed to be within the stipulated standards of CPCB for
the respective zones in the study area except at few places.

The cumulative noise impact from different stationary sources at proposed project
site has been predicted at 100mx100m grid intervals over an area of 33.52 km x 31.8 km
noise impact area mainly covering project premises.

The predicted noise contours indicate that the maximum noise levels outsite the
proposed SEZ would be 22 dBA. The predicted noise levels after superimposing the
predicted noise levels with the baseline data is in the range of 41-60 dBA during the day
time and 34-42 dBA during the night time.

2.3 Water Environment

In order to determine the surface and groundwater quality, three sampling
locations for surface water, 18 sampling locations for groundwater were identified in the
study area.

Surface Water
pH varied in the range of 8.6 – 8.8, turbidity 7 - 12 NTU, total dissolved solids
(inorganic) 393-510 mg/l, hardness 206-313 mg/l, chloride 112-128 mg/l, and sulphate 25-
32 mg/l.

Nutrient values in the form of nitrate-nitrogen and total phosphates are low in the
range of 5.0 – 9.0 mg/l and 0.16-0.21 mg/l respectively. The values for demand parameters

vi
like DO, COD and BOD are in the range of 5.9 – 7.1 mg/l, 43 – 99 mg/l and 20-40 mg/l
respectively. Oil & grease and hydrocarbons are found in non-detectable levels. The
bacteriological characteristics of surface water showed total coliform counts in the range of
220 to 310 CFU/100 ml. Both the reservoirs were found to be faecally contaminated having
faecal coliforms in the range of 30-45 CFU/100 ml.

Ground Water
The groundwater quality showed high mineral contents in the form of total
dissolved solids, total hardness, chloride, sulphate and sodium and were found in the range
of 477-3024 mg/l, 259-1592 mg/l, 123-1200 mg/l, 42-328 mg/l and 36-500 mg/l
respectively. CFU/100 ml.

The groundwater in four villages (Gagwa, Kanachikari, Nanikhavdi and Mungni) is

found to be faecally contaminated and unfit for human consumption, unless suitably
treated.

The Shannon-Weaver Diversity Index for phytoplanktons varies from 2.25-3.79

and from 1.0-2.75 in surface water and groundwater (dug wells) respectively. The Shannon
Weaver Diversity Index of zooplanktons which is found to vary in the range of 1.846-2.320
in surface water and 0.918 to 105 in groundwater indicates low to moderate productivity.

The proposed SEZ project requires water for boilers & heaters, processes,
process cooling, utilities cooling, domestic consumption, fire water make up and greenbelt
development/horticulture. The entire water requirement will be met from the desalination of
seawater and supplemented with water from the Narmada Water project. The desal water
requirement after expansion is estimated to be 15000 m3/hr, and accordingly sea water
requirement will be 36000 m3/hr and the discharge back to the sea will be 23400 m3/hr.

2.4 Land Environment

It is observed that soil texture varies from clay to sandy clay. The bulk density of
soil of the impact zone is found to be 1.11 - 1.35 gm/cm3 which is considered to be
moderate. The porosity and water holding capacity of soil are in the range of 39-66% and
40-69% respectively. The soils have moderate water holding capacity.

The pH of soil in the study area are in the range of 6.52 - 8.6. The pH range of soil
is found to be favorable for plant growth. Electrical conductivity, a measure of soluble salts
in soil is in the range of 0.27-1.6 mS/cm. It is observed that calcium and magnesium
concentrations are in the range of 0.12-3.92 meq/l and 0.02-1.43 meq/l respectively;
whereas sodium and potassium are in the range of 0.08-1.03 meq/l and 0.02-0.15 meq/l
respectively.

vii
 The landuse / landcover classification based on remote sensing analysis indicates
6.65% mudflat, 0.68% fringe vegetation, 2.40% saltpan, 26.09% agricultural land, 24.19
fallow land, 2.65% seawater, 3.07% built-up land, 32.23% barrenland, 2.02% waterbodies.

The major source of solid waste generated from SEZ complex will mainly consists
of oily sludge, spent clay, spent catalysts, slope oil, biological sludge, canteen wastes,
batteries, surplus drums, etc. The quantification of solid/hazardous wastes has been
carried out and handling/management/treatment and disposal of these wastes will be
carried out as per the stipulated guidelines and requirements of CPCB/MoEF.

2.5 Biological Environment

In all 30 locations were selected for study on biological aspects. The study area
around the proposed SEZ comprises of terrestrial and marine ecosystems due to nearness
to Gulf of Kutch. During the floristic survey in study area, a total of 165 plant species were
recorded. A total of 76 tree species, 28 shrub species, 22 herb species, 23 grasses and 16
climbers were recorded from the study area.The study area shows presence of medicinal
plants. Out of total 165 plants studied, 51 plant species including 25 trees, 10 herbs and 16
shrubs are of medicinal value. Not a single species out of 165 plant species was observed
to be threatened in the study area. The staple food of the people in the study region is rice
and wheat. The common Kharif crops of this region are groundnut, sesamum, cotton,
castor, bajra etc. whereas wheat, gram, cumain, ajwan (semi-rabi) are the Rabi crops.

30 sampling sites were selected at various places in the study area for the
assessment of avifauna. A total number of 20 species of birds were encountered during the
survey.

2.6 Socioeconomic Environment

The study comprises 115 villages consisting of 38 villages of Jamnagar taluka, 41
villages of Khambaliya Taluka and 36 villages of Lalpur Taluka from Jamnagar district.

The significant demographic features are:

• The total no of households in the study area are 216222

• The total population in the study area is 1175132

• Sex ratio (No. of females per 1000 males) is 928

• It is observed that the study area has an average literacy rate of 60.24% and
the employment rate is 30.33%

During the socio-economic survey in the 18 villages it was observed that people
are facing certain problems.

viii
 The average QoL index value for the study area is leaning towards satisfactory
level due to good economic status like low income, unemployment and also availability of
basic needs, viz. food, clothing, and housing.

The area lacking with medical, educational facilities and social security, besides
water scarcity, inadequate irrigation, lack of sanitation, which are subjective conditions and
are not much satisfactory as compared to objective conditions.

It is estimated that about 50,000 construction workers on average will be involved

for a period of 2-3 years. The total employment during the construction phase will be about
24 lakh man months (both skilled and non-skilled employment). The manpower required for
these activities should preferably be employed from nearby villages so that avenues of
employment will be open to local people

During the socio-economic survey it was observed that the proposed SEZ might
create certain beneficial as well as adverse effects on the socio economic environment.
Some of these impacts would be more effective for the immediate vicinity with short-term
effects whereas the others would be higher order or of long term in nature.

3.0 Environmental Management Plan

RIL group has got a strong, consistent and committed corporate policy in the
Environmental management in all the complexes. The Environmental parameters are
internalized into the project planning, design, procurement, constructional and operational
aspects. The RIL group as accorded several prestigious environmental management
awards for their complexes by national and international agencies. For the purpose of the
C1 to C8 petroleum and petrochemical complex the technology providers, licensors,
vendors, EPC contractors and possible JV partners will be instructed to follow and
implement the project environmental specifications which will be developed according to the
applicable standards of Govt of India, State government and pollution control boards. The
IFC /WB standards will also be integrated into the design.

3.1 Air Environment

The impact on air quality due to emissions from multiple sources during the
continuous operations has been assessed by use of mathematical models. The incremental
predicted GLC’s of major air pollutants viz., SO2 and NOx due to the proposed SEZ
developmental activities over the baseline air quality are within the stipulated standards of
CPCB for industrial regions 1i.e. 120 μg/m3. However measures proposed for mitigating
impacts on ambient air quality during the project operations include the following:

ix
• Best Available Control Technology (BACT) should be installed at individual
emission sources to minimize the air pollutant emissions

• Regular record on sulphur emission should be maintained at SEZ units as

part of the environmental data records

• Off gases from proposed units should also be treated in amine absorption
units and regeneration unit meant for H2S removal as already in practice for
desulphurization of off gases (fuel gas) in existing Reliance refinery

• Performance evaluation of Sulfur Recovery Units with Tail Gas Treatment

Units should be done on regular basis (at scheduled intervals) through
monitoring off gas flow rate

• In case of any failure in sulfur recovery units appropriate steps should be

taken to match the generation with SRU feed

• FCCU should have particulate control systems such as Electrostatic

Precipitators/cyclones/wet scrubbers

• The measures to reduce the SO2 in furnaces, boilers, gas turbines is by

quantifying the contribution of various sources in order to determine the main
source, increase in the energy efficiency of the plant, heat recovery, vapor
management and change of combustibles

• All the combustion units should be maintained properly at optimum efficiency

• All fuel combustion units should be operated with minimum excess air so that
fuel consumption is optimized and emission of NOx is minimized. Low NOx
burners should be implemented in all combustion units of proposed units in
SEZ

• Energy conservation projects/schemes to result into reduction in quantity of

fuel should be implemented

• Port holes and sampling facilities should be provided at proper location for all
the stacks coming up in the SEZ for monitoring of flue gas velocity and flue
gas temperature and also for checking concentration of different pollutants at
regular intervals

• The SEZ complex should comply with proposed emission standards of CPCB
for stacks located in the SEZ complex

• Ambient air quality with respect to SPM, SO2, NOx, H2S and CO monitoring
shall be done at minimum 4 locations around the SEZ complex. The
monitoring stations should be set up in consultation with the GPCB

x
 • A digital weather station for monitoring wind speed, direction, temperature,
relative humidity and rainfall with automatic data logging and analysis facility
should be installed at the SEZ complex. The same should be operated
continuously for maintaining micrometeorological data record at SEZ site

• Continuous sources of emissions should be installed with stacks having

sufficient height (CPCB norms) to ensure adequate dispersal of pollutants.
Further, pollution control systems such as low NOx burners and low sulphur
fuel should be used

• Gas powered or low sulphur diesel and unleaded petrol in conventional

vehicles should be used within the project area and for product evacuation.

• Proposed Incinerator design and emissions should be as per the Guidelines

of CPCB

• Idling of vehicles should also be minimized during transport and handling

activities

• Loading/unloading and storage areas should be paved to reduce dust

emissions

• All access roads (internal as well external) to be used by the project

authorities should be made pucca (either with WBM, concrete or bitumen) to
suppress the dust generation along the roads

To control fugitive emissions of VOCs in the SEZ complex, following steps should
be taken:

• Provision of internal floating roof tanks with flexible double seal for MS and
intermediate products.

• Provision of mechanical seals in pumps

• Regular inspection of floating roof seals and proper maintenance of floating

roof seals for proposed storage tanks

• Preventive maintenance of valves and other equipment

• Regular skimming of oil from separators/equalization basin in ETP

• Fugitive VOC emissions should be assessed and minimized whenever

possible (vapor recovery systems, joints, pumps, fittings etc.). They shall also
be monitored at regular intervals

• Fugitive emissions should be controlled through proper maintainance

xi
 • It would be a best practice to avoid burning in flaring stacks and to recover
these gases whenever feasible

• Use of high grade gasket material for packing, provision of motor operated
valves for critical services such as high vapour pressure components and
chemicals

• Fuel leaks should be prevented from on land equipment. Further

implementation of Leak Detection and Repair (LDAR) programme using a
portable VOC detection instrument should be done on distribution lines and
tanks

• Inventory of odorous compounds should be maintained and release of such

compounds should be prevented

3.2 Noise Environment

The design of the project will be such that the sound pressure level in the work
area will not exceed 90 dBA. Restricted areas will be those locations where it is not
reasonably practicable to reduce the noise level below the work area limit. Wherever
practicable, attempts shall be made to reduce the noise level below 85 dB(A). The noise
levels will not exceed 60 dB(A) at the perimeter of the project area. The equipment will be
chosen in such a way that the above noise limit is not exceeded. The noise levels at the
nearest habitation after refinery expansion will be less than the stipulated standards of
CPCB. However, as a good operational procedure, the following generic measures will be
implemented in addition to the existing green belt:

• Similar measures as proposed in the construction phase for noise making

machinery, to ensure practicably low noise levels within the work
environment

• Specification for procuring major noise generating machines/ equipments

should include built in design requirements to have minimum noise levels
meeting CPCB/MOEF requirements. The monitored noise levels at sensitive
locations should be taken to ensure that the impact due to high noise levels
is practically minimized

• Monitor job and location specific noise levels for compliance with HSE
regulations by verifying acceptability of noise levels caused by the project
activities and comparison with noise criteria

• Conduct periodic audiometric tests for employees working close to high noise
levels, such as compressors, DG sets, the loading, unloading sections etc.

xii
 • Provision of PPE’s should be done and their proper usage should be ensured
for eardrum protection of the workers as well as visitors

• It should be ensured that low noise (generating) equipment are procured

wherever feasible

• Acoustic laggings, and silencers should be used in equipment wherever

necessary

• Sound proofing /glass paneling should be provided at critical operating

stations, and control rooms

• Either Acoustic barriers / shelter should be developed in noisy workplaces or

acoustic enclosures should be provided for the high noise generating
equipment

• Noise generating sources in the plant areas should be monitored regularly.

Monitoring of ambient noise levels should also be carried out regularly both
inside the refinery area as well as outside the greenbelt

3.3 Water Environment

• Since fresh water is a scarce resource in the area, only seawater should be
used for proposed expansion project. Desalination units should be installed
to meet the water requirement of SEZ units. The impact on the ground
water/saline intrusion if any should be monitored through the existing network
of monitoring wells and piezometers

• An effluent treatment plant based on the raw wastewater quality and required
treated wastewater quality should be designed. However the effluent
standards should be well within the prescribed limits of GPCB & CPCB. The
performance of ETP should be continuously monitored and any deviation in
performance should be corrected on priority

• Reduction in water requirements should be achieved by implementation of

closed circuits within the petroleum and petrochemical complex

• Use of desalinated water as service water should be minimized

• Reuse of effluent should be attempted

• Recycle of pump gland cooling water should be undertaken

• Condensate recovery should be maximized

xiii
• Treated effluent should be used for hydrotesting of vessels/tanks/pipelines
instead of desalinated water. Treated effluent should also be used for
cleaning of columns/vessels during turnaround

• Holding ponds should be provided so that bio-systems of wastewater

treatment system should be prevented against shock load

• Dosing of chlorine or biocides as part of advanced cooling water treatment in

the cooling water system should be done to take care of biological growth

• The detailed record of raw water intake at refinery (for processes, CT

makeup, fire water, green belt development and sanitary and drinking
purpose) as well as township complex and wastewater generation from
different sources should be maintained on daily/regular basis w.r.t. flow rates
and characteristics. These details should be useful in preparing
comprehensive water balance at project site and also for identification and
implementation of reuse/recycle practice of treated effluent at project site
leading to mitigation of effluent discharges

• Water flow measurement facilities (metering) should be provided at inlet and

outlets of major process units, which should help in minimizing wastage,
conserving the water as well as maximizing the recycle/reuse of treated
effluent

• Regular monitoring of effluent from different treatment units and also

combined final discharge of treated wastewater including outlet of STP at
township is recommended. Performance evaluation of effluent treatment
plant as well as sewage treatment plant should be undertaken at regular
intervals for all relevant parameters covered under this study

• Use of polishing pond for aquaculture should be explored, where bio-assay

tests could be conducted at regular intervals

• The effluents discharged into the sea should be done through the multipore
diffuser system designed by the National Institute of Oceanography (NIO).
The location of discharge should also be identified by NIO. The diffuser
system shall discharge the wastewater generated by the refinery, power plant
and the petrochemical units

• The effluents discharged into the surface water or the natural environment,
their physicochemical characteristics after any treatment should comply with
the maximum levels defined by the CPCB

xiv
 • Regular monitoring of the discharge of the main pollutants is required to
ensure that the regulatory maximum levels are complies with. Periodic
measurements of the pollutants in the natural environment is considered best
practice

• A Treatment Scheme for the effluents generated from the petroleum and
petrochemical complex has been suggested in the report. A Sewerage
Treatment scheme also has been suggested in the report for the effluents
generated from the residential colony and the sewage generated from the
various units within the SEZ

3.4 Land Environment

• Soils in the adjoining areas are sandy loam to silty loam with moderate
infiltration rates, amenable to groundwater pollution. Considering this fact,
every precaution should be taken to avoid spillage of oils and other
petroleum products on soils to protect groundwater and to avoid any danger
to other soil microbial groups which are sensitive to oil pollution

• Oil is a potential hazardous substance present in wastes generated from

refinery. Special care has to be taken in all oil removal operations. Disposal
of Oily sludge generated from effluent treatment plant through Coker to be
continued. Oily sludge from other locations may be disposed off by secured
landfill / incineration.

• Greenbelt in and around the refinery may be strengthened/maintained

• A record w.r.t quantity, quality and treatment/management of solid/hazardous

waste shall be maintained at environmental monitoring cell for different
process units (sources)

• Mixers and insitu tank cleaning procedures which maximise recovery of oil
should be adopted to reduce tank bottom sludge

• Recovery of oil from oily sludge using techniques such as centrifuging,

thickening and filtration should be undertaken

• A Common Secured Landfill Facility has been suggested in the report for the
disposal of the Hazardous Waste. The Hazardous Waste within the SEZ shall
be compliant to the Hazardous Waste Management, Handling Storage and
Disposal Rules. A Common Incinerator Facility has also been suggested for
the proposed SEZ, which shall be designed and operated as per the CPCB
guidelines

xv
3.5 Biological Environment
Following measures are recommended to mitigate adverse impacts on biological
activities during operation phase:

• Development of green belt with carefully selected plant species is of prime

importance due to their capacity to reduce noise and air pollution impacts by
attenuation/assimilation and for providing food and habitat for local macro
and micro fauna. This not only overcomes the problem but also enhances
the beauty of area that will attract bird and insect species and by this way
ecology of the area will maintain to great extent

• For developing the greenbelt in and around proposed project site care need
to be taken to plant the evergreen species. The planting of evergreen species
may have certain advantages that may reduce the environmental pollution

• Survival rate of the planted trees should be closely monitored and the trees
which could not survive should be counted. Equal number of trees should be
replaced and their survival should be closely monitored

• The rainwater harvesting should be done. Treated sewage and effluent in the
best combination should be used for greenbelt development. Water scarcity
should not be the reason for not expanding and strengthening greenbelt.
Provision for irrigation water should be made as part of proposed project

3.6 Socio-economic Environment

In order to mitigate the impacts likely to arise out of the proposed project and also
to maintain good will of local people for the proposed project, it is necessary to take steps
for improving the social environment. Necessary social welfare measures by the industry
shall be useful in gaining public confidence depending on local requirement.

The EMP measures are suggested for smooth functioning of the activities are
given below:

• SEZ should continue to undertaken social welfare programes for the

betterment of the Quality of Life of villages around in collaboration with the
local bodies

• Some basic amenities, viz. education, safe drinking water supply to the
nearby villages may be taken up

• Regular medical check up should be continued on routine basis in the

villages around the SEZ and also by providing mobile hospital services

xvi
 • SEZ shall in collaboration with local government improve the road
infrastructure in the vicinity

• Formal and informal training to provide direct and indirect employment to the
affected villagers due to the project shall be taken up on priority

• Entrepreneurship Development programme (EMP) should be undertaken for

both male and female group irrespective of their age and education,
qualification

• Job oriented skill training, courses may be organized. Through

industrial/technical training institutions for educational youth (both for male
and female), like home need appliances, tailoring, plumbing, light & heavy
vehicles driving

• Personal protective facilities like helmets, safety (gas) mask/safety dress,

shoes etc. be ensured for all workers, engaged in operation of process units
within the refinery complex

• The health checkups (diagnostic) for all regular employees at the refinery
complex at scheduled intervals to be maintained along with the
corresponding health records

3.7 Capital / Recurring Expenditure on Environmental Management

The details on proposed SEZ project cost and capital / recurring expenditure on
environmental management.

Project Cost : Rs. 60,000 crores

Cost for pollution control facilities : Rs. 1,800 crores

3.8 Environment Monitoring in Refinery

Since the SEZ Complex is big enough, each industry should have senior
executives who shall report to their respective Site President. The SEZ complex will have
an Environment Cell for the entire SEZ and units therein. The Environment cell should
consists of environmental professionals with experience in various aspects of Environment
Management ranging from 7 years to 20 years. This cell should be set up during the
construction of the SEZ itself and they should have adequate expertise and competency in
handling and implementing the Environment Management systems and practices. The
Environment Cell should monitor and measure the environmental performance of each
industry in terms of efficiency of pollution control devices, and conduct regular energy and
water audits. The cell should also on a regular basis also coordinate third party
Environmental Audits. Members of the Environment Cell shall participate in National Task

xvii
Forces under CREP (Charter for Corporate Responsibility for Environmental Protection)
and in committees for reviewing National Standards for the petroleum and petrochemical
industry. The Corporate Environment Cell at the Headquarters shall be an advisory body on
all environmental related issues and support the Environment Cell at the SEZ.

Every industry within the SEZ should in due time aim to be certified for ISO 14001
standards. The Environment cell in each industry should be responsible for implementing
and maintaining environment management systems. These industry should co-ordinate
with the Environmental Management Cell of SEZ for establishing and monitoring the
compliance of ISO 14001. The Management Systems should be established in compliance
with the ISO 14001 standards which should be audited internally by qualified internal
auditors and externally by the certifying body as per the stipulated frequency.

3.9 Recommendation for compliance to the World Bank Guidelines

NEERI recommends M/s RJIL to develop the SEZ projects in compliance with the
industry specific IFC Guidelines presented in this report as Annexure VII.

3.10 Environmental Clearance Process / Status

As per the Environmental Clearance procedures of 14th Sept- 2006 EC notification

the project application was made (07.02. 2007) in a prescribed format along with the draft
EIA & RA reports (This reports has been prepared before the 14th September 2006
notification) and submitted to MoEF.

The Expert Appraisal Committee (EAC) apprised this project in their meeting
(01.03.2007) and suggested/ directed additional Terms Of Reference (TOR) to be
incorporated in the EIA & RA reports and asked to conduct public hearing (28.03.2007).
The public hearing was conducted (08.01.2008) by the Gujarat Pollution Control; Board
(GPCB) with the EIA and RA reports updated with the additional Terms of Reference and
the Minitues of Meeting was send to Ministry.

The EIA & RA documents were finalized with the public hearing comments and
submitted to ministry (18.07.2008) for the Environmental Clearance. The project has gone
through three appraisal meetings (19.08.2008, 15.04.2009, 15.06.2009 and the project was
approved by the EAC for grant of Environmental Clearance in 15.06.2009 EAC meeting.

Subsequently, the MoEF advised to provide further clarifications with respect to the
Captive Power Plant (CPP) on 3rd Aug 2009 and submit a composite updated document for
the discussion with the newly constituted EAC committee_2.

xviii
Chapter 1

Introduction
1.1 Preamble
Special Economic Zones Act 2005 is a major milestone in India’s Foreign Trade
Policy and a clear pointer to the avowed intention of the Government of India to encourage
growth of the country’s manufacturing and service sectors and to usher an era of enhanced
level of confidence for Indian products and services in the global arena.

The enactment of SEZ Act 2005 by the Central Government and the State SEZ Act
and rules notified by the State Government of Gujarat has enthused Reliance Infrastructure
Limited (RFL) to set up a Special Economic Zone in the backward rural area of Jamnagar
district of Gujarat with modern integrated infrastructure. The SEZ developer, RFL,
subsequently changed its name to Reliance Jamnagar Infrastructure Limited (RJIL). The
development of this project will lead to fast track development of Saurashtra region of the state
and will open up avenues for larger volumes of exports, employment and foreign exchange
earning for the Country.

Reliance continues to be a major contributor to the national economy through its

vision and commitments & believes that Government & Industry have to work together to
create world-class infrastructure, which is now a pre-requisite to attain leadership in the global
market

1.1
 Reliance’s proposes, to build a product specific economic zone of refinery and
petrochemical units, which will be further synergically developed as a multi-product zone. The
Ministry of Industry and Commerce, Government of India has now notified this SEZ as a Multi-
product SEZ. The proposed SEZ will be developed by Reliance Jamnagar Infrastructure
(RJIL) Limited, a RIL group Company. All these proposals fall under the National Policy on
Developing SEZs as notified by the Ministry of Commerce & Industry, GOI. The SEZ will have
all the required infrastructure and facilities to ensure sustainable development of medium and
large-scale industries and service activities. The proposed site is located near the State
Highway No 25 on the way from Rajkot to Okha and is adjacent to the existing refinery
complex of Reliance Industries Limited (RIL). The overall size of the SEZ is approximately
4,545 hectares (11,231 acres). The Fig. 1.1 shows the location of the SEZ at Jamnagar and
Fig. 1.2 shows the location of SEZ area.

RIL has already established a petroleum refinery and petrochemical complex, and is
in operations since 1999. This complex has got the environmental clearance from the Ministry
of Environment and Forest (MoEF) to modernize and expand the refinery capacity to
approximately 60 MMTPA, crude processing in 2005. The existing refinery capacity has been
enhanced to 33 MMTPA by the way of debottlenecking and value/production maximization.
The balance approved capacity is being implemented by Reliance Petroleum Limited as an
Export oriented Refinery Project. This project is called as Jamnagar Export Refinery Project
(JERP) with an integrated 1.0 MMTPA polypropylene unit by Reliance Petroleum Limited, a
group Company of RIL. This Jamnagar Export Refinery Project (JERP) and the PP Plant are
located in the approved SEZ area. The JERP has already got the environmental approval from
the MoEF and other statutory agencies and is already under implementation and expected to
go on stream shortly.

Proposed Land use in SEZ

Reliance proposes to develop a total area of 4545 Hectares, as a Multiproduct

Special Economic Zone. The proposed land use for the entire SEZ is tabulated below:

Proposed land allocation (Area in hectares)

Residential 810
Commercial 275
Industrial 2,275
Public/Semi – Public/Green Belt/Transportation 1,185
Total 4,545

1.2
1.2 Project Setting
Jamnagar district lies in the peninsular region in the North West, in the state of
Gujarat, known as Kathiawar or Saurashtra. The Gulf of Kutch binds this district to the north,
on the East by Rajkot district, on the South by Junagadh district and on the West by the
Arabian Sea. Saurashtra region has been away from the mainstream economic development
of the country. The Jamnagar region falls in an arid zone. The area is covered by Deccan trap
basalt of cretaceous age. The landuse of this region highlights that maximum is scrub land
(wasteland) followed by fallow land. This is one of the reason the site has been selected for
the development of SEZ. Recently, industrial development of public sector undertakings and
Port development has ushered in recognizable economic growth. The latitude and longitude
of the center of the proposed SEZ are 22o 20’ 30” North and 69o 53’ 00’’ East.

Mithapur, 157 kms. from Jamnagar, has heavy chemical industrial unit manufacturing
salt, soda ash, etc. by the TATA group of India named Tata Chemicals Ltd, and Moti Khavdi
(Sikka) near Jamnagar, has a petroleum refinery complex by the Reliance Group, which is one
of the largest grassroots refinery in the world. Even the famous & internationally renowned
wollen textile-manufacturing unit DIGJAM is located in Jamnagar city.
Jamnagar itself is a centre for the Brass industry, Bandhani fabrics (tie-&-dye work on fabrics)
and Zari sarees, Silken & Gold embroidery. Near the refinery complex, there are other
industries like a thermal Power Plant of the Gujarat Electricity Board, Cement manufacturing
unit of Digvijay Cements and a fertilizer unit of the Gujarat State Fertilizer Corporation.

The following siting criterion delineated by MoEF, New Delhi has been followed by
Reliance, which includes:

I. No prime agricultural land/forest land has been proposed for conversion into an
SEZ.
II. Land proposed for the SEZ is a barren arid land and has sufficient space to provide
for a green belt wherein the treated wastewater, could be utilized from wastewater
treatment systems
III. Enough space is available for storage and disposal of hazardous / solid wastes.
IV. Layout and form of the project will conform to the landscape of the area without
affecting the scenic features of that place. However the scenic beauty shall
increase with the development of green belt.
V. Associated township of the project is planned to provide for space for phyto -
graphic barrier between the project and the township and takes into account
predominant wind direction.

1.3
 In addition to the siting criteria listed above, the proposed project location is reviewed
for the following salient issues:

• The site is not prone to natural disaster areas, however the industry shall be
designed to the seismic codes specified by ISI and allied agencies. It is pertinent to
note that Gujarat Earthquake 2002 with epicenter near Bhuj has not affected any
of the facilities of the Refinery.
• The water for operation will be made available from the proposed desalination plant
for SEZ. Further the Narmada water is also available for the construction and for
temporary labor camps. It is proposed that desalination plant related facilities will
be created upfront of the project. A CPP has been planned during the operation
phase to supply power to the SEZ units and the residential colony. Roads with
adequate width and capacity shall be developed to handle the increase in traffic
load. All these facilities shall not exert a pressure on the local infrastructure.

1.2.1 Existing industrial Estate in Jamnagar District

The major industries like Agro & food processing, biotechnology, chemical & allied
industry, drugs & pharmaceuticals, engineering industry including automotive industry, gems &
Jewelry etc, are some of the industries located in the Jamnagar district of Gujarat.

The existing industrial estate by GIDC in Jamnagar is as follows:

• Shankar Tekri industrial estate, Jamnagar1

• Kamsudra industrial estate, Jamnagar 2

• Dared industrial estate, Jamnagar 3

• Jam Khambhaliya industrial estate

• Bhatia (RIDC)

• Arambhada industrial estate

• Dhrol (RIDC)

• Bhanvad

The site for the proposed SEZ covers evaluation of site with special reference to
siting criteria including projects.

1.4
The principal drivers for the proposed projects in the Jamnagar SEZ are:

1. Maximize value addition of raw materials, sourced from the RIL domestic
refinery, and the RPL export oriented refinery.
2. Enhance competitive strengths, by minimizing the cost of production, with
intimate integration between the two refineries and the Jamnagar SEZ
manufacturing complex.
3. Exploit economies of scale for each product in the Jamnagar SEZ.
4. Strive to be the lowest cost producer for each product in the Jamnagar SEZ.
5. Develop world-class infrastructure and logistics facilities to support the Jamnagar
SEZ to exploit the supply chain for each product in the Jamnagar SEZ.
Proposed Jamnagar SEZ has following strengths.

1. Promoters have a successful track record in executing Mega projects and have
set up technically complex projects in record time and at globally competitive
project cost and at the same time adhering to the highest international standards
of safety and environmental protection.
2. The SEZ is located in a highly industrialized state of India and has potential to
attract Petrochemical & other industries with high export potential.
3. Jamnagar is ideally located on the western coast of the country, has a unique
advantage in terms of accessibility to the Middle east & Far-east & European
markets
4. The SEZ will have access to the existing port facilities, which will facilitate easy
evacuation of the export products, which will not call for building new marine
facilities, thereby minimizing the marine impacts.
5. The project will have state of the art infrastructure facilities to attract investment.
The SEZ meets the siting criteria/guidelines of the MoEF for the following:

i. Located away from the coastal belt

ii. Barren land (entire stretch)

iii. Road transportation will be reduced due to utilization of marine facilities

6. SEZ is well connected with the national and state highways.

The Feasibility Analysis for the location of SEZ is given in Table 1.1. Essentially the
various petroleum and petrochemical downstream units are synergically derived of the carbon
chains C1 to C8+ products and their derivatives.

1.5
 The C1 to C8 complex is based on the existing refinery and petrochemical complex
products. It is pertinent to note:

a. Along with the existing modernized and expanded refinery and the proposed petroleum
and petrochemical complex will be under the EOU scheme, aimed to maximize the
value addition along the entire carbon chain of C1 through C8 and higher.
b. The various units within this complex will be homogeneous to the C1 to C8 hydrocarbon
chain. All the units and product plants are integrated with each other to derive the
advantage of optimum utilization of various resources.
c. Jamnagar has the most suitable seafront in the Gulf of Kutch for raw material import and
finished products export. This complex is fully integrated with the existing refinery
complex as well as export oriented Refinery.

This Petrochemical Complex produces distinct petrochemical products by processing

and synthesizing from the various streams of the refinery complex. The manufacturing units of
these products consist of similar equipment and machinery which synergistically work to
produce these distinct products. In this particular configuration of the conglomerate, the raw
materials intermediate products, by-products, material and energy flows are integrated so as to:

a. Maximize value of raw materials, sourced from the RIL & RPL refineries.
b. Optimally utilize the various process streams derived from the refinery complex and
petrochemical units
c. Conservation of the water resources through integrated recycle and reuse among the
various process units.
d. Enhance competitive strengths, by minimizing the cost of production, with intimate
integration between the two refineries and the Jamnagar SEZ manufacturing complex.
e. Exploit economies of scale for each of the products in the Jamnagar SEZ.
f. Minimal transportation cost of raw materials.
g. Minimize the requirement for infrastructural facilities.
h. Optimization of effluent treatment facilities, hazardous waste handling & disposal
facilities, etc
i. Strive to be the lowest cost producer for each of the products in the Jamnagar SEZ.
j. Develop of world-class infrastructure and logistics facilities to support the Jamnagar
SEZ to exploit the supply chain for each of the products in the Jamnagar SEZ.

1.6
These are synergistically integrated in three main areas. i.e

a. Process Integration of various process streams derived from the refinery complex
b. Energy integration of various producing units to optimize / minimize the energy
consumption in the various units.
c. Conservation of the water resources by recycle and reuse through various utilization
processes starting from the raw seawater.

By internalizing the resources and related environmental parameters the overall synergistic
integration is achieved. This in turn leads to optimum utilization of all the streams into various
value added products.

This integration / synergy helps in leaving a smaller carbon foot print and thus a lower
impact on the environment

The environmental parameters at Jamnagar has been continuously studied and assessed
for the Reliance Group of Industries at Jamnagar since 1993. For the existing Refinery a post
project Environmental Impact Assessment (EIA) has been done and was also assessed by the
MoEF in 2003. Later Environmental Impact Assessment (EIA) & Risk Assessment (RA) studies
were conducted for the modernization and expansion of the refinery complex and the MoEF has
granted the Environmental Clearance for the same in 2005 . The modernization and expansion
of project is Commissioned now.

The results of these studies have been considered and internalized in the planning,
design, construction and operations and specific environmental related operational
characteristics like emissions, discharge and other relevant parameters. These cumulative
affects already get reflected in the latest environmental baseline studies for the SEZ petroleum
and petrochemical complex at Jamnagar.

Later, these draft EIA and RA reports were discussed by the MoEF EAC committee and
additional Terms Of Reference (ToR) were given. Accordingly the EIA reports were updated
and upgraded by incorporating the Terms of Reference (TOR). Public Hearing was conducted
in 2008 and the draft EIA was finalized by updating the process related information, emissions
and other relent parameters, Public hearing comments and the final reports were submitted to
MoEF.

1.7
 The process technology suppliers, licensors and vendors are instructed to strictly
comply with the prescribed petroleum and petrochemical standards of the CPCB as the
minimum criteria to be met in the basic engineering design, detailed engineering and
construction, commissioning and operation to maintain the emissions within the prescribed
limits.

The various units which can be set up in the proposed SEZ are as follows:

C1 Based Units

• Coke Gasification

• Methanol Synthesis

• Acetic Acid

• Vinyl Acetate Monomer (VAM)

• Polyvinyl Acetate (PVA)

• Polyvinyl Alcohols (PVOH)

C2 Based Units

• Multifeed Cracker Complex for maximising the C2, C3 , C4 and C5 carbon chains

• Ehtylene Oxide Derivatives like Mono Ethylene Glycol (MEG), Di Ethylene Glycol
(DEG) ,Tri Ethylene Glycol (TEG)

• Polyethylene Polymers like Low Density Polyethylene (LDPE), Linear Low Density
Polyethylene (LLDPE), High Density Polyethylene (HDPE)

C3 Based Units

• Acrylic Acid & derivatives, Super Absorbent Polymer (SAP)

• n-Butyl Acrylate, n-butylaldehyde, n-butanol and 2-ethylhexanol

• Propylene derivatives like Propylene Oxide, Cumene, Phenol

• Propylene Glycols

• Polyols

• Hydrogen Peroxide (H2O2)

• Polypropylene PP (Non woven)

1.8
 • Polypropylene (PP)

C4/C5 Based Units

• Butyl/ Halo Butyl Rubber, ESBR, Styrene Butadiene Rubber (SBR) ,Poly Butadiene
Rubber (PBR), SSBR

• Butene 1

• Maleic Anhydride (MA)

• Fumaric Acid

C6/ C7/ C8 Based Units

• Mono nitro Benzene, Aniline, Methylene Di Aniline, Phosgene, Methylene Diphenyl

Diisocyanate (MDI), Toluene Diisocyanate (TDI) and Benzene

• Styrene

• Paraxylene (PX), Orthoxylene (OX)

• Putrefied Teraphthalic acid (PTA)

• Polyethylene Tera-phthalate (PET)

• Polyesters Complex Polyester Oriented Yarn (POY) Polyester Stable Fiber (PSF)

Carbon Black

Lube Oil cum Refinery Complex

Captive Power Plant

& Jamnagar Export Refinery Project (JERP) which has already been accorded
Environmental Clearance by the MoEF in 2005 / 2006.
The Modernization and de-bottle necking of the existing refinery and expansion
refinery (called as Jamnagar Export Refinery) along with their infrastructure had been accorded
the environmental clearance by the ministry in 2005 and amended in 2006. Since this JERP is
being built in the SEZ area, JERP is included in the EIA. However, the emissions of JERP are
included in the analysis of this study.

The Table 1.2 shows details of the units coming under the proposed SEZ are shown
in Fig. 1.3.

1.9
1.2.2 Common facilities for the SEZ

The common facilities for the proposed SEZ are Captive power plant, Desalination
Plant, Central ETP, Incinerator and a Secured disposal facility.

1.2.2.1 Captive Power Plant (CPP)

Captive power plant comprises of three components

• Gas turbines
• Heat recovery steam generation (HRSG)
• Steam turbo generators
Gas turbines

Gas turbines, consists of axial flow compressor, to compress air in to combustion

chambers. In combustion chambers, fuel (natural gas/ syngas, liquid fuel) is added and the
products of combustion are allowed to expand through impulse turbine. The turbine rotor is
coupled with generator to produce electric power.

HRSG

Turbine exhaust gases are taken to a water boiler, through a duct where
supplementary firing is done using a fuel in the furnace zone. The hot gases heat the water to
generate steam and are exhausted to atmosphere through a boiler stack. Demineralised
water, after dearation ,is fed to the water boiler for steam generation. Duct firing arrangement
to consume unburnt oxygen provided to rise more steam

Steam turbine generators

High-pressure steam is expanded through a turbine/ expander to reduce the pressure

and recover power. This expander is coupled with a generator to produce electric power.
These STG,s can operate on back pressure basis to be integrated into the steam grid.

1.2.2.2 Desalination Plant

Considering the water shortage in the region, the seawater intake is provided at the
maritime terminal area where water is pumped and treated. The desalination plant has been
designed using multiple effect Distillation process integrating it with energy sources. The
energy (heat) requirement for desalination is met from the waste heat from processing units.
This scheme eliminates the venting of low pressure and low temperature steam from the
process units and eliminates the condensing and also used as a steam sink for the effective

1.10
steam requirement and balancing. This plant also integrated with the ultra filtration / reverse
osmosis plant, which will/can process the gray water from the complex.

Currently the water requirement of the existing Refinery cum Petrochemical

complexes is met from the Desalination of Seawater. The desalination plant is of multi affect
distillation of Israeli origin technology. The existing plant capacities is 2600 Cu m/hr or 2.6
million liter/hr of water required for the complex and the residential complex.

The desalination plant is designed with flexibility to operate on a low level energy
input sufficient for the operations.

For the proposed project, for SEZ the overall desalination plants capacity will be
15,000 m3/hr with suitable number of units.

1.2.2.3 Central Effluent Treatment Plant

A central effluent treatment plant has been proposed as a common facility for
effluents generated from all the units of proposed SEZ. The different effluent sources would
be, effluent streams from the Refinery and downstream Petrochemical plants. The details of
the common effluent treatment schemes have been given in Chapter 6.

1.2.2.4 Common Incinerator Facility

The incinerator shall be designed for capacity more than 200 kg/hr. Incinerator shall
be installed with venturi scrubbing system, which is an air pollution control system. The
incinerator will be designed as per the CPCB Guidelines.

The double chamber incinerator shall preferably be designed on "controlled-air"

incineration principle, as particulate matter emission is low in such incinerator. Minimum 100%
excess air shall be used for overall design. Air supply in the primary and secondary chamber
shall be regulated between 30% - 80% and 170% - 120% of stoichiometric amount
respectively. Primary air shall be admitted near / at the hearth for better contact. Flow meter /
suitable flow measurement device shall be provided on the primary & secondary air ducting.
The combustion air shall be supplied through a separate forced draft fan after accounting for
the air supplied through burners. The details of common incinerator facility have been
provided in Chapter 6.

1.2.2.5 Common Secured landfill Facility

The secured landfill facility for disposal of hazardous waste like ETP sludge, oily
sludge, spent clay and incinerator ash will also be designed as per the CPCB guidelines. A
detailed section comprising of selection of landfill site, design of landfill site, facilities at landfill
site and the management scheme is given separately in Chapter 6 of this report.

1.11
1.2.3 Project Cost and Schedule

Investment and NFE Earning Potential of The Zone

Reliance proposes to invest about Rs. 25000 Crores (approx. US$ 5.8 Billion) in
refinery. Based on the feed stock availability, further investment in the downstream
petrochemical units is expected to be around Rs. 35000 Crores (approx. US$ 8.2 Billion).
Thus the Petroleum and Petrochemical Sector Specific Area would attract investment of
approx. Rs. 60000 Crores (approx. US$ 14 Billion)

The Petroleum & Petrochemical Complex in the SEZ is proposed to be set up by Reliance or
as a JV with an international manufacturer. The Complex will have a NFE earning potential of
$18-20 Bn over a 10 year period. The other petrochemical down stream units would further
contribute additional NFE earning for the country to the tune of minimum $ 5-6 Bn over a 10
year period.

Implementation Period

The components of the Special Economic Zone Projects will be implemented by M/s
Reliance Jamnagar Infrastructure Ltd. (RJIL), wholly owned subsidiary of RIL & hence a
Deemed Public Limited Company. The project will be developed progressively over the next 2-
3 years and will be operational by 2008.

1.3 Stage of EIA

The area earmarked for the development of Special Economic Zone at Jamnagar is
of about 4544.76 ha (4545 Ha). In line with the new notification for prior environmental
clearance (S.O. 1533, dated 14/09/2006), this reports has been prepared for the SEZ and the
proposed industrial units therein. The multi product SEZ will house a petroleum and
petrochemicals complex and hence the activities within the SEZ are defined.

EIA is being carried out for the SEZ project so as to incorporate environmental
concerns in the design stage of the project. The basic data required for preparation of EIA has
been taken from the information report provided by the client.

1.4 Scope of EIA

The Ministry of Environment and Forests (MoEF), Govt. of India (GoI), issued a
Gazette Notification on 27th January 1994, called as the EIA Notification under the
Environmental protection Act 1986 and subsequently this notification has been modified /
replaced on 14th Sept 2006. A transition period of two years has been provided between both
notification will be concurrently operative, and the GoI to that effect issued the notification

1.12
instruction /clarification. This notification set up a procedure for environmental approval /
rejection of the various categories of industries and allied projects. Under this process an EIA
Study is required to be conducted for projects that are enlisted in the schedule to the
notification. Subsequently this notification has been replaced by a fresh notification on 14th
September 2006. A transition period of two years has been provided wherein both the
notifications will be concurrently reinforced.

This EIA report has been prepared basing on the guidelines including the EIA manual
issued by the MoEF, New Delhi. Further the sector specific ‘Environment, Health & Safety’
guidelines as applicable to refinery and petrochemicals issued by the International Finance
Corporation (IFC) also have been followed in preparation of EIA report. Please refer
Annexure VII for the relevant sections of the industry specific guidelines issued by the IFC. In
order to assess the environmental impacts due to the proposed development of the SEZ
project, Reliance Infrastructure who is developers of this project retained National
Environmental Engineering Research Institute (NEERI), Nagpur to undertake Environmental
Impact Assessment for various environmental components and delineate a detailed
Environment Management Plan (EMP).

1.5 Objectives

• Assessment of the present status of air, water, land, socio-economic and biological
components of the environment including noise and other parameters of human
interest within a 10 km radial distance surrounding the SEZ area.

• Emissions modelling for Ground Level Concentrations (GLCs) based on the

emissions from units within the SEZ.

• Delineation of the proposed waste disposal scheme for the aforementioned project

• Identification of land use / land cover pattern like forest land, agricultural land,
waste land, water bodies etc. in a 25 km. radius from the project site

• Delineation of the Environmental Management Plan (EMP) in line with the MOEF
guidelines and preparation of EMP to be adopted for mitigation of anticipated
adverse impacts.

• To meet the guidelines of IFC as a part of the process under the equator
principles.

Delineation of the post project environmental quality monitoring program to be

pursued by Reliance as per the requirements of the MoEF and State Government

1.13
1.6 Study Area
To decide whether proposed action is likely to cause significant adverse
environmental effects, the concept of EIA is practiced. Before proceeding to establish the
baseline environmental status, it is important to know the boundary limits and framework
where data can be effectively utilized in impact assessment.

The study area for this EIA study is considered to be 25 km radial distance around the
center of SEZ so as to have atleast 10 km clear distance from the boundary of SEZ for
establishing baseline environmental status. The study area of 25 kms from the centre of the
SEZ is indicated in Fig 1.4.

1. 7 Approaches and Methodology

The approach and methodology adopted is as per the guidelines of MOEF and the
Gujarat Pollution Control Board (GPCB), Govt. of Gujarat (GoG) for baseline data collection,
identification and prediction of impacts for various environmental components are presented
below:

1.7.1 Establishing Baseline Environmental Status

Baseline data describing the existing environmental status of the identified study area
is determined using the procedures presented in Table 1.3.

1.7.1.1 Physical Resources

a) Air Quality and Climate
Design of Ambient Air Quality Monitoring Network

The air quality status in the study area is assessed through a network of ambient air
quality monitoring locations. The baseline studies for air environment include identification of
site and project specific air pollutants prior to implementation of the project. The EIA report is
based on baseline air quality during winter of 2005/06

The baseline status of the air environment is assessed through a systematic air
quality surveillance program, which is planned based on the following criteria:

• Topography / terrain of the study area

• Regional synoptic scale climatological normals

• Densely populated areas within the region

• Location of surrounding industries

• Representation of regional background

1.14
 • Representation of valid cross-sectional distribution in downwind direction

Methodology for Ambient Air Quality Monitoring

Ambient Air Quality Monitoring (AAQM) was carried out at 24 locations in winter
season. Maximum numbers of sampling locations were selected close to the SEZ site and in
the downwind direction i.e. in N-E sector considering predominant wind direction of S-W.

AAQM was carried out at number of locations, though four locations are presented in
CPCB guideline to determine a finer cross-sectional distribution of air pollution in an industrial
developed region. The conventional parameters such as Suspended Particulate Matter (SPM),
Respirable Suspended Particulate Matter (RSPM), Sulphur Dioxide (SO2) and Oxides of
Nitrogen (NOx) were monitored in the study area.

The standards stipulated by CPCB/ MoEF in India are given in Annexure I.

A temporary laboratory was setup at the project site for chemical analysis of
representative air samples. An automatic weather monitoring station was also installed at
project site, keeping the sensors freely exposed to the atmosphere and with minimum
interference with the nearby structures. The micro-meteorological data like wind speed, wind
direction, temperature and relative humidity were collected using the weather station and cloud
cover was recorded manually for the study period.

The 98th percentile concentrations have been compared with stipulated standards of
CPCB (as per the National Ambient Air Quality Standards Notification, April 11, 1994). The
98th percentile level is determined by arranging observed concentrations of any given pollutant
of the ambient air quality monitoring location by arranging in ascending order and determining
the pollutant concentration at 98th percentile number in the series (e.g. if 100 different values
of SO2 levels at any given air quantity monitoring location are arranged in ascending order,
SO2 concentration corresponding to 98th value in the series is termed as 98th percentile).

b) Topography and Soil

Soil samples were collected close to RJIL SEZ site and in the study area from
agricultural fields at 0-20 cm depth. The general parameters of soil analysis, in context of
impact assessment, are texture, pH and conductivity (10% slurry), cation exchange capacity,
infiltration rate (permeability), bulk density, porosity, water holding capacity, organic content
and NPK constituents. Soil sample were collected from selected agricultural fields within the
impact zone and analysed for relevant parameters

1.15
c) Surface and Ground Water

With regard to water environment, two aspects are considered in EIA, the raw water
availability and surface and ground water quality. The water requirement and availability in the
region has been assessed. Surface and ground water quality has been determined and
compared with drinking water standards (Annexure II). One sample was collected at each
location for establishing the baseline water quality.

In addition to above, the coastal/creek waters are classified as given below based
upon the 'best designated uses' of a particular segment:

• SW-I : Salt pans shell fishing, mariculture and ecologically sensitive zones

• SW-II : Bathing, contact water sports and commercial fishing

• SW-III : Industrial cooling, recreation (non-contact) and aesthetics

• SW-IV : Harbour

• SW-V : Navigation and controlled water disposal

d) Noise

Noise standards have been designated for different types of landuse, i.e. residential,
commercial, industrial areas and silence zones, as per ‘The Noise Pollution (Regulation and
Control) Rules, 2000, Notified by Ministry of Environment and Forests, New Delhi, February
14, 2000’. The ambient noise standards are presented in
Annexure III. Different standards have been stipulated during day time (6 am to 10 pm) and
night time (10 pm to 6 am).

The residential, commercial, industrial areas and silence zones close to the project
site and in the study area have been identified. These locations have been chosen away from
the major roads and major noise sources so as to measure ambient noise levels. Equivalent
noise levels (Leq) for a period of about 20 minutes have been measured twice a week during
study period at each monitoring location during day time and night time. Eight observations
have been made at each noise monitoring location.

1.16
1.7.1.2 Ecological Resources

a) Terrestrial Ecology

The terrestrial flora and fauna is assessed through following parameters:

Flora
i) Species List

Such a list includes common and scientific names of plants found or likely to be present in the
study area. This list is prepared based on visual observation during site visits and through
review of site literature. Data available with various agencies is referred for identifying rare or
endangered species in the region.

ii) Plant Cover

The ground area covered by aerial portion of the plant is called its ”cover” and is used
as a measure of plant’s importance. The diameter of tree trunk at breast height (4.5 ft or 135
cm) is used as an expression of cover or dominance. The phytosociological data available for
the area close to the proposed port site and along the infrastructure corridor are also included
in the report.

Qualitatively, flora is assessed by delineating the type, its habitat, unique vegetative
features, interrelations or associations with other community members. Plants are also
observed for morphological aberrations, if any, due to pollution or any other stress. Plant
species are rated visually based on its foliar cover and abundance.

Fauna

Actual counts of the animals are made following the census technique. At each
station a walk-through census of animals is made. Line transects of 1 km selected for the
study is covered by walking and number of animal species are counted directly. Birds were
observed through binoculars. Standard field identification guides were used for identifying
animal species. Data is expressed based on census index, dominance index and Margalef
diversity index.

b) Aquatic Ecology

Water samples were analysed for estimating plankton counts viz. zooplankton and
phytoplankton. Similarly, information was collected about fisheries and coastal resources such
as mangroves from secondary sources.

1.17
1.7.1.3 Economic Development

a) Industries, Infrastructure Facilities and Transportation

The information on industries, infrastructure facilities such as water supply, sewerage,

flood control etc. and transportation such as roads, harbours, railway, airports and navigation
were collected from secondary sources and field visits.

b) Landuse Pattern
Remote sensing data analysis was carried out for determining landuse/land cover in a
study area. In order to strengthen the baseline information on existing landuse pattern, the
following data at the latitude and longitude CO-ORDINATES (approx.) were used.
Data available in CD format from National Remote Sensing Agency (NRSA), Department of
Space and Government of India were used along with collateral data.

Salient features of methodology for landuse/land cover using remote sensing data are
given below:

• Acquisition of Satellite data

• Data loading
• Data processing
• Geo-referencing Image
• Rectification
• Classification
• Ground Truthing /field Checks using Global Positioning System
• Masking
The digital image processing was performed on Erdas Imagine 8.6 System on high
configured computer. Erdas Imagine software package is a collection of image processing
functions necessary for pre-processing, rectification, band combination, filtering, statistics,
classification etc. The powerful HP Work Station allows display and processing of the image
data. Apart from contrast stretching, there are large number of image processing functions,
that can be performed on HP Work Station. The images can be recorded photographically with
the help of Image Coder linked to the workstation.

The satellite data from the compact disc is loaded on the hard disk and by studying
quick looks (the sampled image of the appropriate area), the sub-scene of the study area is
extracted.

1.18
 Supervised classification using all the spectral bands can separate fairly accurately,
the different landuse classes at level II on the basis of the spectral responses which involve
the following three steps:

• Acquisition of ground truth

• Calculation of the statistics of training area

• Classification using maximum likelihood algorithm

The training areas for classification were homogeneous, well spread out throughout
the scene with bordering pixels excluded in processing. Several training sets have been used
through the scene for similar landuse classes. After evaluating the statistical parameters of
training sets, the training areas were rectified by deleting no congruous training sets and
creating new ones. Masks of area within 5 -15 km radius were superimposed on the final
output to generate area statistics for different landuse categories.

1.7.2 Anticipated Environmental Impacts

The environmental impacts due to proposed project have been identified, predicted
and evaluated.

In the present study the mathematical models that have been used for predictions
include

• ISCST3 has been used to model the emission sources from the SEZ and its
units to estimate the GLCs.

• Wave divergence for stationary noise sources, Federal Highway predict the
Administration (FHWA) models for noise levels of vehicular sources

• For impact on water, land and biological components of environment, the

predictions have been made based on available scientific knowledge and
judgment.

1.7.3 Environmental Management Plan

Environmental Management Plan (EMP) is drawn after identifying, predicting and

evaluating the significant impacts on each component of the environment with a view to
maximising the benefits from the project. Post-project Environmental Monitoring programme is
also delineated in the report.

1.19
1.8 Contents of the Report
The EIA Report is based on the primary field data generated at the project site and
data collected from secondary sources.

Chapter 1.0 - Introduction

This chapter provides purpose of the EIA report, background information of the
project, stage of EIA report preparation, scope, methodology and brief outline of EIA report. At
the end of this chapter, the environment clearance status with respect to the project has been
described.

Chapter 2.0 - Description of the Project

This chapter provides the following details:

• Type of project

• Need for the project

• Project location

• Project details including associated activities required for the project

Chapter 3.0 – Process Description

This chapter describes the process description of the refinery and petrochemical units
proposed in SEZ along with the technology details and the process flow diagram.

Chapter 4.0 – Baseline Environmental Status

This chapter presents the information on study area, information on existing

environmental resources, findings of field studies undertaken to establish the baseline
environmental status and has been organized into the following sub-sections:

• Physical Resources

• Ecological Resources

Chapter 5.0 – Identification and Prediction Of Environmental Impacts

This chapter details the identification, prediction and evaluation of impacts on each
resource. The impacts of “the project” are predicted using available computer models during
construction and operational phase. The significance of impacts is determined based on
applicable environmental guidelines. It describes the overall impacts of the proposed project
and identifies the areas of concern, which need mitigation measures.

1.20
Chapter 6.0 - Environmental Management Plan (EMP)

This chapter provides recommendations for Environmental Management Plan (EMP)

including mitigation measure for minimizing the negative environmental impacts of the project

Environmental monitoring requirements for effective implementation of mitigation

measures during construction as well as operation of the project have also been delineated
along with required institutional arrangements for their implementation. Budgetary cost
proposed for pollution mitigation and environmental management are also provided.

Chapter 7.0 – Resettlement & Rehabilitation Plan

In this Chapter Resettlement and Rehabilitation (R&R) Plan of M/s Reliance based on
National Policy on R&R (NPRR-2003) is briefly discussed.

1.9 Environmental Clearance Process

Reliance Jamnagar Infrastructure Limited (RJIL), earlier known as Reliance
Infrastructure Limited (RFL), is proposing to set up a new petroleum and petrochemical complex
in the multi-product SEZ at Jamnagar. This petroleum and petrochemical complex will house
the export-oriented refinery of RPL, a group company of RIL, that already has been accorded
Environmental Clearance by the Ministry of Environment & forests (MoEF) (letter no
.J.11011/232/2005_1A(II)-I dated 3rd August 2005). This refinery complex along with the
existing RIL refinery can supply the raw material and intermediate products to set up a
synergically integrated homogenous petroleum and petrochemical complex.

Based on the EIA Notification of 1994, the Environment Impact Assessment & Risk
Assessment Studies for the Petroleum and Petrochemical Complex were conducted by National
Environmental Engineering Research Institute (NEERI). Subsequently, the EIA Notification of
1994 was superseded by the Environment Clearance Notification of 2006. Based on the new
notification, the above prepared EIA & RA Studies were considered to be draft documents. An
application was filed with the Ministry of Environment & Forests (Letter No
77/070207/RFL/MEL) for the endorsement of the draft Environment Impact Assessment (EIA)
and Risk Assessment (RA) studies that were prepared by NEERI. The proposal was discussed
along with the draft EIA at the EAC 62nd meeting of the Expert Appraisal Committee (EAC)-
Industries, held on 1st & 2nd March-2007 to ascertain the adequacy of the Terms of Reference
(TOR) used for the EIA Studies. Based on the review of the proposal, draft EIA& RA
Documents, by the EAC, the Ministry suggested some additional TORs and directed the project

1.21
proponent to approach the Gujarat Pollution Control Board (GPCB) to conduct the Public
Consultation process, as per the EIA Notification 14th Sept– 2006.

An application was filed with the GPCB to conduct the Public Hearing for the proposed
project. All the requisite documents along with the additional TOR Document were submitted to
the GPCB for the Public Consultation Process. The Public Hearings was conducted on 8th
January 2008, in line with Appendix IV of the EIA Notification-2006. The GPCB prepared the
Minutes of the PH Meetings and a copy of the Minutes has been forwarded to the Ministry. The
Public Hearing ended on a positive note with support for the proposed project. Thus the final
EIA which incorporates the additional TORs suggested by the Ministry, suggestions /
recommendations of the Public Hearing and with the updated project and process information.

The project has been appraised by the Expert Appraisal Committee (EAC) of the
ministry in the month of August 2008. After the presentation and the meeting the ministry has
sought the specific clarifications based on the discussion in the Expert committee meeting. After
providing the specific clarifications, the appraisal committee in a meeting held on April 2009
discussed the clarifications and further asked for the additional information basing on the
discussions. These additional information has been provided to the ministry and further EAC
meeting held on June 2009 and recommended the project for the Environmental Clearance.

The MoEF through the letter dated 3rd Aug 2009 informed that this project proposal will
be reappraised by the newly constituted Industrial Projects 2 committee, particular to the
aspects of the 2100 MW of Captive Power Plant (CPP) and in general the integration of CPP
with other C1 to C8 units.

As understood the instructions of the chairman of Industrial Projects -2 committee, this

document (EIA) incorporates all the clarifications and additional information sought by the
ministry till date as advised by the ministry.

1.22
Fig. 1.1 : Location of SEZ at Jamnagar

1.23
 33.52 km

22-28-30N
Vokatiyo (kado)
Narada

22-27-N Valupir (kado)

Sikka
22-25-30N Digvijagaon

Lakha baval
Vadinar Sapar
22-24-0N Masitiya
Singach Champa beraja
Danyo (Kado) Vav beraja
Kana chikari
22-22-30N Dera chikari

22-21-0N
31.84km

Khatiya beraja
22-19-30N
Sumra terdhan

22-18-0N

22-16-30N Rangpar
Machhu beraja
Sevak bhatiya
22-15-0N Sinhan kakabhai Sevak bharudiya
Anikhana
Jasapar
Daltungi Gajana Mulila
22-13-30N Rafudad moti Memana
Lalpur
Sinnan aher Charantungi
Gujarat
Khambhaliya
22-12-0N Sodha tardhan Mahadeviya Apia Rafudad nani Khirsara Veraval nani
Kanvirdi
690-45’-0”E 690-46’-30”E 690-48’E 690-49’30”E 690-51’0’ 690-52’30” 690-55’30”E 690-57’0’E 690-58’30”E 700-0’0”E 700-1’30”E
690-54’0”E
33.52 km

Fig. 1.2: Location of SEZ Area

1.24
 INDIAN RAILWAY LINE
TO SIKKA

EXISTING REFINERY
COMPLEX

RIL Railway Siding

(upto Tank Farm)

1 3
4

8
EXISTING
MAJOR ROAD
6
5 7

10 INDUSTRIAL
C1 Units
RESIDENTIAL
C2 Units
INDIAN RAILWAY
COMMERCIAL
C3 Units
LINE
C4 / C5 Units
PUBLIC / SEMI PUBLIC
C6/C7/C8
MASTER PLAN GREEN
CBFS
Lube Oil cum Refinery Complex
OPEN SPACE
CPP
PARKING : HELIPAD
JERP
Hazardous Waste
WATER BODY
Disposal Facility

Fig. 1.3 : Overall Plot Plan of Proposed SEZ

1.25
 Gulf of Kachchh

Bed
Gordhanpur
Singach Mungani Jamnagar
Dera
Vadinar
Gagva Kota

M Kana Chhikari
10 km
Nav
Kathi Devaliya Sas 25 km Naranpur
SH-6 Padana
Kanalus
i
Vadaliya Sinhan Sh-27
Arablus
Sevak Dhuniya
Pipartoda
Khambalia
Apla

Rafudad Moti

Kota Gavana Lalpur

Tebhada Chorbedi Ri
Sansora

Fig. 1.4 : Study Area around the proposed SEZ

1.26
 Table 1.1
Feasibility Analysis For The Location of SEZ

ATTRIBUTES EXISTING POTENTIALS POSSIBILITIES FOR

CONDITION DEVELOPMENT
Physiological Attributes
Location
• Located in the state • Proximity to the Sikka & • Basic infrastructure
of Gujarat at village Bedi ports , for export oriented
Motikhavdi, Taluka - petrochemical and
Lalpur, District - • Adjacent to the Reliance petroleum industry is
Jamnagar. Refinery in place.
• 815 km away from • Proximity to: • Ideal for petroleum
Mumbai and Business Capital - and petrochemical
approximately 25 Mumbai, multi-product SEZ
kilometers from the
city of Jamnagar Economic Capital -
Ahmedabad and Rajkot

Topography / Soil • Saline, sandy loam • Virgin Land - No site • Precaution to be

Type to silty loam with restrictions / taken for integrating
moderate infiltration obstructions in terms of the EMP
rate, amenable to the physical topography recommendations
groundwater of the site.
pollution • Plantation to be
undertaken to
conserve the runoff
water and enhance
the scarce vegetation
cover.
Climate
• Semi – arid type of
extreme climate with
deficit Rainfall

Availability of • Water from the • Sufficient quantity to

water desalination plant, meet the immediate
• Integrated water
serving the existing water requirement of the
developmental
refinery – Primary industry.
schemes will be
water source.
• The Reliance developed for
• Water supply from Desalination plant also optimum generation
Narmada canal is supplies water to nearby and usage.
planned and is villages in days of
under shortage.
implementation -
provide additional
water required for
the SEZ .

1.27
 ATTRIBUTES EXISTING POTENTIALS POSSIBILITIES FOR
CONDITION DEVELOPMENT

Other Attributes
Accessibility • The Sikka & Bedi • Proximity to functional • Good accessibility is
ports provide access port with basic the pre-requisite for
through water infrastructure ready for export oriented
• Nearest railway similar activity – asset activities.
station - 3 km away. for the Petroleum and
Petrochemical based
• The proposed SEZ.
Reliance SEZ is 5
km off the SH-25,
connecting Okha
and Rajkot.
• The site is directly
linked to the
National Highway
network through NH-
8A ext., connecting
Ahmedabad and
Rajkot and State
Highways SH6 & SH
48.
• Air
• Nearest Airport 25
kms away at Jamn
agar

Site surroundings • Close to Coastline • RIL Would support the • Ideal for chemical and
• Adjacent to Reliance related downstream allied industries.
Refinery industries

Availability of • Surrounding villages • The SEZ would depend • Export oriented

Socio-Economic and revenue lands – on the Reliance activities will add to
infrastructure poor socio-economic Refinery initially for its the basic socio-
infrastructure. basic infrastructure till it economic
• Reliance Refinery – attains self-sufficiency infrastructure of the
Strong infrastructure and supports the area.
infrastructure of the
surrounding villages.
Access to physical • Power – would be • Basic physical • The availability of
infrastructure met through a infrastructure can be infrastructure, a pre-
captive power plant easily augmented from requisite for industrial
dedicated to SEZ . the adjoining Reliance development in the
• Water – Refinery in the early SEZ would attract the
Desalination plant stages till the SEZ investors.
and water attains self – sufficiency • Expansion of port
augmented from the in terms of its own facilities and
proposed Narmada infrastructure. additional berth/jetties
canal for container/bulk
• Rail – The site has cargo
a rail head which -Do- -Do-
can be utilized
effectively for
transporting freight

1.28
ATTRIBUTES EXISTING POTENTIALS POSSIBILITIES FOR
CONDITION DEVELOPMENT
• Road – Site lies
close to the state
highway 25 and NH-
8A
• Sewerage and
Drainage
• Gentle slope
assures Proper site
drainage

1.29
 Table 1.2

List of Units Proposed for SEZ Project

Capacity Raw material in

Sr.No Proposed Units Raw Material Source
(MMTPA) (KTPA)

I C1 Based Units

Refinery
1 Coke Gasification 8.75 8750 Coke
DTAP + JERP

2 Methanol Synthesis 0.625 660 Syngas Coke Gasification

575 Syngas + Coke Gasification

3 Acetic Acid 1.00
500 Methanol +Methanol Synthesis

Vinyl Acetate 390 Acetic Acid Acetic Acid + Multi Feed

4 0.70
Monomer(VAM) +200 C2= / Cat Cracker

5 Polyvinyl Acetate (PVA) 0.35 320 VAM Vinyl Acetate Monomer

Polyvinyl Alcohols
6 0.125 250 PVA Polyvinyl Acetate
(PVOH)

II C2 Based Units
2 x 625C2=(FCC)
Multifeed Cracker Refinery
1 3.45 1000 C2 (RFG)*
Complex DTAP + JERP
190C2 = (RFG)*
Ethylene Oxide
Derivatives like Mono
Ethylene Glycol (MEG),
2 1.25 800 C2 = Multifeed /Cat Cracker
Di Ethylene Glycol
(DEG) , Tri Ethylene
Glycol (TEG)
Polyethylene polymers
3 like 0.75 765 C2 = Multifeed /Cat Cracker
(LDPE /LLDPE/HDPE)

1.30
III C3 Based Units

Acrylic Acid & 275 C3= Multifeed /Cat Cracker +

1 0.45
derivatives, SAP 65 Acrylic acid Acrylic Acid
n-Butyl Acrylate,
n-butyraldehyde, 315 Acrylic acid + Acrylic Acid +Oxy
2 0.5
n-Butanol, 250 Oxy alcohol Alcohol
2-EthylHexanol
Propylene Derivatives
Multifeed /Cat Cracker +
3 like Propylene Oxides, 0.4 290 C3= + 285 H2O2
Hydrogen Peroxide
Cumene, Phenol

4 Propylene Glycols 0.2 150PO Propylene Oxide Unit

Propylene OxideUnit +
5 Polyols 0.25 225 PO + 25 EO
MEG

Hydrogen Peroxide
6 0.32 165 Syngas Methanol
(H2O2)

0.125
7 PP (Non woven) 125 PP Polypropylene (PP)

8 Polypropylene (PP) 0.25 250 C3 Multifeed / Cat Cracker

IV C4/C5 Based Units

Refinery (DTAP + JERP)

150 iC4= + 250
Butyl/Halo Butyl Rubber, 0.47 + Multifeed Cracker
1 Butadiene +
ESBR, SBR,PBR, SSBR Aromatics 2 + Multifeed
62.5styrene
Cracker

2 Butene 1 0.0625 62.5 C2 = Multifeed Cracker

Refinery
3 Maleic Anhydride (MA) 0.25 NC4
DTAP + JERP

4 Fumaric Acid 0.125 MA Maleic Anhydride

1.31
V C6/ C7/ C8 Based Units

Mono Nitro
Benzene,Aniline, Methylene
Di Aniline,Phosgene,
Refinery
1 Methylene Diphenyl 0.5 500 Benzene
DTAP + JERP
Diisocyanate (MDI),
Toluene Diisocyanate (TDI),
Benzene
700 Benzene + 315 Refinery
2 Styrene 1.0
C2 = DTAP + JERP
Paraxylene (PX), Refinery
3 2.5 Reformate
Orthoxylene (OX) DTAP + JERP
1250 PX+132 Acetic
4 PTA 1.875 Aromatics
Acid

5 PET 1.5 1290 PTA +500MEG PTA+MEG

Polyesters Complex (POY,

6 0.625 140 PTA+ 200MEG PTA+MEG
PSF)

VI Carbon Black 1.5 CBFS + CSO Refinery Unit (DTAP &

(2.5 MMTPA total) SEZ)

Lube Oil Cum Refinery 140 Kbpsd additional

VII 8.5 140 Kbpsd crude
Complex CDU/VDU

2100
VIII Captive Power Plant
MW

Jamnagar Export Refinery

IX 580 Kbpsd Crude
Project
• Refinery Fuel Gas
• SAP: Super Absorbent Polymer.
• PTA: Putrefied Teraphthalic acid
• MEG: Mono Ethylene Glycol
• LLDPE: Linear Low Density Polyethylene
• LDPE: Low Density Polyethylene
• PET: Polyethylene Tera-phthalate.
• POY: Polyester Oriented Yarn.
• PSF: Polyester Stable Fiber
• ESBR: Emulsion Styrene Butadiene Rubber
• SBR: Styrene Butadiene Rubber
• PBR: Poly Butadiene Rubber
• SSBR: Solution Styrene Butadiene Rubber
Note: The Petroleum and Petrochemical Complex will be manufacturing and utilizing the
petrochemicals of the value chain C1 to C8 categories derived from the petroleum refining and their
streams. The products and C1 to C8 derivatives mentioned hear are generic names and most
commonly used and their various synonyms names are not mentioned.

1.32
 The capacities indicated are based on the feed stock available from the approved
capacities of the RIL refinery cum Petrochemical complex and RPL Refinery at Jamnagar.

In case there is any increase in the envisaged product capacities, the company will
approach the concerned authorities and MoEF for the required approvals at that time. will be
approaching the authorities for required approvals as applicable at that time.

1.33
 Table 1.3

Recommended Methods of Monitoring & Analysis for

Criteria Parameters and Pollutants

Attributes Measurement Technique

Meteorological Parameters Automatic Weather Station
Wind speed, wind direction,
ambient temperature, solar
radiation and cloud cover
Air Pollutants
Suspended Particulate matter High volume sampler (gravimetic)
(Particle size 0.5 µ to 100 µ )
Respirable Particulate Matter High volume sampler with cyclone
(<10µ) (gravimetric)
Sulphur dioxide (0.005 to 5 ppm) West and Gaeke Method (Spectrophotometric)
Nitrogen dioxide (0.01 to 0.4 ppm) Arsenite modified Hocheiser Method
(Spectorophotomtric)
Hydrocarbon Gas Chromatography
Noise Sound Level Meter
Water and Wastewater Standard Methods for Examination of Water
and Wastewater Analysis by APHA
Soil Reference book by M.L. Jackson
Reference book by C.A. Black
Geology and hydrology Based on data collected from secondary
sources
Ecological Resources Standard Methods for Examination of Water
and Wastewater Analysis by APHA
Secondary data from Govt. offices and
Published Literature
Flora : Sample plot method, Transects and line
intercepts method, Plotless sampling method
Fauna : Animal species list, Count indices
Topography and Landuse Toposheets and / or Digital Analysis
Techniques

1.34
Chapter 2

Description of the Project

2.1 Indian SEZ Policy
The Export and Import (EXIM) Policy - 2000 introduced by Government of India for
setting up of Special Economic Zones in the country is with a view to provide an internationally
competitive manufacturing and service and hassle free environment for exports. Under the
EXIM Policy-2000, the SEZ is defined as a specifically delineated, duty-free enclave and shall
be deemed to be foreign offshore territory for the purposes of trade operations and duties and
tariffs.

SEZ units may be set up in SEZ for manufacture of goods and rendering of services.
All the import/export operations of the SEZ units will be on self-certification basis. The units in
the Zone have to be a net foreign exchange earner but they shall not be subjected to any pre-
determined value addition or minimum export performance requirements. Sales in the
Domestic Tariff Area by SEZ units shall be subject to payment of full Custom Duty and import
policy in force. Further Offshore banking units may be set up in the SEZs.

2.1.1 Some of the Key benefits of an SEZ are as follows:

• A designated duty free enclave to be treated as foreign territory for trade

operations and duties and tariffs.

• No license required for imports.

2.1
 • Exemption from customs duty on import of capital goods, raw materials,
consumables, spares, etc.

• Exemption from central excise duty on procurement of raw materials, spares,

etc. from the domestic markets.

• Supplies from DTA to SEZ units treated as deemed exports.

• Reimbursement of Central sales tax paid on domestic purchases.

• Reimbursement of duty paid on furnace oil, procured from domestic oil

companies to SEZ units as per the notified rate of drawback.

• SEZ units may be for manufacturing, trading, or service activity.

• SEZ units to be positive net foreign exchange earners for the first five years.

• Performance of the units to be monitored by a Committee headed by the

Development Commissioner.

• 100% FDI in manufacturing sector allowed through automatic route except few
sectors.

• Profits allowed to be repatriated freely without any dividend-balancing

requirement.

• No industrial licensing restrictions on products reserved for small-scale sector

and domestic sales on full duty subject to import policy in force.

• Full freedom for sub-contracting in DTA and SEZ units may also undertake job
work on behalf of domestic exporters for direct exports.

• Duty Free goods could be utilized over the approval period of 5 years.

• Corporate tax holiday as per Section 10 A of the Income Tax Act.

2.1.2 SEZ, Labour and Environmental Laws

While the labour laws of the land apply to units inside SEZs the respective State
Government may declare units within SEZs as public utilities. This in effect means that the
laws would be more entrepreneur-friendly. Moreover, the State Government are allowed to
delegate the powers to the Labour Commissioner of the SEZ or to an Officer of the State
Government posted exclusively for Zone. One-stop Clearance and minimum inspection within
the SEZ will be part of the State rules.

2.2
 As far as the environmental laws are concerned, the approval process is same as for
any other type of developmental activities. However, all units within the SEZ can be assessed
together in a single approval process from environmental angle. Under the Environment
Clearance notification of 2006, projects are categorized into Category A & B. If any one of the
units proposed in the SEZ is categorized as “Category A”, the entire SEZ will be categorized
under Category A.

2.1.3 Emerging Domestic SEZ’s in Gujarat

The attractiveness of the Center’s policy framework on SEZ has not gone unnoticed
by State Governments. At present, all coastal states, as well as some non-coastal ones, are
working on SEZ proposals.

Existing Export Processing Zones (EPZs), besides, have clamored for SEZ status. So
on November 1, 2000, the Union Government gave SEZ status at Kandla, Santa Cruz
(Mumbai), Kochi, and Surat. Besides these, it has granted in principle approval for the
establishment of eleven more SEZs. These are to come up at Positra in Gujarat, Nanguneri in
Tamil Nadu, Navi Mumbai in Maharashtra, Kulpi in West Bengal, Paradeep in Orissa,
Gopalpur in Orissa, Indore in MP, Kanpur in Uttar Pradesh, Bhadoi in Uttar Pradesh, Kakinada
in Andhra Pradesh and Hassan in Karnataka as shown in Table 2.1 and Fig. 2.1.

2.1.4 Gujarat State SEZ Policy

Government of India has announced a Policy of Special Economic Zones (SEZs)

during March 2000 with a view to augmenting infrastructure facilities for export production.

The Central Government has offered various incentives and facilities both to
developer of SEZ as well as the industrial units coming up on SEZ. All kind of units namely
manufacturing, trading of service activities are permitted in SEZ. All approvals are to be given
by the Development Commissioner for establishment of the unit in SEZ. The State
Governments are required under the scheme to offer specified facilities and concessions for
promotion of units in SEZs.

In the context of Government of India guidelines for the establishment of SEZs, the
matter of formulating a policy regarding the dispensations which the State Government will
accord to promote the development of SEZs, has been under consideration of the State
Government for some time past. After careful consideration, it has now been decided that the
following policy will apply to all SEZs in the State namely Kandla SEZ, Surat SEZ and
proposed SEZ at positra, Mundra and Dahej and at any other locations where SEZ may come

2.3
up in Gujarat, subject to the framework of SEZ determined by Government of India from time
to time.

Management of Zones

The management of the Special Economic Zone will be under the designated
Development Commissioner. The Development Commissioner will grant all the permissions as
Single Point Clearance from his office. These will include registration of the unit, allocation of
land, permission for construction of building and approval of building plan, power connection,
environmental clearance, water requirement etc.

SEZs in the State will be declared as Industrial Township (Notified Area)

Power

The SEZ authority will ensure continuous and quality power supply to SEZ units.

SEZ developer will be permitted for arrangement of power through establishing a

Captive Power Plant.

SEZ units will be granted automatic approval to set up captive power plant.

Environment

Applications for site clearance, NOC, consent order and other clearances required
from Gujarat Pollution Control Board for units and activities within SEZ under different Acts
except for the industry/activities which require clearance from Ministry of Environment and
Forests (MoEF), Government of India will be accepted by Development Commissioner of the
SEZ for processing at appropriate levels.

Water

The SEZ developer will be granted approval for development of water supply and
distribution system to ensure the provision of adequate water supply for SEZ units.

Labour Regulations

The powers of the Labour Commissioner, Government of Gujarat shall be delegated

to the Development Commissioner in respect of the area within the SEZs. He will function as
Registration Officer, Conciliation Officer as well as Inspector under various Labour Laws to
provide Single Window Service.

All industrial units and other establishments in SEZ will be declared as “public utility
service” under the provisions of Industrial Dispute Act.

2.4
 For inspections relating to workers health and safety, units will be permitted for
obtaining inspection reports from accredited agencies as may be notified by the State
Government.

Sales Tax and Other Levies

Transactions within the SEZ shall be exempted from all State taxes including Sales
Tax, VAT, Motor spirit tax, luxury tax and entertainment tax, purchase tax and other state
taxes.

Inputs made to SEZ units from Domestic Tariff Area (DTA) will be except from Sales
tax and other State taxes.

Sales tax will be applicable to SEZ goods as applicable to other imported goods.
Same Rules and Procedure will be applicable to SEZ goods as applicable to normal imports.

2.2 The National Economy

The context, in which SEZ policy was framed, as well as the significance of its critical
objectives can be more fully understood against a perspective of recent trends in India’s
economy and its export policy. The performance of the Indian economy in the last fifty years
has had several distinctive phases;

1950s-70s : The Hindu rate of growth phase

1980s: The first liberalization phase that lasted for a decade. This phase witnessed
not only a significant set up in overall growth rates but also saw significant deterioration both in
the external sector and in fiscal management.

1990s and Post 9/11: The third phase which reflect that dynamic development

During the first phase, India’s economy grew at moderate levels, typically between 3
% to 4.5% during the second phase, there were tentative initial steps towards liberalization
and opening up of the economy on several key fronts. This led to the step up of growth rate to
around 5% to 5.5%.

The continued period of fiscal imprudence exhibited during much of the 80s finally
assumed crisis proportion in mid ‘91. This set the step for unleashing a massive wave of
reforms across wide ranging sectors. As a result for the first time in the history of Independent
India, Indian economy persistently grew at the healthy rate of 6% to 7% before the slow down
crept in.

2.5
 The country witnessed the slow down for the Fiscal years 2000-02 more so in the
industrial sector. Quite clearly against the above backdrop, there had been wide ranging
discussions and debates on initiating the second generation of reforms. The promulgating of
the Special Economic Zone Policy framework in May 2000 can be regarded and so positioned
as one of the first attempts of the Government of India to unleash second-generation reforms.

The GDP of the Indian Economy grew at 7% in the third quarter 2004-2005, as per
data released in June 2005. According to the same data, services exports trade posted an
astounding growth with exports more than doubling from at $ 24.9 billion in 2003-04 to $ 51.3
billion in 2004-05, an increase of 105.7%. The total foreign exchange reserves stood at $
139.8 billion at the end of May 2005. The wholesale price indices show that inflation rates
have slowed down from 5.8% in April 2005 to 5.5% in May 2005. Rate of inflation in April –May
2005 was 5.6% as against the 4.8 % in the corresponding period of the previous year.

The boom industries in India include telecom, IT/ITES, biotech, retail, aviation,
entertainment and energy. The Fortune 500 list ( July 2005) of the top Global corporations
includes 4 Indian companies namely, Reliance Industries, Bharat Petroleum, Hindustan
Petroleum and ONGC. Just as China is today considered the “factory to the world”, India is
considered “the world’s back office”.

The SEZ policy is the latest and most ambitious move of export boosting efforts, but it
goes much further, in that it seek to radically change the environment for exports and FDI, by
offering a hassle free business-friendly environment and world class infrastructure over an
unprecedented large geographical area.

India’s SEZ policy can be looked at as a logical outcome of the developments in

India’s export-import policy. Trade Policy reform over the last decade have moved towards
providing the Government of India has already removed or reforms some of the restrictive
regulation and offered a hassle free business through the following ways;

1. In the first place, efforts have been made to remove restrictive export import
regulations. An important first step in this regard is the proposal to set up SEZs.
2. Secondly, conscious steps have been initiated to ensure that the process of
trade liberalization in India remains aligned to the norms of multilateral trading
agreements. Thus, the incentive structure for exporters has recast to make it
consistent with India’s commitments to WTO. Tariff changes and QR reforms in
accordance with WTO commitments have been made.
3. Lastly, the policies have been made to provide special incentives to certain
categories of Indian exports.

2.6
 Importantly, the EXIM policy now seeks to motivate and involve State Governments in
export promotion efforts. The current SEZ framework appropriately leaves the key
administrative initiatives to be implemented by State Governments.

2.3 The State Economy

In the post-liberalization period, Gujarat has pioneered the concept of involvement of
private sector in the development of infrastructure. The State has constituted a mechanism of
single window clearance in the form of Gujarat Infrastructure Development Board (GIDB),
headed by Chief Minister. Concession agreements are finalized in a transparent manner.
GIDB had prepared a detailed Master Plan. "Infrastructure Agenda - Vision 2010", laying down
383 projects estimating an investment of Rs. 1.16,993 crore. Almost 70% of the investment is
envisaged to come from private sector Blue prints for development of power generating plants,
ports, roads, LNG platforms, a common gas grid, industrial parks, urban infrastructure,
airports.

Advantage with Gujarat

• During the period 1960-90, Gujarat established itself as a leader in various

industrial sectors - Textiles, Engineering, Chemicals, and Petrochemicals. Drugs
& Pharmaceuticals. Dairy, Cement & Ceramics. Gems & Jewellery, etc., the
most important one being petroleum refinery set up by Reliance Industries
Limited in Jamnagar, Gujarat.

• Post-liberalization period saw Gujarat's State Domestic Product (SDP) rising at

an average growth rate of 12.4% per annum in real terms (from 1994 -2002).

• Gujarat achieved as much as 35% of augmentation in its power generation

capacity during the period 1995-96 and 2000-01. The Independent Power
Producers (IPPs) have contributed significantly in this addition. Gujarat in fact, is
one of the first few states in India to have encouraged private sector investment
in the infrastructure.

• Gujarat accounts for 21% of India’s Exports.

• Longest coastline - 1600 Kms. dotted with 41 ports 1 major. 11 intermediate and
29 minor. Country's first private sector ports. Pipavav and Mundra. are already in
operation. In addition. The liquid cargo (Chemicals) handling port at Dahej is also
set up in joint sector and made operational.

2.7
 • Excellent road network - exceeding 74,000 Kms. The first phase Ahmedabad-
Nadiad - of the Expressway in Gujarat now opens for transportation.

• Highest number of Airports in India - 11 including an international airport at

Ahmedabad.

• An extensive rail network connecting all major centres in the State.

• The annual growth rate of industrial output on an average was witnessed at

around 18% during the period 1990-2000.

• Largest producer of Salt and Soda Ash in the country.

2.3.1 Economic Growth of Gujarat

During the 1990s, there was no increase in organized sector employment in Gujarat.
The primary sector, particularly agriculture, has been stagnant or even declining. By contrast,
the secondary and tertiary sectors have shown statistically significant and high rates of growth
over the whole period. But the factory sector in Gujarat has undergone a higher degree of
concentration than in the rest of India. More importantly, the capital-intensive nature of the
growth in the factory sector has been even more pronounced in Gujarat.

Looking at the sectoral growth rates, it seems that the economy of Gujarat grew in an
unbalanced and volatile fashion over the period under consideration. There has been a
significant transformation in occupational structure. But that transformation is out of step with
the change in incomes derived from different sectors. A mismatch in the movement of income
and employment shares is stronger in Gujarat than the rest of India. Further, the people living
in rural Gujarat have become significantly proletarianised.

2.3.2 Sectoral growth

The growth pattern of Gujarat is not uniform across different sectors. The primary
sector and particularly the agricultural sector, has been stagnant or even declining in the state.
The estimated trend values indicate that neither agriculture nor the primary sector as a whole
follows any statistically significant time trend over the 31-year period in the state. There is,
however, a general problem of the growth estimate, which varies widely according to choice of
the data source as well as the base and terminal years.

2.3.3 Industrial Development in Gujarat

As mentioned earlier, the economy of Gujarat has witnessed an ever-increasing

share of industry in NSDP during the 31-year period from 1970-71 to 2000-01. Further, as per

2.8
the data compiled by the Annual Survey of Industries (factory sector), the state has witnessed
a marginal fall in the share of the number of factories to the all-India total during the period
1980-81 to 1999-2000.However, the shares of other important indicators (viz, employment, net
value added, productive capital and value of output) to their all-India values have witnessed
rising trends during the period.

The share of the number of factory employees to the all-India total has increased only
marginally; but the corresponding shares of productive capital, value of output, and net value-
added increased at a much faster rate, especially in the1990s. That means that in the 1990s,
the factory sector in Gujarat has undergone a higher degree of concentration than in the rest
of India and more importantly, the capital-intensive nature of growth in the factory sector has
been even more pronounced in Gujarat than in the rest of India.

During the period 1979-80 to 1999-2000, annual compound growth rate of net value
added of the manufacturing sector has-been 7.8 per cent, while that of employment has been
only 0.9per cent.

• Gujarat is one of the most prosperous states and is known for the enterprise of
its people. This along with good infrastructure has enabled it to create one of the
strongest state economies. The state contributes 5% of Net Domestic Product
even though its share of population is only 4%. Its share in bank deposits is 6.1%
with more than 6700 bank branches. The state is also a major trading centre with
one of the country’s largest port – Kandla handling almost 15% of total Indian
port traffic.

• Such strong economics translates into higher purchasing power and hence
higher consumption. The state’s per capita urban consumption expenditure ranks
amongst the top five in the country.

• The most important industries in the state are chemicals (including

petrochemicals), which contribute almost 27% of state industrial production, food
products and rubber and plastic. A large part of the industry is in the small scale
and unorganized sector, especially in downstream chemicals and processing
industries.

• Our database search revealed that more than 250 companies amongst the top
5000 companies in India have plants or offices in the state. Though it will be
premature to quantify the impact on each company, we have attempted to

2.9
 assess the broad impact on industries and companies with a significant presence
in the state.

Chemicals oil and gas

The largest investor in Gujarat is Reliance group who has set up a textile unit in
Naroda, a petrochemical complex at Hazira and Petroleum refinery and a Petrochemical
Complex in Jamnagar.

Industry and environment

The State’s share of factories, [9.8%] organized employment [8.21%], productive

capital [15.27%], output [12.96%], and net value addition [11.45%] in 1998-99, was way above
its share of population [5%] or its geographical area [6%]. As a result, the per capita income in
the sate at Rs. 18792 at current prices (1998-99) is about 30% more than the national
average.

It had 19,771 registered factories and 2,33,777 small-scale industries as on 31st

October 2000. According to the annual survey of industries for the year 1997-98, the chemical
and chemical products group constituted 37.28% of the industries. Rubber, plastics, petroleum
and coal based industries contribute another 14% while textiles contribute 8% of the
industries.

In the last decade economic development has taken place in Jamnagar. Gujarat
already boasts of industrial hubs of Jamnagar and Mundra.

Reliance has the capacity to take up development of large economic zones and
intends to do so within the framework of the national SEZ policy. The development of such
economic zone will create an investor friendly environment supported by infrastructure to
accelerate industrial growth and would also open up employment opportunities for rural
population.

Reliance SEZ is unique in many respects compared to the other SEZ’s, developed
Internationally and Nationally.

2.4 Location & Connectivity

SEZ located in the Jamnagar district, in close proximity to Arabian Sea:

• It is well connected with important state road network (state highway no. 25) and
other important national node via NH- 8A. It is about 30km from Jamnagar and
340km from Ahmedabad.

2.10
 • A broad gauge railway network connects Reliance SEZ with Jamnagar and other
rail network.

• Reliance port at Sikka, being a part of Reliance industries would contribute a

good deal of efficiency in the functioning of the SEZ.

• Airport at Jamnagar are in near proximity to the SEZ site only 25 km.

Any destination in North India is shorter by approximately 300 km in comparison to

Mumbai ports (JNPT/MbPT).

2.4.1 Scale (Size - Scalability)

• Abundant availability of land in the hinterland will boost large scale planning and
development of infrastructure in the SEZ, and therefore, has a vast scope for
expansion and development.

• Large waterfront is available for expansion of Port oriented and terminal facilities
at Sika.

• Numbers of new industries, Industrial parks are already coming up in the region.
Also planned infrastructure and industries are coming up in the SEZ are being
developed by Reliance group.

2.4.2 Port Operations

• Operational and efficient Port infrastructure available, Reliance port at Sikka

• Increased efficiency in functioning due to common management and unified

agency for Port and SEZ operation.

• Multi-purpose terminal with state of art infrastructure / facilities for handling and
storage.

• Liquid products handled are an infrastructural concern. For this purpose, a jetty
dedicated to container depot has to be constructed to handle break bulk and dry
bulk.

• A new terminal is proposed for handling the additional ships for liquid cargo,
container traffic & bulk cargo.

• Deepest draught port in the western part of the country.

• Complete to and fro piping system for connectivity to the port and the SEZ.

2.11
2.5 Regional Attributes of Jamnagar

• The region is rich in mineral resources having a very high economic value.

• Major natural resource reserves in the region are suitable for large scale projects
such as Power plants, Petro-chemical plants, Cement plants and other mineral
based plants.

• An ideal destination in Gujarat for petrochemical products.

• Great business opportunity for Polyster / Textile units.

• Social infrastructure such as Markets, Schools, Hospitals, Children’s Parks,

Community Centers etc. are established in the area. Further, proposal of
meeting international standards in the municipal and social infrastructure of
planned area of Reliance are envisaged to be developed.

The project aims at developing a parcel of 11231 acres of land adjacent to the
Reliance refinery by RJIL.

The multi-product SEZ will have state-of-the-art infrastructure like transportation

system, sanitation, water supply, buildings, recreation facilities, parks and amusement
complexes, multi-modal transport system, manufacturing and processing facilities, Business
Development and International trading centers, etc.

Petrol and petroleum dominated SEZ and its environs fall in the high hazard zone.
Hence utmost care needs to be taken to ensure that emissions and wastes from the refinery
do not pollute the environs. The Reliance group envisages not only the preservation of the
immediate environment but also the enhancement of the same.

Economy flourishes when it exists within the limit of the environment. The Reliance
Group aims at promoting the SEZ as an eco-friendly infrastructure to provide most modern
and hygienic living environment. The Reliance through its policy and programmes like
conservation and further plantation endeavors to bring about awareness amongst the people
and make them more responsive and sensitive to their surroundings.

2.6 The Development Plan

The Reliance Jamnagar SEZ has an integrated planning approach with the Petroleum
and Petro-chemical – the base industries, the allied and complementary industries, the
employee housing co-exist in harmony supported by a world class infrastructure.

2.12
 The Reliance envisages developing the Jamnagar SEZ adjacent to its existing
Refinery on a site of 11231 acres. The SEZ unit would be spread over an area of 8910 acres.
The remaining 2321 acres would be dedicated to housing the employees, their social
activities, Master plan as well as sectoral green buffers. The SEZ is expected to generate
employment for 40,000 people.

The proposed SEZ is to be planned on the lines of gridiron planning with NS corridors
as the avenues and EW corridors as Streets. The configuration in the existing activities of the
Reliance Group and those of the other entrepreneurs would be delineated, though they would
share the socio-economic infrastructure and green belts and open spaces.

The Reliance will develop the industry, housing, social infrastructure needed for
their refinery and its allied activities.

2.6.1 Targeted Industrial Components

The various petroleum and petrochemical downstream units which can be set up in the
proposed SEZ are as follows:

C1 Based Units

• Coke Gasification

• Methanol Synthesis

• Acetic Acid

• Vinyl Acetate Monomer (VAM)

• Polyvinyl Acetate (PVA)

• Polyvinyl Alcohols (PVOH)

C2 Based Units

• Multifeed Cracker Complex

• Ethylene Oxide Derivatives like Mono Ethylene Glycol (MEG), Di Ethylene Glycol
(DEG) , Tri Ethylene Glycol (TEG)

• Poly Ethylene Polymers like Low Density Polyethylene (LDPE) / Linear Low Density
Polyethylene (LLDPE) / High Density Polyethylene (HDPE)

C3 Based Units

• Acrylic Acid and derivatives , Super Absorbent Polymer (SAP)

2.13
 • n- Butyl Acrylate, n-Butyraldehyde, n- Butanol, 2- Ethylhexanol

• Propylene derivatives like Propylene Oxides, Cumene, Phenol

• Propylene Glycols

• Polyols

• Hydrogen Peroxide (H2O2)

• Polypropylene PP (Non woven)

• Polypropylene (PP)

C4/C5 Based Units

• Butyl/Halo Butyl Rubber, ESBR, Butyl Rubber Styrene Butadiene Rubber (SBR),
Poly Butadiene Rubber (PBR), SSBR

• Butene 1

• Maleic Anhydride (MA)

• Fumaric Acid

C6/ C7/ C8 Based Units

• Mono Nitro Benzene, Aniline, Methylene Di Aniline, Phosgene, Methylene Diphenyl

Diisocyanate (MDI), Toluene Diisocyanate (TDI), Benzene

• Styrene

• Paraxylene (PX) , Orthoxylene (OX)

• Putrefied Teraphthalic acid (PTA)

• Polyethylene Tera-phthalate (PET)

• Polyesters Complex (POY, PSF)

Carbon Black

Lube Oil (LOBS) cum Refinery Complex

Captive Power Plant

& Jamnagar Export Refinery Project (JERP) which has already been accorded
Environmental Clearance by the MoEF in 2005 / 2006.
The Modernization and debottile necking of the existing refinery and expansion
refinery (called as Jamnagar Export Refinery) along with their infrastructure had been

2.14
accorded the environmental clearance by the ministry in 2005 and amended in 2006. Since
this JERP is being built in the SEZ area, JERP is included in the EIA. However, the emissions
of JERP are included in the analysis of this study.

2.6.2 The Housing

A new Residential township is being proposed to house the employees and the
growing influx of immigration due to the new industries coming up in the SEZ unit.

An area of 2321 acres has been allocated to residential enclave. The housing would
consist of two segments – the Reliance housing and the employee housing for the other
investors coming to the SEZ distributed in a ratio of 40:60. The two have been separated from
each other by a green buffer zone.

The Petroleum and Petrochemical Industries have been categorized under the high-
risk zone. The Residential quarters have therefore been separated from the industrial zone.
The residential sector is to house 40,000 families.

The proposed gross density of SEZ will range from 150-175 DUs per Ha. The houses
will have three categories in terms of the size of the dwelling unit, its specifications and
location depending upon the income group.

The greenbelt will separate the complete residential enclave from the industrial SEZ.
The Residential zone will have a continuous green belt along its periphery with jogging and
cycle tracks.

The township will be designed on sectoral basis where each sector will be self-
sufficient in terms of commercial, retail, public/semi-public amenities. The housing will be in
the form of plotted development with plenty of open spaces. The sectors planned on the
neighbourhood concept will have gardens, shops, primary education and health centers at 5
minutes walking distance.

The SEZ is being developed as an eco-friendly township. The recycled water from the
industry will be used for irrigation through water channels along green corridors, which not only
alter the microclimate but also would add aesthetic beauty to the layout giving some relief from
the hot arid climate of the region.

The Jamnagar region falls in the arid zone with sparse, thorny vegetation. The
conservation of the existing environment and its enhancement through tree plantation and
development of green cover will be undertaken. The existing plantation by Reliance has gone
a long way in restoring and improving the green cover in the region.

2.15
2.6.3 Building Social Health

With focus on employee and resident safety training, cooperating entrepreneurs or

companies should establish emergency procedures and make essentials thoroughly
understood. Prevention from occupational illnesses.

Health maintenance and enhancement: organizing regular health examination in

order to determine the impact of chemical substances on employees’ health and take
appropriate preventive measures. In addition, employees that work in noisy environments
should be given hearing tests and all employees to be surveyed regarding the hours spent at
video-display terminals and any subjective symptoms they may have. Employees then advised
on the appropriate work environment.

Reliance will hold regularly "Health Seminars" based on the principles of Total Health
Promotion "Promoting Individual Health Maintenance" and "Let's Improve Our Daily Habits"
efforts.

Regularly organize forest and mangrove conservation in which employees participate

in as volunteers with proper coordination with the local governments to support preservation
programs in undeveloped forest areas in future.

Kick off environmental education activities with raising of environment consciousness

and ways to tackle environmental problems (including tours of oil refineries).

Support for Employee Volunteers to participate in increasing employee awareness of

social contributions.

2.7 Infrastructure Facilities

Infrastructure is the prime need for any industrial or housing development but when
the context is a Special Economic Zone it becomes the foundation for attracting investment on
the virgin land with complete web of infrastructure facilities at the doorstep.

2.7.1 Water Supply

Water is a prime need for any petroleum and petrochemical industry. After careful
consideration of the water resources in the area and not to exert any pressure on the existing
resources, seawater was considered for sourcing of water in the SEZ as in the case of the
existing refinery. The existing seawater intake provided at the marine terminal area is
considered adequate to meet the seawater requirement for desalination of seawater to
freshwater. The desalination plant will be designed using Multiple Effect Distillation process

2.16
(MED) integrating it with energy sources. The energy (heat) requirement for desalination is
met from the waste heat from the processing units. This scheme eliminates the venting of low
pressure and low temperature steam from the process units and also eliminates the use of
water as a steam sink for the effective steam requirement and balancing. This plant also
integrated with the ultra filtration / reverse osmosis plant, which will/can process the gray water
from the complex.

The effective way to reduce freshwater consumption is to maximize the recycle and
reuse of the treated wastewaters. In the petrochemical complex, the extent of wastewater
generation and their quality depends on the type of pollutants and composition. One of the
broad categorization is that the wastewater can be segregated as on the basis of total
dissolved solids and is subjected to the pre-treatment/treatment of the specific pollutants. The
treated wastewater will be used in the cooling towers where maximum consumption is for
cooling water and next maximum utilization is for the steam generation. This procedure has
been well utilized in the existing petrochemical and refinery complex and will be utilized in the
SEZ complex also.

The domestic and other waste water is collected and treated at strategically placed
sewage treatment plants, up to tertiary treatment level and the same is re-circulated for
industry and non-domestic uses. The majority of uses are in the refinery & power plant cooling
towers, horticulture watering etc.

2.7.1.1 Sources of Supply:

Existing Sources –

a) Desalinated water

Currently the water requirement for the existing Refinery cum Petrochemical complex
is met from the Desalination Plant installed in the Complex .The desalination plant is providing
2600 cu m/hr (2.6 million liters/hr) of water required for the complex and the residential
complex.

The desalination plant is designed with flexibility to operate on a low energy input
sufficient for units or domestic purpose. This plant also integrated with the ultra filtration /
reverse osmosis plant, which will/can process the gray water from the complex.

b) Effluent Treatment Plant

The effluent treatment plant is set up for the physical, chemical and biological
treatment. The effluent to the Effluent Treatment Plant is being segregated into two streams

2.17
i.e. low total dissolved solids (LTDS) and High total Dissolved Solids (HTDS). They are
treated in three stages, with each stage having two sub-system of oil removal, two stage
biological system and two stage tertiary/ polishing system so that the treated wastewater can
be reused and recycled.

Reduction in Water Utilization:

In the petrochemical complexes bulk of the water is utilized for cooling purposes and
production of steam. For cooling, cooling towers are used where the water evaporates for
cooling the water. The cooling water consumption can be reduced by effective removal of heat
by using air fin-fan coolers, feed product-heat exchange and improving the efficiency of the
cooling towers. Recycling the condensate and utilization of low-low pressure steam in the
desalination plants can reduce water consumption for steam. These are internalized and
integrated with the desalination plant and effluent treatment plant.

a) Desalination plant

A new desalination plant is planned to be set up to meet the requirement of the

proposed SEZ. Seawater shall be desalinated by desalination plants to the standards of water
for the industrial process and potable water and will be supplied primarily for domestic use.
The desalination plant will be designed using Multiple Effect Distillation process (MED)
integrating it with energy sources. The energy (heat) requirement for desalination is met from
the waste heat from the processing units. This scheme eliminates the venting of low pressure
and low temperature steam from the process units and also eliminates the use of water as a
steam sink for the effective steam requirement and balancing. The desalination plant shall
provide 15,000 cu m/hr of water, required for the proposed units coming up in the SEZ and the
residential complex.

Alternative Sources:

Large scale Recycling of Water

Domestic and other waste water shall be collected and treated at strategically placed
sewage treatment plants, up to tertiary treatment level and shall then be re-circulated for
industry and non-domestic uses. Besides this a “gray water” treatment plant with ultrafiltration
and reverse osmosis process can be installed. For the majority of uses in the SEZ, from power
plant cooling to horticulture watering, gray water would be of a high enough quality. It should

also be noted that often “contaminated freshwater is of a lower quality than that of the plant’s
process water”. Therefore, it can be cheaper to reprocess gray water than to clean supposedly
fresh water.

2.18
 In the longer term, industries throughout the SEZ will be entrusted to recycle their
water much more effectively to achieve ‘zero discharge’. While the management can provide
incentives for SEZ units to conserve water resources, the biggest impetus for change would
come from an increase in water prices to reflect its scarcity in the region.

A gridiron system of pipelines shall be used for water distribution network, compatible
with the sector planning of SEZ. Within the gridiron system of pipe network, all arterial and
secondary mains shall be looped and interconnected. This arrangement eliminates dead ends
and permits water circulation such that a heavy discharge from one mains allows draining
water from other pipes. This also helps in preventing water from developing tastes and odors
due to stagnation.

Besides this the dual piped water supply system for potable and non-potable water
can be installed to reduce the pressure on the water where the non-potable water can be
generated from recycling plants or grey water treatment plants while the fresh water can be
from the desalination plants. The water distribution scheme is to be based on independent
storage and distribution of treated water from the above discussed sources, for domestic, non-
domestic and industrial uses. Initially, the treated water shall be stored in underground water
storage tanks, and shall be subsequently pumped up to the corresponding elevated water
tanks. Water shall then be distributed independently through those elevated water tanks.

An Integrated water-sewerage-drainage management plan will be prepared for the

entire SEZ area after evaluating the topographical survey.

In addition to the water supply for domestic, non-domestic and industrial uses, piping
system shall also cater for water supply for fire fighting, including necessary pressure boosting
measures.

The water balance diagram is given in Fig. 2.2. Adding further watershed
management facilities of SEZ will be planned to achieve effective rainwater harvesting. All
buildings and paved areas will be designed in Jamnagar SEZ with built-in latest techniques of
rainwater harvesting and water holding tanks.

2.7.2 Power

The power requirement for the proposed zone would be met through a captive power
plant of 2100 MW capacity is planned to be set up as a part of the SEZ infrastructure, utilizing
the fuels available from both the refineries Additional requirements of fuel will be met by
natural gas.

2.19
 The power and energy requirement is met by the captive power and steam generation
units and should be installed for the SEZ. Power Generation is by Gas Turbines Generators
and Heat Recovery Steam Generator (HRSG) and Steam Turbines (STG). Steam is supplied
to the same unit, which will be supplemented by Steam Boilers. The grid will be so designed
that itself is self-sufficient for all the requirements like peak, normal with an automatic grid
balance systems for optimum fuel consumption in all the cases.

All the units of the SEZ shall be encouraged to have the primary drives based on
energy integration system of electrical motor, steam turbine with extractive steam, the exhaust
steam of the STG will be integrated with the desalination plant.

The use of co-generation systems is a first step in increasing overall energy

efficiency. There are other energy conservation measures requiring either capital investment
on the part of individual companies, and/or changes in attitude through education.
Conservation can be as simple as “smart” lighting which turns off when the space is not in use,
low energy light bulbs, or increased insulation to retain heat or cold (from air conditioning
systems). Or, conservation can be complex with highly technical energy cascading schemes to
attempt to capture and use every last joule of energy created in the industrial system.

Another feasible alternative energy source may be photovoltaic solar technology. The
tropical climate is well suited to the implementation of solar energy programs. For instance,
roof solar panels could run all of the air conditioners throughout the SEZ, and small solar
panels could power environmental monitoring and lighting systems at remote locations, where
running power lines may be impractical.

2.20
Fig. 2.1 : Existing and Proposed SEZ’s in India

2.21
 Losses
12600

7000 100 300

1000

36000
Sea Water Desal Plant Boilers Process Fire
Cap. and Units Domestic Township Water
15000 Heater (400) (6600) Make-up

8400

STP STP

6600
Horticulture & green belt

2.22
development
9450

21000
COOLING TOWERS SYSTEM Note:

1. Dotted lines denote overall heat integration among

6000 units
2400 2. Water Balance is worked out for 40 ppt of
seawater salinity. Salinity changes effect Water
ETP Balance
5250 3. Water requirement for Drip Irrigation is included
in the losses.
750 4. Losses include evaporation, steam, through
Discharge products, firewater, drip irrigation, horticulture and
23400 greenbelt development.
Horticulture
5. Water is produced during operations / reactions /
and Green
from Raw Materials and are excluded in the above
Belt
values.
6. The quantities are values derived based on
ambient atmospheric conditions and changes.
7. Density differences due to temperature, salinity
Fig. 2.2 : WATER BALANCE FOR SEZ (All figures in m3/hr) etc. are not taken into account
 Table 2.1

Existing & Proposed Special Economic Zones in India

Sr. No. Name of the SEZ

1 Manikanchan, Salt Lake SEZ, Kolkata
2 Indore SEZ(Madhya Pradesh)
3 Moradabad SEZ(Kanpur)
4 Sitapura SEZ( Jaipur)
5 Bornada SEZ(Jaipur)
6 Kopata, Maha Mumbai SEZ
7 Positra SEZ(Gujarat)
8 Nanguneri SEZ (Tamil Nadu)
9 Hassan SEZ (Karnataka)
10 Navi Mumbai SEZ
11 Bhadohi SEZ (Uttar Pradesh)
12 Kanpur SEZ(Uttar Pradesh)
13 Greater Noida(Uttar Pradesh)
14 Kakinada SEZ (Andhra Pradesh)
15 Visakhapatanam SEZ (Andhra Pradesh)
16 Paradeep SEZ(Orissa)
17 Gopalpur SEZ ( Orissa)
18 Kulpi SEZ(West Bengal)
19 Vallarpadam/Puthvypeen(Kerala)
20 Noida (UP)
21 Baikampady (Karnataka)
22 Dahej SEZ (Gujarat)
23 Ennore (Tamil Nadu)
24 Mundra SEZ (Gujarat)
25 Ranchi SEZ (Jharkhand)
26 Calcutta Leather Complex (Kolkata)
27 Mahindra City SEZ
28 Nokia SEZ

2.23
Chapter 3
Process Description
The process description updated with the clarifications and additional information
sought by the MoEF in their communications.

3.1 Introduction
Demand pull is the main driver, for setting up the units in the Jamnagar SEZ, based on
the potential of growth in the Asian region. This opportunity has arisen due to the open market
policies being embraced by the governments, and demographics of the region. The economies
of Indian and China are at a threshold limit of US$ 3000 per capita on parity basis. At this
threshold, and the economies that have undergone transition from developing to developed
economies, an exponential growth rate was observed in personal expenditures. The growth rate
was observed in all the areas, which reflected an impact of increase in living standards. The
major areas and significant change in growth rates observed are:
1. Energy Supply – Oil, Gas and Power equivalent
2. Petrochemicals – for industrial and personal products
3. Transportation – primarily personal transportation such as cars.
4. Clothing – primarily textiles
5. Personal Care Products – commensurate with rise in standard of living
6. Agriculture, Health Care & Insurance
7. Organized retailing
8. Infrastructure facilities, like telecom, roads, transport, ports etc.

3.1
 In relevance to the Indian scenario, there is a large refinery complex set up by the
Reliance Group and is in operation at Jamnagar. Jamnagar has arguably the most suitable
seafront in the Gulf of Kutch, for raw material imports and finished product exports center,
Jamnagar has an excellent hinterland connection, for having the natural advantage of protected
sea to operate a very environmental-friendly, import and export terminal. The existing refinery
together with the Export Oriented Refinery being implemented shall provide feedstock and an
excellent integration of the downstream petroleum, petrochemical and intermediate products,
and across the fence transfers.

The Jamnagar SEZ configuration is aimed for maximum value addition along the entire
carbon chain C1 through C8, and higher.

C1 value chain – Petroleum coke is a residue coke from the two refineries in
Jamnagar. Petroleum coke can be gasified to produce power, steam, hydrogen for consumption
of the 2 refineries, as well as a world scale acetyl complex of methanol, acetic acid, vinyl
acetate, poly vinyl acetate and poly vinyl alcohol. Acetic acid has synergy with polyester textiles
and vinyl acetate and its derivatives are important building blocks for personal care products.

C2 value chain – Refinery fuel gas can be a low cost feedstock for ethylene and
ethane cracked ethylene. Ethylene is an important building block for polymers and textile
intermediates, whose demand shall grow exponentially with GDP growth. The C2 Value chain
will be extended to ethylene oxide derivatives.

C3 value chain – Propylene recovered from the refinery streams, and the proposed
cracker products, can be converted to acrylic acid & acrylates, super absorbent polymers, oxo-
alcohols and propylene derivatives which are important for personal care products and whose
demand is again linked to the GDP growth.

C4 / C5 value chain – The intermediates refinery streams can be value added to

elastomer products, which are linked to the growth in personal transportation

C6 / C7 / C8 value chains – The aromatics streams from the refinery can be value
added to derivatives of benzene, toluene and xylene, which are linked to growth in textiles,
white goods and beverage containers.

C8 + value chain – Intermediate low value streams from the stream can be value
added to lube oil and carbon black, which is intimately linked to personal transportation.

The SEZ process configuration and product slate have been generated considering
the following parameters:

3.2
 1. Market outlook (primarily Asian because it is in SEZ)
2. Raw material availability from the 2 refineries.
3. Utility supply from the proposed IGCC
4. Environmental aspects
5. Technologies which can be readily sourced
6. World Scale plant size to exploit the economies of scale
7. Overall funding constraints
8. Price Outlook and projections
9. Environmental specifications to meet the local regional and federal and
international (IFC and World Bank standards)

Basing on the above, the overall feed material, products and utility consumption, the
capacities of each production facility for each project is projected with environmental
parameters (emissions) internalized for optimum use of the resources. A linear model has been
developed modeling each production unit, with the Best Available Technologies (BAT) for the
input-output norms and consumption parameters. All the quantitative inputs have been modeled
and linear programming has been done to arrive at the optimal configuration for the Jamnagar
SEZ, within the supply demand and resource constraints. The configuration of the Jamnagar
SEZ and the product slate has been optimized primarily from feedstock supply push and stream
utilization from the refinery demand-pull for the products from potential growth in Asia. The
output of the environmental emission parameters from this SEZ business model has been
extracted to be used as an input to the EIA and RA Studies.

The project environmental specifications are to be developed based on the EPA rules,
standards prescribed for refinery, petrochemicals, MoEF/EAC stipulations and conditions and
IFC guidelines / Equator principles. The detailed diagrams and descriptions will be available
after the completion of the basic design engineering of the respective units. A brief process
description along with the plant pollution load is given at the end of each process as subtitle
C1, C2, C3, C4, C5, C6, C7, C8+, and Capitive Power Plant, Desal Plant Fig. 3.1 shows the
proposed units of the SEZ..

3.2 C1 based Units

3.2.1 Integrated Gasification Combined Cycle (Petcoke Gassification)

IGCC means Integrated Gasification Combined Cycle. The gasification is partial

oxidation of coke with O2. Coke gasification reaction converts coke into syngas. The primary
constituents of syngas are CO and H2. Syngas can be a gas turbine fuel, which can produce

3.3
power in a combined cycle. Syngas can produce hydrogen and other chemicals,
suchmethanol and acetic acid.

The major elements or processing sections for the IGCC project are:

• Feed preparation
• Gasification
• Effluent handling
• Sour block
• Air Separation Unit (ASU)

Feed preparation

Coke shall be transported by a fully enclosed conveyor, to minimize dust, from the
existing coke hoppers to the IGCC plot area. The coke shall be stored in coke storage silos.
The flux shall be transported by trucks and stored in flux storage silos. Coke and flux, in the
proper ratio, shall be weighed. Coke particles shall be reduced to proper size by grinding.
Coke and flux shall be fed to the gasifier either in the form of a slurry or as dry feed. In slurry
feed, coke slurry is pumped. In dry feed, coke particles are pneumatically conveyed with
nitrogen. Oxygen is supplied from an Air Separation Unit (ASU) to the gassifier.

Gasification

Petcoke feed goes to the gasification section. There will be several gasifier trains. In
the gasifier, the petcoke is mixed with oxygen in a specially designed feed injector. The
oxygen deficient atmosphere inside the gasifier vessel generates syngas at an average
temperature 1425°C. Temperature fluctuations are in the range of +/- 25oC. The operating
range of the petcoke gasifier is 1400 – 1450oC. The fluctuations are due to normal variations in
the petcoke feed flow to the gasifier. Such flow variations in the solid handling are normal and
are always expected. As the partial oxidation reaction is exothermic in nature, variations either
in the petcoke feed or oxygen reflects in variation in the gasifier temperature. The temperature
is controlled automatically by adjusting the oxygen flow to the gasification reactor. Audio visual
alarm indication is always available in case the temperature variation is beyond preset values.
If required the control can be done by manual operation as well.

The raw syngas from the gasifier consists primarily of CO, H2, CO2 and H2S with
minor amounts of other compounds. The fluxant concentrates the ash and minerals in the
petcoke to form a molten slag. The syngas is cooled by raising high pressure steam and is
further cooled in a quench chamber. The by-product slag exits the quench chamber through a
lock hopper.

3.4
Fly Ash Disposal

The ash content in the Petcoke is less than 0.5%. The fluxant is added in the feed preparation
section captures the ash in the petcoke and forms a molten slag in the gasification section.
When the syngas is cooled in the quench section the molten slag is solidified into glassy beads.
There is no generation of fly ash from this process.

These beads will be disposed off in the secured landfill facility. The feasibility of recovering
metals from these beads will also be pursued

Effluent handling

In effluent handling, slag is cooled and slag and water are separated. Slag is an
IGCC by-product. Waste water is recycled to the extent possible and the remaining is sent to
the effluent treatment plant.

Sour block

In the sour block, the raw syngas shall be cooled and scrubbed. Then acid gases –
H2S and CO2 – present in the syngas, are removed by amine scrubbing. It is estimated that for
an annual petcoke consumption of 8750 KT with average sulphur content of 7.5%, the total
flow of amine solvent is estimated at 5700 m3/hr. The syngas used for petrochemicals must
have low CO2, because CO2 is a diluent. Hence a second stage, smaller amine absorber, with
a stronger amine, shall be employed as a scrubbing medium to preferentially remove CO2 from
the syngas before routing it to the petrochemical users. The amine is regenerated in a
regenerator column using LP steam as the reboiler medium. The condensate is sent to an
ammonia stripper for ammonia removal.

The collective acid gas streams shall be fed to the Sulphur Recovery Unit (SRU)
where the streams shall be processed and the liquid sulphur collected in the sulphur
condensers and in the tail gas coalescer drains by gravity into a sulphur pit. The required SRU
capacity is for 1300 TPD of liquid sulphur. From environmental considerations, the IGCC
project shall have a Tail Gas Treating (TGT) unit at the back-end of the SRU.

The Tail Gas Treatment process is incorporated to further treat the flue gases and
reduce the SO2 emissions. The TGT process treats the flue gases from the Sulphur Recovery
Units (SRU) to convert the sulphur in the flue gas to elemental sulphur. The SRU operates with
the advanced Clause and Cold Bed Adsorption process at an efficiency of +99%. With the TGT
following the SRU, the overall efficiency would be enhanced to 99.9%. By reducing the SO2
emissions, TGT helps in reducing the impact on the environment.

3.5
Details of TGT Treatment

In the petcoke gasification section the sulphur present in the petcoke is converted to
H2S because of the low oxygen availability. In the sour block, the raw syngas shall be cooled
and scrubbed. Then acid gases – H2S and CO2 – present in the syngas, are removed
individually by amine scrubbing. The amine is regenerated in a regenerator column using LP
steam as the reboiler medium and recycled.

The H2S stream shall be fed to the Sulphur Recovery Unit (SRU) where the streams will
be processed and the liquid sulphur collected in the sulphur condensers and in the tail gas
coalescer drains by gravity into a sulphur pit. The SRU operates with the advanced Clause and
Cold Bed Adsorption process at an efficiency of +99%. With the TGT following the SRU, the
overall efficiency would be enhanced to 99.9%. By reducing the SO2 emissions, TGT helps in
reducing the impact on the environment

The Tail Gas Treatment process is incorporated to further treat the tail gases and
reduce the SO2 emissions. The SO2 present in the tail gas is converted to H2S in the presence
of H2 in a catalytic reactor. The outlet from the reactor is cooled and amine washed to remove
the H2S. These gases are then sent to an online incinerator to burn off the residual H2S (<100
ppm) before release into atmosphere through a tall stack. The amine rich in H2S is regenerated
for reuse while the released H2S is sent to the SRU feed.

Air Separation Unit (ASU)

The IGCC project shall have multiple ASU trains. The ASU scope shall include liquid
oxygen vaporizers for emergency supply. The N2 available from the ASU can be added as
diluents in the syngas to moderate the flame temperature in the gas turbines and reduce the
NOx emissions.

A process block diagram for the IGCC unit is presented in Fig. 3.2.

Air Emissions:
The SO2 & NOx emissions from the coke gasification process are 0.083 and 0.012 TPH
respectively.
Liquid effluent:
The estimated wastewater generation is 150 M3 /Hr (Can be recycled in the feed
preparation)

3.6
Solid waste:
The estimated solid waste generation from the coke gasification process will be 0.37
MM TPA
3.2.2 Methanol

Synthesis gas a mixture of hydrogen, carbon oxides and methane is compressed to a

pressure of 100 atm by a steam driven multistage centrifugal compressor. With inter coolers
and a recycle flow is added to the intermediate stage. The fresh and recycle synthesis gas at
high temperature and pressure enter the top of the ICI type methanol converter. A portion of the
feed gases is heated to high temperature by heat exchange with the departing reaction gases.
The remaining feed gases are introduced at intermediate reactor stages to act as a thermal
quench to control the temperature. These gases react in the methanol converter in presence of
Zinc-copper-aluminium oxide catalyst to form methanol and water. Gases departing from the
bottom of the converter are cooled by exchange with the feed gases and then in air and water
coolers to condense crude methanol and water. This condensate flows to a pressure blow-down
drum and then to a crude methanol storage tank. Uncondensed gases, with the exception of the
purge stream, are recycled to the synthesis gas compressor.

The crude methanol is purified by fractional distillation in a 60 tray light ends column
where low boiling compounds, principally dimethyl ether, are removed overhead. A second 60
tray distillation column takes methanol product from the 56th tray. A crude stream of higher
alcohols is drawn from the 10th tray and wastewater from the bottom. Process flow diagram for
the production of Methanol by the copper catalyzed intermediate pressure process is given Fig.
3.3.

Air:
The VOC & CO emissions from the process vents will be less than the 150 mg/Nm3
The SO2 & NOx emissions from the Methanol synthesis are 0.0008 and 0.331 TPH
Liquid Waste
The estimated wastewater generation from the Methanol synthesis process will be 25
TPH
Solid waste:
The solid waste generation from the methanol Synthesis is only a Catalyst
3.2.3 Acetic Acid

Methanol and carbon monoxide are continuously fed to a liquid phase reactor. The
reactor contains acetic acid, water, hydrogen iodide, methyl iodide, and the rhodium catalyst
complex. Methanol rapidly reacts with hydrogen iodide to form methyl iodide, and in presence

3.7
of rhodium catalyst system reacts with carbon monoxide to yield product acetic acid. The
reactor operates at high temperature and up to 30 kg/cm2g. Unconverted carbon monoxide
leaves the top of the reactor vessel and is cooled to knock out and recover condensables
before flashing. The vapor stream is then scrubbed with a slipstream of methanol feed in the
gas scrubber. The bottoms stream from the gas scrubber is returned to the reactor vessel and
any unconverted carbon monoxide is purged. A draw off stream is continuously taken from
the reactor vessel and flashed into an adiabatic single stage flash tank, which operates at
reduced pressure. The flashing process vaporizes a portion of the drawoff stream, including
the net acetic acid production and also serves to remove the exothermic heat of reaction. The
liquid phase in the flash tank, containing the homogeneous catalyst system, is pumped back
into the reactor vessel. In this manner, carbonylation products are removed from the reactor
without decomposition or excessive handling of the rhodium catalyst complex. Techniques
have been developed for regenerating any trace of deactivated catalyst species formed from
the reaction with corrosion products of the reactor’s materials of construction.

The overhead stream from the reactor flash tank contains acetic acid, methyl iodide,
water, methyl acetate, and traces of carbon monoxide and hydrogen iodide. This stream is fed
to the lower portion of the product separation column where a concentrated acetic acid stream
is recovered as a side stream containing water, methyl iodide, methyl acetate, and traces of
hydrogen iodide. A small bottoms drawoff from this column, containing acetic acid, water, and
hydrogen iodide, is removed and recycled to the reactor flash tank. The overhead stream from
the product separation column is cooled to knock out condensables and sent to a phase
separator. Noncondensable carbon monoxide is recovered and passed to the gas scrubber.
The condensate is phase separated into a light aqueous phase and a heavy organic phase. A
portion of the light phase, containing water, acetic acid, methyl acetate, and methyl iodide, is
refluxed to the column; the remainder is recycled to the carbonylation reactor. The heavy
phase, containing methyl iodide, acetic acid, methyl acetate, and water, is recovered and also
recycled to the carbonylation reactor. A slip stream of this heavy phase is further processed in
the alkane removal tower for the removal of alkanes prior to recycle to the reactor. Carbon
monoxide is used to strip this stream. The overheads product from the alkane removal tower,
consisting of methyl iodide, methyl acetate, and water, is recycled to the carbonylation reactor.
The bottom products from the alkane removal tower consisting of alkanes, acetic acid, and
traces of methyl iodide, is purged.

The concentrated acetic acid side stream from the product separation column is sent
to the crude acetic acid column for further purification. Methanol is added to the lower portion
of this column. The methanol reacts with the hydrogen iodide to form methyl iodide and water.

3.8
Excess methanol reacts with acetic acid to form methyl acetate. The overhead stream from
the crude acetic acid column consists of acetic acid, water, methyl iodide, and methyl acetate.
The condensate is partly refluxed to the column; the remainder is recycled to the carbonylation
reactor. Any carbon monoxide or noncondensables are passed to the gas scrubber for recycle.
The bottoms product from the crude acetic acid column consists of acetic acid with traces of
water and hydrogen iodide. This stream requires additional purification for iodine removal,
accomplished by distillation with or without the use of chemical agents (e.g. alkali metals).

The acetic acid stream containing traces of water and iodine is fed to the acetic acid
finishing column. A mixture of high boiling acid by-products, primarily propionic acid, are
removed as bottoms from this column. The overhead product from the column is condensed,
with a large portion of the condensate used as reflux to the column and the remainder recycled
to the carbonylation reactor. High purity acetic acid is removed as a liquid side draw near the
top of the column. Process flow diagram for Acetic acid is depicted in Fig. 3.4.

Air Emissions:
Process vents Co and Methanol after scrubbing
The SO2 emissions from Acetic acid process will be 0.00014TPH
Liquid waste:
The estimated wastewater generation from the Acetic acid plant will be 50 M3/Hr
Solid waste:
No solid waste will be generated from the Acetic acid plant.
3.2.4 Vinyl Acetate Monomer

A gas containing ethylene, oxygen and acetic acid is passed through tubular reactors
containing supported palladium-gold and potassium acetate catalyst. At high temperature and
pressure of 8.2 atm, ethylene is converted with selectively to vinyl acetate. The reaction
product is cooled for condensation. The remaining gas is washed first with acetic acid, then
with ethylene glycol diacetate or polypropylene glycol, to recover uncondensed vinyl acetate
and acetic acid. After a small part is purged, the gas is treated with potassium carbonate
solution to remove carbon dioxide and is recycled. The condensate, together with the liquid
recovered by absorption, is distilled to get vinyl acetate-water as the distillate. Acetic acid
vapor withdrawn near the bottom is condensed and recycled for reaction. The bottom product
is evaporated to get rid of the heavy residue.

The distillate consisting of vinyl acetate and water is decanted; the water layer is
stripped to recover residual vinyl acetate, and the organic layer is distilled to remove

3.9
acetaldehyde, which, is recycled together with acetic acid to the reactors. The crude vinyl
acetate, free of light ends and water is then further distilled in a tall column, with a side stream
being withdrawn for distillation in a small column to remove ethyl acetate. The distillate is
refined pure vinyl acetate. Inhibitors( 4-tert-Butylcatechol or other inhibitor) are added in the
vinyl acetate distillation columns, which also are blanketed with nitrogen. A minute quantity of
hydroquinone is added at the condensers. Process flow diagram for Vinyl Acetate Monomer is
depicted in Fig. 3.5. There is no generation or use of Vinyl Chloride Monomer (VCM) in the
process of Vinyl Acetate Monomer (VAM). Hence management of VCM is not applicable in
the VAM Unit.

Air Emissions:
The Non Methane Hydrocarbon (NMHC) emissions from the Process vent- will be less
than 150 mg/Nm3

Liquid Waste:
The estimated wastewater containing traces of vinyl acetate, Acetaldehyde and Ethyl
acetate from the Vinyl Acetate Monomer 75 TPH
Solid Waste:
No solid waste will generate from the Vinyl Acetate Monomer process.
3.2.5 Poly Vinyl Acetate

Inhibitor in vinyl acetate monomer is removed by stripping with steam in an inhibitor

stripping column. Purified VAM is stored in a VAM daytank. A solution of Benzoyl peroxide and
solvent (methanol) is prepared in an initiator make up tank. The initiator solution and VAM are
charged to the polymerizers.

Polymerization is carried out in two stages. Polymerization reaction takes place in

glass-lined polymerizers each equipped with agitator to provide sufficient mixing. Reaction
temperature is controlled with jacket cooling and reflux condensation in condenser. The
polymerization reaction takes place under nitrogen blanketing. Vent gases from the reflux
condenser receiver constitutes of nitrogen, methanol, carbon dioxide and vinyl acetate. Poly
Vinyl acetate solution is transferred to a Polymer solution surge tank. The polymer solution can
be directly diverted to downstream units like Poly Vinyl alcohol or sent to the monomer, solvent
recovery section and finishing section.

The polymer solution is stripped of vinyl acetate monomer in monomer stripping

column and recovered VAM is recycled back to the polymerizers. The solvent (methanol) is
then recovered from the polymer solution in solvent recovery column and is transferred to a

3.10
recycle solvent surge tank. The polymer is then sent to the finishing section which comprises
of product centrifuge and pelletizing extruder. The finished product polymer is stored in
storage bins and is sent to loading and packaging unit for dispatch. Process flow diagram for
Poly Vinyl Acetate is depicted in Fig. 3.6.

Air Emissions:
The Non Methane Hydrocarbon emissions (NMHC) from the Process stack NMHC will
be less than 150 mg/Nm3
Wastewater:
The estimated wastewater generation from the Poly Vinyl Acetate process will be 100
TPH
Solid Waste:
No solid waste will be generated from the poly vinyl acetate process.
3.2.6 Poly Vinyl Alcohol

Inhibitor in vinyl acetate monomer is removed in a stripping column and purified

uninhibited VAM is stored in a day tank. Initiator solution is prepared in a make-up tank, by
mixing methanol with Azobisisobutyronitrile. This solution along with VAM is charged into
polymerization section.

Polymerization of vinyl acetate is carried in two stages. Reaction temperature in both

reactors is controlled by reflux condensation and jacket cooling. Polymer solution from second
reactor (second stage) is collected in a polymer solution surge tank. Also added in the surge
tank is an inhibitor hydroquinone methyl ether which prevents any polymerization in the
monomer stripping column. The polymer product from the bottom of the monomer stripping
column is a 35 wt% poly vinyl acetate solution in methanol.

This solution is hydrolyzed continuously in two hydrolysis reactors in parallel. The

reaction is catalyzed with sodium hydroxide-methanol solution. Neutralized poly vinyl alcohol
slurry is sent to centrifuge where poly vinyl alcohol is separated from the mother liquor and
washed with methanol. Washed poly vinyl alcohol containing 10 wt% methanol is dried in a
rotary dryer. Closed loop nitrogen gas is used to dry poly vinyl alcohol and part of the
methanol in the drying nitrogen from the dryer is condensed in a condenser and separated
from the uncondensed gas in the gas separator. Dried poly vinyl alcohol from the rotary drier is
collected in the product collector and is transferred to storage bins.

Crude solvent collected contains methanol, methyl acetate, some sodium acetate
and water. Methanol and methyl acetate are recovered as overhead from mixed solvent
column and pass into an ester hydrolyser where methyl acetate is hydrolyzed to methanol and

3.11
acetic acid. The top of the hydrolyser column is packed with porous polyethylene fillers
containing cation exchange to catalyze the hydrolysis reaction. The bottom section of column
is packed with raschig rings and is used as a stripping zone to remove any methyl acetate. A
stream of water is added at the top of the column for hydrolysis reaction and for condensation
of rising vapor. Methanol is separated from the acetic acid and water from the hydrolyser
column bottom stream in a methanol column and collected in the methanol storage tank before
being recycled. The dilute acetic acid from the bottom of the methanol column is stored in
crude acetic acid tank.

Aqueous sodium acetate from the bottom of the mixed solvent column is reacted with
sulfuric acid in reactor to convert sodium acetate to acetic acid. The reaction product is
combined with dilute acetic acid from the column in crude acetic acid storage tank and is
extracted with ethyl acetate in a rotating disk contactor to recover acetic acid. In an acetic acid
recovery column acetic acid is separated from ethyl acetate and collected in acetic acid
storage tank. Part of acetic acid is used to neutralize the hydrolysis reaction product. The
remainder is sent as a by product.

The sodium sulfate solution from the contactor contains ethyl acetate and is
combined with the dilute ethyl acetate solution from the lower layer of phase separator for
ethyl acetate recovery in the ethyl acetate recovery column. The recovered ethyl acetate is
combined with ethyl acetate from the upper layer of phase separator and is used for acetic
acid extraction. The bottom stream from ethyl acetate recovery column is sent to waste
treatment. Process flow diagram for Poly Vinyl Alcohol is depicted in Fig. 3.7.

Air Emissions:
The Non Methane Hydrocarbon (NMHC) from the process stack will be less than 150
mg/Nm3
Liquid waste:
The estimated wastewater generation from the Poly vinyl Alcohol will be 140 TPH
Solid Waste:
The only solid waste generated from Poly Vinyl Alcohol is catalyst.

3.3 C2 Based Units

3.3.1 Multifeed Cracker Complex

The Multifeed Cracker Complex proposed will be the largest to process the off gases
from the refinery complex to produce cracked products. This cracker will also have the

3.12
capacity to process different feeds like Naphtha, natural gas etc. The ethylene and ethane
contained in refinery fuel gases / off-gases are recovered and the ethane is converted to
ethylene, in the Multifeed Cracker. The refinery fuel gases are first sent to a contaminant
removal section where in the impurities like H2S, CO2 etc are removed.

The Multifeed Cracker comprises of the following constituent sections.

• Contaminant removal

• Cracking furnaces

• Primary fractionation

• Cracked gas compression and drying

• Cold box / demethanizer

• Refrigeration section

• Deethanizer/ethylene recovery

• Propylene by Propane Dehydrogenation

Contaminant removal

The refinery fuel gas, first goes to a caustic tower, where essentially all of the
hydrogen sulfide and carbon dioxide are removed with circulating caustic. Then it is water
washed to prevent caustic carryover. Next in a sulfided nickel based catalytic converter,
oxygen, arsine, phosphene and carbonyl sulphide are removed.

The offgasses are chilled before sending to a dryer/treater. The dryer/treater beds
are designed to remove water, mercaptans, ammonia, nitriles and nitrous oxides.

Cracking furnaces

The ethane recovered from the de-ethanizer/ethylene column is fed to the Cracking
furnaces along with the dilution steam. The furnace effluent is cooled in the transfer line
exchangers, where in high pressure steam is generated. The cracked effluents from the
furnaces are then sent to the primary fractionation section.

Primary fractionation

In the primary fractionation section the heavies comprising of fuel oil and the
pyrolysis gasoline are separated out.

3.13
Cracked gas compression and drying

The cooled cracked gases are compressed, dried, and sent to the cold box (chilling
train). The acid gases are also removed in a caustic tower, prior to chilling.

Cold box /demethanizer

In the chilling train/cold box, the temperature of cracked gases are reduced and fed
to a demethanizer, whereas methane and hydrogen are separated and the ethylene /ethane
rich streams are sent to a de-ethanizer and to an acetylene hydrogenation section.

Refrigeration system

Ethylene and propylene refrigeration systems provide the refrigeration requirements

to the chilling train at different temperature levels.

De-ethanizer/ethylene recovery

The C2 streams from the deethanizer overheads are routed to an acetylene hydrogenation
section where the acetylene is selectively converted to ethylene. The ethylene stream is then
purified in an ethylene fractionation column where the ethane is separated from ethylene. The
ethane from the bottom of the ethylene stripper is routed back to the cracking furnaces. The
polymer grade ethylene is sent to storage from ethylene fractionator. There are no Ethylene
emissions to the atmosphere. All emissions shall be diverted to the flare stack.
Propylene by Propane Dehydrogenation

Off-gases and LPG from the Refinery complex will be the feed source for conversion of
propane to propylene. The unit is a process for the catalytic dehydrogenation of propane to
propylene using continuous catalyst regeneration. Fresh feed to the unit is treated in a Huels
Selective Hydrogenation Process (SHP) reactor to remove dienes and acetylenes, dried, mixed
with recycle propane and fed to a Depropanizer column in the fractionation section to remove
butanes and heavier components from the propane stream. Depropanizer overhead is sent into
the separation system (cold box) where it is combined with recycle hydrogen and is exchanged
against cold reactor effluent. The combined feed leaves the separation system and is
exchanged against hot reactor effluent in the hot combined feed exchanger. The combined
feed is processed in four reactors with continuous catalyst regeneration (CCR). The hot reactor
effluent is cooled, compressed, then sent through a chloride treater and reactor effluent drier to
remove HCl, H2S, and H2O before entering the separation section, where the effluent stream is
separated into recycle gas, net gas and product liquid.

3.14
 Product liquid is sent to another SHP reactor in the fractionation section. The SHP
reactor effluent is then sent to a Deethanizer. Deethanizer net gas is used to regenerate the
feed driers. The Deethanizer bottoms are sent to a heat-pumped propylene-propane splitter to
produce high purity propylene product. The unconverted propane in the splitter bottoms is
recycled back to the Depropanizer with the fresh propane. The Depropanizer bottoms
containing butanes and heavier material is stripped with tail gas from the PSA unit. The
stripped vapors are sent to fuel gas while the residual liquid is pumped offsite for use as fuel oil.

The net gas is sent to a hydrogen purification system (PSA type) and to the reactor
effluent driers. PSA hydrogen is sent to the SHP reactor unit and is used for various purge
streams in the CCR section of the unit. Tail gas from the PSA is used to regenerate the
reactor effluent driers. The regenerant from the reactor effluent driers is scrubbed and used
for fuel for the heaters while excess gas is exported as fuel for offsite boilers.

Block Flow Diagram for Multifeed Cracker is depicted in Fig. 3.8 and Propoane
Dehydrogenation is depicted as Fig. 3.9.

The MoEF sought clarification on Emissions from Multi-feed cracker complex

The multi-feed cracker will have thirty-six furnaces and these will be using the sweat fuel gas in
the burners. The emissions from the cracker complex will be mainly from these furnaces and
will emit traces of SO2 and NOx.. These Furnaces will have NOx reduction mechanism. Some
of the emission management techniques proposed are listed below:

• NOx Emissions from cracker will be controlled by employing low NOx Burners.
• The off gases from decoking operation will be routed to the fire box of another furnace in
operation.
• Carbon monoxide emissions will be minimized by the use of advanced combustion control
schemes utilizing feedback from continuous flue gas analyzers, which will be installed as a
standard package alongside the normal combustion control systems. The quality of flue
gas from cracking furnace will be continuously monitored by online CO and O2 analyzers.
• Recycling and/or reusing hydrocarbon waste streams. Flare gas systems will be provided
to allow safe disposal of any hydrocarbons that cannot be recovered in the process (i.e.,
during unplanned shutdowns and during start-ups).
• The gas fired cracking furnaces and steam super heaters will have modern firebox design
with extensive energy recovery facilities giving a thermal efficiency of 92 %.

3.15
 • Sampling systems will be of closed loop design. All equipment and piping systems will be
designed to ensure a high level of containment and to minimize fugitive emissions. This
involves seal-less or double / tandem sealed machinery, low-loss valve packing, use of
spiral-wound jointing materials, and minimum use of flange connections.

The salient features of the multi-feed cracker complex are as given in Annexure – X

Fuel gas:
The fuel gas requirement for Multifeed cracker is 437.4 TPH
Air Emissions:
The Emissions SO2 & NOX are1.314 TPH and 0.471 TPH
Liquid Waste:
The estimated wastewater from the Multifeed cracker is 400 TPH
Solid Waste:
The solid waste generation from the Multifeed cracker will be coke.
3.3.2 Monoethylene glycol (MEG)/ Diethylene Glycol (DEG) and Triethylene
Glycol (TEG)

The MEG is produced by first converting ethylene-to-ethylene oxide (EO) through a

direct oxidation process and then hydrolyzing the same.

Ethylene, recycle gas and oxygen are thoroughly mixed, preheated and passed
through the EO reactor, where ethylene is converted into EO at elevated temperature and
pressure. The reaction product gas is scrubbed with neutralising liquid to remove acidic
compounds and further cooled in EO absorber by counter contact with water, which absorbs
EO and forms a dilute aqueous solution. The gas after scrubbing and absorption of EO is
recycled back to the reactor via a recycle gas compressor. A small slip stream is taken to CO2
removal section for removal of CO2 formed in the reactor, by absorption in hot potassium
carbonate solution. Dilute aqueous solution of EO in water is stripped off. EO from stripper
are cooled, condensed and purified by passing through light ends columns, which removes
lighter fractions. Purified EO mixture is heated, mixed with additional water and passed
through tubular glycol reactor. The reaction takes place in liquid phase under elevated
temperatures and pressure. The conversion is almost complete and the glycol water mixture
is sent for evaporation. Fig. 3.10 shows Block Diagram for Mono Ethylene Glycol.

In evaporation section, water is separated from glycol mixture in a triple effect

evaporator with subsequent vacuum column.

3.16
 Crude glycol mixture is separated into MEG, Diethylene Glycol (DEG) and
Triethylene Glycol (TEG)

Air Emissions
The SOx emissions from the Mono Ethylene Glycol(MEG) is 0.00036 TPH VOC &
Stripper vent= 0.04 Kg/hr
Process Incinerator= CO vessel vent -0.44 kg/hr
Liquid Waste:
The estimated wastewater generation is 0.193 M3 / Hr, will have pre treatment with in
the plant battery limits.
Solid Waste:
The Solid waste generation from the Mono Ethylene Glycol plant is Catalyst.
3.3.3 Polyethylene Polymers

Low / High density polyethylene (LDPE / HDPE) and linear low density polyethylene
(LLDPE) are polymers of ethylene. The process involves converting gaseous ethylene into
solid phase PE by solution polymerization process, using cyclo-hexane as the solvent.

A purified solution of ethylene, solvent and co-monomer (octane or butene or both) is

fed to the reactor. Co-monomer is added for low-density PEs. Catalyst helps to polymerise the
ethylene and co-monomer. A chain terminator agent is used to control molecular weight
(polymer chain length).

About 95% of the ethylene is converted to PE on each pass. The molten polymer
solution flows to the extruder which feeds an under water pelletizer. The pellets formed are
water conveyed to a continuous stripper to remove residual solvent, which is condensed and
recovered. The stripped PE pellets are dried and fed to pneumatic blenders for blending into
uniform lots. The PE is then fed to packaging or storage. Fig. 3.11.

Air Emissions:
The SO2 & NOx emissions from the poly Ethylene are 0.03 TPH and 0.011 TPH
Liquid waste:
The estimated wastewater generation from the poly ethylene plant is 80 TPH

Solid Waste:
The solid waste generation from the Poly Ethylene plant is column residue.

3.17
3.4 C3 Based Units

3.4.1 Acrylic acid & Acrylates

The propylene is oxidised with compressed air in a fixed bed multi-tubular single
reactor. Reaction gas is made of propylene vaporized in propylene evaporator, air and the
recycle gas coming from the top of the absorber. The lower half of the reactor is packed with
propylene oxidation catalyst wherein the propylene is converted into Acrolein and further the
Acrolein is oxidized to Acrylic Acid in the upper half of the reactor wherein the Acrolein
oxidation catalyst is packed. The effluent gas containing Acrylic Acid is quenched by
contacting recycled condensate, cooled through cooler and then absorbed with the
descending water and the aqueous solution of acrylic acid is obtained. Part of the off gas from
the top of absorbing column with non-condensables such as acrolein, acetaldehyde, propane
and unreacted propylene is recycled to the oxidation reactor.

The rest of the off gas is the feed to the Waste Gas Catalytic Incineration System
(WGCIS) which consists of a honeycomb type catalyst. The waste gas is heated before
entering the WGCIS and the outlet is cooled through the waste heat boiler, in which the waste
heat is recovered as steam.

In the water separator column, water and acetic acid are eliminated by azeotropic
distillation. In the heavy end cut column the ester grade acrylic acid is obtained from the top of
the column. The bottom contains acrylic dimmer and other heavy ends. This is fed to a film
evaporator where the dimmer is decomposed and recovered as acrylic acid. The heavy end
accumulated is sent to waste oil treatment. Aldehydes and ketones contained in the crude
acrylic acid react with the hydrazine hydrate forming hydazone compounds. These are
separated by distillation in the High Purity Acrylic Acid (HPAA) distillation column. Process
flow diagram is shown in Fig. 3.12.

Acrylic Acid is one of the main raw materials for the manufacture of various other
acrylates. Methanol and Acrylic Acid would give Methyl Acrylates, Ethanol and Acrylic Acid
would give Ethyl Acrylates and 2 Ethyl Hexyl alcohol and Acrylic Acid would give 2Ethyl Hexyl
Acrylate. In this process, the acrylic acid is continuously esterfied with the alcohol in the liquid
phase using cation exchange resin as a catalyst in an Esterification Reactor. A mixture of
acrylate, free alcohol and water is obtained. Water is removed by distilling it off as an
azeotrope. The organic layer is returned to the reactor and the acqueous layer is sent for
further purification.

3.18
Air Emissions:
The purge gases will sent to incinerator.
Liquid waste:
The estimated wastewater generation is 50 M3/hr
Solid Waste:
The solid waste generation from Acrylic acid is catalyst
3.4.2 Super Absorbent Polymer (SAP)

Process Description with process flow diagram for the production of SAP is shown in
Fig. 3.13.

A centrifugal pump transports the monomer solution from the mixing vessel to the
upper side of a vertical polymerization reactor. The reactor is insulated to insure adiabatic
operation. The level of monomer solution in the reactor is maintained at 80% level. A vapor
space must be maintained in the reactor above the monomer solution level. The reactor has
an operating pressure of 50 psig, but a design pressure of 150 psig, consistent with concerns
that sticky polymer gel may adversely affect the operation of pressure safety valves and
rupture disks that are incorporated into the reactor’s design. The design residence time of the
reactor is 6 hours.

Nitrogen gas pressure is maintained at the top of the reactor at 50 psig. The vapor
space at the top of the reactor is continually purged to remove water vapor, unreacted
hydrocarbons, and other contaminants in order to avoid having them accumulate in the top of
the reactor. The purge gas is first directed to a knockout drum to remove sticky gel and other
particulates. The vapor from the purge drum is then directed to the process scrubbing system.
Also fed to the polymerization reactor is a vapor stream containing “fines” from the final
powder processing section. The “fines” are blown in an inert nitrogen gas stream from
compressor. The quantity of fines recycled represents 10% of the throughput of the process.
Twin screw pumps at the bottom of the reactor discharge polymer gel product from the reactor
The reactor operates adiabatically, such that the polymer solution’s temperature rises from the
heat of polymerization. The temperature of the polymer gel at the discharge point at the
bottom of the reactor is approximately 120°C. At the pressure maintained in the reactor, the
water in the reactor will not boil despite the elevated temperature. Due to the potential for a
thermal runaway, the sidewall of the reactor is equipped at two foot intervals with water jet
flood nozzles connected to thermocouples in the wall. Should the temperature anywhere within
the reactor reach a set level the water jets will open automatically and flood the reactor with
water. Besides avoiding a thermal runaway, the water jets also reduce the potential for

3.19
solidification of the polymer gel at high temperature. The top of the reactor is also equipped
with 3 pressure sensors organized in a voting logic system. Should two of the 3 pressure
sensors indicate a pressure exceeding 70 psig, a pressure control valve will open to dump the
vapor into the process scrubbing system. The top of the reactor is also equipped with a rupture
disk designed to fail at 75 psig, which is also connected to the process-scrubbing header. The
combination pressure control valve and rupture disk are required by the propensity of the
feedstock to form a sticky coating on internal services that might otherwise prevent the
pressure instrumentation and pressure safety valves from performing according to design. The
redox polymerization initiator creates the free radicals that begin the polymerization of acrylic
acid at the moment that they are added to the acrylic acid solution. Once the redox initiators
are consumed, and the reactor temperature has reached approximately 60 C, the thermal
initiator, (2-2’-azobis (amidinopropane) dihydrochloride), forms free radicals that help complete
the conversion of acrylic acid to polymer gel. The level of unreacted monomer in the discharge
of the reactor should be approximately 1,000 ppm. The subsequent drying process should
reduce the unreacted monomer content to 200 ppm in the final product.

Air Emissions:
Process stack.- Attached to scrubber for removal of acrylic acid vapoures
Liquid Waste:
The estimated wastewater generation from the Super Adsorbent Polymer is 300 m3/hr
Solid waste:
No solid waste will be generated from the process.
3.4.3 2-Ethyl Hexanol

The condensation reactor is maintained at high temperature and pressure, 15-minute

residence time. The effluent from the reactor passes through heat exchanger to recover heat
and is then distilled. The bottoms from the column are decanted to separate the organic 2-EPA
and the aqueous caustic soda. The remainder is recycled and replenished with fresh caustic.
The organic phase is washed to remove residual caustic soda. The wash water is recycled to
the process. The 2-EPA is decanted again in to remove water and stored before use in the
hydrogenation section. The tops are decanted to separate out water from unreacted
butyraldehyde. The unreacted butyraldehyde is recycled to the condensation reactor. The
aqueous phase from the distillation tops can be used as makeup process water, steam-stripped
to remove residual organics, or sent directly to wastewater treatment. The 2-EPA from the
condensation section, containing a small amount of heavy impurities and water, is fed to cross-
countercurrent heat exchanger; where it is mixed with recycle gas. The aldehyde is then
introduced to feed purification column, where it is vaporized in a stream of feed H2. The vapor-

3.20
exiting column enters heat exchanger and then primary hydrogenation reactors. The shell-and-
tube reactors operate isothermally at higher temperatures and boiler feed water used as a
coolant to generate low-pressure steam. The cooled vapor is then further cooled and then
passes through knockout drum to condense out the alcohol. The remaining gas is recycled, with
a purge stream diverted to the secondary reactor after compression. The alcohol condensed
from the first stage still contains a small amount of Unreacted aldehyde. The liquid is
compressed to 9.6 bar and heated to higher temperature before entering secondary
hydrogenation reactors. As in the primary reactor system, heat is recovered from the reactor
effluent to reduce the heating duty. Because the reactor effluent contains butanol and water
impurities, the crude hydrogenation product is purified by fractionation. The H2 gas is split into a
recycle steam in and a purge stream. The purged H2 is cooled in condenser, with condensable
liquids recovered. Process flow diagram for 2-EthylHexanol is depicted in Fig. 3.14.

A note on Management of unreacted butyraldehyde in two Ethyl Hexanol productions

2-Ethyl Hexanol is produced from n- butyraldehyde in two reaction steps. The first step
is the aldolisation of n-butyraldehyde to butyraldol and dehydration of butyraldol to the more
stable 2-Ethyl 3-PropylAcrolein (EPA). The second step is the hydrogenation of EPA to 2-Ethyl
Hexanol.
The aldolisation and dehydration reactions are conducted in a liquid phase stirred tank
reactor at 120ºC in the presence of aqueous caustic soda. Any un-reacted n-
butyraldehyde is separated from the EPA in a distillation column. The overhead aqueous phase
is steam stripped to recover organics, which are recycled to the column. The EPA, from the
bottom of the column, is decanted from the water phase and passes directly to the EPA
Hydrogenation section.
Basically it is a closed loop cycle and any un-reacted n- butyraldehyde is separated and
recycled back.
Air Emissions
Flare of the purge gases
The Non methane Hydrocarbon (NMHC) from the process vent will be less than 150
mg/Nm3
Liquid Waste:
The estimated wastewater generation from the process is 75 M3/Hr
Solid waste:
The solid waste generation from the process is catalyst.

3.21
3.4.4 n-butyraldehyde
Propylene is passed through an adsorption column for removing catalyst poison.
A similar column is used for treating the syngas feedstock. The syngas is then introduced, with
propylene, into a primary hydroformylation reactor. The catalyst solution is an aqueous solution
of Rhodium complex. Low-pressure steam is raised from the evaporator. The effluent then
passes to decanter to separate the aqueous from the organic phase and to degas any entrained
gases. In C3 stripper column, a stream of syngas feedstock strips any dissolved propane and
propylene from the crude aldehyde product. The syngas, containing the stripped C3
components, is then recycled to the reactor. Stripping by the syngas further cools the crude
aldehyde. The product is then passed through a decanter to remove remaining aqueous
catalyst solution, and is then sent to surge tank before purification. Unreacted gaseous reagents
are collected, cooled, and passed through vent gas knockout drum to remove condensable
components. The liquid effluent from is distilled to separate the aldehyde products from the
catalyst and the high-boiling byproducts. The crude aldehyde product from the secondary
reactor system is combined with the product from the primary reactor system for purification.
The catalyst and higher boiling components are recycled. A purge stream of the catalyst-
containing organic phase is taken to control the concentration of the heavy by-products in the
reactor. Process flow diagram for n-butyraldehyde is depicted in Fig. 3.15.

A note on Emission / effluent management during n-butyraldehyde production

The entire plant heat requirement is met by steam and there are no furnaces involved.
Hence there are no emissions due to fuel firing. Un-reacted process gases are cooled to
remove the condensable matter and then routed to the flare. The aqueous effluents are routed
to water stripper section. Here the organic content is recovered and sent to the fuel oil pool. The
stripped water is pretreated to meet the required effluent characteristics before being sent to the
Central ETP of the Complex.
The spent catalyst has a useful life cycle of more than 2 years. The catalysts are leased
by the process Licensors and will be returned to them at the end of their useful life.

Air Emissions:
Light end gases to fuel pool
The Non Methane Hydrocarbon emissions will be less than150 mg/Nm3
Liquid Waste
The estimated wastewater from the Process is 60 M3/Hr.
Solid Waste:
The solid waste from the process is only a catalyst.

3.22
3.4.5 n-Butyl Acrylate
Acrylic acid is fed directly to esterification reactors. The esterification reaction takes
place in two reactors, in series. To the first reactor acrylic acid, n-butanol and an acid
esterification catalyst is added. p-Toluene sulfonic acid is used as the esterification catalyst. To
minimize polymerization of acrylic acid and n-butyl acrylate, a small amount of Phenothiazine is
added to the reactors and distillation columns. The reactors are operated at 100 0C and 105 0C,
respectively. Total residence time in the reactors is 3 hours. The liquid reaction mixture is
discharged from two reactors. The vapors from the reactors are continuously fed to the water
removal column. Although the reaction is exothermic, the vaporization cools the reaction
mixture. The continuous removal of the water reaction product improves acrylic acid conversion
to butyl acrylate.

In addition to the vapor streams from the reactors, fresh n-butanol and recycle n-
butanol are fed to the water removal column. The column is operated at 5.5 psia. The overhead
vapor stream from the column is condensed in exchanger and separated into two phases. The
organic phase is completely returned to column. The aqueous phase contains mainly water and
a small amount of n-butanol. The bottom stream from column is fed back to reactor. This stream
contains mainly n-butanol and n-butyl acrylate.

The liquid reaction mixture-leaving reactor is fed to the high boiler separation column.
In this column, high boilers, typically oligomers and polymers of acrylic are removed. A
heteroazeotropic mixture containing n-butyl acrylate, water, and butanol is distilled from the
column. The mixture is condensed and separated into an organic phase and aqueous phase.
Portions of the organic and aqueous phases are recycled back into the column to maintain the
heteroazeotropic composition in the column. The remainder of the organic stream containing
mainly n-butyl acrylate and butanol is fed to the butanol separation column. The remainder of
the aqueous stream is sent to wastewater treatment. The bottom stream from column contains
butyl acrylate, acrylic acid, n-butanol, and oligomers and polymers. To prevent the buildup of
oligomers and polymers, a portion of the stream is fed to a cracking vessel. The remainder of
the bottom stream from column is recycled back to the first esterification reactor.

In the cracking vessel, the stream is heated to 180 0C and held at this temperature for
at least 10 minutes. Oligomers and polymers of acrylic acid and n-butyl acrylate are converted
back to the monomers. At the completion of the batch cycle, n-butanol, acrylic acid, and n-butyl
acrylate are distilled off the vessel and fed back to column. The residual heavies from vessel
are fed to an incineration unit.

3.23
 In the butanol separation column, n-butyl acrylate is recovered in the vapor form as a
side stream. The vapor stream is condensed in exchanger and sent to the n-butyl acrylate
rundown tank. The distillate stream containing n butanol, residual water, and any low boilers is
returned to the reactor via column. The small bottom stream containing n-butyl acrylate and a
small amount of acrylic acid is fed back to column. Process flow diagram for n-Butyl Acrylate is
depicted in Fig. 3.16.

Air Emissions
Process Incinerator
The emissions from the process vent will be less than 150 mg/Nm3
Liquid Waste:
The estimated wastewater generation from the process is 75 M3/hr
Solid Waste:
The solid waste from the process is only catalyst.
3.4.6 n-Butanol

Feed NBAL containing a small amount of heavy impurities is fed to cross-

countercurrent heat exchanger where it is mixed with recycle gas. The aldehyde is then
introduced to purification column, where it is vaporized in a stream of feed H2. The vapor exiting
column passes to heat exchanger and then to gas-phase hydrogenation reactors. The shell-
and-tube reactors operate isothermally at higher temperature, with boiler feedwater used as a
coolant to generate low-pressure steam. The gas is recompressed and recirculated to recover
heat. The cooled vapor is then further cooled and passes through a gas-liquid separator to
condense out the alcohol. The remaining gas is recycled, with a purge stream diverted to
secondary hydrogenation reactors after compression. The alcohol condensed from the first
stage contains a small amount of unreacted aldehyde. The liquid is compressed to 9.6 bar and
heated at high temperature. As in the primary reactor system, heat is recovered from the
reactor effluent to reduce the heating duty. Low-pressure steam is generated from cooling the
reactor. The effluent from the reactor is degassed and stored. The H2 gas is split into a recycle
steam, which is compressed in a purge stream. The purged H2 is cooled in to recover
condensable liquids. Process flow diagram for n-Butanol is depicted in Fig. 3.17.

Liquid Waste:
The estimated wastewater from the process is 75 M3/hr
Solid waste:
The solid waste generation from the process is catalyst.

3.24
3.4.7 Propylene Derivatives

Propylene Oxide

The unit consists of three process sections:

1. Reduction and oxidation of a working solution

2. Recovery and purification of hydrogen peroxide solution
3. Working solution regeneration.
The working solution selected is a mixture of ethylanthraquinone (EAQ),
tetrahydroethylanthraquinone (THEAQ), its corresponding hydroquinone (THEAHQ), and inert
compounds in a mixed solvent of 21.4-wt% triethylhexyl phosphate and 76.6-wt% aromatic
solvent (mixed alkylbenzenes). The purified product is a 37-wt% hydrogen peroxide solution.
The epoxidation reactor system comprises four reactors, with three in series on stream and
one under regeneration or stand-by. Hydrogen peroxide solution from the hydrogen peroxide
section is combined with recycled stream containing methanol from absorption column in the
separation section and fed into the top of the first reactor. Fresh polymer-grade propylene and
recycle propylene are combined and fed into the bottom of the third reactor. The propylene
and hydrogen peroxide solution flow counter-currently in the reactors. The reaction is carried
out at 65°C with H2O2/lb catalyst. The overall conversion of H2O2 is 96.8% and the selectivity
to PO is 94.5 mol%. H2O2 decomposition to water and oxygen is the major side reaction. The
deactivated catalyst is first washed with methanol. The liquid product from epoxidation reactor
is flashed and released from the reaction pressure to 200 psia in separator. The loaded liquid
is joined with fresh hydrogen peroxide solution and sent to the epoxidation reactors. The
bottom stream from column is fed into crude PO column. Crude PO stream is recovered as
overhead and is sent to the PO purification section for further purification. Crude PO is first
treated to remove most of the methyl formate impurity. A small amount of PO containing
impurities is purged overhead as fuel. The bottoms containing PO in TBA/water solvent are
distilled in PO column to recover PO with 99.98% purity. The TBA/water solvent is recycled
after the removal of methanol in column.

Propylene Derivative – Cumene

The Cumene process primarily consists of following sections:

Alkylation

The alkylation section of the cumene plant consists of a single 4-bed reactor. The
overall benzene to propylene ratio is 2 to 1 (molar). All of the benzene for alkylation and a
portion of the propylene feed from battery limits storage are pumped to the first bed under flow

3.25
control. The remaining propylene feed is mixed with the alkylator’s circulation and is fed as
quench under flow control to the remaining beds. Note that treaters are included on the fresh
propylene feed for removal of sulfur and nitrogen compounds.

The alkylation reaction is exothermic, and the alkylator inlet temperature as well as
the temperature rise in each bed is controlled by circulation and cooling of the reactor effluent
via cooling water. The net effluent from the alkylator flows to the distillation section of the plant
under pressure control for recovery of the excess benzene and the cumene product.

Benzene Recovery

The benzene column recovers excess benzene from the alkylation and transalkylation
reactor effluents for recycle to the reactors, removes the nonaromatic components which are
contained in the benzene feedstock, and dries the fresh benzene being fed to the unit.

The alkylator effluent flows to the benzene column under static pressure. The tower is
reboiled with high pressure steam as heating medium and condensed with cooling water. Fresh
benzene is fed to the top of the column, and benzene product is recovered as a side stream to
ensure proper removal of moisture before recycle to the reaction sections. The makeup of fresh
benzene is controlled by level in the benzene surge drum, so that total inventory of benzene is
maintained at a constant in the plant. Recycle benzene is sent to the alkylator and
transalkylator reactors under flow control. Treaters are provided for the fresh benzene to
remove basic nitrogen compounds.

The top section of the benzene column concentrates and removes light nonaromatic
components contained in the benzene feed. The nonaromatics are inert in the system and need
to be purged to control the benzene concentration in the recycle benzene. Small vapor and
liquid distillate purges can be taken from the top of the column and an additional purge can be
taken from the benzene sidedraw, depending on the specific nonaromatic compounds in the
benzene feed. The overhead of the benzene recycle column is cooled by cooling water, and
the nonaromatics are normally purged as a vapor product. Liquid purges, if required can be fed
to other parts of the refinery. Any non-condensable light compounds such as propane that are
present in the propylene feed will also be vented overhead.

Cumene Column

The bottoms from the benzene column is fed to the cumene column. This column
separates the final cumene product from PIPB and heavies. The column is reboiled by high
pressure steam, and low pressure steam is generated in the condenser. Cumene product is
recovered as a distillate and the bottoms are pumped to the PIPB column.

3.26
 PIPB Column

The PIPB column recovers DIPB and most of the TIPB from the cumene column
bottoms for recycle to the transalkylation reactor. PIPB is recovered as a side stream from this
column, and fed to the transalkylation reactor for conversion to cumene. A pasteurization
section on top of this column serves as an outlet for aromatic impurities such as butyl benzenes
and cymenes, a byproduct formed from the toluene present in the benzene feed to the plant.
The column is reboiled by high pressure steam and the overhead is condensed by cooling
water. Operating pressure in the PIPB column is maintained by pulling a vacuum with a liquid
ring vacuum pump system. The bottoms product of the PIPB column contains components
heavier than TIPB, and consists mostly of diphenylpropanes. The bottoms is combined with the
PIPB overhead aromatics purge and is cooled with cooling water and purged as residue to
battery limits storage

Transalkylation

The DIPB product from the PIPB column is mixed with benzene (1 to 1 on wt basis),
and fed to the transalkylation reactor. DIPB and TIPB are partially converted to cumene with
benzene. The conversion of PIPB in the transalkylator is optimized to minimize catalyst volume
and byproduct formation by controlling the inlet temperature of the reactor. The effluent from the
transalkylator flows to the benzene column for removal of the excess benzene and the
subsequent recovery of cumene and PIPB. Process flow diagram for Cumene is depicted in
Fig 3.18.

Propylene Derivative – Phenol

Phenol and acetone are produced from cumene by liquid phase oxidation of cumene
to cumenehydroperoxide (CHP) followed by catalytic de-composition of CHP to phenol and
acetone. Phenol, acetone, unconverted cumene, and by-products are then distilled in a series
of distillation towers to recover high purity acetone and phenol, and recycle cumene.

Fresh and recycle cumene is fed to a series of oxidizers where cumene contacts air
and is converted to cumene hydroperoxide (CHP). Over-head vapors from the oxidizers are
cooled and condensed to recover cumene. Spent air is treated by passing it through carbon
beds to adsorb residual Cumene. Process flow diagram for Cumene is depicted in Fig 3.19.

3.27
 A note on Effluent / emission / hazardous waste generation and management
during cumene and benzene production / recovery

The heat requirement for Cumene production is supplied by the steam and hence there
are no emissions due to fuel firing. There is no process emission. The effluent stream will be
within the stipulated parameters to be sent for treatment to the central ETP.

The catalyst used is non-corrosive, environmentally inert, and re-generable. It is free

flowing before and after use and requires no special packaging or handling. It is expected to be
used for two years or longer before regeneration is required. Offsite regeneration, the preferred
method for the long cycle length, is chosen in this design. The catalysts are leased by the
Process Licensors and will be returned to them at the end of their useful life.

Air Emissions
The Non Methane Hydrocarbons from the Process vent and flare stack will be less than
150 mg/Nm3
Liquid Waste:
The estimated wastewater generation from the process is 90 M3/Hr
Solid Waste:
The solid waste generated from the process is catalyst.
3.4.8 Hydrogen Peroxide (H2O2)

The manufacturing process involves the catalysis of the reaction of H2 (obtained from
processing Maui Gas) with atmospheric O2 to give H2O2. Anthraquinone (Q) is used as a H2
carrier. Palladium catalyses the reaction
between H2 and anthraquinone to
Step1 - Hydrogenation create anthrahydroquinone (H2Q) :
Q + H2 → H2Q

The palladium catalyst is filtered

Step 2 - Filtration out of the solution

The solution is oxidised by blowing air

through the solution, forming the H2O2:
Step 3 - Oxidation
H2Q + O2 → Q + H2O2

3.28
 The hydrogen peroxide is removed in
a liquid-liquid extraction column and
Step 4 - H2O2 Extraction concentrated by vacuum distillation.

Hydrogen peroxide is manufactured using the anthraquinone process. This process

is a cyclic operation where the alkyl anthraquinone is reused. The Synthesis Loop consists of
sequential hydrogenation, filtration, oxidation and extraction stages. A number of ancillary
processes are also involved.

Step 1 - Hydrogenation

An alkyl anthraquinone is dissolved in two solvents, one nonpolar and the other polar.
Collectively the anthraquinone and solvents are called the working solution. This working
solution is recycled. The working solution containing the dissolved anthraquinone is
hydrogenated using hydrogen gas in a slurry-type hydrogenator using alumina loaded with a
small amount of palladium catalyst. Temperature is controlled to around 45oC and the reactor is
agitated to ensure good mixing of catalyst with working solution and hydrogen. During
hydrogenation the alkylanthraquinone is converted to both the alkylanthrahydroquinone and the
tetrahydroalkyl-anthrahydroquinone, although productionof the tetra-form of the quinone is
preferred because it can be more easily hydrogenated.The hydrogenation stage is carefully
controlled to avoid over-hydrogenation of the anthraquinone rings. Basicity and moisture
content are important for optimum catalyst and activity.

3.29
Step 2 - Filtration

The working solution that now contains hydrogenated anthraquinone is then filtered
to remove any trace levels of catalyst. If the catalyst is not removed then it will decompose the
hydrogen peroxide in later stages, reducing yields and causing potential hazards.

Step 3 - Oxidation

The working solution is oxidised by blowing air through it. The

tetrahydroalkylanthrahydroquinone is oxidised, forming hydrogen peroxide in an organic phase.
No catalyst is used and hence this step is often referred to as auto-oxidation.

Step 4 - H2O2 Extraction

Since the hydrogen peroxide is present in an organic phase and the product is
required in aqueous phase, demineralised water is added to the top of a 35 metre high liquid-
liquid extraction column. The water flows down the column over perforated trays while the
working solution is pumped up the column. The extractor design and operation ensures a
maximum contact of water with the working solution. The water reaches the bottom of the
extractor and contains 25-35% w/w crude hydrogen peroxide, whilst the working solution that
leaves the top of the extractor is free of hydrogen peroxide and is pumped back to the
hydrogenator. This working solution now contains the original alklyanthraquinone and
tetrahydroalkylanthraquinone. The crude hydrogen peroxide is subsequently purified and
vacuum distilled to concentrations of up to 70% w/w. This concentrated product is stabilized
against unwanted decomposition by adding proprietary stabilisers and then pumped to product
storage tanks for final testing. The process of manufacturing H2O2 by Anthraquinone Process
is shown in Fig. 3.20.

Air Emissions:
The Purge gases from the hydrogen peroxide plant will send to incinerator.
Liquid Waste:
The estimated wastewater generation from the process is 150 M3/hr
Solid waste:
No solid waste will be generated from the process.

3.30
3.4.9 Polypropylene (PP)

Homopolymer

Propylene polymerisation to PP, in presence of hydrogen and catalyst, in a fluidized

bed reactor to form homopolymer resin.

Random Copolymer

Polymerisation of ethylene and propylene to PP in presence of hydrogen and catalyst

in a fluidized bed reactor form random copolymer resin.

Impact Copolymer

Homopolymer PP reacted further, with ethylene, propylene and hydrogen a second

reactor form impact copolymer resin.

Only one type of resin can be produced per line in a batch mode. The resin is then
sent to resin degassing and unreacted monomers are sent to vent recovery and are recycled
back to reactors after separation.

Wet degassed resin is sent to finishing section, wherein additives are added to
stabilize the resin, and extrude it to pellets of uniform size. The block diagram is as shown in
Fig. 3.21.

Air Emissions:
Process flare – CO2+ H20
Liquid waste generation:
The estimated wastewater generation from the process is 20 M3 /Hr
Solid waste
No solid waste will be generated from the process

3.5 C4/C5 Based Units

3.5.1 Butyl /Halo Butyl Rubber

C4 R1 Stream containing approx. 46 % Isobutylene is sent for synthesis of MTBE

with Methanol. MTBE thus produced is cracked to get pure Isobutylene and raffinate is sent to
LPG stream after separation of Butene1 by super fractionation with heat pump. Isobutylene
will be used in Butyl / Halo butyl rubber production. Small amount of MTBE import is required
(approx. 12000 MTA) to meet complete requirement of Isobutylene for Butyl Rubber Project

3.31
Butyl Rubber Production :

Isobutylene and Isoprene are co-polymerized at extremely low temperatures and

operates in a semi continuous mode. The catalyst anhydrous aluminum chloride is dissolved in
methyl chloride and chilled.

Both monomers are mixed, diluted with methyl chloride and chilled. Reaction
produces polymer suspended in liquid methyl chloride.

Suspended polymer overflows from reactor and enters into flash-tank, were additives
are added.

Solvent and un reacted monomers are evaporated by means of steam and warm
water. Un reacted monomers and methyl chloride are flashed, compressed, dried and purified
for reuse.

Polymer slurry from bottom of degasser to finishing equipment where polymer is

separated from water. Water is recycled back to the flash-tank.

Wet polymer is dried, baled, wrapped in film and packaged.

Halo butyl Rubber :

Halo butyl rubber is produced by reaction between butyl rubber solution in organic
solvent and halogenation agent in presence of nitrogen gas.

After removal of water from butyl rubber slurry, butyl rubber chips obtained from
degassing vessel are dissolved in hexane. Rubber solution is pumped through cooler to
halogenation reactor.

Chlorination is performed with Chlorine in gas phase while Bromination is carried out
with Bromine in liquid phase. In both cases nitrogen is used as shipping agent to ship away
the side products formed during reaction.

Gaseous phase leaving top of reactor is washed with caustic solution. Condensed
hexane is recycled back and spent caustic solution from scrubber bottom is discharged from
the plant.

Halogenated rubber in hexane after neutralization and addition of additives is sent to

degassing vessel. Hexane is recovered with the help of steam and recycled back.

Halogenated rubber slurry is dewatered. Rubber crumbs are dried, baled , wrapped
and palletized in wooden boxes.

3.32
SSBR / PBR

For production of SSBR / PBR swing plant will be installed . The process for both is
same except few chemicals and additives.

Monomer Purification / Solvent Purification

Fresh Butadiene 1:3 (BD 1:3) is received from storage area and is mixed with recycle
stream of BD 1:3 which is having lower purity. This mixed stream is fed to a series of two
distillation columns where the water and heavy ends are removed. The dry BD 1:3 stream
having purity of 93%~99% is fed to the polymerization section. The solvent recovered by
stripping contains un reacted butadiene and other c4’s. Butadiene and C4’s are recovered by
distillation and recycled back. Recovered solvent is sent to storage for re use.

Polymerisation

BD and solvent being purified in the purification section are sent to the polymerization
section. Theses are pre cooled in the respective pre coolers by ammonia refrigeration system.
Purified BD and solvent along with catalyst are fed to the reactor.

Reactors in series having agitators for mixing of high viscosity polymer solution and
jackets for refrigerant to remove the heat of reaction. The temperatures of reactors are
maintained in the range of 59º C to 75º C. The reactant material goes from bottom of reactors
and comes out form the top. The reaction is terminated by adding PPA solution and polymer
solution is sent to the blending / homogenization section.

Solvent Recovery

The rubber solution form the blend tank enters into first stripper through cement
slurry mixer in which it is mixed with hot recycle water. In first stripper the BD and solvent are
stripped by low pressure steam and by vapor form top of second stripper. At the same time the
rubber forms crumbs. The crumb slurry from first stripper is pumped to second and then to
third in which residual solvent is stripped out.

Finishing

The crumb slurry from the solvent recovery section is received n the crumb slurry
tank. The crumb slurry tank has overhead condenser where condensed material is decanted
and hydrocarbons are recovered. The crumb slurry from this is tank is fed to the shaker screen
through distributors.

3.33
 The separated hot water form bottom of the shaker screen enters into the fine
crumbs tank from which fine crumbs with hot water are transferred batch wise to crumb slurry
tank for recovery and hot water called serum water is transferred to the serum tank. The
serum water from the serum tank is recycled to the water column in stripping section and part
of water is drained.

From the shaker screen, the crumbs pass to the expeller for dewatering the rubber.
Drained water from the bottom of the expeller is taken to the fine crumb tank. From the
expeller, rubber expander where the water is flashed off when the rubber in the form of small
crumbs leaves expander. Water vapor leaving the crumbs are taken out by blower.

Rubber crumbs are conveyed and cooled in spiral elevator and baled after automatic
weighing. The bales go for packaging through a metal detector device (film wrapper &
bagging). After this bales are finally packed, weighed and moved to Ware House.

3.5.2 E-SBR Project

The SBR plant at Jamnagar will consist of two process areas namely Polymerisation
(including monomer recovery) and Coagulation & Finishing area.

Polymerisation Area

Styrene Butadiene Rubber (ESBR) is manufactured by emulsion polymerization

technology. Main Raw materials are Styrene (23.5%) and Butadiene (76.5%). The term
emulsion polymerization is used to describe polymerization process in which Styrene &
Butadiene (monomers) are emulsified as droplets in water phase, with the help of emulsifying
agents such as soaps.

The reaction is initiated by a catalyst system and takes place in a series of

continuously agitated reactors at 5 to 10 oC and occurs in three phases namely initiation, chain
propagation & termination. Molecular weight of the Polymer is controlled by addition of a
modifier, which regulates the length of the polymer chains.

The reaction is exothermic and is controlled with the help of Ammonia circulating in
specially designed coils inside the reactors. The polymerisation is carried out upto 60-65%
conversion that gives optimum properties in rubber. At this point, conversion reaction is
terminated by addition of shortstop. Product thus produced is called Latex.

Un-reacted Butadiene is recovered by pressure and vacuum flashing. It is

compressed, condensed and recycled to the system. Unconverted Styrene is recovered by
stripping of Latex and subsequent condensation and recycled back. A small portion of Styrene

3.34
& Butadiene is purged out to maintain desired purities of monomers required for
polymerisation. Stripped latex is stored in tanks (and blended if required to achieve proper
physical properties) and sent to finishing lines for conversion into rubber.

Finishing Area

Antioxidant is added to blended latex and latex is coagulated with the help of salt and
sulphuric acid. In case of 1700 grade, Extender oil is added to the latex before coagulation.
Rubber crumbs obtained in coagulation are filtered and washed with water. Crumbs
containing 50% moisture are sent to expeller to reduce water content to about 10%.

Dewatered crumbs are shredded and dried in a tunnel or mechanical dryer where the
moisture content in the rubber crumbs is reduced to less than 0.5%. Dried rubber crumbs are
compressed in Baler to form bales which, passes through a metal detector and finally film
wrapped before packing in paper bags or cartons. The process flow diagram of E-SBR is
shown in Fig. 3.22.

Air Emissions:
The emissions from the process vents will not exceed the following standards.
Butadiene – 5 mg/Nm3
Styrene- 100 mg/Nm3
NMHC- 150 mg/Nm3
Liquid waste:
The estimated wastewater generation is 300 M3/Hr
Solid Waste:
The solid waste generation is 1500 TPA
3.5.3 Maleic anhydride

N-butane and air are fed to a fluid bed catalytic reactor (1) to produce Maleic
anhydride. The fluid bed reactor eliminates hot spots and permits operation at close to the
stoichiometric reaction mixture. This result in a greatly reduced relative to fixed bed process
and translates in to savings in investment and compressor power, and large increase in steam
generation. The fluid bed system permits online catalyst addition/removal to adjust catalyst
activity and reduce downtime for catalyst change out.

The recovery area uses a pretended organic solvent to remove the maleic anhydride
from the reactor effluent gas. A conventional adsorption (2)/stripping (3) scheme operation on
a continuous basis. Crude maleic anhydride is distilled is to separate light (4) and heavy (5)
impurities. A slipstream of recycle solvent is treated to eliminate any heavy byproducts that

3.35
may be formed. the continuous nonaqueous product recovery system result in superior
product quality and savings in steam consumption. Relative to an aqueous recovery system, it
reduces investment, product degradation loss (and byproduct formation) wastewater. Fig.
3.23 shows process flow diagram of Maleic Anhydride

Air Emissions:
Air Emissions: fuel gas to fuel pool
Organic Particulates: 25 mg/Nm3
Liquid Waste:
The estimated wastewater from the process is 10 M3/Hr
Solid Waste:
Solid Waste- catalyst Spent- 200 T/Yr (averaged over a 5 Year term)
3.6 C6/C7/C8 based Units

3.6.1 Mono Nitro Benzene

Benzene is converted to mononitrobenzene (MNB) in a mixture of nitric and sulfuric

acids in a conventional stirred tank reactor at a selectivity of around 97%. Makeup benzene is
fed to the prenitrators along with spent acid, where the excess benzene drives the reaction to
near completion at 60oC. The heat of nitration is removed with cooling water through internal
cooling coils. Effluent from the reactor is decanted into a separator where organic phase is
separated from the acid solution. The denitrated spent acid solution is concentrated by steam
stripping and recycled back to the reactor. The organic phase from the prenitrators is reacted
with replenished mixed acid in nitrators which are tubular heat exchangers. At the reactor
temperature of 60oC, 98% of the nitric acid fed to the nitrator is converted to mono or to
dinitrobenzene.

The nitrator effluent is separated into organic and acid phases in separators. The two
phases pass through decanters which recover entrainments during operating upsets. The
spent acid is recycled to prenitrators. The organic phase is fed to neutralization and benzene
recovery. The acid is neutralized with 10% caustic. The organic phase and the spent caustic
phase are separated. The spent caustic phase is disposed of while the organic phase is
scrubbed with water and fed to the MNB surge tank before entering the finishing column. MNB
is taken as the overhead product from the finishing column along with benzene and water. The
bottom product is dinitrobenzene as a 40% solution in MNB. Fig. 3.24 gives the schematic of
Mono Nitro Benzene Process.

3.36
A note on Emission / effluent management during mono-nitro benzene production

Air Emission management:

There are no furnace / process vents from the manufacturing operations.
Liquid waste management:
The source of effluent generation:
i. The effluent will be generated from the neutralization process of organic layer having likely
contamination of benzene, nitro benzene etc.
ii. The wastewater generated from the acid concentration operations which may contain likely
traces of nitro benzene.
The effluent from above operations will be neutralized and sent to central ETP for treatment.

Air Emissions
The Benzene from process vents will be less than 5mg/Nm3
Liquid Waste:
The estimated wastewater quantity is 10 M3/hr
The Spent caustic treatment will be given inside the battery limits.
Solid Waste:
No solid waste will be generated from the process.
3.6.2 Aniline

Makeup mononitrobenzene (MNB) is preheated at high temperature by heat

exchange with the reactor effluent. Recycle hydrogen is heated at high temperature in the
feed-product exchanger. Preheated MNB and makeup hydrogen are combined with a side
stream of recycle hydrogen to bring the H2/MNB ratio slightly over 3. The MNB/H2 mixture is
fed to the reactor through two-phase nozzle arranged in four tiers. The remainder of recycle
H2 enters reactor below the catalyst grate. The hydrogenation catalyst, copper on a silica
carrier, is fluidized by the H2/MNB feed passing through the reactor at ~1.5 fps. Cyclones
installed internally trap entrained catalyst particles. The reactor operates under high
temperature and at 6.2 Bar. The exothermic heat is removed by 5 bayonet coolers and is
utilized to produce steam.

The reactor effluent is cooled by interchange with recycle hydrogen and makeup
MNB. Finally the reactor effluent is cooled to 40°C to recover the organics from the recycle H2.
The gas and liquid phases are separated in a separator and the H2 is recycled to the reactor
via H2 compressor. The liquid phase enters effluent separator where the organic and aqueous
phases are separated. The aqueous phase is stripped free of aniline in wastewater column.

3.37
The overhead stream contains 15% aniline which is condensed and sent for phase separation.
The organic phase is fed to the drying column. The bottoms are essentially dry aniline and the
overhead is the aniline-water azeotrope and the benzene brought in with the MNB. The
overhead is condensed and the condensate is split into an organic and an aqueous layer. Half
of the organic phase is sent to incineration while the other half is recycled to drying column.
The aqueous layer is sent to wastewater column for recovery of dissolved aniline. The
bottoms, which contain aniline and the high boiling by-products, are fed to the finishing
column. Aniline is taken as overhead while the high boilers are discharged as bottoms. Fig.
3.25 shows Process Flow Diagram for Aniline

Air Emissions:
H2 blend stream after H2 separation
Process Incinerators- As per the CPCB standards
Liquid Waste:
The estimated wastewater generation is 300 M3/Hr
Solid Waste:
The solid waste generation from the process is Catalyst.
3.6.3 Methylene Di Aniline

Methylene Di Aniline (MDA) is produced by the acid catalyzed condensation of aniline

with formaldehyde. The production of MDA is a two-stage process. First, aniline is neutralized
with concentrated hydrochloric acid in aqueous solution at 100°C to form aniline hydrochloride.
This solution is cooled to less than 50°C. Formaldehyde solution is then added with efficient
agitation to the aniline-aniline hydrochloride solution. The reaction is usually staged to control
the condensation and rearrangement steps. The final reaction temperatures are normally 80-
120°C. After completion of reaction, the acidic PMDA is treated with aqueous sodium
hydroxide to neutralize the excess acid. The organic layer is then washed with water and
stripped to remove unreacted aniline and water. The unreacted aniline is recycled back to the
beginning of the reaction. The product is purified to isolate pure 4,4-MDA, packaged for
shipment or treated with phosgene to produce the corresponding isocyanate. Fig. 3.26 shows
the Block diagram for MDA Production process.

A note on Emission / Effluent management during Methylene Di-Aniline production

Air Emission management:

There are no furnace / process vents/emissions from the process operations.

3.38
Liquid waste management:
• The sources of effluent generation during the process operations will be from following
stages:
i. Neutralization process of mixed liquor from condensation process with caustic lye
having traces of organic matter likely contaminants are formaldehyde, aniline etc.
ii. Acidic effluent from the purification process of crude Methylene-Di Aniline.

The waste water generated will be collected and neutralized at the plant and further sent
for treatment at central ETP.

Solid waste Management:

The solid waste generated will be sodium chloride. From the neutralization process. This
contains traces of aniline. The traces of aniline will be recovered through vacuum drying and
the salts will be sent for landfill.
Liquid Waste:
The estimated wastewater generation from the process is 100 M3/hr
Solid waste:
The estimated solid waste generation from the process is Salt: of 10.41 TPA
3.6.4 Phosgene

As shown in Figs. 3.27 A and 3.27 B, carbon monoxide (Stream 1) and chlorine
(Stream 2) are mixed in a small excess of carbon monoxide to ensure complete conversion of
the chlorine over activated carbon catalyst. The product gases (Stream 3) are condensed, the
liquid phosgene (Stream 4) is sent to storage, and the remaining gases (Stream 5) are
scrubbed with a hydrocarbon solvent to remove residual phosgene. Uncondensed phosgene
and the solvent that is used in the scrubber may be used for subsequent processing (e.g., in
the production of isocyanate).

The liquid phosgene is stored in pressurized steel tanks. A typical precautionary measure is to
store the material in two tanks, neither of which is filled to more than half of its capacity. This
allows the transfer of the phosgene to either tank in case a leak develops in one of the tanks
or its piping system. Measures for safe management of Phosgene are listed in Annexure IX.
All requisite approvals for the production, storage and handling of Phosgene will be taken from
the appropriate authority.

3.39
 The MoEF has sought information on the additional TOR regrinding the
measures for safe management of Phosgene & approvals from concerned department
shall be obtained for storage and production of phosgene.

The safe management measures are attached as Annexure IX to the document and
necessary approvals will be taken from appropriate authorities before commissioning of the
facility. .

Phosgene is an intermediate product in the manufacture of Methylene Diphenyl

Diisocyanate (MDI) & Toluene Diphenyl Isocyanate (TDI). Since it is not a stand alone product,
there will be no requirement for storage of the same. Based on the plant layout the inventory
that is in the pipelines and process equipment will be the only quantity in process. The requisite
approvals from the concerned agencies will be obtained for the use of Phosgene in the process.
The Phosgene Panel under the American Chemistry Council has delineated the Safe
management Measures for Phosgene. These measures will be strictly followed for the design
and operation of the MDI & TDI Plants.
Air Emissions:
Stack exhaust from scrubber is 1 mg/Nm3
Liquid Waste:
Spent caustic treatment is given inside the battery limits
Solid Waste:
Activated carbon catalyst

3.6.5 Methylene Diphenyl Diisocyanate & Toluene Diisocyanate

The first step in Methylene Diphenyl Diisocyanate (MDI) production is the

hydrochloric acid catalyzed condensation of aniline with formaldehyde, yielding a mixture of
isomeric forms of diphenylmethane dianilines (MDA's) containing two or more aromatic rings.
Then occurs the phosgenation of MDA's forming crude MDI (Figure 1). The non-distilled or
crude MDI mixture, or polymeric MDI, consists mainly of 4,4'-diphenylmethane diisocyanate,
2,4'- and 2,2'- isomers, and condensation products with more than two aromatic rings. Crude
MDI is used in rigid foam production, where it provides significant advantages in processability
and in mechanical performance, such as mechanical resistance and dimensional stability. The
higher aniline/formaldehyde relationship increases the ratio of di functional product. The
isocyanate is purified via solvent separation and fractionation. Fig. 3.28 represents the
schematic of MDI production.

3.40
 The MoEF sought clarification on Emission / effluent management and risk during
methylene diphenyl diisocyanate, toluene diisocyanate / recovery (Please refer Bhopal
episode)
Methylene Diphenyl Di Isocyanate (MDI):
Air Emission management:
The un-reacted phosgene from the manufacturing process of MDI is completely
removed and decomposed by scrubbing with water and caustic till it becomes completely inert.
The disposal of inert gas will be done after doing complete Risk Assessment under
manufactures guidelines and Safe Management Practices.
Liquid waste management:
The wastewater generated from the HCl absorber & phosgene decomposing column will
be neutralized and sent to Effluent treatment plant for treatment at central ETP.
Solid waste Management:
There are no solid waste generations from the process.
Toluene Di Isocyanate (TDI):
Air Emission management:
Two stage caustic scrubbers will be provided for scrubbing. The emissions generated
from the second stage of phosgenation of di-amino-toluene are scrubbed in a two stage caustic
scrubber. The disposal of inert gas will be done after doing complete Risk Assessment under
manufactures guidelines and Safe Management Practices.
Liquid waste management:
The wastewater generated from the scrubbing of HCl gas & phosgene decomposing will
be neutralized and sent to Effluent treatment plant for appropriate treatment.
Solid waste Management:
There are no solid waste generations from the process.
Air Emissions:
The MDI/TDI from the process vents will be less than 0.1 mg/Nm3
The TDI organic Particulates from the process vents will be less than 25 mg/Nm3
Liquid Waste:
The estimated wastewater generation from the process is 85 M3/hr.
Solid Waste:
No solid waste will be generated from the process.
3.6.6 Styrene

The Benzene feed to the reactor consists of fresh benzene and the benzene
recovered in the distillation section. The mixture preheated and fed to the zeolitic, liquid phase

3.41
reactor section (1). Ethylene feed reacts completely, leaving only inert constituents. Poly ethyl
benzene that are produced by successive alkylalations are Transalkylated with benzene to
produce additional EB(1)

In the distillation section, the benzene column (2) recovers and recycle benzene from
the rector effluent. Two other columns (3,4) recover EB which is sent to the dehydrogenation
section, and PEBs which are recycles to the reactor section.

The EB is then catalytically dehydrogenated to styrene in the presence of steam. The

reaction is carried out at high temperature under vaccum. The EB (Fresh and Recycle) and
primary steam are combined with superheated steam, and the mixture is dehydrogenated in a
multistage reactor system(5). Between dehydrogenated stages, air or oxygen is introduced to
partly oxidized the hydrogen produced over a proprietary catalyst to reheat the process as and
to remove the equilibrium constraint for the dehygrgentaion reaction. The process achieves
greater than 80% EB conversion purpose. Reactor effluent are cooled to recover the waste
heat and condense the hydrocarbons and steam. Uncondensed offgases compressed and
used as fuel. Condensed hydrocarbons (6) are sent to the distillation section. Process
condensate is stirpped to remove dissolved aromatics.

A fractionation train (7,8) separates high purity styrene unconverted EB, which is
recycled, relatively minor reaction by product tar. Toluene is produced (9,10) as a minor
byproduct and benzene is recycled to the EB reactor section. Typical SM product purity is in
the range of 99.99% to 99.95%. The process provides high product, yield, due to unique
combination of catalyst and reactor operating condition. Fig. 3.29 shows process flow diagram
of styrene.

Air Emissions:
The emissions from the process vents will be in compliance with the standards
Styrene from the process vents will be less than 100mg/Nm3
Benzene from the process vents will be less than 5 mg/Nm3
The SO2 and NOx emissions from the Styrene process are 0.001 TPH and 0.004 TPH
respectively.
Liquid waste:
The estimated wastewater generation from the process is 125 M3/hr.
Solid waste:
The estimated solid waste generation from the process is molecular sieve of 1100 TPA.

3.42
3.6.7 Paraxylene and Orthoxylene

The Aromatics Complex comprises of Xylene Fractionation, Parex unit and Isomar
Units. Xylene Fractionation column feeds mixed xylenes to the Parex unit.

Selective adsorption of paraxylene is affected by the Parex Process to produce

Paraxylene (PX), with a purity of 99.8 wt%, and recover 94-97 wt% of PX in a single pass.

Selective adsorption of ‘PX’ is done with molecular sieve adsorption and the
subsequent desorption of ‘PX’ by a suitable desorbent. Adsorbent is a ‘X’-type zeolite
material. Desorbent is liquid para diethyl benzene.

The simultaneous entry and withdrawal of various process streams, are

accomplished by a Rotary valve called Coplanar Manifolding Indexes (CMI).

The separation in a Parex unit takes place in the two adsorbent chambers. Each
adsorbent chamber is divided into 12 beds. Each bed of adsorbent is supported from below by
a specialized grid, which also contains the highly engineered flow distributors. Each flow
distributor is connected to the CMI or rotary valve.

PX gets adsorbed on the molecular sieve and subsequently desorbed. Two streams,
which come out of the chambers are known as raffinate stream and extract stream.

The raffinate stream from the rotary valve is sent to the raffinate column for
separation of C8 hydrocarbons from the desorbent.

The extract stream from the rotary valve is sent to the extract column for separation
of the crude paraxylene from the desorbent. Overhead product from the extract column, which
contains the paraxylene together with toluene, is sent to the finishing column. Extract column
bottoms which is essentially pure desorbent. Block Diagram for Aromatics is presented in
Fig. 3.30.

Fuel:
The fuel oil requirement for Paraxylene and Orthoxylene is 48.451 TPH
Air Emissions:
The over all SO2 and NO2 emissions are 0.045 TPH and 0.127 TPH
The emissions from the Process vent- Aromatics/Xylene/toluene will be less than
100mg/Nm3
Liquid waste:
The estimated wastewater generation from the process is 150 M3/hr

3.43
Solid waste
The estimated solid waste generation from the process is Molecular sieve of 2900 TPA
3.6.8 Purified terepthalic acid (PTA)

PTA manufacturing process consists of two steps:

• Production of PTA by air oxidation of paraxylene (PX)

• Purification of PTA

Production of PTA

The Oxidation Plant consists of three sections: reaction, product recovery and
solvent recovery.

In the reaction section, PX is mixed with acetic acid solvent and catalyst solution and
is fed continuously to the reactor where it is reacted with air. The terephthalic acid produced in
the exothermic reaction is precipitated to form slurry in the reactor.

In the product recovery section, reactor product is depressurized and cooled in a

series of three crystallizing vessels. Precipitated terephthalic acid product is recovered by
continuous filtration incorporating a solvent wash stage. Residual acetic acid is then removed
in a continuous drier.

In the solvent recovery section, contaminated solvent, recovered from the reaction and product
recovery sections, is processed to remove water, catalyst, and unwanted reaction by-products.
The contaminated solvent is continuously fractionated to produce a final product of purified
acetic acid suitable for re-use in the plant. Block Flow Diagram for Production of PTA is
presented in Fig. 3.31.

Purification of PTA

The terephthalic acid (TA) product contains a small quantity of impurities, which must
be removed before the material can be used in the manufacture of polyester.

The principal impurity, 4-carboxy benzaldehyde (4CBA), an oxidation intermediate, is

hydrogenated to para-toluic acid. The para-toluic acid remains in aqueous solution during the
subsequent product recovery stages. This is achieved in the purification plant by selective
catalyst hydrogenation of an aqueous solution of TA saturated with hydrogen at elevated
temperature and pressure. The PTA is subsequently crystallized and recovered by employing
solid/liquid separation and drying steps.

3.44
Air Emissions
The Air emissions SO2 & NOx are 0.008 TPH and 0.001TPH respectively.
Liquid waste generation
The estimated wastewater generation is 510 M3/hr- Own treatment unit with in the
battrery limits.
Solid Waste:
The solid waste from the process is pretreatment sludge.
3.6.9 Polyester/ Polyethylene Tere-phthalate (PET)

The Purified Terephthalic Acid (PTA) and Mono-ethylene Glycol (MEG) are mixed to
produce Oligomer and water in the esterification section. The oligomer is then pumped to
polymerization section after addition of chemicals namely catalyst, TiO2, DEG and Glycol. The
oligomer is converted into polymer, through the polymerization reaction. The polymer is sent
to chippers for making chips. The water generated in the process is first stripped of
hydrocarbons, and sent to ETP.

The polyester chips are post oxidized and are packed in bags. Block and Process
flow diagram for 1000 KTA Bottle Grade PET: Continuous Polymerisation Section (CP) are
depicted in Fig. 3.32 and 3.33.

PET Plant-Process Description

PET Resin – Product Types

1) Resin for water packaging applications.

2) Resin for carbonated soft drinks applications.
3) General purpose PET resin

PET plant consists of two sections Continuous Polymerization (CP) and Solid State
Polymerization (SSP).

Continuous Polymerisation

Raw Materials feeding: -

• Ethylene Glycol (EG)

• Purified Terephthalic Acid (PTA)

• Isophthalic Acid (IPA)

3.45
 PTA and IPA(in ratio control) are fed into the SlurryMixTank to which metered
quantity of Ethylene Glycol is added to control PTA - EG mole ratio. The PTA - EG slurry thus
produced is pumped into the Esterifier reactor.

Esterification

Estirification reaction takes place to produce Oligomer and water. The Water - EG
mixture is distilled in a separating column where the recovered EG is separated out and
recycled into the process . Reaction water is sent to stripping column from were it is discharge
to effluent treatment.The Oligomer produced in the Esterifier is pumped through Oligomer
filter into the Pre-Polymerizer. All additives viz. Catalyst, Diethylene Glycol (DEG), thermal
stabilizer (phosphoric acid) and color inhibitor (Cobalt acetate) are added in the Oligomer
Transfer line.

Polycondensation

Pre-Polymerizer (PP) :

The Pre-Polymerizer is a Dowtherm jacketed vessel. The Oligomer is Pre-heated and

then polymerised under vacuum & high temperature . Excess glycol generated from the
process is recycled back.

Final Polymerizer

The Final Polymeriser is a horizontal, cylindrical vessel with an agitator to achieve

high surface generation. The vessel is operated at high temperature and very high vacuum.
The remaining excess glycol (2 - 3%) is removed in the finisher and the polymer viscosity is
increased to about 2,500 poise, suitable for Chipping in Chipper Unit. Chips produced in
chipper are conveyed to storage silos and then fed to SSP Plant.

Solid State Polycondensation

Precrystallization Section:

In Precrystalliser chips are fludized and precrystallized by means of nitrogen.

Crystallization Section

Pre-crystallized PET chips are fed to two crystallizers connected in series.

Solid State Polycondensation:

The hot chips coming from second crystalliser are fed to the reactor. Inside the
reactor a stream of hot nitrogen is fed counter - currently in order to facilitate removal of

3.46
Acetaldehyde and other organics and increases the viscosity to the desired level by providing
the required residence time and temperature.

Product Cooling Section:

The hot PET chips are cooled in two stage fludized bed coolers and then conveyed
to the Product silos from where it is bagged/stuffed in containers.

Liquid Waste generation

The estimated wastewater generation from the process is 125 M3 /Hr

Solid Waste
The Solid waste generation from the process is spent pellets.
3.6.10 PSF – Process Description

The polyester staple fiber process with a packed production capacity of 720TPD. The
plant is mainly divided into following sections.

• Continuous Polymerization with 4 Reactors (750 TPD)

• Chip production.

• PSF Spinning (4 lines of 185 TPD).

• PSF Drawlines (4 machines each of 185 TPD).

• Balers – 8 nos, 02 each per drawline.

• Auxiliaries - Catalysts, Additives, TiO2, DEG and Spin Finish Pack handling
/cleaning and AHUs.
• PSF bale handling facilities up to Warehouse.

Continuous Polycondensation

¾ Paste Preparation

In this section PTA, EG (split glycol) and the polycondensation catalyst are mixed in
a defined ratio to form a paste. The paste is made by mixing the continuous streams, i.e. the
PTA powder and the EG are filling into the PTA preparation tank while stirring. The mixing
ratio of the two streams is controlled to ensure a constant level even with a varying rate of
throughput.

3.47
 ¾ Esterification 1 and 2

In the esterification section, PTA and EG react to form diglycol terephtalate (DGT)
while water is spilt off, and the polycondensation reaction is initiated while EG is split off.

For this purpose, the PTA paste is subjected in series-connected reactors under
stirring to an elevated temperature. Maintaining the pressure, temperature and residence time
at an appropriate level controls the degree of esterification and polycondensation. The water
split off during esterification and the EG released during polycondensation are discharged from
the reactors in form of vapour and subjected to rectification in the process column. In this way,
a maximum of EG split off during polycondensation is recycled to the esterification process.

The process column and the reactor ES2 internal heat exchanger coils are heated
with liquid heat transfer medium from secondary heating circuits, supplied directly with liquid
heat-transfer medium from the primary heating circuit. Internal heat exchanger of esterification
1 (ES1) is heated directly by primary HTM.

All vapour lines and all heated jackets of the reactors are heated by dowtherm vapour
systems.

¾ Prepolycondensation

The polycondensation process initiated in the esterification is further continued in the

prepolycondensation reactor and a low-molecular PET is obtained.

The product leaving the esterification stage is fed into the prepolycondensation
reactor, equipped with an agitator. Maintaining the pressure, temperature and residence time
at an appropriate level sets the degree of polycondensation. The EG split off during
prepolycondensation is withdrawn in the form of vapour, condensed in the spray condenser
with a cold EG cycle and fed back into the process column. The required vacuum is generated
by a central vacuum system, serving the prepolycondensation stage and the final
polycondensation reactor. The accumulating glycol load is passed back into the process. The
heating coils of the reactor are heated with liquid heat transfer medium from a secondary
heating circuit.

The reactor heat exchangers of the cascade-reactor are heated with liquid heat
transfer medium from a secondary heating circuit, supplied directly with liquid heat-transfer
medium from the primary heating system.

The vapour lines and the heating jacket of the prepolycondensation reactor are
heated by dowtherm vapour systems.

3.48
 ¾ Polycondensation

The product leaving the pre-polycondensation section is fed continuously into the
final polycondensation reactor, where under agitation and high vacuum the final product
qualities are achieved.

The degree of polycondensation measured as viscosity is set to the desired final

value by maintaining the pressure, temperature and residence time at an appropriate level.
The EG (split glycol) vapours are removed by suction with an EG vapour jet system and
condensed with cold EG in a spray condenser system. The split glycol is passed back to the
paste preparation vessel. The inert gases are removed by the vacuum pump system.

The polymer melt is led to the spinning sections respectively to the chip production
by a special designed product discharge pump. Secondary liquid heat transfer medium circuit
heats the product outlet line.

The disc ring reactor is heated by dowtherm vapour. The thermal energy is supplied
via a dowtherm evaporator, which is heated by liquid heat transfer from primary circuit. The
vapour lines and the EG-vapour jet are heated by a separate dowtherm vapour system. The
motive vapour required for the EG-vapour jet system is generated in the glycol evaporator.
The necessary thermal energy is delivered from a secondary liquid heat transfer medium
circuit.

¾ Chip Production

In this section the hot and highly viscous polymer is converted into chips through
underwater pelletizers.

The manufactured chips are inter stored in the intermediate chip silo.

¾ Chip Handling, Chip Storage and Conveying

The processed textile grade chips are fed with a slow motion pneumatic conveyed to
storage silos for bagging.

3.6.11 Staple Fibre Production

PSF Spinning

In the spinning plant the polymer melt is directly spun into tow.

The polymer melt is to be delivered continuously from the polycondensation plant to

the spinning beams.

3.49
 Static mixers in the distribution pipe system guarantee a uniform temperature profile
in the polymer melt without creating any dead spots in the pipe system in the spinning beams.

The polymer melt is fed by metering pumps to the spin packs at a uniform flow rate,
where it is filtered and extruded through small offices in the spinnerets into filaments. The
spinning beams are heated by dowtherm vapour. A special designed vapour distribution
system ensures a uniform temperature for all spinnerets. The extruded filament pass through a
quench duct in which they are cooled and solidified by a laminar and uniformly controlled and
conditioned airflow. From there, they are led through the spinning tube down to the draw-off
machine. The filament bundles of each spinning position are gathered to one single tow. The
tow is then fed to the piddlers, which deposit the tow uniformly into cans.

PSF Drawlines

The various tows are being combined and drawn under constant tension into the
staple fibre line.

The fibre tow passes a dipping bath receiving the necessary finish oil needed for the
subsequent drawing of the fibres.

Between drawing frame I and II a pre-orientation of the fibre tow is achieved while at
the same time the tows are being heated in the drawing path. The complete
orientation(drawing) of the fibres is achieved between drawing frame II and the roller
thermosetting unit. In the next step the fibre tows are thermoset under tension or shrinkage at
high temperature depending upon the fibre type being requested. The high modulus types are
then cooled under tension for stabilizing the properties. Then the tows are then reduced to one
tow, which is heated in the heating chamber. The crimping of the fibre tow can be adjusted in
the crimping device by pressure. After crimping the fibre tow is dried uniformly in the dryer.

Baler

Then the fibre tow is fed under uniform tension into the cutter, where it is cut into the
required staple fibre length. The cut staple fibre is charged into the two baling presses , where
it is compressed into bales.

Additives

Following additives are added to get the product with desired properties.

• DEG
• TiO2

3.50
 In addition to the additives, Catalyst is used to enhance the rate of polymerization in
the polycondensation section.

PSF bale handling facilities

The bales are removed by means of a special designed wagon fitted with gripper and
led via a driven roller conveyor to the in-line weighing and labeling unit and further to the
discharge point over an undriven roller conveyor.

The bales are then led to the warehouse where the attacking of the bales is done and
an inventory maintained for dispatch.

3.6.12 Downstream Process

The Spinning Process

A spinning mill carries out many processes, which transform bales of raw cotton into
a yarn ready for weaving. The term "spinning" can refer to the whole activity or just to the final
process of making the yarn.

Bale to Lap

The raw cotton arrives in the form of large bales. These are broken open and a
worker feeds the cotton into a machine called a "breaker" which gets rid of some of the dirt.
The cotton may not be consistent in quality from bale to bale and samples will be taken.

From here the cotton goes to a "scutcher". (Operated by a worker also called a
scutcher). This machine cleans the cotton of any remaining dirt and separates the fibres. The
cotton emerges in the form of thin "blanket" called the "lap". (Think of how "cotton wool" holds
itself together). An important quantity is called the "tex" which basically measures the mass
per metre. Ideally the tex of the emerging lap should stay more or less the same. The final end
product of the mill, the yarn, needs to be of constant quality and character and this is achieved
by checking the cotton through all the preceeding stages. One way to achieve this is by
blending. The output from several breakers can be fed into the scutcher so that the contents of
different bales are being blended to produce a more uniform output. The stress on quality
control is something that has changed over the years and what used to be achieved by the
experienced eye of the workers now relies more on measurement.

Lap to Sliver

Here we have two processes: CARDING and DRAWING.

3.51
Carding

A machine called a “card” does this. The fibres are separated more completely and
the tex is reduced many times. The output from these machines is more like an untwisted
'rope' than a blanket. ‘strippers’ and ‘grinders’ according to Tippett do maintenance but in the
census they are generally called 'cardroom hands', 'cardroom operatives'.

Drawing

This is carried out on a machine called a 'draw frame'. This further straightens the
fibres. It also combines the output of several carders thus again giving a more uniform product.
This combining is referred to as 'doubling'. [Note that the same term 'doubling' is used to refer
to the twisting together of two finished yarns]. Sometimes drawing is supplemented by
'combing' which gets rid of short fibres. This is normally for higher quality fabrics. The output
from drawing is a loose untwisted 'rope' of cotton.

Sliver to Roving

Here the yarn is further attenuated — i.e. it is being stretched so that the weight per
unit length decreases further. The process is very similar to drawing. ‘Speed frames’ carry out
the process and quite often there are three sets in series. The output from the first is called
'slubbing' The output from the second is called 'inter'(mediate) The output from the third is
'roving'.

'Slubber' and 'rover' are often given as census occupations.

Roving to Yarn (Spinning)

The term "spinning" is sometimes used to denote this final process in the production
of the yarn. This involves attenuating (stretching) the yarn to the required tex. Giving the
thread strength by adding twist. And winding it on to a bobbin. There are two main methods:

• Mule Spinning

• Ring Spinning
The MULE was originally developed by Samuel Crompton from the "jenny". He never
patented his invention and this must have helped its wide introduction. The mule operated in
two stages. In one stage the whole 'front' of the machine (perhaps 100 feet long) moved away
from the back part stretching and twisting the thread as it did so. It would move several feet
(say 5 feet). In stage two the front carriage moved back and at the same time wound the
stretched yarn on to a bobbin (or cop). With the early mules the carriage was moved forward
by the operators turning a wheel but the invention of the self-acting mule meant that the

3.52
carriage moved forward itself. Mules would be placed in lines so that the front of one faced the
front of the next. As the carriages moved forward, towards each other, only a narrow gap
would be left between them for the spinner to walk between. The mules were tended by
spinners, piecers, doffers. Piecers would mend broken threads and doffers would remove the
full cops. Often they would be men. Mules could at one time produce much finer yarns than
ring frames but as the latter have become more capable the mule has become less used.

Ring-Spinning was a development from Richard Arkwright's "water frame". Many Lancashire
manufacturers found that Arkwright's patents were too restrictive so the early water frames lost
out to the mule. Ring spinning was not used much in Lancashire until the later years of the 19th
century (though invented in USA in 1829) and is carried out on a machine called a ring frame.
The process is continuous rather than intermittent, and higher speeds can be achieved. This
became the dominant method by mid-1900s. Ring frame tenters were often women and again
the full bobbins are removed by doffers. THROSTLE spinning was also developed from the
water frame

This is as good a point as any to say something about this occupation which can
have a number of meanings. The most usual meaning in Lancashire census records is
someone who looks after something, cares for something, tends it. So an "engine tenter" is
someone who looks after an engine. Another usage which goes back to the early days refers
to the days when bleaching was carried out by putting the cloth in the sun. In small quantities
the cloth could simply be laid on the grass but later long lines were set up in bleaching crofts
and the cloth was hung from these lines on "tenterhooks". The workers who did this could be
"crofters" or "tenters" or "tenterers". Looking again at the Tippett book I see he has a picture of
cloth going through a bleaching machine which he calls a bleach croft. So prehaps when
modern chemistry enabled bleaching to be done inside the factory the word "croft" stuck.
Perhaps the term "crofters" was also applied to these inside workers.

Winding

The yarn, which emerges from the spinning process, cannot usually be woven
directly and needs some preparation. Winding is the process of transferring the yarn to larger
bobbins or cones. The idea is to get a long continuous length. Weft-winding inolves winding on
to smaller bobbins that will go into a shuttle. "Winder" is a common occupation in the census
records.

3.53
3.6.13 POY process

Polyester Filament Yarn.

Pure terephthalic acid (PTA) and monoethylene glycol (MEG) are mixed to produce
oligomer in the Esterification section. The oligomer is then pumped to polymerization section
after addition of chemicals namely catalyst, TiO2, DEG and Glycol. The oligomer is converted
into polymer through polymerization reaction and is sent to spinning for converting into partially
oriented yarn (POY), Fully drawned yarn (FDY) and chippers for making polyester chips. The
chips will be further polymerized by solid-state polymerization process.

The solid state polymerized chips with higher viscosity is melted and extruded in
extruders and spun, drawn and annealed in a multi drawing and annealing process for
production of Industrial yarn (IY).

POY produced will be partly consumed in-house in a single step false twist draw
texturing process. This process involves drawing and twisting of yarn in hot condition followed
by a cooling & un-twisting process, to produce twist lively yarn.

The finished products of POY, FDY and DTY yarn is finally packed in cartons and
stored in warehouse ready for dispatch.

FDY and IY production is similar to PFY production; prior to wind-up the yarn passes
through sets of hot godet rollers at different draw ratios followed by annealing process to
produce FDY yarn. Block Flow Diagram For POY / FDY / DTY Production is presented in
Fig. 3.34.

Draw Textursing Process

POY bobbins wound on paper tubes is the raw material for draw texturing operation.
This process involves simultaneous drawing and twisting of filaments.

Polyester partially oriented yarn is unwound heated and drawn while twist is
simultaneously inserted using either ceramic or solid ceramic or belt positron unit. The twisted
yarn passes over cooling plate wherein the twist memory is set in the yarn.

Yarn as it leaves the twist unit gets untwisted making the yarn twist lively due to
memory of twist. This yarn forms either helical coils or snarl, which imparts bulk or stretch to
yarn depending on use of secondary heater to partially erase the twist memory.

Oil is then applied after the twisting unit and then yarn is wound on paper tubes.

3.54
 POY filament yarn is thus textured and the yarn has high bulk properties and such
yarn is sent to market for further processing to make fabric.

The Moef sought clarification on effluent management during production of

polyester filament yarn
The effluent from the PFY Unit is low TDS effluent with a pH in the range of 6 to 6.5.
This effluent does not call for any separate pre-treatment and will be pumped directly to the
central ETP for treatment with the other effluent streams.
Air Emissions :
The Air emissions from the polyester complex are SO2 and NOx . The respective
emissions are 0.075 TPH and 0.031TPH

Liquid Waste generation :

The estimated wastewater generation is 100 M3/Hr
Solid waste :
The solid waste generation from the Polyester complex is Spent yarn.
3.7 Carbon Black
Carbon black is produced by partial oxidation of CBFS. This means the reaction of a
CBFS with a limited supply of combustion air, at 1320 to 1540oC in a combustion reactor. The
unburnt carbon from this partial oxidation or combustion is collected as an extremely fine,
black, fluffy particle, 10 to 500 nano meters in diameter.

Fig. 3.35 shows a block flow diagram of the carbon black manufacturing process.
Preheated CBFS is injected continuously in to the combustion zone of a reactor, supplied with
preheated air and natural gas, as supplemental fuel. Both CBFS and air are preheated with
the exhaust gases for energy integration. The CBFS undergoes partial combustion resulting in
formation of carbon black. The reaction furnace is provided with a water quench, which cools
down the gases to 500oC to stop further cracking reaction. The exhaust gases, with entrained
carbon black particles, are further cooled to 230oC by raising steam in a WHB. The carbon
black is separated from the gas streams by an efficient pulse bag filter and separates carbon
black product from the smoke gas to make carbon black content in tail gas lower than
18mg/m3. The recovered carbon black is finished to a marketable product by pulverizing and
wet pelletizing to increase the bulk density. Water from the wet pelletizer is driven off in a
rotary drier, fired with natural gas. The dried pellets are then conveyed to bulk storage.

Carbon black emissions can occur from the vents of the pneumatic conveying
system. The gaseous emissions are controlled by using tail gas as a combustible gas in CO

3.55
boilers. The tail gas contains CO, hydrogen and small amounts of carbon black, which are
burned in the reboiler. The steam raised from process reboilers and CO boilers is used for
generating power. Surplus power to the extent of 26 MW is exported from a 120 ktpa carbon
black plant.

Fuel :
The fuel oil requirement for Carbon black process is 29.73 TPH
Air Emissions :
The SO2 & NOx emissions from the process units are 0.099 & 0.026 TPH respectively.
The emissions from the process vents - Carbon black will be less than 18 mg/m3
Liquid waste:
The estimated wastewater generation is 315 M3/Hr to central ETP
Solid waste:
No solid waste will be generated from the process.
3.8 Lube Oil Cum Refinery Complex
The CDU/VDU of 140 kbpsd does primary separation of crude oils into C3/C4,
naphtha, kerosene, gas oil, vacuum gas oil (VGO) and vacuum residue (VR). The primary
product disposition from the proposed Lube Oil Refinery in the Jamnagar SEZ is given below:

• C3/C4 – mixed with sat LPG and goes as feed to the Alky unit, in the JERP.

• Light naphtha – blended into PC naphtha product, via depentanizer, in the

JERP

• Heavy naphtha – feed to the HNHT 2/Platformer 2 in the JERP

• LK – blended into the jet product, via Kero Merox unit in the DTA refinery

• HK + AGO – blended into the diesel product, after desulphurising in the new
DHDS unit in the Lube Oil Refinery.

• LOBS Feed Stock

The VR from the CDU/VDU’s shall be routed to the Solvent De-asphalting unit (SDA)
in the JERP refinery to be separated into deasphalted oil (DAO) and SDA pitch, with the aid of
a solvent, which may be Propane/ Butane. The SDA pitch shall be routed to the Coker and
Bitumen units in the JERP refinery, for further bottom-of-the barrel processing.

The VGO from the CDU/VDU’s, along with the DAO from the SDA shall be routed to
the existing Hydrocracker in JERP. This Hydrocracker shall be in the Lube oil refinery service.

3.56
The lube hydrocracker does high pressure, aromatics saturation, in the presence of catalyst
and hydrogen. The unconverted hydrocracker residue is an excellent raw material for high
performance LOBS. The VGOHT capacity has to be increased by 110 kbpsd to treat total
VGO and DAO from the JERP. The cracked products of C3/C4, naphtha, kerosene and gas oil
shall be routed to the JERP, for further processing, and blending into transportation fuels.

The unconverted hydrocracker residue shall be further processed in the 30 kbpsd

Catalytic De-waxing unit to eliminate the wax from the LOBS, in a heterogeneous, catalytic
reaction in the presence of hydrogen. Finally, the post processing hydro-finishing step shall be
done in a 30 kbpsd Lube Hydro-finishing unit to manufacture 1.5 mmtpa of premium, LOBS.
The Lube Hydrocracker produces cracked products with the following disposition :

• C3/C4 – mixed with sat LPG, and routed to the JERP Alky unit depropaniser
for separation into propane product, and C4.

• Light naphtha – blended into PC naphtha product.

• Heavy naphtha – feed to the HNHT 1/Platformer 1 in the DTA refinery.

• Kero – blended into jet product in the JERP.

• Gas oil – blended into Euro V diesel product in the JERP.

A note on Emission / effluent including hazardous waste management of lube oil

refinery complex

The lube oil refinery complex is essentially similar to the Jamnagar refinery complex and
the emissions from the lube oil refinery complex are due to the use of fuel in the furnaces. The
emission rates are given in Table 5.4 of the EIA Report and also given in Annexure III enclosed
to this document. . Refinery Fuel Gas and NG utilization is maximized to control the emission of
SO2 . Low NOx burners will be used for the control of NOx emissions.

The effluent / emission / hazardous waste management is similar to the practice

followed for Jamnagar refinery complex. The effluent generation rate is estimated to be 300
m3/hr. The quality will be similar to the effluent generation from the refinery complex (i.e. Easily
biodegradable) and will be treated in the common effluent treatment plant.

The following hazardous wastes would be generated:

1. Spent catalyst
2. Used lube oil

3.57
 3. Oily rags
4. Spent clay
5. Empty drums
The hazardous waste management is described in section 6.2.4.1 of the EIA report. The
specific disposal method for each category of waste is mentioned in Table 6.1 of the EIA report.

Air Emissions:
The SOx & NOx emissions from the process is 0.0008 and 0.036 TPH respectively.
Liquid waste:
The estimated wastewater generation is 300 M3/Hr. This will have a dedicated ETP
inside the plant Battery Limit.
Solid waste:
The solid waste generated from the process is Equivalent catalyst of 3300 tons
(once in 3 Years)

3.9 Captive Power Plant

The Integrated Captive Power Plant consists of
• Gas Turbo Generators
• Heat Recovery Steam Generators
• Steam Turbo Generators
• Auxiliary Boilers
The fuel for the CPP is supplied by both the refineries, Synthesis Gas from Coke Gasification
Plant and Imported Natural Gas. The auxiliary boilers are fueled by the Refinery Fuel Oil
(RFO). The CPP will be operated as an island grit basis and does not use any external fuel
other than the Natural Gas.
The process flow diagram is given in Fig.3.36
Gas turbines (14 Nos. each of 110 MW)
Gas turbines, consists of axial flow compressor, to compress air in to combustion
chambers. In combustion chambers, fuel (natural gas/ syngas) is added and the products of
combustion are allowed to expand through impulse turbine. The turbine rotor is coupled with
generator to produce electric power.
HRSG (14 Nos.)
Turbine exhaust is taken to a water boiler, through a duct where supplementary
generate steam and are exhausted to atmosphere through a boiler stack. Deareated
demineralised water is used in the HRSG. Duct firing facility is provided for additional fuel.

3.58
Auxiliary Boilers ( 8 Nos.)
Eight (8) Auxilary Boilers are provided for balancing out the steam generation
requirement.
Steam turbo generators. (25 Nos. each of 30MW or 7 Nos. each of 110 MW)
High-pressure steam is expanded through a turbine/ expander to reduce the pressure
and recover power. This expander is coupled with generator to produce electric power. These
turbines can float on the back pressure requirement of various levels of Steam required in the
other units of the SEZ. Steam requirement is provided by the HRSGs and Auxiliary boilers in
the CPP and also process steam generation in the units,
Air Emissions:
The SO2 & NOx emissions from the power plant are 0.678 and 2.59 TPH
respectively
Liquid waste
Only cooling water requirement which is recycled water
Solid waste:
No solid waste will be generated.

3.10 Desal Plant

The water requirement of the existing Refinery cum Petrochemical complex is met
from the Desalination Plant installed in the Complex.

Considering the water shortage in the region, the seawater intake is provided at the
maritime terminal area where water is pumped and treated. The desalination plant has been
designed using multiple effect Distillation process integrating it with energy sources. The
energy (heat) requirement for desalination is met by the low pressure steam from processing
units. Thus eliminates the venting condensing of low pressure and low temperature steam
from the process units, this is used as a steam sink for the optional steam balancing.

The desalination plant is designed with flexibility to operate on a low energy input to
produce sufficient water for units and domestic purpose. Overall 15 new desalination units of
capacity 1000 m3/hr each would be installed at proposed SEZ.

The desalination unit is based on the multi-effect distillation process. A series of

horizontal-tude, falling-film type evaporative condenser serve as heat recovery effects.
Through successive steps of evaporation and condensation at equilibrium vacuum conditions,
a multiple amount of distillate [product] is derived from seawater using a given quantity of low-

3.59
temperature steam input / sink. Steam at 3.5 kg/cm2 or a low low pressure steam
availablefrom process units, is the energy source of the MED desalination process.

The train of evaporative-condenser units is divided into three groups of effects, for piping
and feed pumping purposes. These groups are hereafter referred to as the “hot”, “intermediate”
and “cold” groups.

Group Effects
Cold 8 TO 11
Intermediate 4 TO 7
Hot 1 TO 3

The MED process is based on counter-current flow of water vapor against sea water
feed. The feed is first introduced into the cold group of effects. About 10-20% of the feed water
is evaporated in the effects. The non-evaporated feed, now slightly warmed and concentrated,
is introduced into the intermediate group of effects, and then, in the same way, to the hot group.
The input steam is available at pressure of 3.5 kg/cm2 abs, while that required by the
evaporator is about 0.33. The thermal efficiency of the process is considerably increased by
routing the input steam through a conventional jet ejector [thermocompressor], which recycles a
substantial portion of the vapor generated, and reintroduces it into the desalination process.

Sea Water Flow

The incoming seawater stream passes through one ion trap and two filters. Raw
seawater is fed into the falling film condenser and distributed over the heat transfer tubes. The
water is heated to 40oC by vapor condensing inside the tubes. Since the condenser operates at
vacuum, it de-aerates the seawater as well. This seawater stream now becomes feed to the
cold group. The feed is distributed evenly over the top rows of tubes of effects 8-11 by means of
spray nozzles. Flowing in thin films down over the banks of tubes, part of the feed flashes into
vapor as it absorbs the latent heat released by the condensing water vapor inside the tubes.
The remaining feed from the cold group of effects, now slightly concentrated, is collected
through piping and pumped to the intermediate group of effects. There it is similarly sprayed
over the heat transfer tubes, again flashing part of the feed into vapor. This pattern of flow is
repeated finally in the hot group of effects. The remaining feed [now brine] from the hot group is
collected from the 1st, 2nd and 3rd effects and cascaded through a series of eight brine flash
tanks. The brine is flash cooled and the heat of the flashed vapor is recovered in the

3.60
subsequent evaporator effect. From the last flash tank, the residual brine is returned to the sea
by the brine pumps.

Coolant Flow
Vapor from the last effect not being condensed in the main condenser will flow to the
forced circulation condenser to be condensed by coolant stream from a cooling tower.

Steam and vapor Flow

The motive steam is the energy source of the process. It is introduced into the plant
through the steam jet thermocompressor, which withdraws a portion of generated
vapor from effect 8. The combined mixture of motive steam and vapor flows into the tubes of
the 1st [hottest] effect. The vapor temperature is 2-3oC above that of the feed. Heat is always
transferred from the vapors (inside the tubes) to the feed (outside the tubes). Therefore, the
vapors condense inside the tubes, while the feed evaporates outside.
The vapor condensation inside the tubes generates an almost equal mass of vapor
outside the tubes. This vapor serves as the motive steam for generating additional vapor in the
next effect.
The evaporation-condensation process is repeated through to the last effect, each effect
contributing almost a full multiple of additional product. In flowing from each
effect to the next, the vapor first passes through a separator which removes entrained brine
droplets and maintains the required distillate purity. The vapor generated in the last effect flows
into the condensers, giving up its latent heat to the feed stream, which absorb it as sensible
heat.

Condensate
The condensate [distillate] condensed from the vapor in the 1st Effect, drains to the
condensate surge tank. The condensate is a sum of motive steam condensate and excess
condensate of vapors withdrawn by the thermocompressor. The quality of the condensate is
continuously monitored. In case condensate conductivity exceeds 7 ppm, the flow is diverted
out as contaminated condensate. 3 m3/hr of condensate is circulated to the vapor duct for
cooling the superheat of vapor at thermocompressor discharge to 70oC.

3.61
Process Flow
The product from effects 2 to 11 flows through a series of product flash chambers. Since
the vapor space of the product flash chambers is connected to a colder effect, part of the
distillate flashes off. The heat released as vapor joins the vapor generated in the former effect
while the remaining product stream is cooled. The growing product stream is thus cascaded
and flash cooled in stages. As with the brine stream, the heat thus given off and recovered
increases the efficiency of the process. The final stage of condensation occurs in the heat
rejection condensers, from which the distillate joins the cascading product stream. The product
pumps deliver the product to client product storage tank. The quality of the distillate is
continuously monitored. If the conductivity exceeds 7 ppm, the flow is diverted out as
contaminate product. The process flow is given in Fig 3.37

NCG Removal
Non-condensable gases [NCG], accumulated from the steam sea water are removed by
continuously bleeding out the evaporators to improve the efficient heat transfer and also
minimize the corrosive.. The NCG Effect no. 1 is vented to atmosphere by steam stripping. The
NSG from Effects 2 to 7, 9 to 11 are internally vented. NCG mixed with water vapor flow from
effect to effect through the water vapor flow. The concentrated NCG mixed with water vapour
vented directly into the main condenser.

3.11 JERP Refinery

This facility is under commissioning and has the requisite environmental approval
from MoEF in 2005. However this facility will become a part of the SEZ along with the other
C1 to C8 units. This refinery was implemented by Reliance Petroleum Limited (RPL) a group
company of Reliance which is under amalgamation with RIL.. The process description of JERP
refinery has been given below as a ready reference as both the refineries are integrated with
the C1 to C8 projects.

The refinery processing units include primary process units namely atmospheric and
vacuum distillation units and secondary process units like Fluid Catalytic Crackers (FCC),
Delayed Coking Units (DCU) etc. Presently, the refinery has the following processing units:

• Crude complex includes primary crude atmospheric and vacuum distillation

units (CDU and VDU)

3.62
 • Vacuum residue from the crude complex undergoes secondary conversion in a
Delayed Coker in the Coking Complex
• Fluid Catalytic Cracker (FCC) is the principal conversion unit for fuel and
petrochemical (Olefin) products
• Olefins present in the cracked products from the FCC are recovered in the
Olefins complex
• Hydrotreating complex includes hydroprocessing of various streams for superior
product yields and qualities with low sulphur. Hydrogen plant produces required
hydrogen for hydroprocessing
• Aromatics Complex includes Continuous Catalytic Regeneration (CCR)
Reformer and downstream extraction to make paraxylene, benzene and
orthoxylene.
• Amine Treatment Unit (ATU) complex includes individual amine absorber units
in CDU, FCC, Coker, Vacuum Gas Oil Hydro Treater (VGOHT), Diesel Hydro
Treater (DHT), Heavy Naphtha Hydro Treater (HNHT), Light Naphtha Heavy
Treater (LNHT) and Amine Regeneration Unit (ARU).
• Sour water stripping complex includes phenolic Sour Water Stripper (SWS) and
Non-phenolic SWS. Stripped gases are sent to Sulphur Recovery Units (SRUs)
in Sulphur Complex.
• Sulphur Recovery Complex produces elemental sulphur from H2S produced in
hydroprocessing units.

The petroleum products from the crude refinery, LOBS will be accommodated in the
existing Refinery and the Marine Tank Farm area.

Fuel oil and Fuel gas:

The fuel gas requirement for the JERP (under Implementation) is 196 TPH &
The fuel oil requirement for the JERP (under Implementation) is 84.29 TPH
Air Emissions:
The SO2 and NOx emissions from the JERP are 0.456 and 0.47 TPH respectively.
Liquid Waste:
Effluent – 1200 M3/ Hr. Dedicate ETP inside the Battery Limit
The estimated wastewater generation is 1200 M3/ Hr
Solid Waste:
The estimated solid waste generation from the process is Eq.Catalyst of 11200 T/Yr

3.63
(Averaged over 4 Yrs)

3.12 Product, Process and Utility Integration

Along with the existing modernized and expanded refinery and the proposed
petroleum and petrochemical complex will be under the EOU scheme, aimed to maximize the
value addition along the entire carbon chain of C1 through C8 and higher.

The various units within this complex will be homogeneous to the C1 to C8

hydrocarbon chain. All the units and product plants are integrated with each other to derive the
advantage of optimum utilization of various resources.
Jamnagar has the most suitable seafront in the Gulf of Kutch for raw material import
and finished products export. This complex is fully integrated with the existing refinery complex
as well as export oriented Refinery.

This Petrochemical Complex produces distinct petrochemical products by processing

and synthesizing from the various streams of the refinery complex. The manufacturing units of
these products consist of similar equipment and machinery which synergistically work to
produce these distinct products. In this particular configuration of the conglomerate, the raw
materials intermediate products, by-products, material and energy flows are integrated so as to:

• Maximize value of raw materials, sourced from the RIL & RPL refineries.
• Optimally utilize the various process streams derived from the refinery complex and
petrochemical units
• Conservation of the water resources through integrated recycle and reuse among the
various process units.
• Enhance competitive strengths, by minimizing the cost of production, with intimate
integration between the two refineries and the Jamnagar SEZ manufacturing complex.
• Exploit economies of scale for each of the products in the Jamnagar SEZ.
• Minimal transportation cost of raw materials.
• Minimize the requirement for infrastructural facilities.
• Optimization of effluent treatment facilities, hazardous waste handling & disposal
facilities, etc
• Strive to be the lowest cost producer for each of the products in the Jamnagar SEZ.

3.64
 • Develop of world-class infrastructure and logistics facilities to support the Jamnagar
SEZ to exploit the supply chain for each of the products in the Jamnagar SEZ.

These are synergistically integrated in three main areas. i.e

a. Process Integration of various process streams derived from the refinery complex
b. Energy integration of various producing units to optimize / minimize the energy
consumption in the various units.
c. Conservation of the water resources by recycle and reuse through various utilization
processes starting from the raw seawater.

By internalizing the resources and related environmental parameters the overall

synergistic integration is achieved. This in turn leads to optimum utilization of all the streams
into various value added products. This integration / synergy helps in leaving a smaller carbon
foot print and thus a lower impact on the environment The extent of integration achieved in the
area of process, energy and water are depicted in Fig 3.38,Fig 3.39 & Fig 3.40.

The environmental parameters at Jamnagar has been continuously studied and

assessed for the Reliance Group of Industries at Jamnagar since 1993. For the existing
Refinery a post project Environmental Impact Assessment (EIA) has been done and was also
assessed by the MoEF in 2003. Later Environmental Impact Assessment (EIA) & Risk
Assessment (RA) studies were conducted for the modernization and expansion of the refinery
complex and the MoEF has granted the Environmental Clearance for the same in 2005 . The
modernization and expansion of project is under commissioning now.

The results of these studies have been considered and internalized in the planning,
design, construction and operations and specific environmental related operational
characteristics like emissions, discharge and other relevant parameters. These cumulative
affects already get reflected in the latest environmental baseline studies for petroleum and
petrochemical complex at Jamnagar..

Accordingly the EIA reports were upgraded by incorporating the Terms of Reference
(TOR). Public Hearing was conducted in 2008 and the draft EIA was finalized by updating the

3.65
process related information, emissions and other relent parameters, Public hearing comments
and the final reports were submitted to MoEF.

This report further updated by incorporating the details as advised by the ministry

3.66
Fig. 3.1: Proposed C1 to C8 Units of SEZ

3.67
 O2 N2
P ow er

A ir
A SU
O2
S team S team

C lean
syn gas
SO U R
G A SIF IC A T IO N
BLOCK
Flux
Feed

S
FE E D
E F FL U E N T
P R E PA R A T IO N
H A N D L IN G
P etcoke
H 2O
S lag W aste w ater

Fig. 3.2 : Process Flow Diagram for IGCC Unit

3.68
3.69
Fig. 3.3 : Process Flow Diagrams for the Production of Methanol by the Copper Catalyzed Intermediate
Pressure Process
3.70
Fig. 3.4 : Process Flow Diagram for Acetic Acid
3.71
Fig. 3.5 : Process Flow diagram for Vinyl Acetate Monomer by the Vapor Process
3.72
Fig. 3.6 : Process Flow Diagram for Poly Vinyl Acetate
3.73
Fig. 3.7 : Process Flow Diagram For The Production Of Poly Vinyl Alcohol By Solution Polymerization
 Primary Distillation
Quench Section
SRT-VI Cracking
Furnace Section

and Quench
C om pressor S ection
C harge G as C hilling, H ydrogen
C harge G as
Heaters
D em ethanization and
C om pression, A cid G as
H ydrogen P urification
rem oval and D rying
F uel G as

F uel O il
A cid G ases D eC 2,
E thane feed to cracker C 2-R ec A cet-C ,
C 2 F rac E thylene
F C C /C oker
offgas C en t. (O 2)
R em o val
u n it C ondensate D eC 3,
P latform er C 3-R ec M A P D -C ,
offgas C 3 F rac
P ropylene

A cid G ases

D eC 4 /
C 4 H ydro
G asoline C 4 to R efinery

P ropane to P D H

Fig. 3.8 : Block Flow Diagram for Multifeed Cracker

3.74
 Feed Feed Depropanizer Reaction
SHP Section
Propane

CCR
Section

Product Fractionation Separation

Section SHP System
Propylene

H2 (By Product)

Fig. 3.9 : Propane Dehyfrogenation in Cracker Complex

3.75
Fig. 3.10 : Block Diagram for Mono Ethylene Glycol

3.76
3.77
Fig. 3.11 : Block Flow Diagram of PE (I & II) Process
Fig. 3.12 : Process Flow Diagram for Acrylic Acid Production Process

3.78
Fig. 3.13 : Process Flow Diagram for Production of SAP

3.79
Fig. 3.14 : Process Flow Diagram for 2-EthylHexanol

3.80
Fig. 3.15 : Process Flow Diagram for n-butyraldehyde

3.81
Fig. 3.16 : Process Flow Diagram for n-Butyl Acrylate

3.82
Fig. 3.17 : Process Flow Diagram for n-Butanol

3.83
 Benzene Cumene PIPB
Alkylator Transalkylator Column Steam CW Column Steam Column

He
at

Heat Heat Heat

Steam

Water PIPB
Recycle
Recycle
Benzene

Propylene Cumene Residue

Fig. 3.18 : Propylene Derivative – Cumene Process

Fig. 3.19 : Propylene Derivative – Phenol Process

3.84
Fig. 3.20 : The Anthraquinone Process for H2O2 Manufacture

3.85
Fig. 3.21 : Block Flow Diagram of Poly Propylene (PP)

3.86
3.87
Fig. 3.22 : Process Flow Diagram of ESBR
 Tail gas to fuel use Light Ends
HP
or incinerator with 4
Stream
steam generation

2 Pure maleic
5 anhydride

BFW 1

1 3
Crude maleic
N- anhydride to
Butane derivatives

Air
Heavy byproducts

Fig. 3.23 : Process Flow Diagram of Maleic Anhydride

3.88
3.89
Fig. 3.24 : Schematic of Mono Nitro Benzene Process
3.90
Fig. 3.25 : Process Flow Diagram for Aniline
Fig. 3.26 : Block Diagram For MDA Production Process

3.91
 Fig. 3.27 A : Process Flow Diagram : Phosgene Manufacture

Fig. 3.27 B: Process Flow Diagram for Scrubbing of Remaining Gases

3.92
3.93
A) Cold Phosgenator, B) Hot Phosgenator, C) Wash column, D) Solvent distillation,
E) Phosgene removal, F) HCl abosorber, G) Phosgene decomposition

Fig. 3.28 : Schematic of Polymeric Methylene Dianiline Phosgenation Process

 Recycle
Benzene
Polyethylene
Benzene

2 3 4
Benzene 1

Ethylene
9 10
Flux Oil

Ethyl Benzene

Fuel gas

inhibitor Styrene
Compressor Monomer
Steam
7 8

Steam
5 Tar

Superheater
Air/O2 DM
6

Contd.

Fig. 3.29 : Process Flow Diagram of Styrene

3.94
 Benzene
Column Tatoray
Benzene Sale

Isomar
Light Reformate
Toulene

Reformate Toulene Xylene

Reformate Splitter Column Splitter Parex PX
Column

CTA

Ortho Heavy C9 to Tatoray

OX Sale Xylene Aromatic
Column Column Heavy Aromatics Sale

Fig. 3.30 : Block Diagram for Aromatics

3.95
 Acetic Acid Solvent
Recovery

Air Oxidation Rotary

PX Reactor Crystallisation Vacuum CTA Dryer
Catalyst Filter

CTA

Pressure Purif Hydrogen

PTA Dryer & Atmospheric Crystallisation Reactor
PTA Centrifuge DM Water

Solvent
Recovery

Fig. 3.31 : Block Flow Diagram for Production of PTA

3.96
 PTA IPA
BGA
To Chip
To Glycol To Glycol
Process
Ejector Ejector
Column
Catalyst
Additives

To SSP
Unit

Paste Preparation Esterification PP Final Polymerizer

MEG

Polymer
Filter

Chipper

Fig. 3.32 : Bottle Grade PET: Continuous Polymerisation Section (CP)

3.97
 Chips from CP unit

Pre Crystallisation
Unit

Crystallisation Unit

SSP Reactor

Product Cooling

Product Storage Silo

Bagging
(Bottle Grade PET)

Fig. 3.33 : Block Diagram for production and Packing of Bottle Grade PET

3.98
 PTA MEG

ESTERIFICATION

CATALYST TIO2

DEG TITRATIO
N GLYCOL

CONTINUOUS
POLYMERISATION

SPINNING

LAG AREA

GODOWN/ WARE
HOUSE

Fig. 3.34 : Block Flow Diagram For POY / FDY / DTY Production

3.99
Fig. 3.35 : Block Diagram of the Carbon Black Manufacturing Process

3.100
Recovery Section
SRU
Multi Feed Cracker / PDH

3.102
Fig: 3.37 Process Flow Diagram of Desal Plant

3.103
 Steam Fuel gas
C1 Complex CPP

Syn Gas GT Power for Project

Sulphur Sulphur for External Sales
Light FO
Methanol for external sales HRSG
Petcoke
Coke Gasifier CO+H2+CH4 Methanol Methanol for MMA

Recovery Section
Boiler ST
Acetic acid for External Sales
Acetic Acid
Utility

SRU
Nitrogen Oxygen Fuel Gas C4 / C5
Complex

VAM for External Sales HMU

VAM Syn Gas
CO
Hydrogen Bromine /
ASU Unit
Butane Chlorine
Crude Oil PVA PVA for External Sales
(Sat.Gas) Extendor Oil
Oxygen C4 / C5 Complex
C5 + Sat.Gas
Hydrogen Regular Butyl , Bromo Butyl ,
PVOH Rubber Projects Chloro Butyl & Halo Butyl
PVOH for External Sales
Refinery Complex SBR for External Sales
Jamnagar CO to C6 & C7 Complex
C4, iso Propylene, Iso Butylene
n-butane C2 Complex
C4 / C 5 Raffinate
Butene 1 Fuel Gas
Multi Feed Cracker / PDH

Ethylene MEG / DEG /TEG MEG for external sales

Maleic Anhydride for
Maleic Anhydride
LLDPE for External sales External Sales
LDPE / LLDPE /
Gasoline HDPE LDPE for External sales
Fuel Oil
Styrene
Pyro Gases Toulene & C8 Aromatics
Fumaric Acid Fumaric Acid for External Sales
FCC Off Gases
Coker Gases
Propane Sat. Gas
Propylene Hydrogen
C6 / C7 / C8 Complex
C3 Complex
Benzene, MNB,
Methanol Aniline Aniline
Reformate Ethylene MDA,TDA
Propylene
SAP SAP for External Sales

Air
Acrylic Acid Acrylic Acid for External
Sales Benzene Styrene MDI MDI & HCL
PDH MDA & TDA
&
n- butanol Butanols PHOSGENE
2-ethyl Hexanol Butyl / 2- Ethyl Acrylates Xylene Fraction
Acrylates , for External Sales Xylene TDI TDI
Isomer Tatory
Propylene Oxide,
Propylene Oxide Cumene & Phenol for
Acetic Acid OX
and Cumene and External sales
PX & OX C9
Phenol
Extraction Aromatics
Propylene
PX Light Reformate
Propylene Glycols Propylene Glycols for
Fuel Gas
External Sales
PTA
PTA for external Sales
Polyols for External
Polyols Sales
PET PET for external Sales
SG / FO / FG / NG
H2
Naphtha, Kerosene
Gasoil & C3 & C4
H2 O2 Lube Oil Refinery Bitumen & JET
Complex LOBS
For External Sales Polyester Complex Polyster Yarnns for
Crude Oil CBFS
CBFS from FCC PSF,POY external Sales
Poly Propylene
(Woven & Non- Poly Propylene for
SG / FO / FG / NG
Woven) external sales Carbon Black Carbon Black For
External Sales

Fig 3.38 : Overall Integration of Petroleum and Petrochemical Complex

3.104
Natural Gas From External
Source IFG
NG C1 Complex CPP

SG GT Power

Petcoke HRSG
Coke Gasifier CO+H2 Methanol
CO
SRU / TGT Stack (2)

Recovery Section
Boiler ST
Acetic Acid Steam

SRU
H2 HMU
VAM
CO
syngas
ASU Unit
PVA C4 / C5 Complex

Refinery (1995)
PVOH Rubber Projects
Refinery (2005)

C2 Complex
Delayed Coker Butene 1
Styrene / EB
LCO cracker
MS Quality Upgrader
Multi Feed Cracker / PDH

Alkylation MEG / DEG /TEG

DHDS Maleic Anhydride
CDU / VDU
VDU LDPE / LLDPE / HDPE
Bitumen `
Mild Hydro Cracker
Kero HT Fumaric Acid
VGO HT NG
HNUU
Platformer Steam
Parex
Tatory
Hydrogen C3 Complex
SDA C6 / C7 / C8 Complex
PDH
Max Olefin FCC
Benzene, MNB,
SRU / TGT Aniline
MDA,TDA
Acrylic Acid SAP
CDU /VDU
VHO HT
n- butanol DHDS Lube Oil Refinery Styrene MDI
2-ethyl Hexanol Hydrogen Plant Complex
Acrylates , LCO hydrocracker
Lube Stock
Carbon Black
Xylene Fraction
Propylene Odxide Xylene TDI
and Cumene and Isomer Tatory
Phenol Carbon Black

PX & OX
Propylene Glycols Extraction

Polyols PTA

PET
H2 O2
Syn Gas
Fuel Oil
Poly Propylene Fuel Gas
(Woven & Non- Polyster Complex
Natural Gas
Woven)
Steam

Fuel Oil

Fig 3.39 : Overall Energy Integration of Petroleum and Petrochemical Complex

3.105
 Losses

Coke Gasification
Fire Water
C1 Complex Domestic Township
Make-UP
Seawater Desal Plant Boilers & Heaters
C2 Complex

C3 Complex

C4-C5 Complex

C6-C8 Complex
Refinery -2005
STP STP
Lube Oil Refinery Complex
CBFS

Process water

Cooling water
Horticulture and Greenbelt
Development

Domestic / Township

ETP of
ETP of Petroleum and
STP of Cooling Tower System
Refinery 1995 Petrochemical
Refinery 1995
Complex

Note:
1. Dotted lines denote overall heat integration of units
2. Water requirement for drip irrigation is included in the losses
3. Water produced during operations / reactions / from raw
materials is excluded in the above values.

Horticulture and Discharge to Sea

Green Belt
Development Horticulture and
Green Belt

Fig 3.40 : Overall Water Balance of Petroleum and Petrochemical Complex

3.106
 Table 3.1
Proposed Storage tanks – SEZ

Sr. No. Product

Capacity In m3
1 Crude 90683
2 VR feed to coker 51009
3 Sour VGO to VGO Unionfiners 64307
4 Sweet VGO (FCC feed) 90683
5 HNUU feed to NHT 51009
6 DHDS feed (straight run) 68389
7 DHDS feed (LCGO) 68389
8 KHT feed 51009
9 Heavy CN Unionfiner feed 47493
10 Scanfiner feed 68389
11 LSWR 64307
12 PC Naphtha 20347
13 Diesel E IV 68389
14 Diesel Euro I / LHO 68389
15 Gasoline E IV/US RFG 36173
16 Gasoline US RFG/ NIOC 7948
17 Aromatics (Benzene) 4808
18 Aromatics (o-Xyl/P-Xyl) 4808
19 PTU feed / LCNO 9813
20 PTU feed / LCO Diesel 9813
21 Kerosene to diesel blending 7948
22 Alkylate (product) 20347
23 Reformate 14130
24 Scanfiner product 14130
25 Lt Naphtha from LCO 2649
26 Hvy Hvy Naphtha from LCO 7948
27 Meroxed Pentane 7948
28 Light Reformate 7948
29 Cetane Improver 1227
30 ED Raffinate 7948
31 Straight run slop 4808
32 Cracked slop 14130
33 Heavy slops 9813
34 CBFS 4808
35 Flushing Oil 9813

3.107
Sr. No. Product
Capacity In m3
36 Crude 132885
37 Alkylate 47493
38 Gasoline 68389
39 PC Naphtha 68389
40 JET/ATF 36173
41 Diesel 68389
42 O-xylene 20347
43 LSWR 51009
44 Methanol 4808
45 Styrene 31793
46 MEG 31793
47 DEG 31793
48 Refinery Fuel Oil tank 9813
49 CPP Diesel Distillate 4710
50 CPP CSO Fuel Oil 2649
51 Sludge Tank 2722
52 Fresh Acid Tank 6782
53 Swing Acid Tank 6782
54 Spent Acid Tank 6782
55 Amine Make-up Tank 172
56 Amine Storage Tank 622
57 Liquid Sulpher Tank 10613
58 n-Butanol 1050
59 Acrylic Acid 2000
60 Glacial Acrylic Acid 450
61 Hydrogen peroxide 300
62 n-Butyraldehyde 2000
63 Iso-Butyraldehyde 600
64 Glycol Diacetate 200
65 Vinyl Acetate (5 tanks) 11000 (Each)
66 Liquid Acetic Acid (5 tanks) 11500 (Each)
67 Vinyl Acetate Monomer (2 Tanks) 2000 (Each)
68 2 Ethyl Hexanol 900
69 Propylene (Sphere) 1200
70 Toluene 5000
71 Propylene Oxide 11200
72 n Butyl Acrylate 8000
73 Butanol 4500

3.108
 Table 3.2

Proposed Solid Storage Tanks – SEZ

Solid Storage Quantity

Coke Storage Silos 80,000 Tons

Flux Storage Silos 2500 Tons

Table 3.3

Proposed Storage Tanks for the Liquid Products

Sr. No Product Vol in KL (Each)

1 Caustic 50% (CS5) 997

2 Caustic 20% (CS2) 90

3 MEG 10202

4 DEG 1050

5 TEG 626

6 CBFS 1495

3.109
 Table 3.4

Proposed Storage Tanks for Safe Stock

Sr. No Storage tank Safe Stock in MT

1 Propylene(Cry) 11500

2 PX 22000

3 CBFS 3010

4 Benzene 8250

5 Toulene 1300

6 Ethylene(Cry) 11500

3.110
Chapter 4
Baseline Environmental Status
The existing environmental setting is considered to adjudge the baseline environmental
conditions, which are described with respect to climate, physiography, geology, hydro-geological
aspects, atmospheric conditions, water quality, soil quality, vegetation pattern, ecology, socio-
economic profile, land use and places of archaeological importance. This Report incorporates
the baseline data collected during October 2005 to January 2006 (representing winter season)
and secondary data collected from various Government and Semi-Government agencies.
As per Indian statutory regulations, CPCB provided the guidelines for the baseline
environmental status monitoring for air, noise, water, land (land use / land cover), biological, and
socio-economic guidelines to be followed.
Sr. Environmental Parameters CPCB Guidelines on monitoring of
No Env. Parameters
(Distance in km) from centre of SEZ
1 Ambient air quality 7-10
2 Noise 10
3 Water Quality 25
4 Land Environment 25
5 Biological Environment 25
6 Socio-Economic Environment 25
Ref: EIA Manual, Ministry of Environment and Forest.

The methodology to study the baseline status of various environmental components is

highlighted in Table 4.1.1.

4.1
4.1 Air Environment

The knowledge of quality of ambient air plays an important role in assessing the
environmental scenario of the locality. The ambient air quality status in the vicinity of the project
site forms an indispensable part of the Environment Impact Assessment studies. The quality of
ambient air depends upon the concentrations of specific contaminants, the emission sources
and meteorological conditions. Data collected during winter season of 2005-06 has been
analysed and presented herewith.

The baseline studies on air environment include identification of specific air pollutants
and assessing their existing levels in ambient air within the impact zone. The existing status of
air environment with respect to the identified air pollutants is assessed through air quality
surveillance programme with scientifically designed ambient air quality monitoring network.

Micrometeorological data collection is an indispensable part of any air pollution study.

The meteorological data collected during air quality survey is used for proper interpretation of
existing air pollution status. The ambient air quality monitoring was carried out through
reconnaissance followed by air quality surveillance programme and micrometeorological study.

Baseline Ambient air environment was done for the season 2005-06 winter and latter
collected for the 2007-08 winter as per MoEF Commitee advice. The sampling locations and
values are given in appropriate tables.

4.1.1 Design of Network for Ambient Air Quality Monitoring Locations

The ambient air quality status in the impact zone is assessed through a network of
ambient air quality monitoring locations. The studies on air environment include identification of
specific air pollutants for assessing the impacts of existing project operations. Accordingly, air
quality monitoring was carried out in winter season of 2005-06. The existing status of air
environment is assessed through a systematic air quality surveillance program, which is
planned based on the following criteria:

• Topography/terrain of the study area

• Regional synoptic scale climatological normal
• Densely populated areas within the region
• Location of surrounding industries
• Representation of valid cross-sectional distribution in downwind direction of refinery

4.1.2 Reconnaissance

Reconnaissance was undertaken to establish the existing status of air environment in

the study region. Ambient Air Quality Monitoring (AAQM) locations were selected based on

4.2
guidelines of network siting criteria based on meteorological data of winter season. Similarly,
AAQM locations of earlier studies were also considered for locating the AAQM locations. The
ambient air quality monitoring was carried out in a study area of 10 km radial distance around
the proposed SEZ. The relative directions and distances of these locations with respect to the
project site are given in Fig. 4.1.1 and details of these locations are described in Table 4.1.2.

4.1.3 Ambient Air Quality Monitoring

AAQM locations were monitored on 24 hourly average basis as per the guidelines of
CPCB and NAAQS. AAQM was carried out at 24 locations (though AAQM is required at 4
locations as per CPCB guidelines) to determine a finer cross-sectional distribution of air
pollution in an industrial developed region. The conventional and project specific parameters
such as Suspended Particulate Matter (SPM), Respirable Particulate Matter (RPM), Sulphur
Dioxide (SO2), Oxides of Nitrogen (NOx), Ammonia (NH3), Carbon Monoxide (CO) and Non-
Methane Hydrocarbons (NMHC) were monitored at AAQM Locations. Samples of CO and
NMHC were collected in the study area and analyzed in the laboratory (HC mentioned
elsewhere in the report means NMHC).

4.1.4 Instruments used for Analysis

A temporary laboratory was setup at project site for chemical analysis of representative
air samples. The micro-meteorological data on wind speed, wind direction, temperature and
relative humidity were collected using weather monitoring station and cloud cover was recorded
manually during the study period. The make and model of the instruments used for analysis of
the samples collected during the field monitoring are given in Table 4.1.3. The techniques used
for ambient air quality monitoring and their minimum detectable level are given in Table 4.1.4.

The concentrations of various pollutants at all the AAQM locations were processed for
different statistical parameters like arithmetic mean, standard deviation, minimum concentration,
maximum concentration and percentile values.

The existing baseline levels in winter season with respect to SPM, RPM, SO2, NOx and
NH3 expressed in terms of various statistical parameters are presented in Tables 4.1.5 to
4.1.11. The spot concentrations of CO and NMHC are presented in Table 4.1.12.

The 98th percentile concentrations have been compared with stipulated standards of
CPCB (as per the National Ambient Air Quality Standards Notification, April 11, 1994 in
Annexure I) and presented in Table 4.1.13.

4.3
4.1.5 Micrometeorology

The study of micro-meteorological conditions of a particular region is of utmost

importance in knowing the ambient air quality status of that particular region. The prevailing
micrometeorology at project site plays a crucial role in transport and dispersion of air pollutants
released into the atmosphere. The persistence of the predominant wind direction and wind
speed during a particular time period at the project site will decide the direction and extent of
the worst impact zone at that time. The principal variables which affect micrometeorology are
horizontal convective transport (average wind speed and directions), vertical connective
transport (atmospheric stability) and topography of the area.

Climatological Tables of Observatories in India (1951-1980), published by the India

Meteorological Department, were used to obtain historical data for the region. Jamnagar is the
nearest meteorological observatory to the project site established in the year 1899 at
Aerodrome. Temperature varied in the range of 0.7oC (January 28, 1973) – 45.6oC (May 21,
1903). Annual rainfall varied in the range of 78.2 (1911) – 1121.5 mm (1953) with normal annual
rainfall of 578.9 mm. The annual average of rainy days (rainfall above 0.254 cm in a day) is 24.
The annual average wind speed is predominantly observed between 1 and 19 km/h. Seasonal
variation in predominant wind direction is observed at Jamnagar. Winds from N-E sector were
predominant in the winter season.

The months of November, December and January are considered to be representative

of winter season. It is referred that minimum and maximum daily temperature varied in the
range of 10oC – 12oC and 25oC - 27oC respectively. Monthly mean relative humidity was in the
range of 36% -72%. The predominant wind direction is from N-E sector. The wind speed
remains in the range of 1-19 Km/h for most of the days and cloudless sky is observed for
80-85% of the duration during winter season.

The primary data recorded has been processed further to draw wind rose. The wind
rose drawn on 24 hourly basis is presented in Fig. 4.1.2.

The overall 24 hourly windrose during winter season indicates the predominant winds
from N-E sector. During the period of study, calm conditions were observed for only 2.5% of the
time. The predominant wind directions observed during the study period with low and medium
wind speeds (1-15 kmph) were from N-E sector. The wind speed was observed to be
predominantly in the range of 11-15 kmph.

4.1.5.1 Mixing Height/Inversion Study

4.4
 The atmospheric mixing height at project site is one of the most important
micrometeorological parameter, which have direct influence on dilution of air pollutants in the
project region. Mixing height is the thickness of atmospheric layer in which vertical mixing is
vigorous. The vertical extent of mixing is primarily regulated by ambient air temperature at
ground level, atmospheric stability/turbulence and wind speed. The mixing height varies
diurnally, from season to season and it is also affected by topographical features in the impact
zone. The mixing height is generally minimum at late night (before sunrise) and increases
during the daytime reaching maximum in the afternoon hours. The maximum mixing height also
will have seasonal variability with highest values during summer and the lowest values in winter.
The mixing height at a given time of the day can be estimated from the ground level ambient
temperature together with vertical profile of temperature.

In the present study, a minisonde system (Model 3003 of Aero-Aqua Inc., Canada) has
been used for on site measurements of mixing height at plant site including diurnal variations.
The minisonde flight package consists of balloon filled with hydrogen, a battery operated
temperature sensor and signal transmitter assembly. The minisonde is used for measurement of
vertical temperature profiles up to 4 km height in the atmosphere to be carried by a balloon filled
with hydrogen. Temperature is measured continuously and transmitted at 400-405 MHz
frequency range to a receiving station at ground level. The model 3003 consist an electronic
modulator to process non-linearised frequency output from the receiver into linearised signal.
The modulator produces actual temperature profile in engineering units which is fed into
personal computer through the RS232 port to obtain real time ambient temperature and
potential temperature profiles.

The mixing height study using minisonde was carried out during winter season. The
flight packages were released at the intervals of 3 hours round the clock on each sampling day.
The ascent rate of flight package has been fixed at 3m/sec (180 m/min) with necessary
hydrogen fill. The vertical temperature profiles were continuously recorded till the flight package
reaches the altitude of about 3900 m above ground level. These records were used to
determine mixing heights representative in the project area. During the study period the
maximum mixing height was observed about 1100 m in the afternoon hours including local
influences of residential & commercial activities. However during night time the ground based
inversion (radiation inversion) was observed upto 160 m above ground level.

4.1.6 Existing Ambient Air Quality Status

4.5
 The range of 98th percentile concentrations during winter season reflects the levels of
the existing status of ambient air quality. The baseline ambient air quality status is given in
Tables 4.1.5 - 4.1.11.

During winter season, 98th percentile values of 24 hourly SPM concentration ranged
between 99.9-396 μg/m3. The arithmetic mean varied between 87-256 μg/m3 in winter season
(Table 4.1.5 and Table 4.1.7). Similarly, 98th percentile and arithmetic mean of 24 hourly RPM
concentrations varied in the range of 60.8-175 μg/m3 and 6-114 μg/m3 respectively (Table 4.1.5
and Table 4.1.8).

In general, comparatively high levels of SPM and RPM are observed in the study area
due to dry and arid land cover and scanty rainfall. The traffic on dusty roads, agriculture and
construction activities, burning of wood as fuel, etc. also contribute to SPM. The present status
of SPM indicates that Jamnagar region has very high levels of SPM.

The 98th percentile concentrations of 24 hourly SO2 in winter season varied from
6-31 μg/m3. The arithmetic mean ranges from 4.5-22 μg/m3 in winter season
(Table 4.1.5 and Table 4.1.9).

The 98th percentile concentrations of 24 hourly NOx in winter ranged between

10-30 μg/m3. The arithmetic mean values varied between 6-20.33 μg/m3 in winter season
(Table 4.1.6 and Table 4.1.10). It is observed that SO2 and NOx concentrations are well below
the stipulated standards of CPCB for residential/rural region.

The arithmetic mean and 98th percentile values of NH3 were observed in the range of
10-192 μg/m3 and 31-274 μg/m3 (Tables 4.1.6 and 4.1.11). It is also observed that
concentrations of NH3 are also below the stipulated standards of CPCB.

Concentrations of carbon monoxide (CO) and non-methane hydrocarbons (NMHC)

were measured in winter season. The results of the measurements (Table 4.1.12) indicated that
CO and NMHC concentrations at all the monitoring locations are observed to be varying in the
range of 263-1139 μg/m3 and BDL – 138 μg/m3. Concentrations of CO are well below the
stipulated standards of CPCB for residential/rural region.

For the 2007- 08 winter season the SPM, SO2 & NoX values are given Below,.
SPM:
The Ambient Air Quality Monitoring was carried out by NEERI during winter season (2008)
wherein SPM concentration were observed at the border line / more than the average for the
area at 15 places out of 24 locations. It may be observed that ;

4.6
 1) Jamnagar SEZ located in a semi arid area with low green cover and very scanty rainfall
in the years which are the main contributing factors for getting more values of Ground
Level Concentration of SPM. The very low green cover (only 15%) can be seen from
Landuse/land cover pattern satellite image given in EIA Report (Refer EIA Report Page
no. 4.60).

2) The main contributing factor for the variation in the SPM values can be co-related with
rainfall occurred during that period. The rainfall in 2007-08 season spread is confined to
only 3 days. If the rain is spread over the season then moisture content in the soil
remains for longer period which is helpful to minimize the dust resuspension and
subsequently results in lower SPM value.

3) More SPM values are observed at Moti Khavadi, Arablus, Mungani, Satalus can be
attributed because of the higher vehicular traffic, poor road conditions, dirt tracks, cattle
movements etc. in the area.
SO2
The average SO2 concentration was observed to be marginally more than 30 µg/m3 at
three locations. However, These SO2 concentration are much less than the standards of
National Ambient Air Quality Standards (NNAQS) for industrial / residential area.
Cl2
Generally the chloride in the ambient air is found out in the form of sodium chloride in
the aerosol type condition typically near the sea coast due to the wind action. However, it
will be quite difficult to measure by using the standard high volume sampling method. This
is also has been checked in the literature.

As suggested by the honorable members of the committee “the Cl2 concentrations in

the above mentioned range very rarely occur in typical urban pollution.
HCl
As in the case of CL2 the results are very erroneous.

Sources of HCL and CL2

There is no source of HCl and Cl2 emission from refinery, Jamnagar except for
chlorination used in the cooling water treatment. Other source for the emission of chlorides
is the sea

4.7
4.1.7 Ambient Air Quality Concentrations vis-à-vis Stipulated Standards

The comparison of observed levels of air pollutants in winter season with the standards
stipulated by CPCB for the residential/rural region was carried out and presented in Table
4.1.13. It was observed that the concentrations of SO2, NOx, NH3 and CO are well within the
stipulated standards at all the ambient air quality monitoring locations whereas SPM and RPM
concentrations exceeded the stipulated standards at most of the ambient air quality monitoring
locations.

The SPM concentrations at all the AAQM locations were primarily caused by local
phenomena including vehicular activities and natural dust getting air borne due to man made
activities and blowing wind.

At all the air quality monitoring locations, the 98th percentile values of SO2 and NOx
were observed to be within the ambient air quality standards promulgated by CPCB for
residential/rural region. The concentrations of NH3 were observed to be below the standards
stipulated by CPCB, i.e. 400 μg/m3.

The concentrations of CO are observed to be below stipulated standard of CPCB for

residential area i.e. 2000 μg/m3. There is no standard available yet for NMHC in India, however,
the concentrations were observed to be comparable with other industrialized locations in India.

It may be pertinent to note that the set-up of the petroleum and petrochemical SEZ in
the area would categorize the entire area as ‘industrial’. This is because the SEZ has been
notified by the Ministry of Industry and Commerce, Government of India, as a petroleum and
petrochemical sector specific SEZ. The effect of the emissions from the SEZ on the baseline
will have to be compare to the Industrial Standards for ambient environment.

4.8
 Gulf of Kachchh

12
13 18 Jamnagar
3 10 5 21

4 23 2
9 10 km 22

15 Sas 25 km
SH-6 7 oi
14
11 19
16 6
17
24 SH-27
1

Khambalia
20
8

Lalpur

Fig. 4.1.1 : Sampling Location for Ambient Air Quality Monitoring

4.9
 N

Fig. 4.1.2: Windrose diagram during Winter Season

4.10
 Table 4.1.1
Environmental Attributes & Frequency of Monitoring
Sr. Attribute Parameters No. of Frequency of
No sampling Monitoring/Data collection
locations
1 Ambient air SPM, RPM, SO2, NOx, 24 hourly samples everyday
24
quality NH3, CO & HC atleast at 8 locations

2 Meteorology Wind speed and Data collected during the

direction, temperature, study period on hourly basis.
relative humidity and
Historical data also collected
rainfall. 1 from Airport, Jamnagar for
Mixing Height corroborating the data and
planning the monitoring
network.

3 Surface water Physical, chemical and Once during the study period.
quality bacteriological 3
parameters.

4 Groundwater Physical, chemical and Once during the study period.

quality bacteriological 18
parameters.

5 Ecology Existing flora and fauna. Study area Through field visit during the
of 25 kms study period and substantiated
around SEZ through secondary sources.

6 Noise levels Noise levels in dBA Hourly observation once

during the season in industrial,
29
commercial, residential and
silence zones.

7 Soil Physical, chemical and Sub surface composite

characteristics biological parameters to samples collected once during
9
assess agricultural and the study period.
afforestation potential.

8 Land use / Land use for different Study area Land use / Land Cover
Land Cover land use classifications. of 25 kms Analysis using satellite
around SEZ imaging and GIS Technique

9 Socio- Socio-economic Study area Based on field surveys and

economic characteristics, labour of 25 kms data collected from secondary
Environment force characteristics, around SEZ sources
population statistics
existing amenities in the
study area and quality of
life.

4.11
 Table 4.1.2

Details of Ambient Air Quality Monitoring Locations

Sr. No Sampling Location

1. Arablus
2. Gaduka
3. Gagva
4. Jogvad
5. Kana Chhikari
6. Kanalus
7. Khatiya
8. Macchuberaja
9. Meghpar
10. Motikhavdi
11. Mota Lakhiya
12. Mungani
13. Nani khavdi
14. Nani lakhiya
15. Padana
16. Rangpar
17. Rasangpar
18. Sapar
19. Satalus
20. Sevak Bharudiya
21. Jivapar
22. Balambhadi
23. Dera Chhikari
24. Meghavadar

4.12
 Table 4.1.3

Instruments Used For Analysis

Sr. No. Instrument Name Make Parameters

1 Spectrophotometer HACH SO2, NOx, NH3, H2S

2 Electronic Balance Metler SPM, RPM

3 Gas GC-3, VARIAN CO, HC

Chromatograph
with FID & ECD

4.13
 Table 4.1.4

Techniques Used for Ambient Air Quality Monitoring

Sr. Parameter Technique Technical Minimum

No. Protocol Detectable Limit
(μg/m3)

1 Suspended Respirable Dust IS-5182 3.0

Particulate Sampler (Gravimetric
& CPCB
Matter method)

2 Respirable Respirable Dust IS-5182 3.0

Particulate Sampler (Gravimetric
& CPCB
Matter method)

3 Sulphur dioxide Modified West and IS-5182 3.0

Gaeke
& CPCB

4 Nitrogen Oxide Jacob & Hochheiser IS-5182 3.0

& CPCB

5 Ammonia Nessler Reagent IS-5182 3.0

6 Hydrogen IS-5182 3.0

Sulphide

7 Carbon Gas Chromatography 125

Monoxide

8 Hydrocarbons Gas Chromatography 71

4.14
 Table 4.1.5

Ambient Air Quality Status

(Winter Season)

Unit : μg/m3 Avg. : 24 hours

Sr. Sampling SO2 SPM RPM
No Location Avg SD Avg SD Avg SD

5.33 202.7 108.8

1. Arablus 0.82 30.4 10.5
(4-6) (168-258) (94-120)
8 185 83
2. Gaduka 5 55 29
(4-18) (101-267) (43-147)
22 224 96
3. Gagva 5 64 22
(13-31) (121-359) (65-136)
21 242 99
4. Jogvad 5 99 40
(10-30) (149-348) (58-183)
6 204 99
5. Kana Chhikari 2 56 25
(3-10) (136-297) (64-144)
5.7 118.2 98
6. Kanalus 1.03 21.2 12.9
(4-7) (84-141) (58-143)
22 232 114
7. Khatiya 5 79 45
(13-29) (146-324) (77-178)
9.5 107 5.02 97.3
8. Macchuberaja 2.7 6.2
(6-13) (66-170) (88-105)
17 256 114
9. Meghpar 5 91 26
(11-26) (123-396) (63-158)
15 194 92
10. Motikhavdi 4 58 18
(10-23) (117-252) (56-131)

7 185 91
11. Mota Lakhiya 3 42 18
(3-15) (128-241) (68-119)
16 238 99
12. Mungani 4 60 23
(10-28) (123-345) (60-155)
15 206 96
13. Nani khavdi 4 55 19
(10-24) (113-339) (61-136)
7 217 74
14. Nani lakhiya 5 58 22
(3-19) (108-279) (37-106)
6 127 96
15. Padana 2 30 34
(0-6) (85-161) (60-160)
11 208 98
16. Rangpar 3 65 32
(6-15) (107-298) (56-141)
18 249 83
17. Rasangpar 7 94 26
(10-32) (100-332) (55-138)

4.15
Sr. Sampling SO2 SPM RPM
No Location Avg SD Avg SD Avg SD

10 201 72
18. Sapar 6 67 24
(3-25) (104-298) (40-114)
8.83 138.9 78.3
19. Satalus 2.23 20.2 13.23
(6-12) (108-164) (60-99)
20. Sevak 6.83 0.98 87 51.5
14.14 8.41
Bharudiya (6-8) (66-100) (38-61)
21. 4.50 1.38 108.5 17.80 61.7 10.76
Jivapar
(3-6) (83-126) (50-76)
22. 5.17 1.47 95.67 8.62 63.67 17.13
Balambhadi
(3-7) (85-108) (51-97)
23. 5 1.26 106.67 13.25 67.00 11.98
Dera Chhikari
(3-6) (91-125) (55-86)
24. 8.00 3.29 148.83 59.52 85.33 29.55
Meghavadar
(5-14) (69-238) (41-119)

4.16
 Table 4.1.6

Ambient Air Quality Status

(Winter Season)

Unit : μg/m3 Avg. : 24 hours

Sr. Sampling NOx NH3

No Location Avg SD Avg SD

11.5 16.83
1. Arablus 5 7.31
(8-15) (10-31)
8 18
2. Gaduka 4 12
(3-17) (5-48)
18 36
3. Gagva 6 20
(10-32) (10-90)
15 38
4. Jogvad 6 45
(6-29) (10-169)
13 192
5. Kana Chhikari 5 48
(4-19) (121-281)
20.33 25.83
6. Kanalus 4.03 15.42
(15-26) (15-56)
8 21
7. Khatiya 3 13
(3-13) (8-50)
16.67 14.17
8. Macchuberaja 4.37 2.32
(12-23) (11-18)
16 21
9. Meghpar 4 24
(9-24) (3-83)

16 25
10. Motikhavdi 5 12
(11-30) (10-48)
6 36
11. Mota Lakhiya 3 19
(3-13) (4-76)
18 44
12. Mungani 5 31
(11-30) (10-109)
17 28
13. Nani khavdi 5 34
(10-30) (11-142)
8 20
14. Nani lakhiya 5 14
(4-20) (3-54)
7 25
15. Padana 3 14
(3-11) (5-43)

6 10
16. Rangpar 2 16
(3-11) (3-35)

4.17
Sr. Sampling NOx NH3
No Location Avg SD Avg SD

10 24
17. Rasangpar 7 14
(3-31) (9-51)
16 39
18. Sapar 8 21
(3-31) (10-78)
12.33 19.33
19. Satalus 4.13 6.89
(7-18) (15-33)
17.83 3.19 13.17
20. Sevak 3.66
(13-21) (9-18)
Bharudiya
10.83 3.19 10.83
21. Jivapar 3.19
(8-15) (7-15)
17.50 1.87 17.33
22. Balambhadi 6.56
(15-20) (10-28)
11.67 2.34 14.17
23. Dera Chhikari (9-16) 2.79
(10-18)
16.50 1.87 29.67
24. Meghavadar 22.21
(14-19) (13-61)

4.18
 Table 4.1.7

Cumulative Percentile of SPM (Winter Season)

Unit : μg/m3 24 hourly average

Percentiles of SPM
Sr. Sampling
No Location 25% 50% 75% 98%

1. Arablus 188.5 199.5 204.5 252.8

2. Gaduka 134 187 220 266
3. Gagva 175 207 274 344
4. Jogvad 189 213 247 336
5. Kana Chhikari 159 198 237 294
6. Kanalus 109.75 119 134.25 140.8
7. Khatiya 180 228 279 320
8. Macchuberaja 93.75 99.5 100 104.5
9. Meghpar 194 245 329 396
10. Motikhavdi 176 192 224 248
11. Mota Lakhiya 152 188 223 239
12. Mungani 209 233 285 330
13. Nani khavdi 168 203 229 325
14. Nani lakhiya 216 234 235 274
15. Padana 198 204 230 236
16. Rangpar 169 198 259 295
17. Rasangpar 202 234 297 330
18. Sapar 148 178 276 296
19. Satalus 128.25 141 148.5 164.4
Sevak 78.25 90 98.75
20. 99.9
Bharudiya
21. Jivapar 95.5 115 121 125.6
22. Balambhadi 89 97 99.75 107.2
23. Dera Chhikari 96.75 106.5 114.75 124
24. Meghavadar 117.25 141.5 180.75 233.3

4.19
 Table 4.1.8

Cumulative Percentile of RPM (Winter Season)

Unit : μg/m3 24 hourly average

Sr. Percentiles of RPM
Sampling Location
No 25% 50% 75% 98%

1. Arablus 102.3 109.5 117.5 120

2. Gaduka 61 74 108 135
3. Gagva 76. 96 113 132
4. Jogvad 78 92 104 175
5. Kana Chhikari 79 97 116 140
6. Kanalus 65.8 71.5 80.3 84.8
7. Khatiya 88 100 125 174
8. Macchuberaja 54.3 56.5 58 62.5
9. Meghpar 106 115 123 156
10. Motikhavdi 85 94 100 123
11. Mota Lakhiya 77 91 102 119
12. Mungani 85 94 113 149
13. Nani khavdi 85 93 109 130
14. Nani lakhiya 73 74 80 104
15. Padana 92 109 116 119
16. Rangpar 73 101 121 139
17. Rasangpar 62 69 96 109
18. Sapar 54 72 94 134
19. Satalus 71.5 79.5 82.3 97.4
20. Sevak Bharudiya 48.3 51.5 57.8 60.8
21. Jivapar 55.75 66 72.5 75.7
22. Balambhadi 53.25 58.5 63.75 93.8
23. Dera Chhikari 58.25 64 73.5 84.9
24. Meghavadar 70.25 85 108.75 118.6

4.20
 Table 4.1.9

Cumulative Percentile of SO2 (Winter Season)

Unit : μg/m3 24 hourly average

Percentiles of Sox
Sr.
Sampling Location
No 25% 50% 75% 98%

1. Arablus 5 5.5 6 6
2. Gaduka 4 5 13 17
3. Gagva 17 21 27 30
4. Jogvad 19 22 24 30
5. Kana Chhikari 4 5 7 10
6. Kanalus 5.25 6 6 6.9
7. Khatiya 20 21 23 29
8. Macchuberaja 8 9 11.5 12.9
9. Meghpar 13 15 18 25
10. Motikhavdi 13 14 17 22
11. Mota Lakhiya 5 6 8 14
12. Mungani 14 16 18 26
13. Nani khavdi 12 16 18 23
14. Nani lakhiya 4 6 9 18
15. Padana 13 15 16 19
16. Rangpar 9 13 14 15
17. Rasangpar 13 15 24 31
18. Sapar 5 9 12 24
19. Satalus 7.25 9 10 11.8
20. Sevak Bharudiya 6 6.5 7.75 8
21. Jivapar 3.25 4.5 5.75 6
22. Balambhadi 4.25 5.5 6 6.9
23. Dera Chhikari 4.25 5.5 6 6
24. Meghavadar 6 7 8.75 13.5

Table 4.1.10

4.21
 Cumulative Percentile of NOx (Winter Season)

Unit : μg/m3 24 hourly average

Percentiles of NOx
Sr.
Sampling Location
No 25% 50% 75% 98%

1. Arablus 8.5 11.5 14.5 15

2. Gaduka 5 8 10 15
3. Gagva 14 17 21 30
4. Jogvad 11 14 17 27
5. Kana Chhikari 10 13 15 19
6. Kanalus 18 20 22.75 25.7
7. Khatiya 7 7 10 13
8. Macchuberaja 13.25 16 19.5 22.7
9. Meghpar 13 14 18 24
10. Motikhavdi 12 14 18 27
11. Mota Lakhiya 4 5 8 13
12. Mungani 14 17 22 29
13. Nani khavdi 14 15 19 28
14. Nani lakhiya 4 5 8 19
15. Padana 19 21 24 25
16. Rangpar 5 6 7 10
17. Rasangpar 5 7.5 11 27
18. Sapar 9 18 22 30
19. Satalus 9.25 13.5 14 17.6
20. Sevak Bharudiya 15.75 19 20 20.9
21. Jivapar 8 10.5 13 14.8
22. Balambhadi 16.25 17.5 18.75 19.9
23. Dera Chhikari 11 11 11.75 15.6
24. Meghavadar 15.25 16.5 17.75 18.9

4.22
 Table 4.1.11

Cumulative Percentile of NH3 (Winter Season)

Unit : μg/m3 24 hourly average

Percentiles of NH3
Sr.
Sampling Location
No 25% 50% 75% 98%

1. Arablus 14 14.5 16.5 31

2. Gaduka 9 16 21 43
3. Gagva 20 33 46 88
4. Jogvad 18 21 25 155
5. Kana Chhikari 159 188 217 274
6. Kanalus 18 19 26 56
7. Khatiya 13 15 24 47
8. Macchuberaja 13.25 14 14.75 17.7
9. Meghpar 6 10 21 81
10. Motikhavdi 17 19 32 47
11. Mota Lakhiya 24 39 51 69
12. Mungani 17 30 73 107
13. Nani khavdi 54 74 111 140
14. Nani lakhiya 20 28 33 52
15. Padana 18 24 26 34
16. Rangpar 6 15 22 34
17. Rasangpar 14 21 30 50
18. Sapar 15 43 56 71
19. Satalus 15.25 17 18.75 31.6
20. Sevak Bharudiya 10.5 12.5 16 17.9
21. Jivapar 8.25 12 12 14.7
22. Balambhadi 12.75 16.5 20.25 27.3
23. Dera Chhikari 13 14 15.75 17.8
24. Meghavadar 14 17.5 46.5 60.4

4.23
 Table 4.1.12

Concentrations of Non-methane Hydrocarbons and Carbon Monoxide

(Winter Season)

Spot Sample Unit: μg/m3

NMHC
Sr. No Sampling Location CO Concentrations
Concentrations
1. Arablus 699 105
2. Gaduka 263 BDL
3. Gagva 721 121
4. Jogvad 641 79
5. Kana Chhikari 298 83
6. Kanalus 773 116
7. Khatiya 469 80
8. Macchuberaja 486 73
9. Meghpar 1139 137
10. Motikhavdi 912 136
11. Mota Lakhiya 295 BDL
12. Mungani 568 106
13. Nani khavdi 835 102
14. Nani lakhiya 848 138
15. Padana 358 71
16. Rangpar 633 93
17. Rasangpar 581 84
18. Sapar 642 77
19. Satalus 752 113
20. Sevak Bharudiya 551 56
21. Jivapar 496 74
22. Balambhadi 468 75
23. Dera Chhikari 302 BDL
24. Meghavadar 482 72

4.24
 Table 4.1.13

Comparison of Ambient Air Quality Levels with Stipulated Standards

Unit : μg/m3 24 Hourly Average

Pollutants Winter Season Stipulated Standard Stipulated Standard of
(98th Percentile) of CPCB for CPCB for Industrial
Residential Area Area

SPM 99.9-396 200 500

RPM 60.8-175 80 150

SO2 6-31 80 120

NOx 10-30 80 120

NH3 31-274 400 Not Applicable

NMHC BDL-138 Not Available Not Available

CO* 263-1139 2000 5000

* 8 hours average

4.25
As suggested by MoEF the ambient air quality data collected and for the winter season of
2007-08 is given below
Ambient Air Quality Analysis (Winter 2007- 08)

Gulf of Kachchh

12
13 18 Jamnagar
3 10 5 21

4 23 2
9 10 km 22

15 Sas 25 km
SH-6 7 oi
14
11 19
16 6
17
24 SH-27
1

Khambalia
20
8

Lalpur

Sampling Location for Ambient Air Quality Monitoring (2007-08) Winter

4.26
 Environmental Attributes & Frequency of Monitoring

Sr. Attribute Parameters No. of Frequency of

No sampling Monitoring/Data collection
locations
1 Ambient air SPM, RPM, SO2, NOx, 24 hourly samples everyday
24
quality NH3, CO & HC atleast at 8 locations

2 Meteorology Wind speed and Data collected during the

direction, temperature, study period on hourly basis.
relative humidity and
Historical data also collected
rainfall. 1 from Airport, Jamnagar for
Mixing Height corroborating the data and
planning the monitoring
network.

4.27
 Details of Ambient Air Quality Monitoring Locations

Sr. Sampling Direction Distance (Km) Height above

No. Location w. r. RIL From RIL ground Level (m)

1. Arablus SEE 5.63 4.0

2. Gaduka NE 6.88 4.0
3. Gagva NW 5.63 3.5
4. Jogvad W 5.31 3.5
5. Kana Chikari NE 5.94 3.5
6. Kanalus SE 3.44 4.5
7. Khatiya S 5.94 4.5
8. Macchuberaja SSE 8.44 4.0
9. Meghpar SW 4.38 4.5
10. Moti Khavadi N 4.06 5.5
11. Mota Lakhiya SSW 6.25 4.0
12. Mungani NW 6.25 4.0
13. Nani Kavadi NNW 5.94 5.5
14. Nana Lakhiya SSW 7.19 4.5
15. Padana SSW 3.13 5.5
16. Rangpar SSW 6.25 5.0
17. Rasangpar SWW 5.94 5.0
18. Sapar NE 6.25 4.5
19. Satalus SE 4.06 4.5
20. Sevak S 9.38 4.0
Bharudiya
21. Jivapar NE 9.38 5.0
22. Balambhadi E 6.56 4.5
23. Dera Chikari NE 5.31 4.0
24. Meghavadar SE 8.75 5.0

4.28
 Instruments Used For Analysis

Sr. No. Instrument Name Make Parameters

1 Spectrophotometer HACH SO2, NOx, NH3, H2S

2 Electronic Balance Metler SPM, RPM

3 Gas GC-3, VARIAN CO, HC

Chromatograph
with FID & ECD

4.29
 Techniques Used for Ambient Air Quality Monitoring

Sr. Parameter Technique Technical Minimum

No. Protocol Detectable Limit
(μg/m3)

1 Suspended Respirable Dust IS-5182 3.0

Particulate Sampler (Gravimetric
& CPCB
Matter method)

2 Respirable Respirable Dust IS-5182 3.0

Particulate Sampler (Gravimetric
& CPCB
Matter method)

3 Sulphur dioxide Modified West and IS-5182 3.0

Gaeke
& CPCB

4 Nitrogen Oxide Jacob & Hochheiser IS-5182 3.0

& CPCB

5 Ammonia Nessler Reagent IS-5182 3.0

6 Hydrogen IS-5182 3.0

Sulphide

7 Carbon Gas Chromatography 125

Monoxide

8 Hydrocarbons Gas Chromatography 71

4.30
 Ambient Air Quality Status
(Winter Season 2007 - 2008)
Units: μg/m3

Sr. Sampling Location Avg.: 24 Hrs.

No.
SPM RSPM SO2 NOx HCl Cl2
Avg. + SD
1. Arablus 495 ± 90 114 ± 26 17 ± 4 19 ± 6 65 ± 25 13 ± 3

(99 - 589) 65 -178 (12 - 25) (9 - 30) (23 - 99) (10 - 22)
2. Gaduka 117 ± 12 73 ± 23 8 ± 2 11 ± 4 54 ± 20 24 ± 4
(93 - 139) 41 -1 25 (4 - 12) (5 - 18) (23 - 99) (20 - 32)
3. Gagva 125 ± 18 67± 8 5±1 7±2 43 ± 12 4±2

(99 - 155) (53 - 81) (3 - 8) (4 -12) (28 - 64) (2 - 8)

4. Jogvad 242 ± 46 97 ± 14 18 ± 5 15 ± 3 59 ± 19 2±1
(74 - 318) (76 - 125) (10 - 28) (10 - 21) (25 - 97) (1 - 4)

5. Kana Chikari 259 ± 53 103± 18 9±5 31 ± 14 72 ± 14 10 ± 3

(122 - 361) (62 - 137) (3 - 18) (6 - 66) (48 - 97) (5 - 15)
6. Kanalus 427 ± 114 141± 26 36 ± 16 14 ± 5 75 ± 10 24 ± 6
(97- 563) (90 -169) (14 - 65) (8 - 29) (59 - 63) (8 -32)
7. Khatiya 189 ± 59 57 ± 18 19 ± 6 12 ± 4 63 ± 17 6±2
(151 - 266) (90 ± 111) (11 - 31) (6 - 20) (44 - 97) (3 - 9)
8. Macchuberaja 368 ± 142 121± 30 42 ± 19 23 ± 8 49 ± 15 5±2
(153 - 593) 70 - 166 (8 - 78) (9 - 36) (24 - 73) (2 - 8)
9. Meghpar 259 ±104 112 ±34 18 ± 3 15 ± 4 40 ± 14 4±2
(94 - 432) (45 -149) (14 - 22) (9 - 22) (20 -64) (2 - 8)
10. Moti Khavadi 542 ± 37 156 ± 13 14 ± 1 15 ± 5 65 ± 16 6±3
(311 - 590) (140 - 176) (12 - 16) (8 - 23) (32 - 83) (1 - 12)
11. Mota Lakhiya 181 ± 51 88 ± 17 17 ± 3 12 ± 3 70 ± 15 22 ± 6
(81 - 270) 62 -120 (12 - 21) (7 - 17) (35 - 89) (12 - 30)
12. Mungani 386 ± 53 136 ± 18 5±1 17 ± 5 51 ± 22 7±2
(117 - 488) (110 -175) (3 - 8) (9 - 25) (18 - 99) (3 - 12)
13. Nani Kavadi 150 ± 16 97 ± 19 4±1 17 ± 7 73 ± 20 10 ± 3
(108 - 165) (67 - 127) (3 - 7) (10 - 34) (38 - 99) (7-14)
14. Nana Lakhiya 212 ± 80 92 ± 26 16 ± 3 13 ± 4 55 ± 16 15 ± 4
(112 - 377) 44 - 148 (10 - 21) (7 - 21) (24 - 85) (10 - 24)
15. Padana 207 ± 79 96 ± 27 10 ± 1 12 ± 3 64 ± 23 22 ± 3

4.31
Sr. Sampling Location Avg.: 24 Hrs.
No.
SPM RSPM SO2 NOx HCl Cl2
Avg. + SD
(108 - 413) (59 -145) (8 -12) (7-17) (27- 99) (18 - 28)
16. Rangpar 164 ± 59 74 ± 18) 12 ± 4 12 ± 3 41 ± 7 7±2
(108 - 259) 51 - 124 (5 -18) (8 -16) (26 - 55) (3 - 9)
17. Rasangpar 186 ± 74 90 ± 25 7±4 10 ± 5 58 ± 12 3±2
(237 - 364) (64 -146) (3 - 16) (5 - 21) (38 - 86) (1 - 8)

18. Sapar 226 ± 97 88±32 4 ±1 17 ± 10 64 ± 12 13 ± 4

(122 - 406) (45 -142) (3 -6) (7 - 50) (45 -88) (4 - 20)
19. Satalus 338 ± 126 121± 30 32 ± 13 14 ± 3 60 ± 13 20 ± 3
(225 - 590) (77 -157) (15 - 59) (7 - 22) (43 - 92) (15 - 28)
20. Sevak Bharudiya 166 ± 68 112 ± 34 13 ± 3 15 ± 3 51 ± 19 3±1
(86 - 354) (45 -149) (9 -18) (9 -23) (25 - 88) (1 - 6)
21. Jivapar 163 ± 71 79 ± 22 9±3 17 ± 4 52 ± 11 6±3

(60 - 342) (36 -119) (4 - 14) (11 - 27) (35 - 84) (2 -12)
22. Balambhadi 286 ± 57 107 ± 19 11 ± 4 11 ± 6 66 ± 20 31 ± 18
(120 - 382) 74 -139 (3 - 17) (4 - 23) (35 - 99) (2 - 58)
23. Dera Chikari 273 ± 96 104 ± 28 6±2 12 ± 4 75 ± 13 11 ± 5
(155 - 432) (49 - 138) (3 - 10) (7 - 22) (54 - 98) (3 - 19)
24. Meghavadar 163 ± 51 81 ± 17 10 ± 3 13 ± 3 58 ± 7 6±2
(60 - 250) (57 ± 111) (5 -14) (9 -18) (46 -75) (3 - 8)

4.32
 Cumulative Percentile of SPM
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Min Percentile Max

No. Location th th th th
25 50 75 98
1. Arablus 322 289 330 378 453 471
2. Gaduka 186 113 118 122 139 139
3. Gagva 184 110 126 137 154 155
4. Jogvad 74 232 238 264 313 318
5. Kana Chikari 122 221 268 292 348 361
6. Kanalus 97 372 417 520 562 563
7. Khatiya 151 128 194 244 265 266
8. Macchuberaja 153 276 304 479 589 593
9. Meghpar 94 199 269 332 422 432
10. Moti Khavadi 311 510 536 561 590 590
11. Mota Lakhiya 81 150 158 209 270 270
12. Mungani 117 341 383 405 486 488
13. Nani Kavadi 99 486 519 553 587 589
14. Nana Lakhiya 112 170 235 254 351 377
15. Padana 108 142 207 238 379 413
16. Rangpar 108 129 139 185 260 269
17. Rasangpar 237 129 146 231 345 364
18. Sapar 490 150 181 313 392 406
19. Satalus 225 252 290 434 566 590
20. Sevak 86 133 148 171 338 354
Bharudiya
21. Jivapar 93 102 159 193 319 342
22. Balambdi 120 246 267 338 375 382
23. Dera Chikari 155 228 270 338 423 432
24. Meghavadar 60 116 169 202 243 250

4.33
 Cumulative Percentile of RSPM
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Min Percentile Max

No. Location
25th 50th 75th 98th
1. Arablus 65 100 109 122 167 178
2. Gaduka 41 65 69 75 125 125
3. Gagva 53 62 68 70 80 81
4. Jogvad 76 90 94 102 123 125
5. Kana Chikari 62 93 105 112 132 137
6. Kanalus 90 123 149 159 168 169
7. Khatiya 57 71 92 101 111 111
8. Macchuberaja 70 97 114 153 165 166
9. Meghpar 45 89 122 138 148 149
10. Moti Khavadi 140 148 149 169 175 176
11. Mota Lakhiya 62 75 88 99 117 120
12. Mungani 110 126 136 143 174 175
13. Nani Kavadi 108 147 157 160 164 165
14. Nana Lakhiya 44 79 98 111 138 148
15. Padana 59 71 95 119 141 145
16. Rangpar 51 63 69 85 114 124
17. Rasangpar 64 72 75 107 141 146
18. Sapar 45 66 84 109 141 142
19. Satalus 77 99 120 151 156 157
20. Sevak 45 71 76 86 137 144
Bharudiya
21. Jivapar 36 64 79 91 117 110
22. Balambhadi 74 98 104 118 138 139
23. Dera Chikari 49 91 110 126 137 138
24. Meghavadar 57 65 86 93 107 111

4.34
 Cumulative Percentile of SO2
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Min Percentile Max

No. Location
25th 50th 75th 98th
1. Arablus 12 15 17 20 24 25
2. Gaduka 4 6 8 10 12 12
3. Gagva 3 4 5 6 8 8
4. Jogvad 11 14 16 22 27 28
5. Kana Chikari 3 6 8 11 18 18
6. Kanalus 14 20 35 46 64 65
7. Khatiya 3 15 18 22 30 31
8. Macchuberaja 8 31 43 53 77 78
9. Meghpar 14 16 17 20 22 22
10. Moti Khavadi 12 13 14 14 16 16
11. Mota Lakhiya 12 15 17 20 21 21
12. Mungani 3 4 5 5 8 8
13. Nani Kavadi 3 3 4 5 7 7
14. Nana Lakhiya 10 14 16 19 21 21
15. Padana 8 9 10 11 12 12
16. Rangpar 5 9 11 15 18 18
17. Rasangpar 3 4 5 6 16 16
18. Sapar 3 3 4 5 6 6
19. Satalus 15 22 27 44 57 59
20. Sevak 9 12 13 15 17 18
Bharudiya
21. Jivapar 4 8 9 10 14 14
22. Balambhadi 3 9 12 14 17 17
23. Dera Chikari 3 5 7 7 10 10
24. Meghavadar 5 8 9 12 14 14

4.35
 Cumulative Percentile of NOx
(Winter Season 2007 - 2008)
Units:μg/m³

Sr. Sampling Min Percentile Max

No. Location
25th 50th 75th 98th
1. Arablus 9 16 18 20 30 30
2. Gaduka 5 8 9 14 18 18
3. Gagva 4 5 7 8 11 12
4. Jogvad 10 13 16 18 21 21
5. Kana Chikari 6 24 32 36 59 66
6. Kanalus 8 10 14 17 26 29
7. Khatiya 6 9 12 14 19 20
8. Macchuberaja 9 17 21 28 36 36
9. Meghpar 9 13 15 16 21 22
10. Moti Khavadi 8 12 13 20 22 23
11. Mota Lakhiya 7 10 13 14 17 17
12. Mungani 9 15 17 20 25 25
13. Nani Kavadi 10 12 15 18 33 34
14. Nana Lakhiya 7 11 13 14 21 21
15. Padana 7 10 12 14 17 17
16. Rangpar 8 11 12 14 16 16
17. Rasangpar 5 7 8 10 20 21
18. Sapar 7 12 17 18 42 50
19. Satalus 7 12 14 16 21 22
20. Sevak 9 13 16 17 22 23
Bharudiya
21. Jivapar 11 16 16 19 26 27
22. Balambhadi 4 7 8 13 22 23
23. Dera Chikari 7 10 12 13 21 22
24. Meghaavadar 9 11 13 15 18 18

4.36
 Cumulative Percentile of HCl
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Min Percentile Max

No. Location
25th 50th 75th 98th
1. Arablus 23 51 67 80 99 99
2. Gaduka 23 42 50 59 98 99
3. Gagva 28 35 43 52 63 64
4. Jogvad 25 45 56 65 92 97
5. Kana Chikari 48 63 71 81 96 97
6. Kanalus 59 68 74 84 91 93
7. Khatiya 44 50 59 70 97 97
8. Macchuberaja 24 43 46 57 73 73
9. Meghpar 20 28 37 53 62 64
10. Moti Khavadi 32 60 70 75 83 83
11. Mota Lakhiya 35 67 71 78 89 89
12. Mungani 18 35 52 60 95 99
13. Nani Kavadi 38 57 71 91 99 99
14. Nana Lakhiya 24 47 55 63 85 85
15. Padana 27 46 62 86 98 99
16. Rangpar 26 36 41 44 54 55
17. Rasangpar 38 51 56 61 85 86
18. Sapar 45 55 64 74 86 88
19. Satalus 43 55 58 65 89 92
20. Sevak 25 36 53 66 82 88
Bharudiya
21. Jivapar 35 46 50 55 79 84
22. Balambhadi 35 54 57 90 99 99
23. Dera Chikari 54 67 72 86 98 98
24. Meghavadar 46 53 56 64 72 75

4.37
 Cumulative Percentile of Cl2
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Min Percentile Max

No. Location
25th 50th 75th 98th
1. Arablus 10 11 12 14 21 22
2. Gaduka 20 21 25 26 32 32
3. Gagva 7 3 4 5 8 8
4. Jogvad 1 1 2 3 4 4
5. Kana Chikari 5 8 11 13 15 15
6. Kanalus 8 23 25 27 32 32
7. Khatiya 3 5 7 8 9 9
8. Macchuberaja 2 4 5 6 8 8
9. Meghpar 2 3 4 5 7 8
10. Moti Khavadi 1 4 5 7 12 12
11. Mota Lakhiya 12 17 25 26 30 30
12. Mungani 3 5 7 8 12 12
13. Nani Kavadi 11 8 11 12 14 14
14. Nana Lakhiya 10 12 15 18 23 24
15. Padana 18 20 22 24 28 28
16. Rangpar 3 6 7 8 9 9
17. Rasangpar 1 2 2 3 7 8
18. Sapar 4 12 13 15 20 20
19. Satalus 15 18 19 22 27 28
20. Sevak 1 2 2 3 6 6
Bharudiya
21. Jivapar 2 4 6 7 11 12
22. Balambhadi 2 18 27 47 57 58
23. Dera Chikari 3 7 10 16 19 19
24. Meghavadar 3 5 6 7 8 8

4.38
 Concentrations of CO, Non-Methane Hydrocarbons and VOC
(Winter Season 2007 - 2008)
Units: μg/m³

Sr. Sampling Spot Sampling

No. Location
CO NMHC 1-3 Benzene Toluene Ethyl m/p
Butadine Benzene xylene
1. Arablus 655 111 0 0.1 0.2 0.1 0
2. Gaduka 300 78 0.2 0.1 0.3 0.1 0
3. Gagva 750 140 0.1 0.1 0.3 0.1 0
4. Jogvad 669 80 0 0.1 0.4 0.1 0.05
5. Kana Chikari 302 85 0.2 0.2 0.5 0.1 0
6. Kanalus 721 111 0.1 0.1 0.4 0.1 0.05
7. Khatiya 501 89 0.05 0.2 0.4 0.05 0
8. Macchuberaja 499 81 0.1 0.1 0.3 0.1 0
9. Meghpar 999 122 0.2 0.1 0.3 0.1 0
10. Moti Khavadi 950 142 0.1 0.2 0.5 0.15 0.05
11. Mota Lakhiya 302 79 0 0.1 0.6 0.1 0
12. Mungani 612 115 0.2 0.2 0.4 0.1 0
13. Nani Kavadi 806 109 0.2 0.2 0.5 0.15 0.05
14. Nana Lakhiya 822 128 0 0.1 0.4 0.1 0
15. Padana 408 78 0 0.1 0.35 0.1 0
16. Rangpar 621 90 0.1 0.1 0.4 0.1 0
17. Rasangpar 558 82 0 0.1 0.4 0.1 0
18. Sapar 633 72 0 0.1 0.3 0.1 0
19. Satalus 722 118 0.1 0.1 0.3 0.1 0
20. Sevak 559 82 0 0.1 0.45 0.1 0
Bharudiya
21. Jivapar 500 79 0.1 0.1 0.3 0.1 0
22. Balambhadi 453 81 0 0.1 0.4 0.1 0
23. Dera Chikari 278 BDL 0.1 0.1 0.3 0.1 0
24. Meghavadar 502 83 0.1 0.1 0.2 0.1 0

4.39
 A note on ground level concentration for SPM, SO2, HCL and CL2 was high at
some of the monitoring locations

The 2008 winter ambient air monitoring data indicates that GLC values of SO2 were littlie
more than the average for the area at a few locations but they were well below the National
Ambient Air Quality Standards. However, the SPM concentrations were found to be marginally
more than the average at some of the locations.

The predicted average incremental ground level concentrations is in the order of 18

μg/m³ & 22 μg/m³ for SO2 and NOx respectively with a standard deviation of 7 μg/m³and
maximum predicted incremental value being 32 μg/m³ and 41 μg/m³ respectively in the SSW
direction. All these values indicate GLC are well below the NAAQS.

Co_rrelation between varying SO2 emission rates from the Individual source and
Stack Height

It is confirmed and clarified that all the stack height meets the statutory requirements prescribed
by the MoEF / CPCB.

We very respectfully submit that, even though generally the SO2 emission and stack height are
correlated to minimize ground SOx concentrations, the stack heights are determined by the
pressure drop / draft requirements, furnace configuration, thermal efficiency and mechanical
considerations. Some heaters have intrinsically higher stack height for the above reasons
unrelated to fuel sulphur and SO2 emissions, as highlighted below:

1) The CDU / VDU heater stack height is 72 m in spite of low SO2 emission. The CDU /
VDU heaters, have high heater duty, with two radiation chambers, with a common
convection section, above. Minimum stack height has to be maintained above the
convection section for safety and draft requirement reasons. The stack height is
dependent on the heater duty and convection section height and not the SO2
emissions.

2) In case of the Parex unit heater also the stack height is governed by the size and
height of the heater, instead of SO2 emissions.

In case of HRSG and boilers the stack height is at 80 meters, though HRSG has lower SO2
emissions than Aux. Boilers. In this case the draft requirements govern the stack height
requirement instead of SO2 emission.

4.40
4.2 Noise Environment

Monitoring of noise levels in and around the project area was carried out to assess the
impact of noise generated due to refinery operations and vehicular traffic on human settlements.
Studies pertaining to noise environment were conducted as follows:
• Reconnaissance

• Measurement of noise levels

• Identification and characterization of noise sources

• Impact of noise exposure on community

4.2.1 Reconnaissance

The proposed SEZ is located near the village Kanalus. A fertilizer plant of Gujarat
State Fertilizer Corporation (GSFC) is situated in front of the existing Reliance refinery. GSFC
township is approximately at a distance of 3 km from the GSFC plant. The residential colony of
Reliance Industries Limited is located adjacent to GSFC colony.

The State Highway from Jamnagar to Dwarka has higher vehicular density during the
daytime. Approximately 500 vehicles per hour ply on the road during the day and 50-60 vehicles
per hour during night. The nearest railway station for goods train is Motikhavadi, which is on the
periphery of the existing RIL complex and in the vicinity of the SEZ proposed area.

Jamnagar Airbase is situated about 22 km from the SEZ site. The Indian Airforce
aircrafts, which are mainly of supersonic category, fly three hours in the morning and two hours
in the afternoon or evening during their routine exercise in this region.

4.2.2 Background Noise

Noise standards have been designated for different types of landuse, i.e. residential,
commercial, industrial areas and silence zones, as per ‘The Noise Pollution (Regulation and
Control) Rules, 2000, Notified by Ministry of Environment and Forests, New Delhi, February 14,
2000’. The ambient noise standards are presented in
Annexure III. Different standards have been stipulated during daytime (6 am to 10 pm) and
nighttime (10 pm to 6 am).

The residential, commercial, industrial areas and silence zones close to the proposed
SEZ and in the study area have been identified. These locations have been chosen away from
the major roads and major noise sources so as to measure ambient noise levels. Equivalent
noise levels (Leq) for a period of about 20 minutes have been measured at each monitoring
location during day time and night time.

4.41
 The background noise levels were measured using Dawe - Lucas Cell Sound Level
Meter. The sampling locations are shown in Fig. 4.2.1 and noise levels during day time and
night time are presented in Table 4.2.1.

All measurements were carried out when the ambient conditions were unlikely to
adversely affect the results as wind speeds were 1-3 m/sec and precipitation was not recorded.

4.2.2.1 Noise Levels in Residential and Commercial Areas

The noise levels in the villages have been monitored within study area of 10 km radial
distance from proposed SEZ. Noise monitoring locations are shown in Fig. 4.2.1. The noise
levels ranged between 43-51.5 dBA during daytime and 33-49 dBA during nighttime.

There is no major commercial activity and market in the study area. The noise levels
in commercial areas varied in the range of 53-60 dBA during daytime and 30-40 dBA during
nighttime.

4.2.2.2 Noise Levels in Industrial Areas

There are other major industrial units viz., Reliance Industries Limited, Refinery,
fertilizer plant of Gujarat State Fertilizer Corporation (GSFC), power plant of Gujarat Electricity
Board and cement plant of Digvijay Cement Company Limited.

Noise levels were measured in front of these industries during daytime and nighttime
and observed to varying in the range of 46-59 dBA during daytime and
42-51 dBA during nighttime.

4.2.2.3 Noise Levels in Silence Zone

Noise levels were also monitored in schools, hospitals and temples in the study area.
The noise levels varied from 37-45 dBA during daytime and 31-39 dBA during night time.

The noise levels are observed to be within the stipulated standards of CPCB for the
respective zones in the study area.

4.42
4.2.3 Traffic Study

The existing refinery has facilities comprising of loading bays for LPG, light & heavy
liquid products, sulphur and coke. Approximately 1000 trucks per day are loaded. The present
rail gantry has provision to load one LPG rake and two white oil rakes simultaneously. Around 2
MMTPA of products are dispatched through this facility. The utilization of this facility is low due
to the availability of rakes.

Traffic Count was made in front of Refinery Gate to account for traffic on SH-25 as well
as vehicular movement due to refinery. Traffic survey was undertaken in December, 2005.
Traffic survey undertaken indicated hourly traffic of 389 – 561 vehicles during daytime (0600 -
2200 Hrs). The heavy vehicles like trucks and buses form about
20-25% of total traffic count. Traffic count includes tankers transporting products from the
adjacent Reliance refinery complex.

4.43
 Gulf of Kachchh

20

14
15 7 Jamnagar
13 16 1

12 5 2
8 10 km

10 Sas 25 km
SH-6 17 oi
18
19
11 3
SA-27
6

Khambalia
4
9

Lalpur

Fig. 4.2.1 : Sampling Location for Noise Monitoring

4.44
 Table 4.2.1

Background Noise Levels in the Study Area

Sr. Monitoring Locations Noise Levels in dBA Remarks

No.
Day Time Night Time
(Leq) (Leq)
Residential/Commercial Area
1 Jivapar 50.8 42 Residential area
2 Balambhdi 51.4 41.6 Residential area
3 Kanalus 50.2 42 Residential area
4 Sevak bharudiya 44.0 39 Residential area
5 Dera Chikari 51.5 41.8 Residential area
6 Arablus 51.0 43.2 Residential area
7 Sapar 50.2 38 Residential area
8 Meghpar 49.1 48 Residential area
9 Machhu beraja 49.3 42.2 Residential area
10 Padana 46.8 41 Residential area
11 Rangpar 48.2 44.2 Residential area
12 Jogvad 50.2 41 Residential area
13 Gagva 53 30 Commercial area
14 Mungani 49.9 40 Residential area
15 Nani khavdi 48.7 41 Residential area
16 Motikhavdi 60 40 Commercial area
17 Khatiya berja 49 40 Residential area
18 Nana Lakhiya 43 33 Residential area
19 Mota Lakhiya 46 36 Residential area
Industrial Area
20 Sikka 57 50 In front of GEB
Power Plant –
Industrial Area
21 RIL Jetty 46 42 Industrial Area
22 Digvijay Cement Plant Gate 59 51 Industrial Area
23 GSFC Gate 52 44 Industrial Area with
no traffic from GSFC

4.45
Sr. Monitoring Locations Noise Levels in dBA Remarks
No.
Day Time Night Time
(Leq) (Leq)

Silence Zone
24. Community medical center, 45 38 150 m away from
Motikhawadi main road
25. Ashapura temple 40 39
26. School, Khatia 38 32
27. School, Gagva 37 31
28. School, Vasai 44 39 25 m away from SH-
25
29. School, Navagam 41 34 25 m away from SH-
25

4.46
4.3 Water Environment
4.3.1 Reconnaissance

The project is located in Saurashtra region of Gujarat which is known for drought and
water scarcity. The annual rainfall in the Jamnagar region is 578.9 mm with 24 rainy days
(rainfall above 0.254 cm in day) in the year. May and June are generally the hottest months with
a mean maximum temperature of about 360C. January is the coldest month with a mean
maximum temperature of about 260C. The relative humidity is high throughout the year
exceeding 70% on an average.

4.3.2 Baseline Data

Physico-chemical parameters alongwith biological indicators of pollution have been

used for ascertaining the status of water environment around proposed SEZ. In order to
determine the surface and groundwater quality, three sampling locations for surface water, 18
sampling locations for groundwater were identified in the study area. The water quality data
collected in winter season 2005-06 were used to establish baseline status of water environment
around the SEZ. The sampling locations for surface and ground water around the proposed
SEZ are depicted in Figure 4.3.1 and presented in Table 4.3.1.

4.3.2.1 Surface Water Resources

Jamnagar district of Gujarat is divided into two watershed regions by the Madhya
Saurashtra plateau. The general slope of these watersheds is towards the Gulf of Kuchchh and
the Arabian Sea. Rivers like Sasoi, Und, Sinhan, Bhagedi, Puna etc. flow towards north
discharging into the Gulf of Kuchchh, whereas the river Vartu with its tributaries flow to
southwest and ultimately meets the Arabian Sea. Dams have been constructed on these rivers
to provide the irrigation water in the region. A small percentage of the reservoir water is used for
drinking water supply to the nearby towns and villages. Water demand in most of the villages of
the region is met from dug wells, hand pumps etc. and partly by river water.

There are three surface water sources in the form of reservoirs in the vicinity of the
proposed project site. However, water demand of units in SEZ would be met from the new
desalination plant coming up in SEZ and no external water resources will be used for this
project . The Narmada Water Supply Project is in the pipeline and could be an added source to
the SEZ water demand, if required.

There is no perennial river in the study area. The surface water samples have been
collected from Kanalus, Gajana and Apia reservoirs located in the study area.

4.47
4.3.2.2 Methodology for Water Quality Assessment

Reconnaissance was undertaken and monitoring locations were decided based on:
• Drainage pattern;

• Location of residential areas representing different activities/likely impact areas and,

• Likely areas, which can represent baseline conditions.

The water samples were analyzed as per the procedures specified in 'Standard
Methods for the Examination of Water and Wastewater' published by American Public Health
Association (APHA) and ‘A Course Manual for Water and Wastewater Analysis’ by NEERI,
Nagpur.

Samples for chemical analysis were collected in polyethylene carboys. Samples

collected for metal content were acidified with HNO3 acid (conc. 98%). Samples for
bacteriological analysis were collected in sterilized glass bottles. Selected physico-chemical and
bacteriological parameters have been analyzed for projecting the existing water quality status in
the study area. Parameters like temperature, Dissolved Oxygen (DO) and pH were analyzed at
the time of sample collection. Standard Operating Procedures (SOP) for water and wastewater
sampling and analysis are presented in Table 4.3.2. The analytical techniques and the test
detectable limits are given in the Table 4.3.3.

4.3.2.3 Surface Water Quality

The physico-chemical characteristics of surface water in winter season are

summarized in the Tables 4.3.4 to 4.3.7. pH varied in the range of 8.6 – 8.8, turbidity
7 - 12 NTU, total dissolved solids (inorganics) 393-510 mg/l, hardness 206-313 mg/l, chloride
112-128 mg/l, and sulphate 25-32 mg/l.

Nutrient values in the form of nitrate-nitrogen and total phosphates are low in the range
of 5.0 – 9.0 mg/l and 0.16-0.21 mg/l respectively. The values for demand parameters like DO,
COD and BOD are in the range of 5.9 – 7.1 mg/l, 43 – 99 mg/l and 20-40 mg/l respectively. Oil
& grease and hydrocarbons are found in non-detectable levels.

The overall water quality indicates that surface water is alkaline in nature having good
buffering capacity with marginal inorganic and negligible organic load.

4.48
4.3.2.4 Groundwater Resources

The intrusion of seawater has affected the groundwater which has become saline in
the areas adjacent to the sea. The major source of water around the area is groundwater. Most
of the villages are having public dugwells and handpumps. The hydrogeology of the area is
mainly affected by coastal salinity posing its complex pattern and grouped under hard rock,
comprising “Deccan Trap”. The top soil cover consists of weathered formation of soft basalt rock
of thickness varying from 3 to 4 m followed by rocky strata of basalt/laterite origin.

Water bearing zone in this area is found in the form of intermediate flow of basalt and
can be tapped at 30-50 m, 60-65 m and 90-95 m. The rocks in this area do not have any
primary porosity in the lower massive portion, but the top vesicular portion has some porosity
because of vesicles formed due to escaping gases during cooling of lava. These rocks have no
primary permeability as the vesicles are seldom interconnected. Water moving or flowing in the
rock is due to fracturing and jointing. It provides passage for infiltration, storage and movement
of groundwater. The water level of this area varies from 4 m to 12 m depending upon the rainfall
and its duration. The average water level is at 6 m in the area covered right from State Highway-
25 to village Gagwa as also in village Mungni, Sikka, Moti Khavadi and Jogwad. During the
scarcity period, the water level in this area goes remarkably deep (14-16 m) in open wells. The
upper water bearing zones get dry in the summer (after the month of March) and only deeper
zones yield water. There is no direct connection observed between these zones and sea.
Hence, the capacity of yielding water is also very less.

Small streams and nallahs are recharging the groundwater but have not affected the
hydrology of this area. The direction of flow of streams and nallahs of this area is towards north
(towards sea). The water quality in this area varies with distance from sea and the depth wise
variation shows high dissolved solids having high nitrate but good buffering capacity. From the
earlier study the area is demarcated into three zones and groundwater up to a depth of 90 m
was found to be potable even during summer season. However, at areas near the coastal
zones, pronounced effect of salinity (600-8,000 mg/l) from 30 m to 90 m depth was recorded. It
is observed that the rate of intrusion of seawater into groundwater is very low as moved away
from the coastal region and vice versa. Since the refinery complex is near to the coastal zone,
soil is highly saline in nature and thus bearing high compactness indicating poor permeability
and low groundwater discharge pattern as compared to the other zones.

4.49
4.3.2.5 Ground Water Quality

Eighteen groundwater samples inclusive of sixteen from tube well and two from dug
well were collected in and around refinery complex and analysed. The physico-chemical
characteristics of groundwater are presented in Tables 4.3.4 to 4.3.7. The groundwater quality
showed high mineral contents in the form of total dissolved solids, total hardness, chloride,
sulphate and sodium and were found in the range of 477-3024 mg/l,
259-1592 mg/l, 123-1200 mg/l, 42-328 mg/l and 36-500 mg/l respectively. Typical high mineral
content in groundwater indicates seawater intrusion in groundwater with depth variation from 30
m to 90 m. The mineral content is high near the coastal areas and decreases with the distance
away from the coastline.

4.3.3 Bacteriological Characteristics

Coliform group of organisms and faecal streptococci are indicators of bacterial

pollution. The water samples were analysed for estimating total and faecal coliforms deploying
membrane filtration techniques. The bacteriological characteristic for winter season is presented
in Table 4.3.8. The bacteriological characteristics of surface water showed total coliform counts
in the range of 220 to 310 CFU/100 ml. Both the reservoirs were found to be faecally
contaminated having faecal coliforms in the range of
30-45 CFU/100 ml.

The groundwater in four villages (Gagwa, Kanachikari, Nanikhavdi and Mungni) is

found to be faecally contaminated and unfit for human consumption, unless suitably treated.

4.3.4 Biological Characteristics

Studies on biological characteristics of water are important in EIA studies in view of the
conservation of environmental quality and safety of natural flora and fauna including human
being. As biological community depends on the conditions and resources of its location, it
changes according to the changes in the habitat. The impact of pollution in aquatic ecosystem
manifests itself first on the biotic aquatic ecosystem communities. The species composition of
aquatic organisms in natural communities is directly related to water quality. The response of
animals and plants to pollutants when measured quantitatively, gives an insight into the
condition of existing aquatic ecosystem.

Because of complex inter-relationship, a change in the ecosystem causes one or more

of the pollutants to change and be replaced by others, distinguishable as a different community.
The changes in the diversity of biological communities, as a result of pollution in an aquatic
ecosystem, can be mathematically expressed as diversity indices. Organic wastes eliminate
sensitive organisms and provide food for the surviving tolerant forms. However, with natural

4.50
stream purification, water quality improves so that the tolerant forms can flourish and
subsequently diversity increases. On the other hand, toxic material eliminates sensitive
organisms, and because of the restriction of food to that naturally occurring in the stream,
numbers of tolerant surviving forms are limited. Very toxic materials may eliminate all organisms
below a waste source. Thus, the nature and quality of such biological species in a particular
environment is dependent on various physico-chemical characteristics of water and also on the
nature of water body.

In fact, estimation with respect to plankton community structure in a water body would
indicate its quality as follows:

(a) Indicator Organisms

Organisms have been listed in standard publications according to increasing tropic

levels of aquatic environment. Increasing dominance of diatoms, flagellates, ciliates etc.
indicate progressively increasing tropic conditions. Presence of euglenophycease indicates
highly eutrophic conditions. Also, an increase in the abundance of total rotifers indicates
advancing eutrophication.

(b) Diversity

Diversity of planktons depends on physico-chemical characteristics of water especially

on trophic levels. In oligotrophic water diversity of plankton is high. While with increasing
levels of pollution such as mesotrophic and eutrophic condition diversity of planktons
decreases. Shannon Weaver Index is a measure of diversity of planktons, which takes into
account the total count, and individual species count in a water sample.

d = - Σ (ni/n) log2 (ni/n)

where,
d = Shannon Weaver Diversity Index
ni = number of individual of each individual species in a sample
n = total number of individual and of all species in the sample

It is also noted that the diversity is susceptible to other parameters like turbidity, colour,
flow rate etc.

A widely accepted ecological concept is that the communities with large number of
species (i.e. with high diversity) will have high stability that can resist adverse environmental
factors and thus greater is the structural complexity of the food web. The index values of 3 and
above are generally considered healthy conditions of water bodies. The values between 1 and 3
and less than 1 are believed to be for semi and poor-productivity respectively. Systematic

4.51
ecological monitoring of population dynamics and species composition of relevant parts of the
ecosystems in surface water and groundwater around refinery complex was carried out.

The biological characteristics in terms of phytoplankton for surface and groundwater

are presented in Table 4.3.9. Total counts in surface water and groundwater (dug wells) vary
from 846 to 2266 per 100 ml and 987 to 4700 per 100 ml respectively. Phytoplanktons were
recorded in four groups, out of which Bacillariophyceae is the dominant group. The Shannon-
Weaver Diversity Index for phytoplanktons varies from 2.25-3.79 and from 1.0-2.75 in surface
water and groundwater (dug wells) respectively.

The data on zooplankton in surface and groundwater is presented in

3
Table 4.3.10. Samples show zooplankton population from 7500 to 18000 no/m and from
3
267-4500 no/m in surface and groundwater (dug wells) respectively. The Shannon Weaver
Diversity Index of zooplanktons which is found to vary in the range of 1.846-2.320 in surface
water and 0.918 to 105 in groundwater indicates low to moderate productivity.

4.52
 Gulf of Kachchh

21

9
8 Jamnagar
13 10

10 km
19
11 Sas 25 km
SH-6 oi
12
6
5 1
SA-27
4
7
Khambalia 20
3 2

16

17
Lalpur
14
18

Fig. 4.3.1: Sampling Locations for Water Quality Monitoring

(Surface and Ground Water)

4.53
 Table 4.3.1
Sampling Locations for Water Quality

Sr. Sampling Location

No.
Surface Water
1. Kanalus
2. Gajana
3. Apla

Ground Water
Hand Pump
4. Arablus
5. Rangpar
6. Mota Lakhiya

Dug Well
7. Sevak Dhunia
8. Nanikhavdi

Bore Well
9. Mungani
10. Kana Chhikari
11. Padana
12. Nana Lakhiya
13. Gagva

Tube Well
14. Rinzpur
15. Godavari
16. Moti Rafudad
17. Kota
18. Bajana
19. Naranpar
20. Pipartoda
21. Gordanpar

4.54
 Table 4.3.2

Standard Operating Procedure for Water and Wastewater Sampling &

Analysis
Sr.No. Parameter Sample collection Sample size Storage/
preservation
1 pH Grab sampling 50 ml On site analysis
Plastic /glass container
2 Electrical Grab sampling 50 ml On site parameter
Conductivity Plastic /glass container
3 Total suspended Grab sampling 100 ml Refrigeration,
solids Plastic /glass container can be stored for 7
days
4 Total Dissolved Grab sampling 100 ml Refrigeration,
Solids Plastic /glass container can be stored for 7
days
5 Oil & Grease Wide mouth glass 500 ml Add HCl to pH>2,
container refrigeration,
28 days
6 BOD Grab sampling 500 ml Refrigeration,
Plastic /glass container 48 hrs
7 COD Grab sampling 100 ml Add H2SO4 to pH>2,
Plastic /glass container refrigeration; 28 days
8 Hardness Grab sampling 100 ml Add HNO3 to pH<2,
Plastic /glass container refrigeration; 6
months
9 Chlorides Grab sampling 50 ml Not required;
Plastic /glass container 28 days
10 Sulphates Grab sampling 100 ml Refrigeration;
Plastic /glass container 28 days
11 Sodium, Potassium Plastic container 100 ml Not required;
6 months
12 Fluorides Plastic containers only 100 ml Not required;
28 days
13 Hexavalent Plastic/ Glass rinse with 100 ml Grab sample;
Chromium, Cr+6 1+1 HNO3 refrigeration; 24 hrs
14 Heavy Metals (Hg, Plastic/ Glass rinse with 500 ml Filter, add HNO3 to
Cd, Cr, Cu, Fe, Zn, 1+1 HNO3 pH>2; Grab sample;
Pb etc.) 6 months
15 Microbiology Sterilized bottles 1 lits Sterilized, Grab
sample
16 Pesticides Silicate glass sample, 1000 ml Add 1000 mg
PTFE-lined cap ascorbic acid/lit of
sample; 7 days
Source: Standard methods for the examination of Water and Wastewater, published by APHA,
AWWA, wef 21st Edition

4.55
 Table 4.3.3

Analytical Techniques and Test Detectable Limits for

Water and Wastewater Sampling and Analysis

Sr. Parameters Analytical Method ** Detection Limit

No.

1 pH 4500-H+ B
2 Color 2120 C 1
3 Temperature 2550 B 0.1°C
4 Conductivity 2510 B 0.5 micro mho/cm
5 Total Dissolved Solids 2540 C 0.5 mg/l
6 Total Suspended Solids 2540 D 0.5 mg/l
7 Dissolved Oxygen 4500-O C 0.1 mg/l
8 B.O.D. (3days at 270c) 5210 B 0.5 mg/l
9 C.O.D. 5220 B 0.1 mg/l
10 Total Coliform 9255 1
11 Feacal Coliform 9230 1
12 Total Hardness as CaCO3 2340 C 0.1 mg/l
13 Sodium as Na 3500-Na 0.1 mg/l
14 Potassium as K 3500-K 0.1 mg/l
-
15 Chlorides as Cl 4500-Cl 0.01 mg/l
16 Sulfates as SO42 4500-SO4 0.1 mg/l
-
17 Fluorides as F 4500-F 0.1 mg/l
18 Total Kjeldhal Nitrogen 4500-Norg 0.5 mg/l
19 Copper as Cu 3500-Cu 0.01 mg/l
20 Lead as Pb 3500-Pb 0.01 mg/l
21 Manganese as Mn 3500-Mn 0.01 mg/l
22 Iron as Fe 3500-Fe 0.01 mg/l
23 Mercury as Hg 3500-Hg 0.001 mg/l
24 Zinc as Zn 3500-Zn 0.01 mg/l
25 Chromium as Cr 3500-Cr 0.01 mg/l
26 Total Coliform 9255 1
** Source : Standard methods for the examination of Water and Wastewater, published by
APHA, AWWA, wef 21st Edition

4.56
 Table 4.3.4

Water Quality - Physical Parameters

Total
Tempe- Total
S. Sampling Turbidity Dissolved Conductivity
pH rature Suspended
No. Location (NTU) Solids (μS/cm)
(OC) Solids (mg/l)
(mg/l)
Surface Water

1. 8.6 28 12 18 400 610

Kanalus
2. 8.6 28 8 22 393 595
Gajana
3. Apla 8.8 29 7 8 510 749

Ground Water
Hand Pump

4. 8.5 28 3 1.0 800 1100

Arablus
5. 8.1 28 2 1.0 1450 2420
Rangpar
6. Mota Lakhiya 8.0 30 6 2.0 1230 2050

Dug Well

7. 8.0 28 2 7 3024 5040

Sevak Dhunia
8. Nanikhavdi 7.5 26 2.3 3.1 1242 2262
Bore Well
9. Mungani 8.1 27 1.6 4.0 612 1140

10. Kana Chhikari 7.5 29 1.3 3.2 650 1230

11. Padana 8.1 28 2.1 4.3 1025 1940

12. Nana Lakhiya 8.0 27 2.1 3.5 930 1650

13. Gagva 7.6 26 <1 3. 477 850

Tube Well

14. Rinzpur 8.4 26 1 11 1290 2150

15. Godavari 8.4 27 2 2 910 1431

16. Moti Rafudad 8.6 27 2 1 1000 1567

17. Kota 8.3 26 2 7 1841 2670

18. Bajana 8.7 28 3 8 1140 1959

19. Naranpar 8.6 27 2 1 650 1071

20. Pipartoda 8.9 27 3 1 756 1145

21. Gordanpar 8.9 28 1 1 760 1255

4.57
 Table 4.3.5

Water Quality - Inorganic Parameters

Total Total Calcium

S. Sampling alkalinity hardness hardness Chloride Sulphate Sodium Potassium
No. Location (as CaCO3)
(mg/l)
Surface Water
1 134 206 142 114 32 64 02
Kanalus
2 115 235 157 128 25 47 01
Gajana
3 Apla 213 313 191 112 32 58 01

Ground Water
Hand Pump

4 156 465 258 278 69 90 01

Arablus
5 221 667 431 430 135 221 01
Rangpar
6 Mota Lakhiya 223 419 210 450 65 292 03

Dug Well
7 538 1592 1113 1200 328 500 05
Sevak Dhunia
8 Nanikhavdi 327 777 402 317 278 141 05
Bore Well
9 Mungani 106 259 160 123 75 59 02

10 Kana Chhikari 192 367 253 164 90 81 01

11 Padana 307 912 509 317 209 111 02

12 Nana Lakhiya 202 432 230 260 249 188 06

13 Gagva 106 259 160 123 75 59 02

Tube Well
14 Rinzpur 200 694 502 361 122 82 04

15 Godavari 222 585 350 270 100 90 01

16 Moti Rafudad 159 516 400 336 78 145 01

17 Kota 555 861 605 531 155 300 02

18 Bajana 445 752 559 274 142 124 01

19 Naranpar 322 447 234 134 42 70 01

20 Pipartoda 306 563 379 161 68 36 01

21 Gordanpar 247 448 322 202 55 68 02

4.58
 Table 4.3.6

Water Quality - Nutrient, Demand and Organic Parameters

Chemical
Nitrate Total Dissolved Bio-chemical
4S. Sampling Oxygen
as N Phosphates Oxygen Oxygen Demand
No. Location Demand
(mg/l)
Surface Water

1. 5.0 0.20 6.7 48 22

Kanalus
2. 5.0 0.16 5.9 43 20
Gajana
3. Apla 9.0 0.21 7.1 99 40

Ground Water
Hand Pump

4. 11 0.16 2.4 2.0 -

Arablus
5. 50 0.10 1.4 17 <3
Rangpar
6. Mota Lakhiya 36 0.10 5.6 10 <3

Dug Well

7. 11 0.18 4.6 6.0 -

Sevak Dhunia
8. Nanikhavdi 6.6 0.25 4.3 5.2 <3

Bore Well

9. 6.0 0.31 5.4 5.8 <3

Mungani
10. 5.6 0.26 4.3 3.8 <3
Kana Chhikari
11. 6.6 0.30 4.0 3.9 <3
Padana
12. 7.2 0.31 4.1 4.2 <3
Nana Lakhiya
13. 4.2 0.30 6.1 5.2 <3
Gagva
Tube Well

14. 20 0.16 3.8 30 -

Rinzpur
15. 11 0.16 2.9 6 -
Godavari
16. 33 0.15 2.3 2 -
Moti Rafudad
17. 11 0.24 1.9 22 -
Kota
18. 11 0.18 2.4 10 -
Bajana
19. 9 0.20 2.6 27 -
Naranpar
20. 11 0.17 2.8 32 -
Pipartoda
21. 2 0.14 2.9 51 20
Gordanpar

4.59
 Table 4.3.7

Water Quality - Heavy Metals

S. Sampling Manga-
Cadmium Chromium Copper Lead Iron Zinc
No. Location nese
mg/l
Surface Water
1. 0.013 0.004 0.010 0.214 0.19 0.017 14.45
Kanalus
2. 0.017 0.073 0.014 0.406 0.813 0.239 33.45
Gajana
3. Apla 0.009 0.004 0.013 0.140 0.178 0.013 0.027

Ground Water
Hand Pump
4. 0.029 0.039 0.040 0.432 0.453 0.026 4.93
Arablus
5. ND ND 0.02 ND ND ND 7.32
Rangpar
6. Mota Lakhiya ND 0.01 ND ND 0.98 ND 0.63

Dug Well
7. 0.025 0.047 0.035 0.390 0.394 0.020 27.45
Sevak Dhunia
8. Nanikhavdi 0.01 ND ND ND 0.56 ND ND

Bore Well
9. ND 0.15 ND ND 0.75 ND ND
Mungani
10. ND 0.16 ND ND 0.15 ND ND
Kana Chhikari
11. 0.04 0.03 ND ND 0.25 0.12 0.19
Padana
12. 0.03 0.08 ND ND 0.28 0.37 0.48
Nana Lakhiya
13. 0.02 0.05 ND ND 0.89 0.15 0.07
Gagva
Tube Well
14. 0.011 0.024 0.012 0.192 0.432 0.014 22.01
Rinzpur
15. 0.008 0.011 0.014 0.154 0.58 0.05 10.26
Godavari
16. 0.007 ND 0.008 0.128 ND 0.009 8.12
Moti Rafudad
17. 0.011 0.026 0.032 0.224 0.875 0.061 16.36
Kota
18. 0.010 0.037 0.011 0.190 1.475 0.043 7.47
Bajana
19. 0.008 0.005 0.015 0.162 0.647 0.006 22.16
Naranpar
20. 0.011 0.029 0.013 0.202 0.273 0.006 62.56
Pipartoda
21. 0.010 0.015 0.014 0.205 1.38 0.017 24.01
Gordanpar
ND - Not Detectable

4.60
 Table 4.3.8

Water Quality - Bacteriological Parameters

Sr. Total Coliform Faecal Coliform

Sampling Location
No. CFU/100 ml
Surface Water
1. Kanalus 230 30
2. Gajana 220 45
3. Apla 310 35
Hand Pump
4. Arablus 150 40
5. Rangpar ND ND
6. Mota Lakhiya 70 10
Dug well
7. Sevak Dhunia 520 105
8. Nanalakhiya 484 248
Groundwater
9. Mungani 200 238
10. Kana Chhikari 2030 460
11. Padana ND ND
12. Nana Lakhiya 358 56
13. Gagva 5300 460
Tube Well
14. Rinzpur 240 30
15. Godavari 150 30
16. Moti Rafudad ND ND
17. Kota ND ND
18. Bajana 70 ND
19. Naranpar 70 ND
20. Pipartoda ND ND
21. Gordanpar ND ND
ND - Not Detectable CFU - Colony Forming Unit

4.61
 Table 4.3.9

Water Quality – Biological Parameters (Phytoplankton)

Percentage of Composition of Algal Groups Shannon

Total
Sr. Sampling Weaver
Count Bacillario- Cyano - Chloro- Eugleo-
No. Locations Diversity
no/ 100ml phyceae phyceae phyceae phyceae Index
Surface Water
1. Kanalus 846 50 17 - - 2.25
2. Gajana 1222 27 18 - 9 3.19
3. Apla 2266 23 12 - 12 3.79
Hand Pump
4. Arablus ND - - - - -
5. Rangpar - - - -- - -
6. Mota Lakhiya - - - - - -
Dug well
7. Sevak 987 64 12 12 12 2.75
Dhunia
8. Nanalakhiya - - - - - -
Groundwater
9. Mungani 1880 50 - 50 - 1
10. Kana - - - -- - -
Chhikari
11. Padana - - - - - -
12. Nana - - - - - -
Lakhiya
13. Gagva 4700 40 - 60 - 1.522
Tube Well
14. Rinzpur ND - - - - -
15. Godavari ND - - - - -
16. Moti Rafudad ND - - - - -
17. Kota ND - - - - -
18. Bajana ND - - - - -
19. Naranpar ND - - - - -
20. Pipartoda ND - - - - -
21. Gordanpar ND - - - - -
- Not found

4.62
 Table 4.3.10
Biological Parameter – Zooplankton

Percentage of Organisms in Groups

Total
Sr Sampling Protozoa Rotifera Cladocera Shannon
Count
No. Locations Weaver
no/ m3
Diversity Index
Surface Water
1. Kanalus 7500 - - 60 2.320
2. Gajana 18000 - 58 25 2.190
3. Apla 15000 - 50 10 1.846
Hand Pump
4. Arablus ND - - - -
5. Rangpar - - - - -
6. Mota Lakhiya - - - - -
Dug well
7. Sevak Dhunia 4500 - - - 0.918
8. Nanalakhiya - - - - -
Groundwater
9. Mungani 133 50 50 - 1
10. Kana Chhikari - - - - -
11. Padana - - - - -
12. Nana Lakhiya - - - - -
13. Gagva 267 25 25 50 105
Tube Well
14. Rinzpur ND - - - -
15. Godavari ND - - - -
16. Moti Rafudad ND - - - -
17. Kota ND - - - -
18. Bajana ND - - - -
19. Naranpar ND - - - -
20. Pipartoda ND - - - -
21. Gordanpar ND - - - -
- Not found

4.63
4.4 Land Environment
4.4.1 Reconnaissance

The study area around SEZ complex covers parts of Saurashtra region. The rainfall
brought by south-west monsoon in the region is scanty and irregular with an average rainfall of
470 mm per annum. The detail information regarding the landuse pattern of these villages is
also collected.

Eighteen locations were identified for collection of soil samples in study area located at
different distances and in different directions from the project site. Sampling locations are shown
in Fig. 4.4.1 and listed in Table 4.4.1. Soil samples were analysed for relevant parameters
using standard procedures of Soil Chemical Analysis (M.L. Jackson). In some of the villages,
water samples were collected to assess their irrigation quality.

4.4.2 Geology at Project Site

The study area is covered by Deccan Trap basalt of cretaceous age. A geological
succession of the study area is presented below:

Mesozoic Era Lower Eocene to Upper Deccan Trap Formation

Cretaceous Epoch

Basalt occurring in this region is dark black, hard and compact, with variations in
texture leading to massive, weathered and amygdoloidal types. The traps of this area are
invariably jointed. Besides vertical and horizontal joints and sheet joints, horizontal shears
occurring at a depth of 40 m below ground level have connection with upper strata through
vertical joints or fractures. The fractures are oriented in NE-SE and NW-SW directions.

The top most basalt layer is often weathered with thickness varying from 6 to 12 m
below ground level. This formation also has number of open fractures and joints. At places the
weathering of this formation has given rise to pale-brown fragmented material with admixture of
brownish or pale yellow soil.

Basic dykes are present in the region and could be observed as prominent ridges cris-
crossing the entire study area. The lithologs indicate that these dykes are extending upto
greater depths.

4.64
4.4.3 Baseline Status

Eighteen (18) villages/site were identified for existing soil quality assessment. The
locations and names of villages/site of project site are given in Table 4.4.1 and their relative
distribution is depicted in Fig. 4.4.1.

Representative soil samples from depth (0-25 cm) were collected from these villages
and project site for estimation of the physicochemical characteristics of soil. Standard methods
have been followed for the analysis of soil samples.

The international pipette method (Black, 1964) was adopted for determination of
particle size analysis. The textural diagram was generated using “SEE soil class 2.0 version
based on the United States Department of Agriculture (USDA) classification of soil. Physical
parameters such as bulk density, porosity and water holding capacity were determined by KR
box method (Keen and Raczkowski, 1921)

The chemical characteristics of soil were determined by preparing soil extract in

distilled water in ratio 1:1 (Jackson, 1967). Organic carbon was determined by Walkley and
Black method (1972). Fertility status of soil in terms of available nitrogen was determined by
Kjeldhal method and available phosphorus was determined by Chlorostannus Reduced
Molybdo Phosphorus Blue Colour method (Olsen method). Potassium was determined by
flame photometric method (Jackson ML 1967)

Heavy metals in soil were determined by extracting soil will conc. H2SO4 conc. HNO3
followed by analysis on ICP or AAS (APHA, 1995).

4.4.3.1 Physical Characteristics of Soil

For studying soil profile of the region, sampling locations were selected to assess the
existing soil conditions around the project area representing various land use conditions. The
physical, chemical and heavy metal concentrations were determined along with biological
parameters. The samples were collected by ramming an augur into the soil upto a depth of 100
cm. The soil samples were collected during the winter season. The sampling locations have
been identified with the following objectives:

1. To determine the baseline soil characteristics of the study area; and

2. To determine the impact of proposed project on soil characteristics.

The soils are Vertic Ustochrepts. They are residual soils predominantly having basaltic

4.65
trap as a parent material and at some places granite and gneiss as a parent material. They are
calcareous in nature with a murum layer below 40 cm depth. The soils are well drained with
subangular blockey structure, sticky and hard in consistency. They can be broadly classified
into alluvial, black, light brown and alkaline.

Soils were analysed for physical characteristics delineated through specific parameters
viz. particle size distribution, bulk density, porosity, water holding capacity and texture. The
particle size distribution in terms of percentage of sand, silt and clay is presented in Table 4.4.2
and shown in Fig. 4.4.2. It is observed that soil texture varies from clay to sandy clay. The bulk
density of soil of the impact zone is found to be 1.11 - 1.35 gm/cm3 which is considered to be
moderate.

Soil porosity is a measure of air filled pore spaces and provides information about
movement of gases, inherent moisture development of root system and strength of soil. The
porosity and water holding capacity of soil are in the range of 39-66% and 40-69% respectively.
The soils have moderate water holding capacity.

4.4.3.2 Chemical Characteristics

The chemical characteristics of soil, viz. pH, electrical conductivity, soluble anions and
cations, cation exchange capacity (CEC), exchangeable cations, exchangeable sodium
percentage, nutrients, organic contents and heavy metals are presented in Tables 4.4.3 to
4.4.8.

It is observed that pH of soil in the study area are in the range of

6.52 - 8.6. The pH range of soil is found to be favorable for plant growth. Moreover, soil does
not indicate acidification due to operation of various industries in the region which emit acidic
precursor gases such as SO2 and NOx. Electrical conductivity, a measure of soluble salts in soil
is in the range of 0.27-1.6 mS/cm as presented in
Table 4.4.4. It is observed that calcium and magnesium concentrations are in the range of 0.12-
3.92 meq/l and 0.02-1.43 meq/l respectively; whereas sodium and potassium are in the range of
0.08-1.03 meq/l and 0.02-0.15 meq/l respectively.

Variations in cation exchange capacity (CEC) of soil in the study area are presented in
Table 4.4.5. CEC was observed in the range of 40.6-50.2 meq/100 gram. Amongst the
exchangeable cations, calcium and magnesium are found in the range of 22.4-30.7 and 11.2-
15.2 meq/100 gm of soil respectively. Exchangeable sodium percentage (ESP) is ranged from
2.1-3.18%. The relationship of CEC with productivity and absorptivity is presented in Tables
4.4.6 - 4.4.7.

Organic matter present in soil influences its physical and chemical properties and is

4.66
responsible for stability of soil aggregates. Organic carbon is in the range of 0.1 – 0.82%.
Nitrate nitrogen in the available form is very essential nutrient for plant growth and observed in
the range of 138.1-197.2 kg/ha of soil (Table 4.4.8).

Fertility status of these soils is given in Table 4.4.8. The soils are poor to medium in
nitrogen and poor to medium in potassium and phosphorus contents. The presence of organic
carbon indicates the soil is rich in organic manure.

Plants require some heavy metals at microgram level for their metabolic activities.
These heavy metals are termed as micro-nutrients and their deficiency becomes a limiting
factor in plant growth. Levels of heavy metals in soils are presented in Table 4.4.9.

4.4.4 Soil Microbiology

Various ecological cycles in rhizosporo of plant depend upon microbial population. The
population of bacteria, fungi and actinomycetes are vital components of soil and help in
maintaining stability. Characteristics of soil microorganisms are presented in Table 4.4.10.

Rhizobium and Azotobactor are symbiotic and non-symbiotic nitrogen fixing

microorganisms and improve soil fertility by fixing nitrogen in soil. Fungi also constitute an
important part of the microflora at normal soil. Total viable micro-organism population per gram
of soil varied from 13 x 106 to 94 x 106 Colony Forming Units. Different microflora observed per
gram of soil were fungi (2x104 - 15 x 104 CFU), actinomycetes (2 x 104 – 10 x 104 CFU),
rhizobium (2 x 104 – 8 x 104 CFU), and azotobacter (2 x 104 - 16 x 104).
4.4.5 Landuse Pattern

The landuse pattern in the study is presented in Table 4.4.11. The Unirrigated land is
the maximum 50% followed by area not available for cultivation 24%. A pie chart
representing landuse pattern is shown in Fig. 4.4.3.
4.4.6 Remote Sensing Studies for Land use Analysis

Remote Sensing Studies

Remote Sensing technology has emerged as a powerful tool in providing reliable

information on various natural resources at different levels of details in a spatial format. It has
played an important role in effective mapping and periodic monitoring of natural resources
environment.

With the availability of high resolution remote sensing data, newer areas of remote
sensing applications have been identified, techniques of data processing have been improved
and computer based image processing systems have become more effective.

4.67
 Data Used

In order to strengthen the baseline information on existing landuse pattern, the following
data at the latitude (22°07’-22°35') N longitude (69°38'-70°08’) E (approx.) were used:
A. Remote sensing data

IRS P6 LISS III Scene

Path 90, Row 56 dated 31-Dec-2003; CD format

B. Collateral data

Detailed location map

Methodology

Salient features of Methodology are given below:

• Acquisition of Satellite data

• Data loading

• Data processing

• Geo-referencing Image

• Rectification

• Classification

• Ground Truthing / field Checks using Global Positioning System

• Masking

The spatial resolution and the spectral bands in which the sensor collects the remotely
sensed data are two important parameters for any landuse survey. IRS P6 LISS III data offers
spatial resolution of 23.5 m with the swath width of 141 x 141 km. The data is collected in four
visible bands namely green (Band 2) (0.52-0.59μ), red (Band 3) (0.62-0.69μ), near Infrared
(NIR) (Band 4) (0.77-0.89μ), Short wave infrared band (Band 5) (1.55-1.75μ) with orbit repeat
period of 24 days (three days revisit). The shapes, sizes, colours, tone and texture of several
geomorphic features are visible in IRS data. Four spectral bands provide high degree of
measurability through band combination including FCC generation, bands rationing,
classification etc. These features of the IRS data are particularly important for better
comprehension and delineation of the landuse classes. Hence, IRS P6 LISS-III data has been
used for landuse mapping.

The digital image processing was performed on ERDAS IMAGINE 8.7 System on high-

4.68
configured computer. This software package is a collection of image processing functions
necessary for pre-processing, rectification, band combination, filtering, statistics, classification
etc. Apart from contrast stretching, there are large numbers of image processing functions that
can be performed on this station.

The satellite data from the compact disc is loaded on the hard disk and by studying
quick looks (the sampled image of the appropriate area), the sub-scene of the study area is
extracted.

Supervised classification using all the spectral bands can separate fairly accurately, the
different landuse classes at level II on the basis of the spectral responses, which involve the
following three steps:
a) Acquisition of ground truth

b) Calculation of the statistics of training area

c) Classification using maximum likelihood algorithm

The training areas for classification were homogeneous, well spread throughout the
scene with bordering pixels excluded in processing. Several training sets have been used
through the scene for similar landuse classes. After evaluating the statistical parameters of
training sets, the training areas were rectified by deleting no congruous training sets and
creating new ones.
Results

Landuse refers to man’s activities on land, utilitarian in nature whereas landcover

denotes the vegetation cover, water body cover and artificial constructions etc.

The landuse/landcover classification system standardized by Department of Space, for

mapping different agro-climatic zones has been adopted. This classification system has six
major landuse classes at level I and twenty eight at level II (Table –4.4.12). The six major
classes at level I was further enunciated in the following six categories:
a) Built up land: This comprises areas of land covered by structures

b) Agricultural land: Land used for production of food, fiber, crop and plantation

c) Forest: This includes land such as dense or sparse evergreen forests, deciduous

Forests and degraded forests.

d) Wastelands: Land having potential for development of vegetation cover but not

being used due to constraint includes salt affected land, eroded land and water

4.69
 logged areas.

e) Water bodies: Area persistently covered by water such as rivers/streams, reservoirs

/ tanks, lakes / ponds and canals

f) Others: Grassland and snow covered land are included in this category.

Landuse / landcover distribution in the study area has been estimated

as given below using the above classification system and digital analysis techniques.
Plate I

Plate I is the LISS III Imagery showing 25 Km. radial area around the proposed SEZ at
Jamnagar. In the image, vegetation (plantation, shrub, forest) appears red, water bodies
and river as blue/dull green. Attributes such as colour, tone, texture, shape and size are
used to interpret the image visually. Morphologically the area is a flat terrain as it belongs
to the coastal plain. The study area mostly covers vegetation cover, water body and
agricultural land. Fallow land is also depicted in the imagery by its light green tone.
Saltpan is identified by its typical rectangular pattern and white tone seen along coast.
Inland Water bodies are well spread in the vicinity of the study area. Settlements are
also well identified by its typical spectral response.

Plate II

It is the colour-coded output of supervised classification of 25 Km. radial area

around proposed SEZ at Jamnagar with colours assigned to various classes. In this image,
colours are assigned to various classes as given in legend. The landuse / landcover
classification indicates 9.3% area covered by water bodies, 39.52% agricultural land (crop land,
fallow land, Plantation), and 4.36 % fringe vegetation etc.) (Table – 4.4.13). Fourteen different
classes are identified along with corresponding area. Water bodies are mainly seawater and
reservoir water. Agricultural activity mostly occurs through out the area. The Yellow colour in the
landuse map indicates the agricultural land. The fallow is found to be associated with
agricultural lands. The water bodies and seawater is assigned by the blue and light blue colour
in the land use map respectively.

4.70
 Gulf of Kachchh

13

16 Jamnagar
15 14
17
11
10 km
9
Sas 25 km
SH-6 oi
12
3 18

SA-27
2
1
Khambalia
7

6 4

Lalpur

8 5

Fig. 4.4.1: Locations Identified for Soil Sampling

4.71
Fig. 4.4.2 : Texture Diagram for Soil Samples

4.72
 Area not available Forest
for cultivation 3% irrigated
24% 14%

culturable waste
Forest
land
9%
irrigated
unirrigated
50% unirrigated

culturable waste land

Area not available for

Source: Census Book of Jamnagar 1991
cultivation

Fig. 4.4.3 : Pie Chart Showing the Land use Pattern in the Study Area

4.73
Plate I -False Colour Composite of Study area around Proposed
SEZ Site at Jamnagar

4.74
Plate II – Landuse/Landcover of Study area around
Proposed SEZ site at Jamnagar

4.75
 Table 4.4.1

Soil Sampling Locations

S. No. Sampling Locations

1. Sevak Dhunia

2. Arablus

3. Kanalus

4. Lalpur

5. Godavari

6. Moti Rafudad

7. Apla

8. Bajana

9. Naranpur

10. Barwar

11. Navagam

12. Padana

13. Gordanpur

14. Motikhavdi

15. Gagva

16. Nanikhavdi

17. Gaduka

18. Satalus

4.76
 Table 4.4.2

Soil Texture in Study Area

Particle size distribution (%)
S. Sampling
Coarse Fine Textural class
No. Locations Silty Clay
sand sand

1. Sevak Dhunia 20.6 6.2 28.6 44.6 Clay

2. Arablus 14.4 32.6 11.8 41.2 Sandy Clay

3. Kanalus 9.8 15.6 30.2 44.4 Clay

4. Lalpur 10.2 16.2 25.4 48.2 Clay

5. Godavari 9.8 18.2 25.8 46.2 Clay

6. Moti Rafudad 30.6 17.2 13.4 38.8 Sandy Clay

7. Apla 12.2 15.8 28.8 43.2 Clay

8. Bajana 18.8 28.0 14.6 38.6 Sandy Clay

9. Naranpur 10.8 15.6 30.2 43.4 Clay

10. Barwar 9.8 14.4 27.6 48.2 Clay

11. Navagam 30.2 17.2 13.8 38.8 Sandy Clay

12. Padana 10.2 13.4 28.2 48.2 Clay

13. Gordanpur 9.2 15.8 27.4 47.6 Clay

14. Motikhavdi 9 46 10 35 Sandy Clay Loam

15. Gagva 18 34 15 33 Sandy Clay Loam

16. Nanikhavdi 11 32 25 32 Clay Loam

17. Gaduka 10 30 30 30 Clay Loam

18. Satalus 12 33 21 34 Sandy Clay Loam

4.77
 Table 4.4.3

Physical Characteristics of Soil

S. Sampling Bulk density Porosity Water holding

No. Locations (gm/cm3) (%) capacity (%)

1. Sevak Dhunia 1.11 43 50

2. Arablus 1.23 40 45

3. Kanalus 1.12 42 48

4. Lalpur 1.12 49 50

5. Godavari 1.18 47 50

6. Moti Rafudad 1.32 42 45

7. Apla 1.26 43 45

8. Bajana 1.30 39 40

9. Naranpur 1.28 42 46

10. Barwar 1.18 49 51

11. Navagam 1.32 40 41

12. Padana 1.22 49 50

13. Gordanpur 1.24 47 50

14. Motikhavdi 1.35 61 54

15. Gagva 1.30 66 62

16. Nanikhavdi 1.19 38 64

17. Gaduka 1.26 64 69

18. Satalus 1.23 60 67

4.78
 Table 4.4.4

Chemical Characteristics of Soil Extract

S. Sampling pH EC Ca+ + Mg++ Na+ K+

No. Locations
(mS/cm) (meq/l)

Sevak
1. 6.54 0.34 0.17 0.06 0.60 0.04
Dhunia

2. Arablus 6.84 0.44 0.17 0.06 0.89 0.02

3. Kanalus 6.71 0.53 0.18 0.06 0.55 0.04

4. Lalpur 7.23 0.55 0.18 0.11 0.93 0.03

5. Godavari 6.76 0.46 0.12 0.02 0.08 0.10

Moti
6. 6.65 0.27 0.14 0.64 0.48 0.02
Rafudad

7. Apla 6.55 0.90 0.20 0.06 1.01 0.12

8. Bajana 6.66 0.35 0.17 0.02 0.87 0.03

9. Naranpur 7.04 0.58 0.19 0.07 0.68 0.12

10. Barwar 6.66 0.44 0.12 0.03 0.40 0.05

11. Navagam 6.52 0.36 0.17 0.03 0.74 0.05

12. Padana 6.62 0.40 0.17 0.06 0.24 0.02

13. Gordanpur 6.70 0.53 0.17 0.05 0.16 0.03

14. Motikhavdi 8.2 0.7 1.30 0.49 0.34 0.15

15. Gagva 8.3 1.0 2.01 1.15 0.56 0.09

16. Nanikhavdi 8.5 1.6 3.92 1.43 0.96 0.06

17. Gaduka 8.3 1.0 1.05 0.84 0.8 0.10

18. Satalus 8.6 0.6 1.25 0.76 1.03 0.09

4.79
 Table 4.4.5

Cation Exchange Capacity of Soil

S. Sampling Ca+ + Mg+ + Na+ K+ CEC ESP
No. Locations meq/100 gm (%)

1. Sevak Dhunia 28.8 11.2 1.2 1.8 48.8 2.46

2. Arablus 24.6 11.4 0.98 1.6 42.6 2.3

3. Kanalus 22.6 14.2 1.1 1.4 46.8 2.35

4. Lalpur 24.6 14.8 1.6 1.4 50.2 3.18

5. Godavari 22.4 14.6 1.2 1.8 48.4 2.48

6. Moti Rafudad 26.2 12.8 1.1 1.6 40.6 2.7

7. Apla 22.6 14.2 1.1 1.4 45.2 2.43

8. Bajana 23.4 15.2 0.96 1.2 40.6 2.36

9. Naranpur 26.4 11.8 1.08 1.4 44.6 2.42

10. Barwar 25.4 11.2 1.02 1.2 46.7 2.10

11. Navagam 28.2 14.2 1.2 1.2 47.6 2.52

12. Padana 30.2 11.6 1.4 1.8 49.2 2.84

13. Gordanpur 28.8 12.8 1.2 1.6 48.8 2.46

14. Motikhavdi 26.6 11.3 1.2 1.5 41.2 2.9

15. Gagva 22.6 12.6 0.95 1.7 44.5 2.1

16. Nanikhavdi 30.7 13.9 0.97 1.8 45.3 2.1

17. Gaduka 24.8 13.8 1.22 1.4 40.6 2.7

18. Satalus 24.7 11.5 1.25 1.5 47.3 2.6

4.80
 Table 4.4.6

Relationship of CEC with Adsorptivity

Range in cmol Locations

CEC Adsorptivity
(P+) kg-1 (Sr. No)

Limited or low <10 Low or Limited

adsorption

Moderate 10 – 20 Moderate
adsorption

High 20-30 High adsorption

Very High >30 Very high 1,2,3,4,5,6,7,8,9,10,11,12

adsorption ,13,14,15,16,17,18

Table 4.4.7

Relationship of CEC with Productivity

Range in cmol Locations

CEC Productivity
(P+) kg-1 (Sr. No)

Very low <10 Very Low

Low 10 – 20 Low

Moderate 21 – 50 Moderate 1, 2, 3, 4,5,6,7,8,9,10,

11,12,13,18

High >50 High 14,15,16,17

4.81
 Table 4.4.8
Fertility Status of Soils in the Study Area

S. Sample Total Nutrients

No. Locations
Organic N P2O5 K2O
Carbon
(%) Kg/ha

1. Sevak Dhunia 0.20 138.1 13.1 134.87

2. Arablus 0.23 165.8 6.3 142.43

3. Kanalus 0.43 169.9 8.8 144.87

4. Lalpur 0.57 175.8 13.7 143.65

5. Godavari 0.82 195.1 22.03 142.19

6. Moti Rafudad 0.1 140.7 5.2 138.8

7. Apla 0.50 179.9 12.8 144.63

8. Bajana 0.36 142.3 9.5 142.51

9. Naranpur 0.67 178.3 15.6 134.63

10. Barwar 0.12 163.3 6.1 138.90

11. Navagam 0.14 150.7 5.6 146.09

12. Padana 0.04 149.02 5.2 133.30

13. Gordanpur 0.35 174.1 10.9 138.50

14. Motikhavdi 0.42 179 14.7 184

15. Gagva 0.81 192 13.6 107

16. Nanikhavdi 0.58 178 9.1 146

17. Gaduka 0.78 172 12.7 136

18. Satalus 0.82 197.2 15.6 131

Level in poor soil < 0.5 < 280 < 23 < 133
Level in medium soil 0.5-0.75 280-560 23-57 133-337
Level in fertile soil > 0.75 > 560.0 > 57.0 > 337.0

4.82
 Table 4.4.9

Soil Quality - Heavy Metals

S. Sampling Cd Cr Cu Pb Mn Zn Fe
No. Locations mg/kg of soil

1. Sevak 12.6 88.8 74.4 115.6 729.5 47.2 45548.4

Dhunia

2. Arablus 12.7 68.4 68.9 116.2 599.6 58.9 44798.4

3. Kanalus 14.8 81.4 79.9 130.7 999.6 80.4 60742

4. Lalpur 13.3 77 74.4 117.7 709.6 54.2 53742

5. Godavari 13.3 71.9 80.4 118.7 704.6 129.9 48398.4

6. Moti 11.9 36.4 43.9 119.2 554.4 37.3 39998.4

Rafudad

7. Apla 11.4 68.4 65.4 106.7 544.6 86.4 39048.4

8. Bajana 17.3 70.9 122.9 149.2 824.6 64.4 67492

9. Naranpur 18.7 206.4 89.4 149.7 034.6 76.9 83492

10. Barwar 16.1 57.9 96.4 133.2 979.6 75.4 78242

11. Navagam 17.8 117.9 89.9 152.7 929.6 84.8 81742

12. Padana 21.2 109.4 121.9 146.2 1069.6 84.9 9549.2

13. Gordanpur 17.9 74.9 113.9 166.7 1014.6 77.4 70492

14. Motikhavdi 0.3 5.2 46.3 6.2 578 80.2 7270

15. Gagva 0.1 4.7 27.3 5.7 790 46.3 9280

16. Nanikhavdi 0.7 1.8 73.8 10.9 680 93.8 53260

17. Gaduka 0.8 31.0 69.2 13.7 802 96.8 60280

18. Satalus 0.8 41.0 54.9 8.1 917.7 126.7 56290

ND - Non detectable

4.83
 Table 4.4.10
Microbiological Characteristics of Soil

Sr. Sampling TVC Fungi Actinomycetes Rhizobium Azotobacter

No. Locations (CFU per gram of soil)

1. Sevak 16x106 7 x104 2 x104 2 x104 2 x104

Dhunia

2. Arablus 23x106 5x104 2 x104 3 x104 2 x104

3. Kanalus 13x106 2x104 4 x104 8 x104 7 x104

4. Lalpur 44 x106 12x104 5 x104 4 x104 2 x104

5. Godavari 94 x106 15x104 7 x104 8 x104 16 x104

6. Moti 52x106 2x104 2 x104 4 x104 2 x104

Rafudad

7. Apla 91x106 15x104 4 x104 4 x104 13 x104

8. Bajana 83x106 9x104 5 x104 2 x104 7 x104

9. Naranpur 62x106 7x104 9 x104 4 x104 6 x104

10. Barwar 58x106 16x104 10 x104 2 x104 8 x104

11. Navagam 22x106 4x104 3 x104 6 x104 2 x104

12. Padana 52x106 4x104 4 x104 3 x104 11 x104

13. Gordanpur 53x106 7x104 5 x104 3 x104 3 x104

14. Motikhavdi 51x106 7x104 2 x104 7 x104 10 x104

15. Gagva 39x106 5x104 5 x104 4 x104 5 x104

16. Nanikhavdi 25x106 7x104 4 x104 8 x104 9 x104

17. Gaduka 27x106 6x104 3 x104 5 x104 4 x104

18. Satalus 62 x106 13x104 3 x104 3 x104 6 x104

CFU - Colony Forming Unit

TVC - Total Viable Count

4.84
 Table 4.4.11

Landuse Pattern in Villages of the study Area

Area in hectares
Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
1. Jamnagar
District
2. Vasai 1,565.45 - GC (203.50) W(17.50) 827.15 99.95 348.85
WE(68.50) T(289.50)

3. Amra 1,432.14 - GC(243.72) W(36.25) 727.80 141.00 110.41

WE(100.00) R(72.96)
T(452.93)

4. Jivapar 596.39 - GC(262.22) W(71.16) 12.62 47.08 41.69

WE(160.00) R(1.62)
T(495.00)
5. Gaduka
6. Balambhdi 685.69 GC(296.29) W(9.76) 207.03 66.07 73.49
WE(30.00) O(3.05)
T(339.10)
7. Dodhiya 1031.03 GC(49.34) W(43.13) 582.87 174.00 96.39
WE(60.00) O(25.30)
T(177.74)

8. Vaw Beraja 716.02 - W(42.10) WE(50.14) 484.86 60.16 78.76

T(92.24)
9. Chela 2999.68 - W(300) 1707.09 351.75 251.88
WE(388.96)T(688.96)

10. Harshadpar 1724.35 - W(73) WE(143.14) 873.64 161.18 473.39

T(216.14)

11. Naranpar 1226.03 - W(244.41) WE(350.00) 155.17 131.65 344.80

T(594.41)

12. Changa 1858.11 - W(120) WE(63) T(183) 1494.21 55.63 125.27

13. Chandragadh 801.66 - W(85) WE(200.30) 345.82 34.52 136.02

T(285.30)
14. Khoja Beraja 1710.75 GC(64.02) W(121) 651.90 230.79 357.80
WE(272.15) R(13.09)
T(470.26)

15. Lonthiya 697.60 - W(48) WE(106.65) 255.80 28.32 258.83

T(154.65)
16. Bawariya 325.38 - W(50) WE(21.65) 178.66 33.55 41.52
T(71.65)

4.85
 Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
17. Lovadiya 1140.72 - W(60.22) WE(104) 733.04 155.73 87.73
T(164.22)

18. Mokhana 608.16 - W(30) WE(51.85) 208.50 249.82 67.99

T(81.85)
19. Dhandha 799.46 - W(50.60) WE(60.11) 344.95 47.04 296.76
T(110.71)
20. Chandraga 519.01 - W(50) WE(66.92) 299.52 64.92 37.65
T(116.92)

21. Bed 1895.87 GC(144.84) W(200) 992.82 266.76 36.75

WE(254.7) T(599.54)
22. Mungni 889.78 W(20) WE(15.74) 556.81 158.20 139.03
T(35.74)
23. Gagva 676.82 - W(14.15) WE(70) 437.49 93.38 61.80
T(84.15)
24. Nanikhavdi 675.89 - W(83.79) WE(50) 356.48 73.59 112.03
T(133.79)
25. Sapar 609.53 GC(85.18) W(30) 196.72 93.07 132.73
WE(71.83) T(187.01)
26. Champa 939 - W(47) WE(20) T(67) 692.56 56.69 122.75
Beraja
27. Gordhanpur 493.15 GC(28.39) W(18.30) 65.69 51.17 281.34
WE(48.26) T(94.95)
28. Dhinchda 1235.53 - W(47.12) WE(90.04) 560.09 73.79 464.49
T(137.16)
29. Moti Khavdi 2605.33 GC(150) W(100) 1534.66 288.46 460.82
WE(71.39) T(321.39)
30. Lakha Baval 1342.89 GC(278.09) W(30) 464 207.90 226.49
WE(79.23) E(57.18)
T(444.50)
31. Kansumara 928.67 - W(60) WE(81.01) 599.52 55.22 132.92
T(141.01)
32. Masitiya 883.47 - W(11.5) WE(155.56) 457.87 71.62 83.42
T(270.56)

Khambhalia-Taluka
33. Khambhalia
34. Danta 1764.19 87.66 GC(24.28) W(48.56) 817.53 80.53 685.40
WE(20.23) T(93.07)
35. Bhatgam 532.58 - W(76.93) WE(4) 338.58 47.83 65.24
T(80.93)
36. Kota 837.79 - W(52.70) WE(8) 603.70 8.09 165.30
T(60.70)

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 Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
37. Kolava 2383.9 202.34 W(60.70) WE(108.93) 1227.59 192.78 591.56
T(169.63)

38. Bhandariya 1407.89 37.58 W(11.15) WE(7.23) 656.35 206.39 489.19

T(18.38)
39. Bajana 2728.46 163.28 W(161.88) WE(242.82) 803.74 174.86 1181.88
T(404.70)
40. Kandorna 1676.68 - W(68.07) WE(194.63) 670.00 101.69 642.29
T(262.70)
41. Bhadthar 2196.60 - W(16.30) WE(10.21) 1664.01 7.45 498.63
T(26.51)
42. Sagariya 1187.59 - W(9.45) WE(3.28) 640.97 15.69 518.20
T(12.73)
43. Mota Mandha 2061.98 - GC(61) WE(95) T(156) 1382.00 95.98 428
44. Nana Mandha 1484.71 - W(263.43) WE(34.07) 596.87 141.75 448.57
T(297.52)
45. Nava Ambla 407.28 - W(20.43) WE(5.07) 269.37 32.79 79.62
T(20.48)
46. Mota Ambla 881.28 - W(19.86) T(19.86) 571.07 85.12 205.23
47. Vadiner 669.79 - W(10.00) WE(1.10) 450.76 71.04 136.89
T(11.10)
48. Bharana 1849.81 - W(40.47) WE(20.23) 1385.09 144.46 259.56
T(60.70)
49. Timbdi 967.68 - W(29.33) WE(8.23) 705.10 80.66 144.36
T(37.56)
50. Kajurda 1150.00 - W(26.42) WE(12.02) 894.67 74.14 142.75
T(38.44)
51. Haripar 1311.81 - W(119.23) WE(49.96) 626.85 51.19 464.58
T(169.19)
52. Kanchanpur 639.21 - W(30.35) WE(17.18) 273.52 85.79 232.37
T(47.53)
53. Sinhan Kakab 974.52 - W(202.35) WE(214.49) 292.54 121.41 143.73
T(416.84)
54. Lakhasar Hap 1,547.52 87.36 W(51.50) WE(8.93) 798.07 485.10 116.56
T(60.43)
55. Devaliya 1081.02 92.27 W(8.09) WE(12.14) 544.43 16.18 407.91
T(20.23)
Taluka
Lalpur
56. Lakhiya Nava 437.63 - W(49.7) WE(81.34) 161.19 41.32 104.00
T(131.12)
57. Lakhiya Mota 1101.12 - W(93.37) WE(32.37) 748.31 88.84 138.23
T(125.74)
58. Rangpar 979.29 - W(107.06) WE(36.43) 565.85 122.51 147.44
T(143.49)
59. Veraval Moti 1886.74 - W(230.36) WE(441.60) 1016.66 161.56 36.56

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 Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
T(671.96)
60. Sevak Bhatiya 483.23 - W(2.43) WE(5.66) 289.20 59.22 126.72
T(8.09)

61. Sevak 1328.02 - W(4.05) WE(16.18) 964.36 129.56 213.87

Dhuniya T(20.23)
62. Dabasang 1805.88 - W(75) WE(75) T(150) 1262.53 176.10 217.25
63. Machhu 1799.72 - W(104.30) WE(63.42) 1019.54 92.88 519.58
Beraja T(167.72)
64. Sevak 991.74 - W(101.23) WE(52.10) 516.11 30.24 292.06
Bharwdia T(153.33)
65. Modpar 2559.87 - GC(100.00) W(50.00) 1432.58 235.06 492.23
WE(250.00) T(400.00)
66. Rafuded Moti 2410.32 - W(60) WE(60) T(100) 1699.40 159.04 451.88
67. Gajana 1247.69 - W(180.06) WE(120.04) 672.13 159.04 451.88
T(300.10)
68. Mulila 697.13 - W(114.93) WE(48.56) 291.27 65.63 176.74
T(163.49)
69. Piper Nawi 2952.21 232.37 W(100.0) WE(136.0) 1034.00 251.21 1198.63
T(236.0)
70. Kanvirdi 716.45 - W(45.36) WE(10.07) 308.79 44.64 307.59
T(55.43)
71. Apia 1357.66 476.29 W(40.15) WE(32.10) 509.03 62.77 237.32
T(72.25)
72. Govava 3527.91 323.75 W(73) WE(100) T(173) 1439 206.91 1385.25
73. Singach 1473.39 - W(79.18) WE(99.17) 962.84 210.35 121.85
T(178.35)
74. Jasapar 1087.92 - GC(9.20) W(101.25) 610.83 51.33 280.05
WE(35.26) T(145.71)
75. Veraval Nani 597.61 - W(36.0) WE(36.0) 350.85 63.04 111.72
T(72.0)
76. Dhuniya Nava 580.63 - W(40) WE(42) T(82) 260.63 83.0 155.0
77. Khadba Mota 5273.70 - W(300.0) WE(500.0) 2342.34 290.79 1840.57
T(800.0)
78. Veraval Nani 597.61 - W(36.0) WE(36.0) 350.85 63.041 111.72
T(72.0)
79. Godavari 1554.48 300.48 GC(40.17) W(74.56) 334.30 127.87 461.56
WE(200.46) TK(15.08)
T(330.27)
80. Nanduri 2092.18 - W(285.7) WE(325.02) 895.72 313.34 272.4
T(610.72) 0
81. Bharwdiya Mo 808.15 - W(74.0) WE(100.0) 426.0 97.0 111.15
T(174.0)
82. Vijaypur 285.88 21.26 W(18.0) WE(18.0) 127.0 80.0 21.62
T(36.0)

4.88
 Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
83. Raka 810.67 70.33 W(35.00) WE(35.00) 235.0 121.67 313.67
T(70.00)
84. Khatiya 1066.29 588.14 W(40.0) WE(41.0) 191.29 76.0 129.86
T(81.0)
85. Khadba Nana 2404.57 - W(33.0) WE(100.0) 912.57 245.0 1114.00
T(133.00)
86. Babariya 485.95 51.51 W(25.0) WE(15.0) 71.69 40.39 282.36
T(40.0)
87. Pingpur 1335.29 91.42 W(36.00) WE(100.00) 510.29 394.0 203.58
T(136.00)
88. Tebhada 1741.14 337.83 W(105.09) WE(215.09) 335.50 99.27 698.36
T(320.18)
89. Sanosri 2747.62 265.25 W(100.0) WE(150.0) 1333.20 287.63 611.54
T(250.0)
90. Kathitad 724.51 85.79 W(37.07) T(37.07) 334.83 - 266.82

91. Sansora 1779.85 253.31 W(191.99) T(191.99) 756.42 - 578.13

92. Chorbedi 2679.56 613.10 W(175.0) WE(125.0) 506.20 84.81 1175.45

T(300.0)

93. Panchsarom 871.04 - W(50.0) WE(50.0) 510.0 84.04 177.0

T(100.0)
94. Badhla 866.29 - W(30.0) WE(46.0) 389.0 102.29 299.0
T(76.0)
95. Vadpanchasa 1022.91 52.83 W(24.28) WE(100.0) 657.15 169.36 82.87
T(60.70)
96. Padama 2967.66 64.35 W(90.35) WE(98.36) 1916.19 167.18 631.23
T(188.71)
97. Navagam 1998.99 29.92 GC(192.06) W(143.93) 936.73 129.25 329.10
WE(238.00) T(573.99)
98. Dera Chikari 228.80 - GC(2.43) WE(4.04) 167.06 30.0 25.27
T(6.47)
99. Kanechikari 1247.29 - GC(52.04) WE(180.0) 482.89 66.55 445.81
TK(20.0) T(252.04)

4.89
 Culturable Area not
Sr. Name of Total Area Forest Irrigated land Unirrigated waste land available
No. Village land including for
Gouchar and cultivation
groves
100. Kanalus 2142.09 - W(80.94) WE(202.34) 809.17 134.73 914.91
T(283.28)
101. Arblus 1550.84 40.47 W(136.09) WE(83.30) 798.87 63.61 428.50
T(219.29)
102. Meghavadar 657.82 - W(88.05) WE(57.38) 164.65 91.78 255.96
T(145.43)
Source: Census Book of Jamnagar 1991

4.90
 Table 4.4.12

Land use/Land Cover Classification System

Sr. No. Level - I Level – II

1. Built-up Land 1.1 Built-up land
1.2 Road
1.3 Railway

2. Agricultural Land 2.1 Crop land

2.2 Fallow (Residual)

3. Forest 3.1 Evergreen/Semi-evergreen forest

3.2 Deciduous forest
3.3 Degraded/Scrub land
3.4 Forest blank
3.5 Forest plantation
3.6 Mangrove
3.7 Cropland in forest

4. Wasteland 4.1 Salt affected land

4.2 Waterlogged land
4.3 Marshy/Swampy land
4.4 Gullied/Ravinous land
4.5 Land with or without scrub
4.6 Sandy area (coastal and desert)
4.6 Barren rocky/Stony
waste/sheetrock area

5. Water bodies 5.1 River/Stream

5.2 Lake/Reservoir
5.3 Tank/Canal

6. Others 6.1 Grassland/Grazing land

6.2 Shifting cultivation
6.3 Snow cover/Glacial area

4.91
 Table: 4.4.13

Inventory of Landuse / Landcover

JAMNAGAR-AREA STATISTICS (25 Km.radius)

Sr. No. CLASS NAME AREA (ha) AREA (%)

1 Crop Land 36133.46 18.40

2 Fallow Land 41295.46 21.03

3 Land with / without Scrub 49419.19 25.17

4 Settlement Area 4898.76 2.50

5 Industrial Area 3014.15 1.54

6 Plantation 180.12 0.09

7 Fringe Vegetation 8564.26 4.36

8 Bare Soil 17207.54 8.76

9 Mud Flat 13870.54 7.06

10 Salt Pan 2618.84 1.33

11 Dumping Area 175.74 0.09

12 Airport Area 688.03 0.35

13 Water Body 2731.51 1.39

14 Sea 15533.51 7.91

Total 196331.10 100.00

4.92
4.5 Biological Environment

4.5.1 Introduction

Study of biological environment is one of the most important aspects for

Environmental Impact Assessment, in view of the need for conservation of environmental
quality and biodiversity. Ecological systems show complex inter-relationships between biotic
and abiotic components including dependence, competition and mutualism. Biotic components
comprises of both plant and animal communities, which interact not only within and between
them but also with the abiotic components viz. physical and chemical components of the
environment.

Generally, biological communities are the indicators of climatic and edaphic factors.
Studies on biological aspects of ecosystems are important in Environmental Impact
Assessment for safety of natural flora and fauna. Information on the impact of environmental
stress on the community structure serves as an inexpensive and efficient early warning system
to check the damage to a particular ecosystem. The biological environment includes mainly
terrestrial ecosystem and aquatic ecosystem.

Biological communities are dependent on environmental conditions and resources of

its location. It may change if there is change in the environment. Several variables like
temperature, humidity rainfall, soil characteristics, topography etc., are responsible for
maintaining the homeostasis of the environment. A change in any one of these variables may
lead to stress on the ecosystem. The animal and the plant communities exist in their natural
habitats in a well-organized manner. Their natural setting can be disturbed by any externally
induced anthropological activities or by naturally induced calamities or disaster. So, once this
setting is disturbed it becomes practically impossible or takes a longer time to come to its
original state. Plants and animals are more susceptible to environmental stress.

A change in the composition of biotic communities under stress is reflected by a

change in the distribution pattern, density, diversity, frequency, dominance and abundance of
natural species of flora and fauna existing in the ecosystem. These changes over a span of time
can be quantified and related to the existing environmental factors. The sensitivity of animal and
plant species to the changes occurring in their existing ecosystem can therefore, be used for
monitoring Environmental Impact Assessment studies of any project.

4.93
4.5.2 Study Area

The proposed SEZ project site is located near the village Kanalus in Jamnagar
District of Gujarat State. The study area is around 25 km radial distance from the proposed
project site taking Kanalus as center. In all 30 locations were selected for study on biological
aspects.

Selection of sampling locations was made with reference to topography, land use,
vegetation pattern, etc. The observations were taken on reserve forest, village forest and non-
forest area (agricultural field, catchment area, on hills, in plain areas, village wasteland, etc.) as
per the objectives and guidelines of MoEF for Environmental Impact Assessment. All
observations were taken in and around sampling locations for quantitative representation of
different species.Sampling locations selected for biological environment study are given in
Table 4.5.1 and depicted in Fig. 4.5.1. Study area mostly comprises of agriculture and barren
land. Most of the vegetation is aggregated on agricultural bunds, near roadside, on degraded
village land, canal sides and wastelands.

The study area around the proposed SEZ comprises of terrestrial and marine
ecosystems due to nearness to Gulf of Kutch. The region has flat topography with Fulzar and
Sasoi rivers flowing in the study area. The coastal zone is predominantly sandy, muddy covered
with patches of mangrove vegetation. The terrestrial area was observed to be covered with
tropical dry thorn vegetation characterized by the dominance of Prosopis juliflora and Acacia
senegal alongwith agricultural fields and scrub land.

There exist five industries around the proposed project site within 25 km radius.
These are Reliance Industries Limited, Essar Oil Limited, Gujarat State Fertilizer Company GEB
Power Plant and Digvijay Cement Limited.

The climatic conditions in the study area are severe with hot climate and medium
rainfall. Therefore, the terrestrial vegetation consists of thorny, shrubby and xerophytic scrub
vegetation. The vegetation is extremely sparse dominated by shrubby growth of Prosopis
juliflora. However, it has good growth in low-lying areas, by the side of agriculture fields and
near villages.

4.5.3 Survey Methodology

Monitoring of biological environment was carried out by random sampling method.

The structure and composition of vegetation was studied by taking observations on diverse
plant species and their numerical composition at each sampling station. Diversity of plant
species was studied by using Simpson’s Diversity Index. Simpson’s Diversity Index is
calculated by following formula:

4.94
 n ni (ni - 1)
Simpson's Diversity Index = Σ ------------
i=1 n (n - 1)

ni - is the number of individuals of the ith species in the sample and

n - is the total number of individuals in the sample.

Coexistence and competition both are affected directly by the number of individuals in
the community. Therefore, it is essential to know the quantitative structure of community. To
characterize the community as a whole, certain parameters are used. The parameters like
frequency, dominance and Simpson's Diversity Index give a clear picture of community
structure in quantitative terms. The values of these parameters are derived from the sampling
observations done in the field, which are close to the real value.

To characterize the vegetation in the study area, the data was collected and analyzed
for describing the properties of vegetation with reference to species composition and structural
attributes. The diversity measurements reflect as to how many diverse species are present, the
density measurements indicate number of individuals of a species in a sample plot; the
dominance measurements denote which species is largest in terms of its presence; the
frequency measurements indicate, how widely a species is distributed or occurred. Species
diversity is the best measure of community structure. It is sensitive to environmental stresses
that affect the community. Low value of Simpson’s Diversity Index indicates healthy ecosystem
and the high value shows that an ecosystem is under environmental stress.

Actual counts of birds were made following the standard survey technique.
Observations were made during a walk through in the chosen transect for sighting birds and
animals. The number of animals and birds observed in one-kilometer stretch of the site were
directly counted and listing was made. The milometer of the car/jeep was used to measure the
stretch of the study transect. Birds were noted, counted and identified with the help of binocular
and standard field identification guides. Other animals were directly counted from amongst the
vegetation, bushes and the roadside fields.

Information was collected on the livestock, fisheries and indigenous fauna of the
locality from the State/Central Government Departments. This information has been
incorporated in the report wherever essential.

4.5.4 Vegetation Biodiversity in Study Area

According to Champion and Seth, the vegetation in the study area can be classified
as Dry Tropical Type, Tropical Dry Thorn type and Littorial and Swamp Type. That can be
further classified as Riverian forests, Plain forests and Mangrove forests. The most dominant

4.95
trees in this region are Acacia sp., Mangifera indica, Ficus religiosa, Butea monosperma,
Terminalia bellerica, Terminalia tomentosa are found in co-association and phytosociological
order with Syzygium cumini, Azadiracta indica, Bauhinia racemosa, Emblica officinalis, which
are sparse in distribution.

The subdominant species recorded are Prosopis sp., Capparis sp., Euphorbia sp.,
and Opuntia sp. Ficus bengalensis is observed near villages and by the roadside. Other rare
species in this area recorded are Casuarina, Parkinsonia and Cocos nucifera. Among the
shrubs Euphorbia sp. and Opuntia sp. are abundant followed by Cassia sp., Zizyphus sp., and
Phoenix sp., are dominantly observed along with Cassia siamea and Delonix regia at some
places in villages and on private land. Many tree species are found to be planted in the
greenbelt of small and large industries in the area consisting of Cassia siamea, Delonix regia,
Bauhinia, Parkinsonia, Acacia auriculoformis, Eucalyptus, Mangifera indica etc.

During the floristic survey in study area, a total of 165 plant species were recorded. A
total of 76 tree species, 28 shrub species, 22 herb species, 23 grasses and 16 climbers were
recorded from the study area. The list of total number of different plant species (trees, shrubs
and herbs) recorded during field survey is depicted in Table 4.5.2.

Study area shows presence of medicinal plants. Out of 165 plants studied, 51 plant
species of 25 trees, 10 herbs and 16 shrubs are of medicinal value. However, the scattered
distribution and low density of these plants does not allow their commercial use. The Simpson’s
Diversity Index for trees, shrubs, and herbs of the study area is given in Table. 4.5.4.

4.5.5 Floristic Structure and Composition

4.5.5.1 Floristic Characteristic within 15 km radius from the Proposed Project Site
Within 15 km radial distance of Proposed Project site the land is covered by
agriculture and fallow land besides built up land and greenbelts developed by Reliance
Industries Limited, Essar Oil Refinery and Gujarat State Fertilizer Company. The primary data
were collected at around proposed project site, Kanalus, Apia, Ratudad Moti, Padana, Dera
Chhikari, Kana Chhikari, Motikhavdi, Navagram, Gavana, Vadaliya Sinhan, Lonthia, Arablus,
Veraval Nani, and Sevak Dhuniya.

The floristic study reveals species composition, which represents poor gene pool
uniformly spread in restricted vegetation patches around human settlements. Collection of dead
and dried branches for fuel, hard wood and local trees for construction purpose, grazing
practice on vegetated land is also common. The nature of vegetation cover in this region is
mixed, tropicaldry, uneven-aged-deciduous vegetation with marked dominance of Acacia sp.,
Dalbergia latifolia, Bauhinia purpurea, Ficus racemosa, Mangifera indica, Butea monosperma,

4.96
Sapindus emarginatus, and Gmelia arborea. Most of the vegetation aggregates on agricultural
bunds, near roadsides, on degraded village lands, canal sides and wastelands.

The vertical structure of the vegetation shows three distinguished storey i.e. Top,
Middle and Ground. Azadirachta indica, Dalbergia latifolia, Bauhinia purpurea, Ficus racemosa,
Mangifera indica, Butea monosperma etc. comprises top storey of the forest. Adhatoda vasica,
Bougainvellia tochglory, Cassia fistula, Calotropis gigantean, Dalbergia sissoo, Lantana
camara, Euphorbia nevulia, Opuntia elator, Prosopis juliflora, Zizyphus rugosa etc. forms middle
storey of region. Ground vegetation cover is of Ageratum conizoides, Argemone mexicana, Aloe
vera, Dipcadi montanum, Erantemum roseum, Leucas aspera, Phyllanthus niruri, Solanum
xanthocarpum, Tinospora cardifolia etc.

A view of vegetation structure and composition in the study area is shown in Plate
4.5.1.

4.5.5.2 Floristic Characteristic within 15-25 km radius from the Proposed Project Site
The region within 15-25km radial distance of the project site has sparse vegetation
cover. This includes terrestrial region like Gordhanpur, Kathi devaliya, Kota, Sansora, Tebhada,
Chorbedi, Rinzpur, Pipartoda, Naranpar as well as some coastal region near Sikka, Singach,
Vadinar, Bharana, Gagva, Mungani, Bed. The composition of vegetation is littorial and swamp,
uneven-aged, mixed, moist deciduous natural forests. Vegetation is extremely irregular and
varying considerably in condition, composition, and density. Generally trees observed here
have low stunted branches, diffuse crown. Dependency of villagers on natural vegetation in this
region is more for timber and firewood. Most of the vegetation aggregates near villages mainly
composed of Albizzia chinensis, Bauhinia racemosa, Ficus recimosa, Syzygium cumini,
Terminalia tomentosa etc.

The phyto-ecological structure of vegetation shows three different strata i.e. Top,
Middle and Ground. Top storey covered by, Albizzia chinensis, Bauhinia racemosa, Bombax
malabaricum, Butea monosperma, Ficus recemosa, Syzygium cumini, Sapindus emarginatus,
Terminalia tomentosa etc. Middle storey in this region comprises Adhatoda vasica, Capparis
spinosa, Euphorbia nevulia, Crotolaria retusa, Emblica officinalis, Lantana camara etc. The
dominant herbs in ground vegetation are Aegeratum conyzoides, Argemone mexicana, Celosia
argentea, Aloe vera, Indigofera tinctoria, Tridax procumbens etc.

Near the coastal area i.e. near jetty sides, saltpan, mangrove species are found.
Mainly six species of mangrove are commonly found in this area are Avicenia marina, A alba, A.
officinalis, Ceriops species, Rhizophora mucronata and Aegiceros corniculata. The density and
vegetation changes with change in locations. A view of mangrove vegetation near Vadinar
saltpan area is shown in Plate 4.5.2. The area near coastal villages has poor vegetation as

4.97
compared to other places. Trees species like Coccos nucifera, Phoenix robusta, Ficus sp,
Bahunia racemosa, Cassia fistula, Acacia catechu and Azadiracta indica along with Prosopis
juliflora are observed in some places. The vegetation is degraded due to the human and live
stock interferance in this region. Herbs are abundant only during monsoon. The area is
dominated with tree members as compared to shrubs and herbs. The vegetation in this region
has been exploitated in the past, therefore the present condition is degraded. Mangifera indica
and Azadiracta indica are the dominant tree species.

Productivity of the agricultural crops in this region is very low because of poor soil
quality, infrequent and inadequate rainfall, water scarcity, low consumption of fertilizer, shifting
cultivation, lack of improved agricultural technology and improper communication.

4.5.6 Medicinal Plants in Study Area

Ayurveda says “There is no plant on the Earth, which does not possess medicinal
property”. This means that each and every plant is equally important for its biological activities,
ecology and environment. The conservation of medicinal plants means every species of plant in
its actual habitat should be protected and preserved. Conservation of biodiversity is a national
and international agenda. Because of continuous exploitation of medicinal plants from their
natural habitats, it is required to replant and regenerate them in other areas having similar
habitat or environment. Due to over-exploitation of natural resources many of plant species
have become extinct from the wild.

The study area shows presence of medicinal plants. Out of total 165 plants studied,
51 plant species including 25 trees, 10 herbs and 16 shrubs are of medicinal value.

Ground floor in study area is covered by herbaceous vegetation, which has many
Ayurvedic medicinal plants. In addition, the area abounds in production of many kinds of fruits,
flowers, seeds and leaves.

The common herbal medicinal flora of the area is Adhatoda vasica (Adulasa), Acacia
catechu (Khair), Cassia fistula, Eranthemum roseum (Dashmuli), Mangifera indica, Vitex
nigundo (Nirgudi), etc. The local people collect the medicinal plants from forest area, but they
are not dependent economically on collection of medicinal plants. The list of medicinal plants
and their medicinal value is presented in Table 4.5.3.

4.5.7 Social Forestry

Social Forestry wing under State Forest Department has carried out plantation in few
areas along roadsides, highways and on village lands.

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 The tree species used in social forestry are Prosopis, Azadirachta indica, Albizzia
lebbeck, Ficus bengalensis, Acacia senegal, Emblica officinalis, etc. which are native species.
Prosopis is planted in few villages to develop village forest.

4.5.8 Reserved Forest

Four reserved forests are falling within the radius of 25 km radius from the proposed
project site. The names of these reserved forests along with the area are as follows:

Rinzpur reserve forest : 91.42 ha

Chorbedi reserve forest : 228.65 ha

Tebhada reserve forest : 141.00 ha

Sansora reserve forest : 91.05 ha

These reserved forests are in degraded condition with very poor gene pool of plant
species. Plant species mainly comprises of Prosopis juliflora, Pithecellobium dulce Euphorbia
nevulia, Opuntia elatior, Lantana camara, Achyranthes aspera, Celosia argentea, Cassia tora
etc.

Animals found in these reserved forests are mainly comprises of mammal, reptiles
and birds. In mammals Nilgai, Wild boar, Common Langur, Bat and Common Fox are found. In
reptiles snakes like Cobra, Monitor Lizard, Indian Chamelion while in birds Common Myna,
Small Blue Kingfisher, Blue Rock Pegion, Babbler, Black Drongo and Common Peafowl are
commonly found. However none of these forest area come in the overall SEZ Development
Area.

4.5.9 Threatened Plant Species

National threatened species are those found only in small numbers or those very
near to extinction in the country. India has a list of threatened species at the All India level,
published by the Botanical Survey of India entitled ‘Red Data Book‘. Not a single species out of
165 plant species was observed to be threatened in the study area. However, there is intense
industrial and anthropogenic pressure on flora fauna and forest resources, which are observed
to be dwindling.

4.5.10 Agriculture

The staple food of the people in the study region is rice and wheat. The common
Kharif crops of this region are groundnut, sesamum, cotton, castor, bajra etc. whereas wheat,
gram, cumain, ajwan (semi-rabi) are the Rabi crops. Productivity of the agriculture crops in this
region is medium to low because of low per hectare consumption of fertilizer, illiteracy, lack of
improved agricultural technology and improper communication and also due to the weather

4.99
condition. List of Agricultural crops in the study area is given in Table 4.5.5. A view of
agriculture (cotton crops) is shown in Plate 4.5.3.

4.5.10.1 Agroclimatic Condition of Study Area

Jamnagar district is in North Saurashtra Agroclimatic Zone of State. The typical

climate condition is arid and semiarid, with shallow medium black to sandy soil. Study area has
coastal climate, which are salt affected soil. Jamnagar district is drought prone area. Ground
water table is going down and depleted due to industrial activities in near by area therefore well
irrigation is drastically affected.

4.5.11 Assessment of Wildlife and Avifauna

Since animals are capable of movement from one place to another, this makes their
study entirely different. Therefore, specific methods were adopted for counting these animals in
the field. The on-site information collected during survey was further enriched by the information
collected from different secondary sources.

4.5.11.1 Faunal Diversity

a) Wild Animals
The diversity in fauna basically depends upon density and diversity of flora. The
richer the diversity among the flora better will be the diversity in fauna. The study area has
sparse, dry and thorny vegetation. Present conditions of the area do not support higher
mammals. There are animals like hare, mouse, wild boar, fox, wildcat, nilgai, and squirrels. The
faunal elements commonly reported in the study area are presented in Table 4.5.6.

b) Domestic Animals
The animals in study area mostly consist of domestic species such as camels, cow,
buffaloes, sheep, goats, donkeys, horses, dogs and pigs. Animal census data revealed that
among domestic animals cattle constituted the most abundant species, followed by buffaloes,
goats, sheep and other animals.

4.5.11.2 Avifauna
a) Around Study Area
30 sampling sites were selected at various places in the study area for the
assessment of avifauna. The birds were studied by direct observation with the help of 7 – 15 x
35 “Optima Zenith” binocular. A species list was prepared by walking through the areas.

A total number of 20 species of birds were encountered during the survey. (Table
4.5.6).

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 The birds like peafowl, mynas, crows, sparrows, bulbuls, babblers and pigeons are
observed in and around villages. In areas with agriculture fields, the grain eating herbivorous
species are dominant. These species are doves, sparrows, Cattle egrets, parakeets etc.
Insectivorous bird species viz. Bee eaters, Wagtails, White breasted kingfisher, Egrets,
Swallows, Indian Roller, Larks, are found around water bodies and in low-lying vegitation areas.
A view of birds observed in the study area is shown in Plate 4.5.4.

b) Around Coastal Areas

Varieties of shore birds are found to nesting and roosting on the coastal area. There
are about 190 species available in the Marine National Park (MNP) area, which is spread
around an area of 162.89 Sq. Km found in the Gulf of Kutch provides very good grounds for
roosting and the mangroves vegetation provides nesting ground to the avifauna. Birds nesting
on the island mainly feed in the surrounding reef and mudflats but sometimes they move to
nearby islands or coasts during low tide. The birds nesting on the coastal sites collect food from
the mudflats, reefs, tidal creeks and channels on the coast. The coastal wetlands in Jamnagar
with broad intertidal mudflats, mangroves, coral reefs, salt pans, sand and rock beaches offer a
great diversity of habitats for birds to utilize for roosting, nesting and breeding. The area is very
rich in the diversity and sheer number of both migratory and residence birds. A number of
migratory birds pass through the Gulf of Kachchh and non-breeding adults of many species
spend the summer in this region.

4.5.11.3 Rare, Endangered and Vulnerable Faunal Species

A list of rare, endangered and vulnerable species of birds is given in Table 4.5.7. Out
of 12 species, 2 species i.e. Eastern knot and Eastern little stint are found to be rare and
endangered, 2 species viz. little green herons and black necked stork are found to be
endangered and remaining 8 species are found to be vulnerable. Out of birds recorded, only
two birds viz. Peafowl and spoonbill are included in Schedule-I. There are no rare and
endangered species of birds observed in the project area.

Among animals, Indian cobra (Reptiles), Jungle cat (Mammals) and Jackal
(Mammals) are included in Schedule-II of Wildlife Protection Act.

4.5.12 Fishery

As the study area located nearby the coastal belt major fishing activities takes place
in sea by the villages of Vadinar, Bharana, Sikka, Mungani, Gagva and Bed. However, some
fresh water fishing activities are also done by the local people in dams situated in Lalpur and
Khambalia talukas, but in a small scale. Fresh water fishes are mainly comprises of Rohu, Catla
and Mrigal.

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 There are three dams in Khambalia taluka namely Sheda Bhara Thari (275 ha.),
Khad Khambalia (48 ha.) and Ghee (405 ha.). These dams are usually given for fresh water
fishing activities on lease basis. In Lalpur taluka two dams – Sasoi (1278 ha.) and Panna (363
ha.) are used for fishing activities.

A list of marine fishes found in Jamnagar district and different Prawn species
occurring in the Gulf of Kutch are given in Table 4.5.8 and Table 4.5.9 respectively.

4.102
 Gulf of Kachchh

24
30 15

16 Jamnagar
26 25 29 7 5
28 17
6

8
10 km

16 Sas 25 km
oi 23
SH-6 4 11
1
10
Sh-27
12
14
Khambalia 22
2

13
3

17 9 Lalpur 21

19 20

18

Fig. 4.5.1: Locations Identified for Biological Survey

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Plate 4.5.1: A View of Thorny Vegetation near the Tebhada Reserve Forest

Plate 4.5.2: A View of Mangrove Vegetation near Vadinar Village salt pan

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Plate 4.5.3: A View of forest observed near the Sansora Reserve Forest

Plate 4.5.4: Reef Heron observed near the Vadinar Jetty

4.105
 Table 4.5.1

Sampling Locations for Biological Environment Survey in the Study Area

Sr. No. Name of the Villages
Within 15 km radial distance from
the proposed project site
1. Kanalus
2. Apla
3. Rafudad Moti
4. Padana
5. Dera Chhikari
6. Kana Chhikari
7. Motikhavdi
8. Navagam
9. Gavana
10. Vadaliya Sinhan
11. Lonthia
12. Arablus
13. Veraval Nani
14. Sevak Dhuniya
Within 15-25 km radial distance from
the proposed project site
15. Gordhanpar
16. Kathi devaliya
17. Kota
18. Sansora
19. Tebhada
20. Chorbedi
21. Rinzpur
22. Pipartoda
23. Naranpar
24. Sikka
25. Singach
26. Vadinar
27. Bharana
28. Gagva
29. Mungani
30. Bed

4.106
 Table 4.5.2
Common Plant Species Present in Jamnagar Dist

Sr. No. Botanical Name Local Name Family

Trees
1. Acacia catechu * Khair Mimoseae
2. Acacia ferrugenia Kanti Mimoseae
3. Acacia leucophloea Hermo Mimoseae
4. Acacia nilotica * Baval Mimoseae
5. Acacia planifrons Chhatralo baval Mimoseae
6. Acacia senegal * Gorad Mimoseae
7. Aegle marmelos * Bili Rutaceae
8. Ailanthus excelsa* Arduso Simaroubaceae
9. Albizia lebbeck * Kalo sarsdo Mimoseae
10. Albizia odoratissima Dholo sarsado Mimoseae
11. Albizia odoratissima Sarasdo Mimoseae
12. Albizia procera * Kamai Mimoseae
13. Allangium salivifolium Ankol Alangiaceae
14. Annona squamosa * Anuri Annonaceae
15. Avicennia officinalis * Cher Avicenniaceae
16. Azadirachta indica * Limbdo Meliaceae
17. Balanites aegyptiaca Ingoriyo Balanitaceae
18. Bauhinia racemosa Asundro Caesalpiniaceae
19. Bombax ceiba * Semlo Bombacaceae
20. Borassus flabellifer * Tad Arecaceae
21. Boswellia serrata Saledi Burseraceae
22. Bridelia retusa Akal kanto Euphorbiaceae
23. Butea monosperma * Khakhro Fabaceae
24. Cassia fistula * Garmalo Caesalpiniaceae
25. Cassia siamea * Kasid Caesalpiniaceae
26. Casuarina equisetifolia * Saru Casuarinaceae
27. Ceriops candolleans Kunri Rhizophoraceae
28. Cocos nucifera * Narial Arecaceae
29. Commiphora wightii Gugal Burseraceae
30. Cordia dichotoma Gundi Ephretiaceae
31. Cordia monoica Cut gundi Ehretiaceae
32. Dalbergia sissoo * Sissoo Caesalpiniaceae
33. Delonix elata Sandesaro Caesalpiniaceae
34. Delonix regia * Gulmohar Caesalpiniaceae

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Sr. No. Botanical Name Local Name Family
35. Diospyros melanoxylon * Timru Ebenaceae
36. Emblica officinalis * Amla Euphorbiaceae
37. Erythrina variegata Jungli khakhro Fabaceae
38. Erythrina variegta Panarv Fabaceae
39. Eucalyptus hybrid * Nilgiri Myrtaceae
40. Ficus benghalensis * Vadlo Moraceae
41. Ficus racemosa * Umro Moraceae
42. Ficus religiosa * Pipalo Moraceae
43. Ficus tsiela Piper Moraceae
44. Garuga pinnata Karpati Burseraceae
45. Grewia tiliaefolis Dhaman Tiliaceae
46. Holoptelea integrifolia Charal Ulmaceae
47. Lannea coromandelica Moledi Anacardiaceae
48. Mangifera indica * Ambo Anacardiaceae
49. Manilkara hexandra Rayan Sapotaceae
50. Melia azedarach * Bakan limdo Meliaceae
51. Mellingtonia hortensis Akash nim Bignoniaceae
52. Mimusops elengi * Bakul or borsali Sapotaceae
53. Mitragyna parvifolia Kalam Rubiaceae
54. Morinda tinctoria Al or rangari Rubiaceae
55. Moringa oleifera Saragvo Moringaceae
56. Parkinsonia aculeate * Ram baval Caesalpiniceae
57. Phoenix sylvestris * Khajuri/Khaleranuzad Arecaceae
58. Pithecellobium dulce* Goras amli Mimoseae
59. Polyalthia longifolia * Asopalav Annonaceae
60. Pongamia pinnata * Karanj Fabaceae
61. Prosopis juliflora * Gando baval Mimoseae
62. Prosopis spicigera * Khijado Mimoseae
63. Rhizophora conjugata * Karod Rhizophoraceae
64. Salvadora oleoides Mithijar Salvadoraceae
65. Salvadora persica Kharijar Salvadoraceae
66. Sapindus emarginatus Aritha Sapindaceae
67. Schleichera oleosa Kusum ujan Sapindaceae
68. Soymida febrifuga Ron Meliaceae
69. Sterculia urens Kadayo Sterculiaceae
70. Syzygium cumini * Jambudo Myrtaceae
71. Tamarindus indica * Amli Caesalpiniaceae
72. Terminalia bellirica * Behdo Combretaceae

4.108
Sr. No. Botanical Name Local Name Family
73. Terminalia catappa Badam Combretaceae
74. Terminalia arjuna * Arjun sadad Combretaceae
75. Thespesia populnea Paraspipalo Malvaceae
76. Wrightia tinctoria * Dudhlo Apocynaceae
Shrub
77. Abutilon indicum* Khaper Malvaceae
78. Acacia jacquemontii Tal baval Mimoseae
79. Adhatoda vasica * Ardushi Acanthaceae
80. Alhagi pseudalhagi Dhomso Fabaceae
81. Alysicarpus longifolius Ghoda samervo Fabaceae
82. Calotropis gigantea * Ankdo moto Asclepiadaceae
83. Capparis deciduas Kerdo Capparidaceae
84. Cassia auriculata Awal Caesalpiniaceae
85. Commiphora wrightii Gugal Burseraceae
86. Cressa cretica Lano Convolvulaceae
87. Dichrostachys cinerea Majith Mimoseae
88. Euphorbia neriifolia Kantalo thor Euphorbiaceae
89. Euphorbia tirucalli Karsani thor Euphorbiaceae
90. Euphorbia nevulia * Thor Euphorbiaceae
91. Gardenia resinifera Dikamali Rubiaceae
92. Hibiscus vitifolius Bhindi Malvaceae
93. Lantana camara * Danidharia Verbenaceae
94. Lawsonia inermis * Mehndi Lecythidaceae
95. Leptadenia spartium Khip Asclepiadaceae
96. Ocimum americanum Jungli tulsi Lamiaceae
97. Ocimum sanctum * Tulsi Lamiaceae
98. Opuntia elatior * Hanthalo Thor Cactaceae
99. Tamarix stricta Chini Tamaricaceae
100. Thevetia peruviana Kaner Apocynaceae
101. Triumfetta rotundifolia Zipto Tiliaceae
102. Xanthium stromarium * Gadaria Asteraceae
103. Xeromphis spinosa Mindhol Rubiaceae
104. Zizyphus nummularia * Chanibor Rhamanaceae
Herb
105. Achyranthes aspera * Aghedo Amaranthaceae
106. Agave americana * ketki Agaveceae
107. Aloe barbadensis * Kunwar Liliaceae
108. Argemone mexicana * Darudi Papveraceae
109. Cassia tora * Tarota Caesalpiniaceae

4.109
Sr. No. Botanical Name Local Name Family
110. Celosia argentea * Lamdi Amarantaceae
111. Datura metel * Dhaturo Solanaceae
112. Flacourtia occidentalis Lodri Flacourtiaceae
113. Haloxylon recurvum Kharilani Chenopodiaceae
114. Helicteres isora Atedi or marda sing Sterculiaceae
115. Indigofera tinctoria * Gali Fabaceae
116. Martynia annua Vichhhudo Martyniaceae
117. Maytenus emarginata Vikro Celastraceae
118. Pedalium murex Ghokharu Pedaliaceae
119. Premna obtusifolia Kanther Verbenaceae
120. Pupalia lappacea Dhola zipto Amarantaceae
121. Solanum nigram * Piludi Solanaceae
122. Solanum suratense * Bhoyringani Solanaceae
123. Suaeda fruticosa Luno Chenopodiaceae
124. Suaeda nudiflora Luni Chenopodiaceae
125. Typha angustata Gabajaria Typhaceae
126. Urgenia indica Jangli kand Liliaceae
Bamboo and Grasses
127. Apluda mutica Bhangr Poaceae
128. Aristida adscensionis Lapdu Poaceae
129. Bambusa bamboos * Katis (Vans) Poaceae
130. Bothriochloa inschaemum Zinzavo Poaceae
131. Bothriochloo glabra Dhrafdo Poaceae
132. Chloris dolichostachya Sikaria Poaceae
133. Cymbopogon jwarancusa Gandharia Poaceae
134. Cymbopogon martini * Rosha Poaceae
135. Cynodon dactylon * Dhrub Poaceae
136. Dendrocalamus strictus * Mavel (Vans) Poaceae
137. Desmostachya bipinnata Darabh Poaceae
138. Dichanthium annulatum Jhinvo Poaceae
139. Dinebra retroflexa Khariu Poaceae
140. Eragrostis unicloides Chaklu Poaceae
141. Heteropogon controtus Dabh saliu Poaceae
142. Ischaemum rugosum Dholiu Poaceae
143. Iseilema prostratum Moshti Poaceae
144. Oplismenus burmanii Gandhelu Poaceae

4.110
Sr. No. Botanical Name Local Name Family
145. Sehima sulcatum Shaniar Poaceae
146. Seteria glauca Ziptis ghas Poaceae
147. Sorghum halepense Baru Poaceae
148. Sporolobus coromandelianus Khario Poaceae
149. Themeda quadrivalve Ratad Poaceae
Climbers
150. Abrus precatorius Chanothi Fabaceae
151. Acacia pinnata Khirvel Mimoseae
152. Asparagus racemosus Satawari Liliaceae
153. Bougainvillea spectabilis * Boganvel Nyctaginaceae
154. Capparis sepiaria Kanther Capparidaceae
155. Celastrus paniculata Malkankani Celastraceae
156. Cissus quadrangularis Hadsankal Vitaceae
157. Cocculas villosus Vevadi Menispermaceae
158. Combretum ovalifolium Malvel Combretaceae
159. Convolvulus microphyllus Sankhawali Convolvulaceae
160. Cuscuta reflexa * Amarvel Convolvulaceae
161. Ipomoea biloba * Rawal patri Convolvulaceae
162. Leptadenia reticulata Khirikhodi Asclepiadaceae
163. Pueraria tuberosa Vidari Fabaceae
164. Rivea hypocrateriformis Fagvel Convolvulaceae
165. Tinospora cordifolia Galo Menispermaceae
Source: State Forest Department, Jamnagar
*These species were observed during the Survey by NEERI Team

4.111
 Table 4.5.3
Medicinal Plants in Jamnagar District and their Medicinal Value

Sr. Scientific Name Common Family Medicinal Value

No. Name
Trees
1. Acacia catechu Khair Fabaceae Bark is used in Asthma
and bronchites
2. Alstonia scholaris Saptaparni Apocynaceae Roots are used in
biliousness
3. Atlantia racemosa Makadi Rutaceae Antispasmodic (fruit),
dyssentry (leaf)
4. Bombax malabaricum Kate sawar Bombacaceae Aphrodisiac (root bark),
debility (gum)
5. Bridelia retusa Khaja Euphorbiaceae Astringent, debility rheum
6. Butea monosperma Palas Fabaceae Blood pressure (root
bark), diarrhoea, dog bite
(flower)
7. Careya arborea Kumbha Myrtaceae Cold, cough (calyx),
stomache ache (bark,
fruit)
8. Caryota urens Bherali mad Palmae Laxative (wood sap)
9. Cassia fistula Bahava Fabaceae Burns, eczema (leaf),
purgative (root),
ringworm (leaf)
10. Cordia dichotoma Bhokar Boraginaceae Asringent (bark), cough
11. Dillenia pentagyna Karmal Dilleniaceae Cold (leaf, root)
12. Emblica officinalis Awala Euphorbiaceae Wound maggots (leaf)
13. Erythrina stricta Pangara Fabaceae Snakebite (bark),
vermicidal leaf
14. Ficus racemosa Umbar Urticaceae Dermatites (bark) urinry
disease (bark),
15. Garcinia indica Kokam Guttiferae Skin diseases (bark)
16. Gmelina arborea Shivan Verbenaceae Cholera (bark), rat bite,
syphilis, spleen trouble
17. Macaranga peltata Chandava Euphorbiaceae Bleeding wounds
18. Mallotus phillipinensis Shendari Euphorbiaceae Vermifuge (fruit)
19. Mangifera indica Am Anacardiaceae Dysentery (bark)
20. Memeceylon Anjani Melastomataceae Swell (bark)
umbellanum
21. Pongamia pinnata Karanj Fabaceae Diarrhea (leaf), ear

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Sr. Scientific Name Common Family Medicinal Value
No. Name
22. Sygygium cumini Jambhul Myrtaceae Diabetes (seed, fruit)
Fish poison (bark)
23. Terminalia bellerica Beheda Combretaceae Asthma (fruits) cholera,
cough, measles
24. Terminalia chebula Hirda Combretaceae Bronchitis, constipation
(fruit bark), purgative
(fruit)
25. Thespesia populnea Ranbhendi Malvaceae Arthritis, eczema (leaf)
Shrubs
26. Abutilon indicum - Malvaceae Cough (seed),
demulcent (leaf),
laxative
27. Adhatoda vasica AduArushalasa Acanthaceae Rheumatisium
28. Barleria prionitis Kholeta Acanthaceae Leucoderma, toothache
(leaf)
29. Calotropis gigantia Rui Asclepiadaceae Diarrhea, dysentery,
skin disease
30. Carrisa carandus Karwanda Apocynaceae Skin disease (root)
31. Cassia auriculata Tarwad Fabaceae Antifertility (root), labour
pain
32. Euphorbia nerifolia Niwdung Euphorbiaceae Asthma, earache (leaf)
33. Gnidia glauca - Thymelaeaceae Bruises, swell (leaf)
34. Helicteres isora Murudsheng Sterculiaceae Cholera, demulcent
(fruit), colic,
35. Holarrhena Kuda Apocyanaceae Amoebic dysentery
pubescens (bark), antitetanic
36. Homonoia riparia Sherani Euphorbiaceae Gravel (root)
37. Indigofera cassioides Chimnati Fabaceae Piles (leaf)
38. Lepidagathis Kate-adulasa Acanthaceae Measles (whole plant)
cuspidate
39. Murraya koenigii Kadhi-patta Rutaceae Stomach ache (bark
root),
tonic (leaf)
40. Vitex nigundo Nirgudi Verbenaceae Rheumatism, head
ache,
liver disease
41. Woodfordia fruiticosa Dhayati Lythraceae Bleeding, menorrhagia,
sprains (flower)
Herbs
42. Alternanthera sessilis - Amaranthaceae Eye complaints (leaf)

43. Argemone maxicana Dhatura Papaveraceae Eczema (seed oil),

4.113
 jaundice
(seed, root) scabies
(leaf, root)
44. Ascelpias Halad-kunku Asclepiadaceae Hemorrhage (leaf),
curassavica piles (root)
45. Eranthemum roseum Dashmuli Acanthaceae Leucorrhoea (root)
46. Lagascea mollis - Asteraceae Ear complaints (leaf)
47. Launaea Pathari Asteraceae Piles (leaf),
procumbens
48. Polygonum glabra Sheral Polygonaceae Dislocated bone
49. Sopubia delphinifolia - Scrophulariaceae Heals sores (whole
plant)
50. Sphaeranthus indicus Gorakhmundi Asteraceae Digestive disorders
(whole plant)
51. Tridax procumbens Ek dandi Asteraceae Bruises, cough, cuts,
injuries (leaf)

Source: State Forest Department, Jamnagar

4.114
 Table 4.5.4

Simpson’s Diversity Index (SDI) of Flora in the Study Area

Sr. Category of Flora Simpson’s Diversity Index (SDI)
No.
1 For trees 0.1611
2 For shrubs 0.1935
3 For herbs 0.2429

4.115
 Table 4.5.5
List of Agricultural Crops in Jamnagar District

Sr. No. Scientific Name Common Name

Rabi
Cereals
1 Triticum aestivum Wheat
2 Hordeum vulgare Barley
Pulses
3 Phaseolus Gram
4 Lens culinaris Lentil
Oil Seeds
5 Brassica juncea Mustard
Vegetables
6 Coriandrum anum Coriander
7 Allium sativum Garlic
8 Capsicum anum Chilly
9 Solanum tuberosum Potato
10 Daucus carata Carrot
11 Pisum sativum Pea
Kharif
Cereal
12 Oryza sativa Rice
13 Zea mays Maize
14 Sorghum vulgare Jowar
15 Millet Bajra
Pulses
16 Cajanus cajan Arhar
17 Phaseolus angularis Urd
18 Phaseolus mungo Moong
Oil seed
19 Seasamum Til
20 Arachys hypogea Groundnut
21 Glycine max Soyabean
22 Riccinus communis Castor
Others
23 Saccharum officinarum Sugarcane
24 Gossipium species. Cotton
Vegetables
25 Capsicum anum Chilly
26 Zingiber officinale Ginger
27 Piper nigrum Pipper

Source: District Agriculture Office, Jamnagar

4.116
 Table 4.5.6
List of Fauna found in the Jamnagar District

Sr. No. Scientific Name Common Name

Animals
1. Axis axis Chital
2. Boselaphus magocamelus Nilgai (Blue bull)
3. Canis laureus Jackal
4. Canis lupus Wolf
5. Equus hemionus khur Indian Wild Ass
6. Felis caracal schreber Caracal
7. Felis chaus Jungle Cat
8. Felis constantina Desert Cat
9. Funambulus pennati * Squirrel
10. Gazelles gazelles benetti Chinkara
11. Hemiechninas auritus Long Eared Hedge Hog
12. Anropunctatus * Mongoose
13. Hyaena hyaena Hyaena
14. Hystris indica Porcupine
15. Lepus nigricollis Hare
16. Manis carassicauta Pangolin
17. Micro chiroptera * Bat
18. Panthera pardus Panther
19. Presbytis entellus * Common Langur
20. Sus scrofa Wild Boar
21. Vulpes bengalensis Common Fox
22. Vulpes bucopus Desert Fox
Birds
23. Accipiter badius The Shikara
24. Acridotheres ginginianus Bank Myna
25. Acridotheres tristis * Common Myna
26. Aloedo atthis * Small Blue Kingfisher
27. Anas clypeatea Shoveller Duck
28. Andea alba * Large Egret
29. Anhinga rufa Darter
30. Anthropoides virgo The Demoiselle Crane
31. Ardea cinerea* Grey Heron
32. Ardeola grayii * Pond Heron
33. Athene brama Spotted Owlet
34. Bubulcus ibis * Cattle Egret
35. Ceryle rudis Pied Kingfisher

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Sr. No. Scientific Name Common Name
36. Chlamydotis undulata Houbara Bustard
37. Choriotis nigriceps The Great Indian Bustard
38. Circus aeruginosus Marsh Harrier
39. Clamator Jacobinus * Pied Crested Cuckoo
40. Columba livia neglecta * Blue Rock Pegion
41. Coracias benghalensis * Indian Roller
42. Corvus macrorhynchos * Jungle Crow
43. Corvus splendens * House Crow
44. Cypsiurus parvus The Palm Swift
45. Dicrurus adsimillis * Black Drongo
46. Egreta garzetta Little Egret
47. Egretta gularis* Reef Heron
48. Elanus caeruleus Blackwinged Kite
49. Eudynamys scolopacea * Koel
50. Francolinus pondicerianus Grey Partridge
51. Galerida deva Crested Lark
52. Gyps bengalensis Whitebecked Vulture
53. Haliastur indus Brahminy Kite
54. Himantopus himantopus Blackwinged Stilt
55. Hydrophasianus Pheasant tailed Jacana
56. Lanius schach Rufousbacked Shrike
57. Larus argentatus Herring Gull
58. Limosa lapponica Bartalied Godwit
59. Limosa limosa Blacktailed Godwit
60. Monticola gularis Blue Rock Thrush
61. Motacilla alba dukhuensis White Wagtail
62. Motacilla cincerea Grey Wagtail
63. Mycteria leucorodia * Painted Stork
64. Nectarinia asiofica brevirostris Purple Sunbird
65. Neophron percnopterus White Scavenger Vulture
66. Numenius arquata Curlew
67. Orthotomus sutocius Tailor Bird
68. Pandion haliaetus Osprey
69. Parus major Grey Tit
70. Pavo cristatus * Common Peafowl
71. Pelecanus qnocrotalus Rosy Pelican
72. Perdicula asiatica The Jungle Bush Quil
73. Phalacrocorax niger * Little Cormorant
74. Phalacrocorax qarbo * Large Cormorant
75. Phoenicopterus roseus * The Flamingo

4.118
 Sr. No. Scientific Name Common Name
76. Platalea leucorodia * The Spoonbill
77. Pluvialis squatarola Grey Plover
78. Podiceps raficollis Little Grcbe
79. Pseudibis papillosa Black Ibis
80. Psittacula krameri * The Roseringed Parakeet
81. Recarvirostra avosetta Avocet
82. Saxicoloides fulicata Indian Robbin
83. Sterna aurantia River Tern
84. Strebopelia decaocto Ring Dove
85. Strebopelia senegalensis * Little Brown Dove
86. Sturnus pagodarum Brahminy Myna
87. Sturnus roseus Rosy Pastor
88. Sypheotides indica Lesser Florican
89. Tephrodornis pondicerianus Common Wood Shrike
90. Threskiornis aethiopica White Ibis
91. Tringa tetanus Redshank
92. Turdoides striatus The Jungle Babbler
93. Vanellus indicus Redwattled Lapwing
Reptiles
94. Crocodiles palustris Crocodile
95. Geochelone elegans Star Tortoise
96. Python molurus Python
97. Varanus bengalensis * Monitar Lizzard
98. Varanus salvator Water Monitor
99. Naja naja Indian cobra
100. Bungarus caeruleus Common Indian Krait
101. Vipera russelli Russell’s Viper
102. Calotes versicolor Garden lizard

Source: State Forest Department, Jamnagar

*These species were observed during the Survey by NEERI Team

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 Table 4.5.7
Rare, Endangered and Vulnerable Status of Birds
in Jamnagar District

Sr. Scientific Name Common Name Status

No.

1 Ephippiorhynchus Black necked stork Endangered

Asiaticus
2 Haliastur indus Brahminy kite Vulnerable
3 Anhinga rufa Darter Vulnerable
melanogaster
4 Calidris tenuirostris Eastern knot Rare and Endangered
eastern knot
5 Coruficollis Eastern little stint Rare and Endangered
6 To nebularia Green Shank Vulnerable
7 Phalaerocorax Indian Shag Vulnerable
fuscicollis
8 Butorides striatus Little Green Heron Endangered
9 Falco peregrinus Peregrine Falcon
10 Asio flammeus Shorteared owl Vulnerable
11 Tringa erythropus Spotted Red Shank Vulnerable
12 Emberiza striolata Striolated Bunting Vulnerable
Source: State Forest Department, Jamnagar

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 Table 4.5.8
List of Marine Fish Species
Sr. No. Name of Fish
1. White pomfret
2. Black pomfret
3. Bombay duck
4. Thread fin
5. Jew fish
6. Hilsa
7. Clupeid
8. Coilia
9. Shark
10. Mullet
11. Cat fish
12. Eel
13. Leather Jacket
14. Seer fish
15. Indian salmon
16. Ribbon fish
17. Silver bar
18. Perch
19. Small Sceindies
20. Shrimp
21. Prawn (Medium)
22. Prawn (Jambo)
23. Lobster
24. Crab
25. Levta
26. Cuttle/Squids
27. Miscellaneous

Source: Assistant Director of Fisheries, Jamnagar

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 Table 4.5.9
Different Prawn Species Found in the Gulf of Kutch

Family Species
Penacidae
1. Penaeus indicus
2. P. latisulcatus
3. P. meguiensis
4. P monodon
5. Penicillatus
6. P. semisulcatus
7. Metapenaeus affinis
8. M. brevicornis
9. M. burkenroadi
10. M. lysianassa
11. M. lysianassa
12. M. monoceros
13. M. stebbingi
14. Paprpenaeopsis harswickii
15. P. psculptilis
16. P. stylifera
17. Trachypenaeus granulosus
18. T. pescadoreensis
19. Solenocera crassicornis
20. Metapenaeopsis stridulans
Sergestidae
1. Acetes indicus
Palaemonidae
1. Palaemon semmelinkii
2. P. styliferus
3. P. tenuipea
Hippolysmata
1. Hippolysmata ensirostris
2. Saron marmoratus
Alpheus
1. Alpheus distinguendus
Source: Marine National Park, Jamnagar

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4.6 Socio- economic Environment

4.6.1 Reconnaissance

The study of socio-economic component of environment incorporates various facets

viz. demographic structure, availability of basic amenities such as housing, education, health
and medical services, occupation, water supply, sanitation, communication and power supply,
prevailing diseases in the region as well as features such as places of tourist attraction and
monuments of archaeological importance. The study of these parameters helps in identifying,
predicting and evaluating the likely impacts due to the proposed project.

The area within 25 km radius from the project site is designated as study area, which
includes 115 villages from Jamnagar District covering 3 talukas namely Jamnagar, Khambaliya
and Lalpur. The main occupation of the people in the study area is agriculture and its allied
activities. These villages surveyed are presented in Table 4.6.1 alongwith their distance and
direction from the project site and the locations is depicted in Fig. 4.6.1

The major industrial establishments near the project site include a fertilizer plant of
GSFC, power plant of GEB, cement plant of Digvijay Cement Limited, ESSAR Industries
Limited and Reliance Industries Limited. It is envisaged that the proposed project would lead to
certain impacts on the surrounding area with reference to socio-economic environment. The
data on baseline status of the socio-economic profile is collected and the impacts are predicted.

4.6.2 Baseline Status

Baseline information is collected to define the socio-economic profile of the study

area. The database thus generated in the process includes the following:

1) Demographic structure

2) Infrastructure base in the study area

3) Economic attributes

4) Health status

5) Socio economic status with reference to Quality of Life

6) Awareness and opinion of the people about the project

The data is generated using secondary sources viz. Census Records, District
Statistical Abstract, Primary Health Centers, Official records etc. and primary data collection
through field survey as well as field observations.

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4.6.2.1 Demographic Structure

The study comprises 115 villages consisting of 38 villages of Jamnagar taluka, 41

villages of Khambaliya Taluka and 36 villages of Lalpur Taluka from Jamnagar district. The
summary of a demographic data based on primary census abstract (CD) 2001 of Jamnagar
district with reference to population, employment, household, literacy and community structure
is presented in Table 4.6.2 and the summarized information is given in Table 4.6.3.

The area is highly dominated by Hindu Community while the other religions group
accounts for the very small percentage out of the total population in the study area. The society
in the villages is traditionally rooted with old beliefs like patriarchal system and feudalism.
Gender differences can also be seen in the study area.

Agriculture is the main occupation of the people in the study area and the major food
crops grown in the district are wheat, rice, jowar, bajra and chilies whereas non-food crops
grown are cotton and fodder crops.

The significant demographic features are:

♦ The total no of households in the study area are 216222

♦ The total population in the study area is 1175132

♦ Sex ratio (No. of females per 1000 males) is 928

♦ It is observed that the study area has an average literacy rate of 60.24% and the
employment rate is 30.33%

4.6.2.2 Infrastructure Resource Base

The infrastructure resource base with reference to education, medical, water resources, post
and telegraph, transportation and power and power supply is abstracted from Household, Assets and
Amenities CD-2001 of Jamnagar district, Gujarat and presented in Table 4.6.4. However, the information
is collected through socio-economic survey about the facilities in the villages is described below:

Education
Anganwadi Center is available in most of the surveyed villages. The figures from survey
reported that most of the villages have primary and middle school facility while for further higher
education people have to travel to more than 20 km.

The literacy rate of the study area is 60.24%, female literacy rate in the study area is quite
low. Maximum educational level of the people in the study area is up to 10th class. The reason behind
the low educational level may be due to lack of educational facilities, poor transportation facilities to
schools and low motivation level of parents and students.

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 The scope of higher and technical education is available only at the district and only few
people are able to take benefits of these educational institutions.

Medical Facility
Medical facilities in terms of community health workers and medical practitioner are available
in most of the villages. The villages devoid of government medical facility avail them from private clinics
or RIL center at Motikhavadi or visit to Lalpur and Khambaliya for treatment.

Power Supply
Electricity is available in all the villages for both domestic and agriculture purposes. Electricity
connections for irrigation are also very few as the problem of shut down of electricity prevails in the study
area.

Water Supply
The rural people from Jamnagar district use untreated well water for drinking purpose. Water
supply is available in all villages that include bore wells, water tanks and water tankers provided by
panchayats at the time of water scarcity. The quality of water is salty in some villages.

Transport and Communication

Transportation facilities are satisfactory. Bus stop is available in every village and bus
visits villages for more than 4-5 times a day. The approach route is either Kuccha or pacca.

Post and communication facilities are extensively available with the PCO, STD and ISD
facility. People are satisfied with the communication facilities.

Fuel
Fuel that is mainly used for cooking and other domestic purpose is wood, kerosene and LPG.
LPG agencies are available in most of the villages while some people have to fetch it from the villages
located more than 5 km.

4.6.2.3 Economic Attributes

The information on economic resource base of the area reveals that the main occupation of
the people in the study area is agriculture and its allied activities. As rainfall is scanty and draught is
common, agriculture production is not higher in the study area. The main food crops grown are wheat,
rice, jowar, bajra, chilies and while the non-food crops grown are cotton and fodder crops. People
residing near the coast mainly carry out fishing activity. The salt pans generated, also provides good
source of employment for the local people. Local people are also employed in the nearby industries on
contract basis. The employment pattern of the study area is shown in Fig. 4.6.2 and is described below:

♦ Total main workers in the villages of the study area are 356450 (30.33 %)

♦ There are 54417(15.27%) workers as cultivators

♦ There are 21456 (6.01%) agriculture labours

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 ♦ Non-worker population in the study area is 781603 (66.51%)

4.6.2.4 Health Status

Health of the people is not only a desirable goal, but it is also an essential investment
in human resources. As per the National Health Policy, Primary Health Care has been
accepted as main instrument for achieving this goal of development and strengthening rural
health infrastructure through a three-tier system, viz. sub-centers, primary health center (PHCs)
and community health center, which have been established.

Lack of building, shortage of manpower and inadequate provision of drug supplies

are hampering the operational activities of these units. The standards to be met according to
National health Policy are given below:

Population Infrastructure Personnel

3,000 – 5, 000 1 Sub center 1 ANM

25,000 – 30, 000 1 PHC, 6 beds 2 Medical officers

1,00,000 Rural Medical superintendent

Data regarding health status has been collected from Primary Health Centers; Community
Health Center Lalpur and Rural Hospital Khambaliya. From the data collected different health problems
are reported to be prevalent in the community. Cases of acute watery diarrhea are reported to be high in
the month of August. Other diseases like gastroenteritis and malaria are also highly prevalent in the study
area besides common fever and tuberculosis.

The primary health center conducts various health camps and vaccination camps, health
awareness programmes such as family welfare camps to motivate people for family planning operations,
AIDS awareness programme and regular medical check-up camps are organized by PHC.

4.6.2.5 Cultural and Aesthetic Attributes

The ancient temples of “Krishna” and “Asapura Mata” are situated in villages Khambaliya (21
km) and Jogwad (15 km) from the project site.

4.6.3 Socio-economic Survey

In order to assess and evaluate the likely impacts arising out of any developmental projects
on socio-economic environment, it is necessary to gauge the apprehensions of the people in the project
area. Socio-economic survey serves as an effective tool for fulfilling this requirement. Socio-economic
survey was conducted by NEERI in 18 villages of the study area located in all directions with reference to
the project site. Sarpanch of each village and respondents (adults male-female) were chosen for the

4.126
collection of awareness and opinion, by using judgmental or purposive sampling methods representing
various socio-economic sections of the community.

During the socio-economic survey in the 18 villages it was observed that people are facing
certain problems. The field observations from each of these villages during survey with reference to
critical issues such as expectations from the project and their quality of life is described below:

♦ In most of the villages, respondent reported that their monthly income is near by
Rs. 2000-2500/- unemployment problem are most prevalent in the study area.
People are mainly engaged on temporarily or on contract basis in RIL and
ESSAR Oil Limited and its associates

♦ Due to improper planning of drainage system respondents have reported the

problems related to mosquito nuisance. Malaria and respiratory diseases are
commonly found in study area. Existing medical facility in the surveyed villages
are not satisfied

♦ All the surveyed villages are facing electricity shortage problems. Electricity is
available for only 6-8 hours in a day, therefore daily activity mainly agriculture is
highly affected. This results in low production and low income affecting economic
level of villagers. Most of the villages are not having streetlights

♦ Primary survey revealed that educational level in the region is relatively low. The
status of female literacy is reported to be very low. It was observed that the
literacy is reported to be very low. It was observed that the literacy rate in the
study area is higher in the younger age group as compared to people above 35
years

♦ Low educational status in the region has increased the level of unemployment, as
people are not able to fulfill the requirement of the job

♦ People are demanding that technical education must be introduced to locals that
may held to create employment opportunities

♦ People expected construction of infrastructure facilities like school, community

hall, temple etc. with the help of SEZ authority

♦ Villages are facing the problem of pollution due to the near by industries

♦ Poor and inadequate medical facilities are common complaint in surveyed

villages. Some of the villages have no accessibility to health care facilities.
People have to go to long distance to access the medical facilities. People
expect extension of mobile health van facility in the villages

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 ♦ Most of the surveyed villages do not have any pucca road. There are only Kuccha
roads in the villages. The condition of roads is very poor and maintenance of
roads has been not done since long time. People expect periodic maintenance of
major roads

♦ People complained of long distance, lack of proper approach roads and pathways
and low motivation level for low enrolment rate in getting higher education

4.6.4 Awareness and Opinion of the People about the Project

Querries were made to the local people regarding awareness about the project. During
discussions following observations were recorded:

♦ Most of the respondents are aware about in the study area proposed project,

♦ People are expecting that the project will bring new development in the region
and may generate jobs for the local population

♦ People are expecting that project authority will improve the basic infrastructure of
the villages and may ultimately help in improving the Quality of Life of the region

♦ People are expecting medical facilities from proposed project and desire
improvement in facilities and extension of the facilities to some more nearby
villages

4.6.5 Quality of Life

Quality of life (QoL) is a term, which indicates overall status of socio-economic

environment in a given area. Quality of life (QoL) is defined as a function between “objective
conditions” and “subjective attitudes” involving a defined “area” of concern.

The “objective conditions” are defined as numerically measurable artifacts of a

physical, sociological event or economic event. Objective conditions may be defined as any
number, which stands for a given quantity of a variable of interest so long as it is independent of
subjective opinion.

“Subjective attitude” is primarily concerned with affective and cognitive dimensions. It

is specifically concerned with how aspects of cognition vary with variation in objective
conditions.

Once objective measures are obtained for each factor, they are transformed to a
normal scale varying from 0 to 1 (value function curve) in which 0 corresponds to the lowest or
least satisfactory measure, and 1 corresponds to the highest. The weights are assigned to each
factor by ranked-pairwise technique, by the expert group based on the secondary data and

4.128
general observations.

For each objective measure, a corresponding subjective measure is developed for

each individual of the sample population by asking him to rate his satisfaction scale (value
function curve). It is used such that 0 corresponds to the lowest level of attitudinal satisfaction
and 1 corresponds to the highest level of satisfaction. Weights are assigned to each factor
using ranked - pairwise comparison techniques.

The Socio-economic Indicators for QoL Assessment are:

1. Income, Employment and Working Conditions
2. Housing
3. Food
4. Clothing
5. Water Supply and Sanitation
6. Health
7. Energy
8. Transportation and Communication
9. Education
10. Environment and Pollution
11. Recreation
12. Social SecurityHuman Rights
I. Subjective quality of life
m p
QoLs = 1/p ∑ ∑ QIij X Wi
i =1 j=1
Where,

QoLs = Subjective quality of life index

p = No. of respondents, j = 1, ......, p

m = No. of factors, i = 1, ......, m

QIij = Subjective quality index for “i” th factor assigned by jth respondent

∑ Qiij = Subjective quality index for ”i” th factor assigned by all respondents in
an area
Wi = Relative weightage of the “i” th factor

II. Objective quality of life

i=n
QoLo = ∑ QIi X Wi
i=1
Where,

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 QoLo = Objective quality of life index
n = No. of QoL Factors
i = 1, ......, n
QIi = Satisfaction level (assigned by the expert group) for the “i” th objective
indicator
Wi = Normalized weight for “i” th factor

III. Quality of Life (Cumulative Index)

QoLo + QoLs
QoLc = -------------------
2

The subjective and objective QoL indices prior to commissioning of the project are
presented in Table 4.6.6.

The average QoL index values are estimated as:

QoL (s) = 0.50
QoL (o) = 0.52
QoL (c) = 0.51

The average QoL index value for the study area is leaning towards satisfactory level
due to good economic status like low income, unemployment and also availability of basic
needs, viz. food, clothing, and housing. The area lacking with medical, educational facilities and
social security, besides water scarcity, inadequate irrigation, lack of sanitation, which are
subjective conditions and are not much satisfactory as compared to objective conditions.

4.130
 Gulf of Kachchh

Jamnagar
5 16

15

14
10 km

Sas 25 km
1
SH-6 13
oi
17
18 Sh-27
6
Khambalia 3
8
9

7 12
4 Lalpur
10
11

Fig. 4.6.1: Socio-economic in the study area

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 Marginal workers
3.2% Household workeres
1.6%

Other workers
Main workers 77.1%
Non workers 30.3%
66.5%

Agricultural Labour
Cultivators 6.0%
15.3%

Fig. 4.6.2: Employment pattern in the study area

 Table 4.6.1
Distance and Direction of the Villages Surveyed

Sr. Villages Aerial Distance Direction

No. (km)

1. Naranpar 20 ENE
2. Gordhanpar 20 NNE
3. Pipartoda 18.3 E
4. Kota 19 WSW
5. Vadinar 18.3 NW
6. Sevak Dhuniya 6.6 E
7. Rafudad Moti 5 S
8. Gajana 8 SE
9. Apia 9 SW
10. Govana 12.6 S
11. Godavari 16 SSE
12. Rinzpur 23.3 SE
13. Padana 5.6 NW
14. Navagam 10 NNE
15. Dera Chhikari 7.3 N
16. Kana Chhikari 10 N
17. Kanalus - -
18. Arablus 5.6 NE
 Table 4.6.2
Demographic Structure in Study Area

Sr. No_House
No. NAME hold H TOT_P TOT_M TOT_F P_SC P_ST P_LIT MAIN_W_P MR_W_P NON_W_P
Jamnagar- District
1. Jamnagar 156241 836256 435975 400281 68359 4264 537823 244647 14132 577477
2. Vasai 251 1693 856 837 118 0 377 434 5 1254
3. Amra 691 4141 2137 2004 165 0 2273 1517 232 2392
4. Jivapar 446 2405 1223 1182 107 0 1402 1117 58 1230
5. Gaduka 87 447 229 218 9 0 221 124 75 248
6. Balambhdi 108 497 253 244 0 0 249 84 102 311
7. Dodhiya 252 1389 725 664 221 0 781 626 218 545
8. Vav Beraja 148 775 393 382 7 0 418 302 8 465
9. Chela 1024 5696 2994 2702 978 67 2556 1989 256 3451
10. Harshadpar 336 1755 868 887 112 0 1005 837 57 861
11. Naranpar 302 1886 976 910 180 11 1060 568 21 1297
12. Changa 265 1531 760 771 190 0 839 558 150 823
13. Chandragadh 207 1054 520 534 0 0 692 504 7 543
14. Khoja Beraja 164 871 443 428 91 7 482 346 141 384
15. Lonthiya 150 795 396 399 11 0 373 359 45 391
16. Bavariya 37 189 97 92 3 0 104 96 4 89
17. Lavadiya 226 1398 723 675 144 0 640 581 40 777
18. Mokhana 222 1234 617 617 123 0 584 333 0 901
19. Dhandha 76 461 238 223 44 0 246 194 7 260
20. Chandraga 104 533 265 268 144 0 327 237 64 232
21. Bed 999 6260 3213 3047 144 0 3187 1926 97 4237
22. Mungani 450 2644 1361 1283 267 117 1560 584 154 1906
Sr. No_House
No. NAME hold H TOT_P TOT_M TOT_F P_SC P_ST P_LIT MAIN_W_P MR_W_P NON_W_P
23. Gagva 157 837 428 409 148 0 425 199 111 527
24. Nani Khavdi 277 1410 733 677 61 0 901 370 32 1008
25. Sapar 381 1921 983 938 373 0 1053 798 171 952
26. Champa Beraja 178 879 462 417 0 7 473 249 34 596
27. Khoja Beraja 164 871 443 428 91 7 482 346 141 384
28. Gordhanpar 136 775 399 376 4 0 384 174 51 550
29. Khara Beraja 97 537 287 250 220 0 213 184 0 353
30. Dhinchda 493 2790 1448 1342 207 0 1350 749 181 1860
31. Moti Khavdi 1973 7422 4033 3389 131 9 5098 2356 322 4744
32. Lakha Baval 607 3504 1791 1713 602 0 1685 1438 49 2017
33. Kansumara 350 2045 1053 992 267 0 1045 579 85 1381
34. Haripar 142 704 349 355 0 0 412 257 116 331
35. Pipartoda 33 138 68 70 0 0 71 65 15 58
36. Khengarka 200 1148 577 571 243 4 654 354 280 514
37. Lakha Baval 607 3504 1791 1713 602 0 1685 1438 49 2017
38. Masitiya 494 3180 1659 1521 0 0 1084 782 57 2341
Khambhalia- Taluka
39. Khambhalia 10636 63354 32350 31004 3211 57 31905 16792 1262 45300
40. Danta 189 1133 583 550 116 31 439 303 1 829
41. Bhatgam 65 445 247 198 50 0 162 168 16 261
42. Kota 96 623 334 289 0 0 189 183 7 433
43. Kolava 313 2018 999 1019 151 0 802 911 145 962
44. Bhandariya 240 1509 737 772 78 0 709 699 79 731
45. Bajana 310 2079 1059 1020 102 0 810 714 466 899
46. Kandorna 180 1062 526 536 49 0 468 500 106 456
47. Bhadthar 692 3937 2039 1898 313 1 1836 1455 528 1954

4.135
Sr. No_House
No. NAME hold H TOT_P TOT_M TOT_F P_SC P_ST P_LIT MAIN_W_P MR_W_P NON_W_P
48. Sagariya 74 428 212 216 9 0 202 216 83 129
49. Mota Mandha 254 1446 732 714 73 0 560 418 172 856
50. Nana Mandha 216 1330 706 624 99 0 582 247 122 961
51. Nana Ambla 238 1443 738 705 0 0 436 403 275 765
52. Mota Ambla 105 594 289 305 14 0 269 167 73 354
53. Vadinar 1166 6578 3400 3178 742 23 3133 1643 199 4736
54. Bharana 605 4113 2110 2003 99 0 1211 969 135 3009
55. Timbdi 155 870 434 436 118 0 436 219 81 570
56. Kajurda 163 952 483 469 104 0 333 265 143 544
57. Haripar 147 868 460 408 68 0 541 229 25 614
58. Kanchanpur 131 626 336 290 6 0 250 159 23 444
59. Sinhan Kakabhai 124 561 277 284 85 0 248 171 12 378
60. Lakhasar Hapa 155 1020 514 506 89 3 519 289 130 601
61. Devaliya 163 1051 514 537 29 0 382 441 86 524
62. Lakhiya Nana 91 546 287 259 64 0 345 139 25 382
63. Lakhiya Mota 178 992 495 497 48 0 548 271 154 567
64. Rangpar 164 954 482 472 95 0 495 353 96 505
65. Veraval Moti 297 1692 876 816 92 0 1078 732 130 830
66. Sevak Bhatiya 85 380 181 199 18 0 226 218 4 158
67. Sevak Dhuniya 163 1006 536 470 113 46 597 300 39 667
68. Dabasang 256 1298 647 651 246 0 634 340 108 850
69. Machhu Beraja 273 1626 810 816 38 3 825 610 211 805
70. Sevak Bharudiya 96 474 241 233 255 43 243 206 68 200
71. Modpar 475 3193 1600 1593 132 7 1485 1036 61 2096
72. Rafudad Moti 307 1771 883 888 22 90 956 557 364 850
73. Gajana 218 1094 589 505 94 0 528 431 108 555

4.136
Sr. No_House
No. NAME hold H TOT_P TOT_M TOT_F P_SC P_ST P_LIT MAIN_W_P MR_W_P NON_W_P
74. Mulila 203 1196 597 599 40 4 572 517 3 676
75. Pipar Navi 243 1387 692 695 76 0 696 502 80 805
76. Rafudad Nani 321 1938 1011 927 151 0 1072 577 528 833
77. Kanvirdi 77 526 282 244 10 0 282 278 30 218
78. Apia 168 1011 491 520 56 0 415 533 93 385
79. Govana 315 1875 953 922 48 0 785 487 408 980
Lalpur-Taluka
80. Lalpur 18421 101637 52076 49561 10080 618 53154 35568 8283 57786
81. Singach 593 3514 1840 1674 152 0 1606 1544 116 1854
82. Jasapar 214 1376 688 688 21 2 630 497 193 686
83. Veraval Nani 154 1003 526 477 0 0 437 307 171 525
84. Dhuniya Nava 89 509 251 258 0 0 235 228 49 232
85. Khadba Mota 408 2210 1088 1122 323 18 1115 682 476 1052
86. Jogvad 144 724 397 327 122 0 430 251 74 399
87. Karana 200 1036 495 541 130 4 549 432 66 538
88. Dhuniya Nava 89 509 251 258 0 0 235 228 49 232
89. Khadba Mota 408 2210 1088 1122 323 18 1115 682 476 1052
90. Veraval Nani 154 1003 526 477 0 0 437 307 171 525
91. Godavari 197 1202 629 573 74 0 596 371 336 495
92. Nanduri 470 2659 1355 1304 112 0 1230 848 335 1476
93. Bharudiya Mota 104 668 349 319 0 0 335 214 10 444
94. Vijaypur 79 440 223 217 0 0 181 205 2 233
95. Raka 195 1051 555 496 133 0 534 336 208 507
96. Khatiya 221 1134 593 541 203 0 644 426 22 686
97. Khadba Nana 294 1816 920 896 456 84 766 658 38 1120
98. Babariya 41 282 155 127 0 0 41 84 67 131

4.137
Sr. No_House
No. NAME hold H TOT_P TOT_M TOT_F P_SC P_ST P_LIT MAIN_W_P MR_W_P NON_W_P
99. Rinzpur 337 2114 1064 1050 86 15 887 697 147 1270
100. Tebhada 240 1392 739 653 363 0 536 561 171 660
101. Sanosri 410 2176 1084 1092 298 4 1075 775 257 1144
102. Kathitad 142 659 371 288 4 9 380 150 52 457
103. Sansora 245 1540 791 749 116 0 693 398 445 697
104. Chorbedi 190 1108 577 531 124 0 481 461 135 512
105. Panchsara Mota 80 375 188 187 36 0 227 173 17 185
106. Badhla 200 946 486 460 150 0 466 444 0 502
107. Khadba Nana 294 1816 920 896 456 84 766 658 38 1120
108. Vadpanchasara 157 846 412 434 133 0 484 296 21 529
109. Padana 636 3364 1803 1561 489 5 1637 1051 112 2201
110. Navagam 330 1615 818 797 92 0 854 596 29 990
111. Dera Chhikari 113 529 265 264 0 0 262 149 18 362
112. Kana chhikari 118 706 364 342 0 0 300 278 81 347
113. Kanalus 388 2059 1044 1015 245 9 1075 858 64 1137
114. Arablus 287 1550 771 779 421 0 800 700 82 768
115. Meghavadar 158 780 395 385 36 0 393 388 22 370
Total 216222 1175132 609595 565537 96747 5671 708004 356450 37079 781603

Source : Primary Census Abstract : Jamnagar District CD 2001

4.138
 Table 4.6.3

Summary of Demographic Structure

Sr. Demographic Parameter Details

No.

1. No. of District 01

2. No. of Taluka 03

3. No. of Villages 115

4. Total No. of Household 216222

5. Total Population 1175132

6. Sex Ratio (No. of female 1000 Males) 928

7. Scheduled Castes (%) 96747(8.23%)

8. Scheduled Tribes (%) 5671 (0.48%)

9. Literate (%) 708004 (60.24%)

10. Main Workers (%) 356450 (30.33%)

11. Marginal Workers (%) 37079 (3.15%)

12. Non-workers (%) 781603 (66.51%)

Source: Primary Census Abstract CD (2001) Jamnagar District, Gujarat.

 Table 4.6.4

Infrastructure Resource Base of the Study Area

Sr. District Educational Medical Power Source Of Drinking Water

No. institution facilities supply
Tap Hand Tube Well Tank, River, Spring Any
pump well pond, canal other
lake

Jamnagar District

1. Total 2,629 902 296,004 189,197 60,678 10,919 46,066 1,265 902 185 30,230

2. Rural 2,074 448 157,963 86,479 40,523 6,345 43,379 1,184 898 183 11,724

3. Urban 555 454 138,041 102,718 20,155 4,574 2,687 81 4 2 18,506

Source: Housing, Household Amenities & Assets – CD (2001) Jamnagar District, Gujarat.

4.140
 Table 4.6.5

Mortality Rate of the Study Area

Taluka Name Year Birth Death IMR

Jamnagar 1999 18389 4439 196
2000 17549 4604 146
2001 18338 5292 0
Kambaliya 1999 3965 587 06
2000 5665 476 10
2001 4962 500 21

Lalpur 1999 3168 378 27

3124 389 12
2000
2822 435 08
2001

Source: Statistical Abstract Book 2002 - 03 Jamnagar District, Gujarat.

4.141
 Table 4.6.6

Existing Quality of Life in the Study Area

Sr. No. Villages QoL (s) QoL (o) QoL (c)

1. Naranpar 0.50 0.52 0.51

2. Gordhanpar 0.48 0.50 0.51
3. Pipartoda 0.47 0.49 0.48
4. Kota 0.49 0.51 0.50
5. Vadinar 0.49 0.51 0.50
6. Sevak Dhuniya 0.51 0.53 0.52
7. Rafudad Moti 0.52 0.54 0.53
8. Gajana 0.50 0.52 0.51
9. Apia 0.47 0.49 0.48
10. Govana 0.52 0.54 0.53
11. Godavari 0.51 0.53 0.52
12. Rinzpur 0.53 0.55 0.54
13. Padana 0.47 0.49 0.48
14. Navagam 0.52 0.54 0.53
15. Dera Chhikari 0.48 0.50 0.49
16. Kana Chhikari 0.49 0.51 0.50
17. Kanalus 0.53 0.55 0.54
18. Arablus 0.52 0.54 0.53
Average 0.50 0.52 0.51

QoL (s) : Subjective Quality of Life

QoL (o) : Objective Quality of Life
QoL (c) : Cumulative Quality of Life

4.142
C hapter 5

Identification and Prediction of

Environmental Impacts

Impact prediction is a way of ‘mapping’ the environmental consequences of the

significant aspects of the project and its alternatives. Several techniques and methodologies are
in vogue for predicting anticipated impacts due to projects on natural and social aspects of the
environment. These predictions are superimposed over the baseline (pre-project) status of the
environment to derive the ultimate scenario of environmental conditions. These conditions are
then subsequently evaluated for acceptability by screening them against standards for ambient
environmental quality, against toxic effect, thresholds, etc. Based on results of prediction and
evaluation, pollution abatement and control measures in order to mitigate the adverse impacts
on the environment are delineated in an Environmental Management Plan for further
implementation during the construction and commissioning of the proposed activities, as well as
during the operational phase.
Impact predictions are made against a 'baseline' established by the existing
environment (or by its future state) known as baseline studies, the collection of data on relevant
biophysical, social and economic aspects provides a reference point against which the
characteristics and parameters of impact-related changes are analysed and evaluated. In many
cases, it is likely that the current baseline conditions will still exist when a project is
implemented.

5.1
 The characteristics of environmental impacts to be taken into account in impact
prediction and decision-making include:

i) Nature (positive, negative, direct, indirect, cumulative);

ii) Magnitude (severe, moderate, low);

iii) Extent/location (area/volume covered, distribution);

iv) Timing (during construction, operation, decommissioning, immediate, delayed,

rate of change);

v) Duration (short term, long term, intermittent, continuous);

vi) Reversibility/irreversibility;

vii) Likelihood (probability, uncertainty or confidence in the prediction); and

viii) Significance (local, regional, global)

The anticipated environmental impacts are predicted and evaluated in terms of the
above mentioned characteristics during construction and operation phases of the proposed
petroleum and petrochemical units in SEZ.

Various industries in India have been classified as green, orange and red by Central
Pollution Control Board (CPCB), a statutory organisation under Ministry of Environment and
Forests (MoEF), depending upon pollution potential of these
industries. The pollution potential is rated as low, medium and high for green, orange and red
category of industries respectively. The industries proposed in SEZ are Refinery and
Petrochemicals, which all fall under red category.

Green

i) Non-obnoxious and non-hazardous emitting industries

ii) Do not discharge industrial effluent of polluting nature
Orange

i) Industries with proper environmental assessment and adequate pollution

control measures to treat their waste
Red

i) Polluting industries

Prediction of impacts is the most important component in environmental impact

assessment process. Several mathematical/statistical techniques and methodologies are
available for predicting impacts due to developmental activities on physico-ecological and socio-
economic environment. The quantitative prediction of impacts is also essential to delineate

5.2
pragmatic Environmental Management Plan (pollution abatement and control measures) for
implementation during and after the commissioning of proposed activities for minimising the
adverse impacts on environmental quality.

Mathematical models are the best tools to quantitatively describe cause-condition-

effect relationships between sources of pollution and different components of environment. In
case, mathematical models are either not available or it is not possible to identify/validate
models for a particular situation, predictions are arrived at through available scientific
knowledge and judgments.

The environmental impacts of the proposed project are further categorized into the
following:

• During the construction phase which may be regarded as temporary or short

term; and

• During the operation phase which would have long-term effects

The construction and operation of the proposed project comprises various activities
each of which shall have varied environmental impacts. The impacts identified have been
presented in the following sections.

The mathematical models used for carrying out predictions in the present study
included, steady state Gaussian Plume Dispersion model designed for multiple point sources
for air quality and wave divergence model for noise quality. In case of land, biological and socio-
economic environments, the predictions have been made based on the available scientific
expertise and judgments.

5.1 Impacts during Construction Phase

The project construction phase (though generally short-term in comparison to the
operation phase) can lead to significant environmental impacts. Significant impacts can result
through short-term, high-intensity pressures on the physico-chemical environment in relation to
air, groundwater, surface water, soils and land. Risks to environment parameters are of
particular importance while assessing the construction stage impacts, in addition to hazards and
risks posed to construction stage workers.

The stress on infrastructure, socio-cultural incompatibility due to immigration of

construction workers and living conditions and consequent public hygiene are also important
issues that has been considered while assessing impacts during construction stage.

The prediction of construction stage impacts includes any impacts occurring as a

5.3
result of project infrastructure setup during construction, (e.g. roads, temporary labor colonies
etc.). The waste and refuse generated during construction, and any likely impacts resulting
through de-commissioning of temporary structure(s) created during construction phase.

The construction activities will mainly involve:

• Land preparation for proposed project units

• Civil construction and mechanical erection of the facilities

• Internal pipeline laying and development of associated roads

The construction phase activities of any development shall cause short-term and
temporary impacts. The various impacts during construction i.e. on air, water, land, soil,
biological, social etc. their characteristics are listed in Table 5.1.

5.1.1 Air Environment

During the short period of site preparation mechanical shovels and earthmovers will
be used for site clearance, cut and fill and other site leveling activities. These activities could
generate dust particles which will be mobilised by wind, and affect the ambient air quality.
However, these activities will be only temporary and with the sandy nature of the soil, the
impact to ambient air quality would be only in areas in close proximity to project site.

During the construction phase, all emission sources will be intermittent which
include emissions from heavy equipment used for construction and materials transport, from
heavy vehicles on site. The power for construction purpose will be made available from the DG
sets. The emissions are temporary and not expected to contribute significantly to the ambient
air quality and will be within prescribed limits for industrial regions by CPCB.

The construction phase activities of any development in the SEZ shall mostly cause
negative, short-term and temporary impacts. Adjoining proper mitigation measures could
minimize these impacts.

i) Air quality and noise level impacts from site clearing, soil excavation,
transportation of raw materials, construction activities and trenching on land

ii) Soil erosion to a small extent (flat terrain) due to site clearing, soil excavation,
construction activities and trenching on land

iii) Land, soil and aesthetic impacts due to labour camps and land reclamation

iv) Impact on water quality from discharge of wastes from labor camps through
sewage treatment units will show turbidity increase due to soil erosion at the
project site

5.4
 v) Marginal loss of flora and fauna due to site clearing

vi) Impacts on socio-economic environment due to employment generation in

construction activities

5.1.2 Noise Environment

a) Impacts due to Construction Equipment: The noise due to construction

equipment will be a temporary phenomenon. However, noise levels due to construction
equipment may result into significant impacts due to operation of several equipment at a time.

b) Noise due to Transportation: The noise impact due to transportation will occur during the
construction phase when many trucks (each way) per day will be plying on State Highway due
to transportation of construction materials, man and machinery. This will not be a continuous
operation but it may last up to 2-3 years. This will add to noise impact as background noise
level will increase by 2-3 dBA.

5.1.3 Water Environment

Only temporary and localised impacts on hydrology are expected due to the
construction activities. These could arise from temporary obstruction to natural flow of water
due to foundation excavation, stacked material etc. There is a low significance of these impacts
which can be easily overcome by appropriate construction methodology and practices.

During construction phase, water of appropriate quality is required for the following
activities:

• Earth material compaction and stabilization during embankment construction

• In-situ cement concrete preparation for RCC and PCC requirements
• Drinking water needs of construction workers
• Equipment washing and cleaning, especially those involved in earth material
compaction and stabilization
• Maintaining the embankment slope landscape, roadside, kerbside, median-side
vegetation and compensatory plantation near the completed stretches of road
The water requirement during the construction period is estimated about 500 m3/hr
for construction and campsite requirements. The water will be made available from existing
refinery resources (desalination plant) without affecting local water resources as the region is
water scarce. The employment of the local people for the unskilled and semi-skilled jobs will
ensure minimal temporary construction camp facilities thus minimise the migration of the
people. Adequate sanitation facilities will be provided at the campsites.

5.5
5.1.4 Land Environment
The SEZ project will require acquisition of additional land; land is being acquired
through the Land Acquisition Act and Direct Purchase. Since most of the land is barren no
change is anticipated on the landuse due to such activities outside the SEZ boundaries.
The impacts on soil due to land disposal of solid wastes such as construction
rubble, campsite garbage and discarded topsoil may impact soil quality. However, the impact is
likely to be insignificant as the project authorities will take adequate measures to ensure that all
waste generated at the construction site and at the labour camps are collected and disposed
off in an appropriate manner in a dump site or recycled or reused where feasible. Moreover,
experience gained while setting up RIL refinery will be made use of in handling solid wastes
emanated during construction phase.

No quarry material will be required as the land is a gentle slope and mostly even
and will not involve major cutting and filling. During the site preparation work, the soil from the
higher gradient shall be utilized to level the areas with lower gradient. The amount of cutting
and filing is well balanced. The current topography and usage of the area will be used as a
basis for the development of a reinstatement plan that will be implemented after the quarry
activities have ceased.

5.1.5 Biological Environment

As the project will be developed mainly in barren land therefore there will be very
less tree cutting and tree felling. But since the proposed project will acquire a large amount of
land it can cause damage to soil micro fauna like earthworms and scavengers which helps in
maintaining soil fertility.

There exist five industries around the proposed project site within 25 km radius of
the study area. These are Reliance Industries Limited, Essar Oil Limited, Gujarat State
Fertilizer Company, GEB Power Plant and Digvijay Cement Limited. Due to these industries
and traffic in the region the air pollution and noise pollution causing damage to the
environment, due to which the natural habitats of the wild animals (Nilgai, Wild Boar, Fox) are
reducing day by day. Because of shortage of food it is learnt that these animals enter the
villages and destroy agricultural land.

Minimal vegetation will be cleared for the construction activities. The necessary
stockpiles will be maintained within the SEZ complex. The construction labourers will be
prohibited from using vegetation for fuel wood. Common kitchens at the camp site will be
provided with cooking gas/fuel for this purpose.

The construction phase of the project will not have any impact on the biota
freshwater bodies considering its location and operations philosophy.

5.6
5.1.6 Socio-economic Environment
The potential impacts of the project construction on local public infrastructure and
civic amenities could arise due to pressure on resources (power, water, roads) due to the
construction activities and the presence of the construction camps.

The electricity requirement for construction activities will be met from the existing
RIL refinery resources and the project proponents’ will not source electricity from the State
electricity grid supply during the construction activities. No existing resources/water sources
(surface/groundwater) which are currently being used by the villagers for the purpose of
obtaining drinking water and/or water for irrigation or other purposes will be tapped into. As
mentioned previously construction water will be procured by desalinating the saline water.
Drinking water requirements during the construction phase will be met from desalination plant
of refinery complex.

The SH-25 (Jamnagar – Dwarka) will be the main roadway for transportation of
construction equipment and material. About 500 trucks per day are expected to ply on the
road. Although such incremental traffic is not likely to cause major impacts on the national
highway, any adverse impacts on the road infrastructure shall be adequately addressed. The
village roads in the project area, if required, will be widened and strengthened for the use.
However any strengthening/widening of any village roads shall not call for resettlement and
rehabilitation. After the completion of the project activity village roads in the vicinity of the
project area will be repaired for any damage caused by the movement of project related
vehicles.
The construction camps will be located on sites acquired by Reliance and no
impacts are expected on the local infrastructure in terms of land requirement. Separate
arrangements shall be made at the construction camps for water and power supply, sanitation
facilities and fuel to ensure that there are no pressures on the local resources.

5.1.7 Impacts on Health & Safety

Given the minimal intrusion into the existing natural resources of the region (land,
freshwater sources), adequate measures for dust suppression (the only credible source
impacting the air environment) and adequate distance from nearest habitation; minimum
adverse health impacts are expected, either during construction or operation phase of the
project.

The movement of heavy earthmovers, excavators, transporting vehicles during the

construction phase may increase the risk of accidents and injuries. Interaction of local labour
with outside labour force during the construction may lead to transference of communicable
diseases if left uncontrolled and unchecked. A road safety awareness campaign will be

5.7
undertaken to better inform the communities about safer road habits. The project proponent
proposes to carry out community awareness program in partnership with the local health
authorities on communicable sexually transmitted diseases well ahead of the commencement
of the construction of project to minimize such risks. Also adequate facilities for the health of
construction workers will be provided at the campsite.

5.8
 Table 5.1
Likely Impacts of Construction Phase
Environmental Primary /
Activity Duration Reversibility Significance
Impact Secondary
Site Particulate Short- Reversible Primary Moderately significant
clearing emissions term due to high wind speed
and large area involved
Noise Short- Reversible Primary Moderately Significant to
generation from term the workers at the site
earthmovers as the noise level
generated is about 95-
100 dB(A)
Insignificant as the
silence zone is away
from the SEZ site
Loss of flora Short- Reversible Primary Not significant as land is
and fauna term mostly barren and
mangroves are far away
Increased soil Long- Irreversible Primary Not significant as the
erosion from term soil has moderate
cleared area erodibility potential and
site sometimes receive
heavy rainfall and wind
Project affected Long- Irreversible Primary Significant as people
population term from 6 villages will be
affected
Soil Particulate Short- Reversible Primary Moderately significant
excavation / emissions term due to high wind speed
quarrying and large area involved
Noise Short- Reversible Primary Moderately Significant to
generation from term, the workers at the site
excavating intermitte as the noise level
equipment / nt generated is about 95-
explosives 100 dB(A)
Insignificant as the
silence zone is away
from the SEZ site
Turbidity and Interm- Reversible Secondary Moderately significant
suspended ittent as creek and sea are
solids increase nearby and area is
in the nearby prone to heavy rain fall,
water body so runoff effect
Transportati Particulate and Short- Reversible Primary Slightly
on of gaseous term significant/temporary
construction emissions (CO,
materials HC, NOx)
Noise Short- Reversible Primary Insignificant as the
generation term silence zone is away
from the SEZ site but
temporary for locals
Construction Particulate and Short- Reversible Primary Moderate
activities gaseous (CO, term
HC, SO2, NOx)

5.9
 Environmental Primary /
Activity Duration Reversibility Significance
Impact Secondary
emissions
Noise Short- Reversible Primary Moderately Significant to
generation term the workers at the site
as the noise level
generated is about 95-
100 dB(A)
Insignificant as the
silence zone is away
from the SEZ site
Sewage Short- Reversible Primary Insignificant because
generation in term sanitation facilities and
labour camps sewage treatment plant
will be provided
Cutting of trees Long- Reversible Primary No impact at all as
due to usage of term workers will be provided
wood as fuel with alternate fuel
DG sets for Gaseous Short- Reversible Primary Slightly Significant
power emissions (SO2, term
generation HC, CO, NOx)
Trenching Soil erosion Short- Reversible Primary Insignificant as soil will
for laying term be backfilled within a
pipelines/se few days after removal
wers/cables
Land Impact on soil Long- Irreversible Primary Insignificant as proper
reclamation quality and term compaction will be
erodibility undertaken
Increase in Short- Reversible Primary Insignificant as increase
turbidity of water term in turbidity will be small
body and for short duration
Construction Employment Short- Reversible Primary Significant positive
activities generation term impact

5.10
5.2 Impacts during Operation Phase
Every industry during the operational phase has certain emissions, which create an
impact to the environment. The operational phase activities due to the proposed SEZ have the
potential to cause long-term environmental impacts. A pre-requisite to estimating the potential
environmental impacts for the proposed SEZ was the identification and recording of the total
project inputs including process technology, raw materials, water and energy. These impacts
during the operation phase have been minimized by considering the use of the Best Available
Technology, adopting cleaner options, physical and chemical nature of raw materials,
precautionary measures, requirements of processing, transportation and handling of any
hazardous/toxic /flammable/explosive material(s), usage of any recycled/salvaged material from
industrial waste in the process, optimum usage of water, wastewater recycle and reuse etc.
The potential impact identification along with their impact characteristics are
presented in Table 5.2.

5.2.1 Air Environment

The impacts on air quality from any project depend on various factors like design
capacity, configuration, process technology, raw material/fuel used, envisaged emission control
measures, operation and maintenance practices. Apart from the above, other activities, viz.
transportation of raw materials and products, storage facilities and material handling within the
plant may also contribute to air pollution. The air pollutant emission scenarios have been
considered for air quality modeling.

5.2.1.1 Air Pollutant Emissions

Emissions due to Existing Refinery

The major air pollutants from the proposed SEZ which will contain refinery and
petrochemical units are SO2 and NOx due to the fuels burnt in the various process units. The
fuel gas/liquid fuels in the complex are generated from the various process units and it is
hydrotreated so that the fuel has low sulphur content which in turn reduces the emissions from
the stacks. The fuel gas and fuel oil are fed to the furnace in a controlled manner so as to have
minimum emissions. Natural gas / Synthesis Gas will also be used as a supplementary fuel.
The efficient burner management system controls the NOx emissions.

Emissions due to Proposed Project of SEZ

The SEZ complex consists of 9 major units as given in the Table 5.3. The emission
details of air pollutants due to SEZ is given in the Table 5.4.

5.11
5.2.1.2 Micro-Meteorology

The micro-meteorological data for the region during winter season indicates the
predominant winds from N-E and N-W sectors. Winds from almost all the directions were
observed during the study period without significant diurnal shift in wind direction. The sea
breeze and land breeze phenomena could not be clearly distinguished due to dominance of
synoptic winds. Synoptic winds dominated the wind pattern. The wind speed class of 10-20
km/h dominated the wind pattern. The mixing height details have been given in Table 5.5.

The hourly wind speed, solar insulation and total cloudiness during day time and
wind speed and total cloudiness during night time were used to determine the hourly
atmospheric stability class (Pasquill and Gifford) viz., A to F. The hourly stability was
determined based on the technique suggested by Turner.

Turner’s system used for determining the stability classes is as follows:

- For day or night: If total cloud cover (TC) = 10/10 and ceiling <7000 ft (2134
m), NR=0

- For night-time (defined as period from one hour before sunset to one hour
after sunrise):

a) If TC<4/10, use NR = -2

b) If TC>4/10, use NR = -1

- For daytime: Determine insulation class number (IN)

a) If TC<5/10, use NR=IN

b) If TC>5/10, modify IN by the sum of the following applicable criteria

i) If ceiling<7000 ft (2134m), modification = -2

ii) If ceiling>7000 ft but <16000 ft (4877 m), modification = -1

iii) If TC=10/10 and ceiling>7000 ft, modification = -1, and let

modified value of IN=NR, except for day-time NR cannot be <+1

All the stability classes were observed to be prevalent during the study period.
However, the stability classes B and C were predominant during daytime, whereas stability
class F was predominant in the nighttime.

5.2.1.3 Air Quality Modeling

The impact on air quality due to emissions from single source or group of sources is
evaluated by use of mathematical models. When air pollutants are emitted into the atmosphere,
they are immediately diffused into surrounding atmosphere, transported and diluted due to
winds. The air quality models are designed to simulate these processes mathematically and to

5.12
relate emissions of primary pollutants to the resulting downwind air quality. The inputs include
emissions, meteorology and surrounding topographic details to estimate the concentration of
conservative air pollutants.

The Industrial Source Complex – Short Term Version 3 (ISCST-3) model has been
developed to simulate the effect of emissions from point sources on air quality. The ISCST-3
model was adopted from the USEPA guideline models and routinely used as a regulatory
model to simulate plume dispersion and transport from up to 100 point sources and 20000
receptors. ISCST–3 is the state of the art model with USEPA and extensively used for
predicting the Ground Level Concentrations (GLCs) of conservative pollutants from point, area
and volume sources. The impacts of primary air pollutants are predicted using this air quality
model keeping in view the plain terrain at the project site. The micrometeorological data
monitored at project site during study period have been used in this model.

The ISCST-3 model is, an hour-by-hour steady state Gaussian plume dispersion
model which takes into account the following:
- Terrain adjustments
- Stack-tip downwash
- Gradual plume rise
- Buoyancy-induced dispersion, and
- Complex terrain treatment and consideration of partial reflection
- Plume reflection off elevated terrain
- Building downwash
- Partial penetration of elevated inversions is accounted for
- Hourly source emission rate, exit velocity, and stack gas temperature

The ISCST-3 model thus provides estimates of pollutant concentrations at various

receptor locations.

The MoEF sought clarification on data of the data of the ISCST model has been lumped
for all the stacks for prediction of environmental GLC. Since there are more than 160 stacks
that are envisaged, it is necessary that the exact location of these stacks and their emission
rate are included and the GLC then predicted for relevant pollutant including HC

The ISCST3 Model has been used for the air modeling study to predict the pollutant
concentration at the ground level. The various stacks, as listed in Table 5.4 of the EIA Report,
were marked on the overall plot plan to arrive at their co-ordinates. These co-ordinates were
fed into the grid network along with the respective emission rates. In the modeling exercise,

5.13
each stack has been considered as a point source and the impact of all the point source stacks
together has been modeled.

It is clarified that the emissions from all the stacks listed in Table 5.4 of the EIA
report have been considered as multi-point sources and not lumped together as a single point
source.

The impact of the gaseous emissions from all the 167 stacks has been studied.
Each stack has been considered as an individual point source. Accordingly the emissions from
167 point sources have been modeled using the approved ISCST3 air modeling software to
arrive at the maximum GLCs in the area. As per the model, the maximum GLCs of SO2 and
NOX from SEZ emission are estimated to be 57 μg/m3 (4.16 km, SSW Direction) and 56 μg/m3
(4.16 km, SSW Direction) respectively in winter season. The isopleths showing GLCs of SO2
and NOX in winter season are presented in Fig. 5.1 and Fig. 5.2. The estimated GLCs after
superimposing with the baseline are within the stipulated standards for the industrial areas and
is indicated in Table 5.6.

5.14
 20

18

16

14
Distance in North Direction,km

12

10

0
0 2 4 6 8 10 12 14 16 18 20
Distance in East Direction,km

Fig. 5.1 Estimated GLCs of SO2 due to Proposed SEZ in Winter Season

5.15
 20

18

16

14
Distance in North Direction,km

12

10

0
0 2 4 6 8 10 12 14 16 18 20
Distance in East Direction,km

Max. Conc. : 56 μg/m3

4.16 km, SSW Direction

Fig 5.2: Estimated GLCs of NOx due to Proposed SEZ in Winter Season

5.16
 Table 5.2
Likely Impacts of Operational Phase
Impact Characteristics
Environment
Activity
al Impact Positive/ Primary /
Duration Reversibility Significance
Negative Secondary

Transporta Particulate Long- Irreversible Negative Primary Slightly significant

tion of raw emissions and term
materials gaseous
emissions
(CO, HC,
NOx) during
vehicular
movement

Noise Long- Irreversible Negative Primary Slightly significant

generation term
from vehicular
movement

Noise Long- Irreversible Negative Primary Can be assessed only after

generation term undertaking EIA for power
from power plant
plant

Water quality Long- Irreversible Negative Primary Insignificant as the

impacts from term discharge will be properly
cooling water designed using diffuser
discharge

Resource Competitive Long- Irreversible Negative Primary Insignificant as large

utilization water demand term quantity of water will be
required though treated
sewage will also be used

Product Air emissions Long- Irreversible Negative Primary Slightly significant as

generation from process term predominantly non-polluting
plant / industries having cleaner
industry technologies will be set up
operation in SEZ

Noise Long- Irreversible Negative Primary Insignificant as silence zone

generation term is away from SEZ
from process
plant /
industrial
machinery

Solid waste Long- Reversible Negative Secondary Slightly significant as waste

generation term will be segregated, treated
and disposed at appropriate
landfill sites or incinerated

(Table 5.2 contd….)

5.17
 Impact Characteristics
Environmental
Activity
Impact Positive/ Primary /
Duration Reversibility Significance
Negative Secondary

Industries proposed in
SEZ will generate only
small quantity of
hazardous waste which
will be disposed as per
the Hazardous Waste
Collection, Handling
and Disposal Rules at
common facility
Wastewater Long- Irreversible Negative Secondary Slightly significant as
generation term the wastewater will be
appropriately treated
and reuse to maximum
and excess will be
disposed off at
locations away from
fishing / breeding zones
/ other beneficial water
use areas
Treated effluent after
recycled to maximum
extent will be
discharged into the sea
Raw Impact on Long- Irreversible Negative Secondary Slightly significant as
material / groundwater term storage tanks will be
product quality due to properly lined
storage leakage of
material during
rains
Product Vehicular Long- Irreversible Negative Primary Slightly significant
distribution emissions term
during
transportation of
product to
consumers
Noise Long- Irreversible Negative Primary Insignificant as silence
generation term zone is away from SEZ
during
transportation of
product to
consumers
Traffic Long- Reversible Negative Secondary Slightly significant as
congestion term the existing road will
experience increased
volume

5.18
 Table 5.3
SEZ Units
Sr.
Proposed Units
No
I C1 Based Units Coke Gasification
Methanol Synthesis
Acetic Acid
Vinyl Acetate Monomer
Polyvinyl Acetate (PVA)
Polyvinyl Alcohols (PVOH)
II C2 Based Units Multifeed Cracker Complex
Ethylene Oxide Derivatives like Mono Ethylene Glycol
(MEG), Di Ethylene Glycol (DEG), Tri Ethylene Glycol
(TEG)
Polyethylene polymers - Linear Low Density Polyethylene
(LLDPE), Low / High Density Polyethylene (LDPE / HDPE)
III C3 Based Units Acrylic Acid & derivatives, Super Absorbent Polymer (SAP)
n-Butyl Acrylate
n-butyraldehyde
n-Butanol
2-Ethyl Hexanol
Propylene derivatives like Propylene oxides, cumene,
phenol
Propylene Glycols
Polyols
Hydrogen Peroxide (H2O2)
Polypropylene (Non woven)
Polypropylene (PP)
IV C4/C5 Based Units Butyl/Halo Butyl Rubber, Emulsion Styrene Butadiene
Rubber (ESBR), Styrene Butadiene Rubber (SBR), Poly
Butadiene Rubber (PBR), Solution Styrene Butadiene
Rubber (SSBR)
Butene 1
Maleic Anhydride (MA)
Fumaric Acid
V C6/ C7/ C8 Based Units Mono Nitro Benzene, Aniline, Methylene Di Aniline,
Phosgene, Methylene Diphenyl Diisocyanate, Toluene
Diisocyanate, Benzene
Styrene
Paraxylene (PX), Orthoxylene (OX)
Putrefied Teraphthalic acid (PTA)
Polyethylene Tera-phthalate (PET)
Polyesters Complex Polyester Oriented Yarn (POY),
Polyester Stable Fiber (PSF)
VI Carbon Black
Lube Oil Cum Refinery
VII
Complex
VIII Captive Power Plant
Jamnagar Export Refinery
IX
Project

5.19
 Table 5.4
Stack Details for the Refinery, Power Plant and the Petrochemical Units
Unit Stack name Diameter Stack Temp. Velocity Emission Rate (g/s)
(m) Height K (m/s) SO2 NOX
(m) (g/s) (g/s)
C1 Based Units
Coke gassification SRU/TGT Stack 1.7 117.3 595 10.1 11.66 1.69
SRU/TGT Stack 1.7 117.3 603 10 11.66 1.69

Acetic Acid Process Stack 0.4 50 320 6.9 0.04

Methanol Process Stack 1.2 50 483 7
Furnace Stack 1.5 50 468 13.2 0.13 46.07
Furnace Stack 1.5 50 472 14.1 0.13 46.07
Poly vinyl Acetate Process Stack 1.2 50 483 7.7
Poly Vinyl Alcohol Vent Dryer Stack 1.2 50 480 7.2
Vinyl Acetate
Process Stack 0.6 50 458 6.2
Monomer
C2 Based Units
Multifeed cracker Fresh feed Furnace 1.6 50 437 17 9.73936 3.500083
Fresh feed Furnace 1.6 50 428 17.6 10.0831 3.623615
Fresh feed Furnace 1.6 50 429 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 430 17.1 9.796651 3.520671
Fresh feed Furnace 1.6 50 435 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 433 16.9 9.68207 3.479494
Fresh feed Furnace 1.6 50 432 17 9.73936 3.500083
Fresh feed Furnace 1.6 50 437 17.2 9.853941 3.54126
Fresh feed Furnace 1.6 50 434 17.3 9.911231 3.561849
Fresh feed Furnace 1.6 50 428 17.6 10.0831 3.623615
Fresh feed Furnace 1.6 50 429 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 430 17.1 9.796651 3.520671
Fresh feed Furnace 1.6 50 433 17 9.73936 3.500083
Fresh feed Furnace 1.6 50 431 16.9 9.68207 3.479494
Fresh feed Furnace 1.6 50 435 17.4 9.968522 3.582438
Fresh feed Furnace 1.6 50 433 17 9.73936 3.500083
Fresh feed Furnace 1.6 50 436 17.3 9.911231 3.561849
Fresh feed Furnace 1.6 50 432 17.6 10.0831 3.623615
Fresh feed Furnace 1.6 50 429 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 431 17.4 9.968522 3.582438
Fresh feed Furnace 1.6 50 427 17.3 9.911231 3.561849
Fresh feed Furnace 1.6 50 429 17 9.73936 3.500083
Fresh feed Furnace 1.6 50 433 17.1 9.796651 3.520671
Fresh feed Furnace 1.6 50 437 16.9 9.68207 3.479494
Fresh feed Furnace 1.6 50 431 17.1 9.796651 3.520671
Fresh feed Furnace 1.6 50 429 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 430 17.3 9.911231 3.561849
Fresh feed Furnace 1.6 50 435 17.5 10.02581 3.603026
Fresh feed Furnace 1.6 50 438 17.4 9.968522 3.582438
Fresh feed Furnace 1.6 50 429 17.1 9.796651 3.520671

5.20
 Unit Stack name Diameter Stack Temp. Velocity Emission Rate (g/s)
(m) Height K (m/s) SO2 NOX
(m) (g/s) (g/s)
Fresh feed Furnace 1.6 50 427 17.3 9.911231 3.561849
Fresh feed Furnace 1.6 50 439 17.6 10.0831 3.623615
Fresh feed Furnace 1.6 50 433 16.9 9.68207 3.479494
Fresh feed Furnace 1.6 50 437 17.6 10.0831 3.623615
Fresh feed Furnace 1.6 50 438 17.4 9.968522 3.582438
Fresh feed Furnace 1.6 50 428 17 9.73936 3.500083
LLDPE Process Stack 1.5 50 562 17.06 8.590196 3.087102
MEG+DEG+TEG CO2 Stripper Vent 0.4 50 320 6.9 0.04039
Incinerator 0.44 50 337 7.3 0.126511 0.056831
CO Vessel Vent 0.5 50 338 7.2 0.062346
C3 Based Units
n-Butyraldehyde Process Stack 0.75 50 460 4.1
Process Stack 0.75 50 460 4.1
PP Absorber 0.8 50 326 7
Vent Absorber 0.96 50 340 7.2
2 Ethyl Hexanol Flare Stack 0.5 75
Propylene
Process Stack 0.25 50 430 4
derivatives
Flare Stack 0.3 60
Acrylic acid &
Flare Stack 0.4 65
derivatives
SAP Process Stack 1.1 50 411 7.6
C4 / C5 Based
Units
n-Butanol Flare Stack
ESBR Flare Stack 0.5 60
Butyl /Halo Butyl
Flare Stack 0.7 80
rubber
Poly Butyl rubber Process Stack 0.2 50 475 2.4
C6 / C7 / C8 / C9
Based Units
Mono Nitro
Flare Stack 0.45 60
Benzene
Styrene 3.8 50 414 5.3 0.033333 1.227778
Polyster Complex DTA Vapouriser 1.2 50 483 7.1 2.288034 0.822262
DTA Vapouriser 1.2 50 483 7 2.255808 0.810681
DTA Vapouriser 1.2 50 483 7.3 2.352485 0.845424
DTA Vapouriser 1.2 50 483 6.9 2.223582 0.7991
DTA Vapouriser 1.2 50 483 7.2 2.320259 0.833843
DTA Vapouriser 1.2 50 483 7 2.255808 0.810681
DTA Vapouriser 1.2 50 483 7.3 2.352485 0.845424
DTA Vapouriser 1.2 50 483 7.1 2.288034 0.822262
DTA Vapouriser 1.2 50 483 7.7 2.481389 0.891749
PTA Vent Scrubber 1.1 50 411 7.6
Turbine Expander 1 50 318 23.2 0.683285 0.427053
Atm. Absorber 0.8 50 335 7.2 0.128827 0.080517
Incinerator 1 50 361 6.8 1.521775 0.546888
Paraxylene and
Platforming 4.82 50 489 3.6 3.958333 16.13889
Orthoxylene
Xylene 4.43 50 485 4.1 2.183333 1.786111

5.21
 Unit Stack name Diameter Stack Temp. Velocity Emission Rate (g/s)
(m) Height K (m/s) SO2 NOX
(m) (g/s) (g/s)
Xylene 4.43 50 485 4.1 2.183333 1.786111
Xylene 4.43 50 485 4.1 2.183333 1.786111
O-Xylene 4.42 50 486 3.7 2.005556 14.025
Carbon black
Fuel Stack 2 50 430 7.7 9.25 2.477081
Fuel Stack 2 50 429 7.5 9.25 2.412741
Fuel Stack 2 50 432 8 9.25 2.57359
Lube Oil Cum
Refinery
Complex
CDU/VDU 4.5 72 478 4 0.061111 2.697222
CDU/VDU 4.5 72 473 4.2 0.061111 2.697222
VHO HT 2.8 50 451 4 0.038889 1.691667
DHDS-1 3.8 50 491 3.6 0.011111 0.463889
Hydrogen Plant 2.94 50 456 6.5 0.025 1.15
Hydrogen Plant 2.94 50 453 6.2 0.025 1.15
LCO Hydrocracker 1.4 50 588 3.5 0.008333 0.380556
Power Plant
(2100 MW)
HRSG 3.2 80 468 13.2 0.138889 46.07222
HRSG 3.2 80 472 14.1 0.138889 46.07222
HRSG 3.2 80 470 13.8 0.138889 46.07222
HRSG 3.2 80 469 13.9 0.138889 46.07222
HRSG 3.2 80 469 14.8 0.138889 46.07222
HRSG 3.2 80 475 14 0.138889 46.07222
HRSG 3.2 80 465 14.2 0.138889 46.07222
HRSG 3.2 80 468 13.6 0.138889 46.07222
HRSG 3.2 80 473 14.5 0.138889 46.07222
HRSG 3.2 80 475 13.4 0.138889 46.07222
HRSG 3.2 80 474 13.3 0.138889 46.07222
HRSG 3.2 80 469 13.7 0.138889 46.07222
HRSG 3.2 80 468 14.3 0.138889 46.07222
HRSG 3.2 80 470 13.5 0.138889 46.07222
Auxiliary Boilers 2.3 80 423 13.1 23.33333 9.602778
Auxiliary Boilers 2.3 80 432 13.5 23.33333 9.602778
Auxiliary Boilers 2.3 80 430 13.6 23.33333 9.602778
Auxiliary Boilers 2.3 80 423 13.4 23.33333 9.602778
Auxiliary Boilers 2.3 80 433 14.1 23.33333 9.602778
Auxiliary Boilers 2.3 80 427 13.7 23.33333 9.602778
Auxiliary Boilers 2.3 80 425 14 23.33333 9.602778
Auxiliary Boilers 2.3 80 429 13.9 23.33333 9.602778
JERP
Delayed Coker 3.25 54 458 3.7 0.033 1.495
Delayed Coker 3.25 54 457 3.6 0.033 1.495
Delayed Coker 3.25 54 458 3.8 0.033 1.495
Delayed Coker 3.25 54 460 3.6 0.033 1.495
Styrene 1 3.8 45 411 3.8 0.441667
Styrene 2 3.8 45 414 3.7 0.011111 0.441667

5.22
 Unit Stack name Diameter Stack Temp. Velocity Emission Rate (g/s)
(m) Height K (m/s) SO2 NOX
(m) (g/s) (g/s)
LCO Hydrocracker 1.4 45 588 3.5 0.008333 0.380556
MS Quality Upgrader 3.8 45 571 3.6 0.047222
Alkylation 3.8 45 468 3.3 0.055556 2.452778
DHDS – 1 3.8 45 491 3.4 0.011111 0.463889
DHDS –2 3.8 45 498 3.6 0.011111 0.444444
CDU / VDU 4.5 72 478 3.3 0.061111 2.697222
CDU / VDU 4.5 72 470 3.5 0.061111 2.697222
CDU / VDU 3 52 472 3.2 0.061111 2.697222
VDU 3 52 488 3 0.061111 2.697222
Bitumen 1 40 471 3.8 0.019444 0.858333
Mild Hydrocracker 3.8 54 451 3.5 0.038889 1.797222
Mild Hydrocracker 3.8 54 454 3.6 0.038889 1.797222
Kero HT 2.2 45 441 3.1 0.005556 0.238889
VGO HT 2.8 45 451 3.3 0.038889 1.691667
HNUU 1.6 45 485 3.2 0.016667 0.738889
Platformer 1.8 55 491 3.5 0.111111 5.047222
Parex – 1 4.3 73 446 3.3 0.055556 2.558333
Parex – 2 4.3 73 441 3.5 0.055556 2.558333
Parex – 3 4.3 73 443 3.4 0.055556 2.558333
Parex – 4 4.3 73 444 3.5 0.055556 2.558333
Hydrogen – 1 3.8 45 458 6.5 0.022222 0.952778
Hydrogen – 2 3.8 45 452 6.3 0.022222 0.952778
Hydrogen – 3 3.8 45 455 6.4 0.022222 0.952778
SDA – 1 2 40 430 4 0.036111 1.594444
SDA – 2 2 40 435 4.2 0.036111 1.594444
Propane
2 40 436 3.9 0.083333 3.691667
Dehydrogenation
Tatory 2 40 633 3.4 0.002778 0.166667
Max Olefin FCC 3.45 82 544 19.5 97.22222 68.05556
SRU – 4 1.7 117.3 593 9.9 9.813889 1.694444
SRU – 5 1.7 117.3 595 10.1 9.813889 1.694444
SRU – 6 1.7 117.3 603 10 9.813889 1.694444

Total 768.5865 1138.304

5.23
 Table 5.5

Meteorological Data for winter season

Day Hour Wind Direction Wind speed Temp. Stability Class Mixing Height
(in degrees) (m/s) (0K) (m)
1 1 337.5 1.5 293.9 6 10
1 2 292.5 1.8 293.3 6 20
1 3 337.5 2.3 293.3 5 100
1 4 67.5 2.6 292.8 5 200
1 5 315 2 292.1 5 250
1 6 67.5 3.5 291 4 400
1 7 315 2.5 289.9 3 500
1 8 45.5 3 291.3 3 550
1 9 360 2.5 293.9 3 600
1 10 45 2 294.8 3 700
1 11 67.5 2.6 295.9 3 800
1 12 45 2.5 296.8 2 900
1 13 315 2.3 297.7 2 1000
1 14 337.5 2.5 298.1 2 1100
1 15 22.5 2.1 298.3 2 1000
1 16 360 1.5 298.6 2 900
1 17 22.5 2 297.7 3 800
1 18 315 2.5 295.9 3 600
1 19 360 3 294.5 4 450
1 20 22.5 3.6 293.8 4 400
1 21 360 3.2 293.3 5 250
1 22 45 4.1 292.9 5 200
1 23 270 3.4 293.3 5 150
1 24 292.5 2.5 292.9 6 50
2 1 337.5 1.5 293.9 6 10
2 2 292.5 1.8 293.3 6 20
2 3 360 2.3 293.3 5 100
2 4 67.5 2.6 292.8 5 200
2 5 45 2 292.1 5 250
2 6 270 3.5 291 4 400
2 7 90 2.5 289.9 3 500
2 8 45.5 3 291.3 3 550
2 9 360 2.5 293.9 3 600
2 10 337.5 2 294.8 3 700
2 11 360 2.6 295.9 3 800
2 12 45 2.5 296.8 2 900
2 13 225 2.3 297.7 2 1000
2 14 337.5 2.2 298.1 2 1100
2 15 22.5 2.4 298.3 2 1000
2 16 360 1.5 298.6 2 900
2 17 22.5 2 297.7 3 800
2 18 315.5 2.5 295.9 3 600
2 19 135 3.2 294.5 4 450
2 20 22.5 3.5 293.8 4 400
2 21 360 3.2 293.3 5 250

5.24
Day Hour Wind Direction Wind speed Temp. Stability Class Mixing Height
(in degrees) (m/s) (0K) (m)
2 22 45 4.1 292.9 5 200
2 23 90 3.4 293.3 5 150
2 24 292.5 2.2 292.9 6 50
3 1 180 1.5 293.9 6 10
3 2 292.5 1.8 293.3 6 20
3 3 135 2.3 293.3 5 100
3 4 67.5 2.6 292.8 5 200
3 5 202.5 2.3 293.1 5 250
3 6 360 3.5 291 4 400
3 7 90 2.7 289.9 3 500
3 8 45.5 3 290.3 3 550
3 9 360 2.5 293.9 3 600
3 10 337.5 2.2 294.8 3 720
3 11 225 2.6 295.9 3 800
3 12 45 2.5 296.6 2 900
3 13 22.5 2.3 297.7 2 1020
3 14 45 3.5 298.1 2 1150
3 15 67.5 2.4 298.3 2 1060
3 16 360 4.1 299.2 2 900
3 17 22.5 2.3 297.7 3 800
3 18 315.5 2.5 295.9 3 600
3 19 135 3.2 294.5 4 450
3 20 67.5 3.1 293.8 4 400
3 21 360 3.2 293.3 5 250
3 22 45 3.3 292.9 5 200
3 23 90 2.8 293.3 5 100
3 24 315 1.8 292.9 6 50
4 1 292.5 1.2 294 6 10
4 2 67.5 1.5 293.6 6 20
4 3 135 2.4 293.3 5 100
4 4 270 2.2 292.8 5 200
4 5 360 2.4 293.1 5 250
4 6 225 3.3 292 4 350
4 7 135 2.5 289.9 3 480
4 8 45.5 3.2 290.3 3 550
4 9 157.5 2.1 292.9 3 600
4 10 247.5 2.2 293.8 3 720
4 11 315 2.7 294.9 3 830
4 12 292.5 2.3 296.6 2 900
4 13 22.5 2.6 298.7 2 1020
4 14 90 3.5 299.1 2 1150
4 15 45 4.1 299.3 2 1060
4 16 360 4 299.6 3 900
4 17 67.5 2.5 298.7 3 800
4 18 360 2.4 296.9 3 600
4 19 112.5 3.1 295.5 4 450
4 20 90 3 293.8 5 400
4 21 360 3.3 293.3 5 250
4 22 45 3.4 292.9 5 200

5.25
Day Hour Wind Direction Wind speed Temp. Stability Class Mixing Height
(in degrees) (m/s) (0K) (m)
4 23 180 2.6 293.3 6 100
4 24 202 2 292.9 6 50
5 1 225 1.2 294 6 10
5 2 45 1.5 293.6 6 20
5 3 337.5 2.4 293.3 5 100
5 4 315 2.2 292.8 5 200
5 5 360 2.4 293.1 5 250
5 6 270 3.3 292 4 350
5 7 67.5 2.5 289.9 3 480
5 8 45.5 3.2 290.3 3 550
5 9 157.5 2.1 292.9 3 600
5 10 22.5 2.2 293.8 3 720
5 11 292.5 2.7 294.9 3 830
5 12 180 2.3 296.6 2 900
5 13 22.5 2.6 298.7 2 1020
5 14 112.5 3.5 299.1 2 1150
5 15 67.5 4.1 299.3 2 1060
5 16 360 4 299.6 3 900
5 17 45 2.5 298.7 3 800
5 18 360 2.4 296.9 3 600
5 19 247.5 3.1 295.5 4 450
5 20 45 3 293.8 5 400
5 21 315 3.3 293.3 5 250
5 22 337.5 3.4 292.9 5 200
5 23 225 2.6 293.3 6 100
5 24 292.5 2 292.9 6 50

5.26
 Table 5.6

Cumulative Values of GLCs for SO2 and NOx after Superimposing with the
Baseline AAQM Data

Sr. Sampling Cumulative Value Cumulative Value NOx

No. Location SO2
1. Arablus 26 29
2. Gadhuka 26 25
3. Gagwa 42 44
4. Jogwad 38 43
5. Kanachikari 18 24
6. Kanalus 36 49
7. Khatiya Beraja 38 30
8. Macchuberaja 21 48
9. Meghpur 40 48
10. Motikhavdi 31 38
11. Motalakhiya 39 36
12. Mungani 34 38
13. Nanikhavdi 32 34
14. Nanalakhiya 39 37
15. Padana 23 31
16. Rangpar 26 37
17. Rasangpar 50 51
18. Sapar 30 36
19. Setalus 32 30
20. Sevak Bharudiya 18 44
21. Jivapar 14 23
22. Balambhadi 15 28
23. Dera Chikari 14 24
24. Meghavadar 22 33

5.27
5.2.2 Noise Environment

5.2.2.1 Impacts due to Stationary Noise Source

Cumulative noise level at a particular location due to noise source can be computed
by using Wave Divergence Model as given below:

Lp2 = Lp1 – 20 log (r2/r1) – Ae1,2

Where,

Lp2 and Lp1 are the noise levels at the distances r2 and r1 respectively from the
source and Ae1,2 is the excess attenuation along the path r2-r1 due to environmental adsorption,
scattering and other shielding effects.

Total noise level Lp (Total) due to all sources can be determined as follows :

Lp (Total) = 10 log (10Lpa/10 + 10Lpb/10 + 10Lpc/10 + ………….) (1)

Where,

Lpa, Lpb, Lpc are the noise levels at a given location due to sources A, B, C etc.

Noise levels have been predicted at proposed noise sources in all the process units
within the refinery and petrochemical complex.

The major stationary noise generating sources expected at proposed SEZ during
operation phase are given in Table 5.3. The noise generation from major equipment will be
restricted through manufacture specifications like BFPs, GTG, STGs, etc.: 85 dB(A). These
sources have been considered for prediction of impact on ambient noise levels at nearby
human settlements as well as the occupational exposure to workers within the project premises.
Accordingly the net cumulative noise generation due to multiple sources at one location have
been derived following standard logarithmic sum (log. Sum) formula.
The cumulative noise impact from different stationary sources at proposed project
site has been predicted at 100mx100m grid intervals over an area of
33.52 km x 31.8 km noise impact area mainly covering project premises Fig. 5.3. The predicted
results of cumulative noise levels at each grid points are used to draw noise contours through
Surfer ver.6 graphics package. The predicted noise contours around proposed sources are
shown in Fig. 5.3. These prediction results are applicable to only present layout plan. In case of
any change in layout the distribution/pattern of predicted noise contours are also expected to
change accordingly. It is also to be noted these noise contours derived without considering any
attenuation factors due to structural interferences or green belt, i.e. the prediction results are
conservative. As per the prediction results, the impact of noise out side the proposed project
premises would be less than 22 dB(A) (Fig. 5.3).

5.28
 The impact of noise levels from the stationary sources within SEZ is predicted to be
below 24 dBA as given in Table 5.7. This table also shows the pre-project status and post
project status that is prediction of noise impact in the nearby vicinity of the proposed SEZ. The
predicted noise level after superimposing the predicted noise levels with the baseline data are
well within the stipulated norms of CPCB and is indicated in Table 5.7.

5.29
 33.52 km

22-28-30N
Vokatiyo (kado)
Narada

Valupir (kado)
22-27-N

Sikka
22-25-30N Digvijagaon

Lakha baval
Vadinar
Sapar Masitiya
22-24-0N Singach Champa beraja
Danyo (Kado) Kana chikari Vav beraja

22-22-30N 31.84km Dera chikari

31.84km
22-21-0N
31.84km

Khatiya beraja
22-19-30N Sumra terdhan

22-18-0N

22-16-30N Rangpar

Machhu beraja
Sevak bhatiya
22-15-0N Sinhan kakabhai Sevak Bharudiya
Anikhana
Jasapar Rafudad moti
Daltungi Gajana Mulila
22-13-30N Memana
Sinnan aher Charantungi Lalpur
Khambhaliya Rafudad nani Gujarat
Kanvirdi
22-12-0N Sodha tardhan Mahadeviya Apla Khirsara Veraval
690-45’- 690-46’- 0
69 -48’E 690- 0 0
69 -51’0’ 69 -52’30” 0 0 0 0 0
69 - 69 - 69 - 69 - 70 - 700-

33.52 km

Note : Contour Units in dB(A)

Fig. 5.3 : Predicted Noise Contours due to Proposed Units at SEZ

5.30
 Table 5.7

Noise Impact from Stationary Sources at SEZ at Nearby Communities

Sr. Village Name Pre-project Status Predicted Post-project Status

(Baseline) dB(A) Noise Level dB(A)
Day Night from SEZ dB(A) Day Night
1. Padana 46.8 41.0 19 46.81 41.02

2. Motikhavdi 60.0 40.0 15 60.01 40.01

3. Sapar 50.2 38.0 13 50.21 38.01

4. Navagam 41.0 34.0 19 41.01 34.01

5. Kanalus 50.2 42.0 24 50.21 42.02

6. Dera chikari 51.5 41.8 16 51.5 41.8

5.31
5.2.3 Water Environment
5.2.3.1 Water requirement

Considering the water shortage in the region, seawater shall be used for the
proposed SEZ after desalination to meet water requirement. The domestic and process water
requirements in the SEZ and in township shall be met by desalination of the seawater.

Sea water is the only source of water for the SEZ Project. The energy (heat)
requirement for the desalination plant (Desal) shall be met from the waste heat from the
processing units. A very low pressure steam (0.7 kg/cm2 g) shall be used in the Desal Plant.
This energy integration eliminates the venting of low pressure and low temperature steam from
the process units and / or eliminates the condensation requirements. Water requirement for
the SEZ Project and Units therein is estimated at 15000 m3/hr.

The proposed SEZ project requires water for boilers & heaters, processes, process
cooling, utilities cooling, domestic consumption, fire water make up and greenbelt
development/horticulture. The entire water requirement will be met from the desalination of
seawater. Thus no fresh water of the region will be used. However the Narmada supply
project is in the pipeline and can be supplementary source, if required.

Total water management system is designed integrating the sea water, desal water,
cooling tower and effluent treatment systems using targeted recycle and reuse.

The overall water balance, water requirement and wastewater generation scenario
for proposed SEZ project are presented in Fig. 5.4.

The water requirement and effluent generation from the each individual unit is
provided in Table 5.12 of the EIA report. The total effluent generation from the various
complexes and the overall water balance at the intake of the complex is given in the Fig 5.4 of
the EIA report

5.32
5.33
5.2.4 Land Environment
5.2.4.1 Land use Pattern
The breakup of land of SEZ complex is presented in section 1.1 of Chapter 1. This
table indicates that the total land area proposed for the SEZ project is 4,545 Ha and proposed
units would occupy about 2,275 Ha of land apart from 1185 Ha of land utilized for public/semi-
public/greenbelt and transportation. The proposed residential complex will be set up in an area
of 810 acre. The commercial complex would occupy 275 acre. The change in the
landuse/land cover pattern remains insignificant.

5.2.5 Biological Environment

A greenbelt development plan has been recommended by NEERI in Chapter 6. The
plantation of over 3.0 million trees has already been completed for existing adjacent Reliance
refinery. RIL has developed extensive greening of the area in the existing complex using novel
technological agricultural methods/techniques using the recycled water. Basing on this
experience, a further extensive high-density plantation is proposed to be developed. The
impact shall be positive as the greenbelt will be developed on a barren land in and around
various units within the SEZ.

5.2.6 Socio-economic Environment

The proposed project will involve employment of workers during the operation phase.

During the socio-economic survey it was observed that the proposed project would
create certain beneficial effects as well as adverse effects on the socio economic environment.
Some of these impacts would be short-term whereas the others would be of long term in nature.

It is necessary to identify the extent of these impacts for further planning of control
measures leading to mitigation of the adverse impacts. The impacts on parameters of human
interest have been assessed in terms of positive and negative impacts.

The potential impacts due to the project are presented in Table 5.8, whereas the
expected change in Subjective Quality of Life is presented in Table 5.9 and Table 5.10
respectively. The potential impacts due to the project are presented below:

Positive Impacts

♦ The proposed project is expected to generate large indirect employment besides

marginal direct employment

♦ Local population will be benefited by the project as the indirect employment

opportunities will increase in the region that will help in increasing the economic
status of the region

5.34
 ♦ The project has favorable ranking by majority of the local people and is looked
upon as a step for further development of the area

♦ The proposed project will enhance quality of life of the people in the study area

♦ Infrastructure will increase due to the project by way of transport and

communication and amenities like school, health center, telephone booths and
other basic requirements will be generated for working population of the project
and village community.

♦ Local Population may get benefited dew to increased Business activated. viz.
Market, trade and commerce

Negative Impacts
The adverse impacts on socio-economic environment due to proposed activities in the
region will be :

♦ During the construction period there will be short-term socio-economic impacts in

the study area that may include increase in floating population (contract
labourers) which marginally strain on the civic amenities like drinking water,
sanitation, road transport and other facilities

♦ Change in population density and diversity through the immigrants may cause
cultural & health related problems in the region.

♦ Proposed project activity may increase pollution level in the area during the
construction and operation period.

♦ Dust pollution due to transportation in dry areas may cause, poor yield of crops
etc.

♦ Social security problems may in the region due to influx of population

As in the case of previous refinery implementation, the negative effects will be mitigated by
extensive socio and health monitoring and support the local population groups in terms of
cultural, medical and resource sharing with the people. For eg: Reliance has extended drinking
water supply to the Jamnagar and neighbouring communties, whenever there is a shortage of
water.

5.35
 Table 5.8

Prediction of Qualitative Impacts on Socio-economic Environment

Parameter Local Regional Direct Indirect Reversible Irreversible

Employment + + + + • +
Income + + + + • +
Transport + + + + • +
Education + • + • • +
Medical facilities + • + • • +
Communication + + + • • +
Availability of power - + + • • +
Sanitation - • + • • •
Housing + + + • • +
Health - • - - - •
Recreation + + • + • +
Agriculture - • • - • •
Cost of living + • • - • -
Business + + + • • •
Per Capita Income + + + • • •
Pollution - • • - • •
+ : Positive Impact
- : Negative Impact
• : Insignificant

5.36
 Table 5.9

Expected Change in Subjective Quality of Life

Sr. No. Villages QoL (s) QoL (S) after

Implementation of
EMP and welfare
Measure
1 Naranpar 0.50 0.52
2 Gordhanpar 0.48 0.50
3 Pipartoda 0.47 0.50
4 Kota 0.49 0.51
5 Vadinar 0.49 0.50
6 Sevak Dhuniya 0.51 0.54
7 Rafudad Moti 0.52 0.54
8 Gajana 0.50 0.52
9 Apla 0.47 0.49
10 Gavana 0.52 0.54
11 Godavari 0.51 0.52
12 Rinzpur 0.53 0.55
13 Padana 0.47 0.49
14 Navagam 0.52 0.54
15 Dera Chhikari 0.48 0.50
16 Kana Chhikari 0.49 0.51
17 Kanalus 0.53 0.55
18 Arablus 0.52 0.54
Average 0.50 0.52
QOL (s) = Subjective Quality of Life

5.37
 Table 5.10

Expected Change in Cumulative Quality of Life

Sr. No. Villages QoL (s) QoL (S) after

Implementation of
EMP and welfare
Measure
1 Naranpar 0.51 0.52
2 Gordhanpar 0.51 0.53
3 Pipartoda 0.48 0.50
4 Kota 0.50 0.52
5 Vadinar 0.50 0.53
6 Sevak Dhuniya 0.52 0.54
7 Rafudad Moti 0.53 0.54
8 Gajana 0.51 0.53
9 Apla 0.48 0.50
10 Gavana 0.53 0.55
11 Godavari 0.52 0.55
12 Rinzpur 0.54 0.57
13 Padana 0.48 0.51
14 Navagam 0.53 0.55
15 Dera Chhikari 0.49 0.51
16 Kana Chhikari 0.50 0.52
17 Kanalus 0.54 0.57
18 Arablus 0.53 0.55
Average 0.51 0.53

QOL (c) = Cumulative Quality of Life

5.38
5.3 Pollution Load
The proposed petroleum and petrochemical complex is composed of different
units as listed earlier in this document. The various units will have point sources as emissions
and will generate wastewater and solid waste which will contribute to the overall pollution load
of the complex. Even though the best possible technology and environment friendly fuel
(natural gas & syngas) are proposed to be maximized in the complex, there will be a certain
contribution to the pollution load on the environment. The pollution load has been estimated
taking into account the CPCBs proposed standards for Refineries and Petrochemical Units. The
pollution load also takes into account the World Bank Standards for Refineries and
Petrochemical Complexes. The CPCB standards prescribed for the non-criteria pollutants will
be incorporated into the design of the various units in the design stage of the project. The
pollution load due to each unit proposed in the petroleum and petrochemical complex is
tabulated in Table 5.11. As seen from the Table, the overall pollution load from the complex in
terms of SO2 and NOx is estimated at 67 TPD and 99 TPD, respectively. The main source of
raw water will be the sea water that will be desalinated for process use. Water management will
be implemented to incorporate recycle and reuse. Various Units will have their dedicated
Effluent Treatment Plants and methodology for reuse / recycle / disposal of solid and hazardous
wastes.

5.4 Public Consultation Summary

The Public Consultation process was conducted by the Gujarat Pollution Control Board
in line with Appendix IV of the Environment Clearance Notification dated 14th September 2006.
The Public Hearing for the Petroleum and Petrochemical Complex in the SEZ was conducted
on 8th January 2008. The entire project including major findings of Environmental Impact
Assessment and Risk Assessment reports was presented to the Public and various queries
were answered by the project proponent and NEERI. There was overall support for the entire
project and no specific objection or comments was raised with respect to the proposed project.

However, the public had some general comments with respect the air emissions, air
borne dust, storm water flows and land acquisition issues with respect to the existing facilities.
All issues raised by the Public were answered in the Public Hearing and the same have been
documented by the Gujarat Pollution Control Board. Various environmental management
measures and post project environmental monitoring being conducted for the existing refinery
complex were explained to the Public to resolve.

Issues were raised with respect to the benefit of the proposed project to the local
community. The Public was informed that the necessary measures would be carried out in

5.39
consultation with the local governing bodies and Village Gram Panchayat to meet the various
requirements of the various villages. It was also mentioned to the villagers that an amount of
Rs 1 crore would be spent for environmental and social benefits in each of the villages that
would be covered in the SEZ Area.

Employment opportunities were sought by the Public and it was assured that preference
would be given to local persons who possess the required skills. Further, the secondary
employment generation and potential was also explained with back-up of the existing secondary
employment generated due to the existing facilities.

Overall, the Public supported the project and appreciated the various efforts of the
project proponent towards community development and participation. The Public Hearing ended
with a positive note and the locals are looking forward to industrial development in the region.
The proceedings of the Public Consultation process have already been sent by the Gujarat
Pollution Control Board to the Ministry of Environment & Forests.

5.40
 Table 5.11

Pollution Load from Units in Petroleum & Petrochemical Complex

Sr. Plant Air Emissions Liquid Solid

No. Effluent Waste
3
SO2 NOx Other Emissions (M /hr)
(TPH) (TPH)
1. Pet Coke gasification 0.083 0.012 - 150 0.37
MMTPA
2. Methanol Synthesis 0.0008 0.331 VOC&CO - < 150 25 Catalyst
mg/Nm3
3. Acetic Acid 0.00014 - - 50 None
4. Vinyl Acetate - - NMHC - < 150 mg/Nm3 75 None
Monomer
5. Poly Vinyl Acetate - - NMHC - < 150 mg/Nm3 100 None
6. Poly Vinyl Alcohol NMHC - < 150 mg/Nm3 140 Catalyst
7. Multifeed Cracker 1.314 0.471 400 Coke
Complex
8. Ethylene Oxide 0.00036 VOC & Stripper Vent - 193 Catalyst
Derivatives – MEG 0.04 Kg/hr
etc. CO - 0.44 kg/hr
9. Polyethylene 0.03 0.011 80 Column
Polymners residue
10. Acrylic Acid & Purge Gases sent to 50 Catalyst
derivatives incinerator
11. Super Absorbent Acrylic acid vapours 300 None
Polymer removed with scrubber
attached to process stack
12. n-Butyl Acrylate Emissions from process 75 Catalyst
vent - < 150 &
Incinerator
13. N-Butraldehyde NMHC - < 150 mg/Nm3 60 Catalyst
14. n-Butanol 75 Catalyst
15. 2-EthylHexanol Purge gases – Flared 75 Catalyst
NMHC - < 150 mg/Nm3
16. Propylene Derivatives NMHC - < 150 mg/Nm3 90 Catalyst
and Flare
17. Hydrogen Peroxide Purge Gases sent to 150 None
H2O2 incinerator
18. Poly Propylene Process Flare 20 None
19. Rubber Projects Butadiene - 5 mg/Nm3 300 1500
Styrene - 100 mg/Nm3 TPA
3
NMHC – 150 mg/Nm
20. Maleic Anhydride Particulates 25 mg/Nm3 & 10 Spent
Fuel gas to fuel pool Catalyst
3
21. Mono Nitro Benzene Benzene < 5 mg/Nm 10 None
22. Aniline H2 blend stream after H2 300 Catalyst
Separation & Incinerator
23. Phosgene Stack exhaust < 1 Activated
mg/Nm3 Carbon
Catalyst
24. Methylene Di Anililne 100 Salt

5.41
Sr. Plant Air Emissions Liquid Solid
No. Effluent Waste
3
SO2 NOx Other Emissions (M /hr)
(TPH) (TPH)
25. Methylene Diphenyl MDI/TDI - < 0.1 mg/Nm3 85 None
Diisocyanate Particulate < 25 mg/Nm3
26. Styrene 0.001 0.004 Styrene - 100 mg/Nm3 125 1100
Benzene – 5 mg/Nm3 TPA
27. Paraxylene & 0.045 0.127 Aromatics/Xylene/toluene 150 2900
Orthoxylene - <100 mg/Nm3 TPA
28. Putrefied Teraphthalic 0.008 0.001 510 Pre-
Acid treatment
sludge
29. Polyethylene Tera- 125 Spent
phthalic (PET) Pellets
30. Polyester Complex 0.075 0.031 100 Spent
Yarn
31. Carbon Black 0.099 0.026 Carbon Black – 18 315 None
3
mg/Nm
32. Lube Oil Refinery 0.0008 0.036 300 Eq.
Complex Catalyst
33. Captive Power Plant 0.678 2.59 Recycled None
water
34. JERP 0.456 0.47 1200 Eq.
Catalyst

5.42
 Table 5.12

Water Requirement & Effluent generation for the Units in the Complex

Water Requirment Liquid Effluent in

Sr.No Unit in TPH TPH
1 Pet Coke Gasification 250 150
2 Methanol 2 25
3 Acetic Acid 2 50
4 Vinyl Acetate Monomer 2 75
5 Poly Vinyl Acetate 4 100
6 Poly vinyl Alcohol 100 140
7 Multifeed Cracker Complex 425 400
8 Ethylene oxide derivatives 250 193
9 Poly ethylene Polymers 150 80
10 Acrylic Acid and Derivatves 115 50
11 SAP 325 300
12 n- Butyl Acrylates 5 75
13 n-butaraldehyde 3 60
14 n-butanol 3 75
15 2- Ethyl Hexanol 2 75
16 Propylene Derivatives 5 90
17 Hydrogen Peroxide 200 150
18 Poly Propylene 50 20
19 Rubber Projects 400 300
20 Maleic Anhydride 40 10
21 Mono Nitro Benzene 50 10
22 Aniline 400 300
23 Methylene Di Aniline 5 100
Methylene Diphenyl
24 Diisocynate 100 85
25 Styrene 250 125
26 Paraxylene and Ortho Xylene 280 150
27 PTA 600 510
28 PET 200 125
29 Polyster Complex 180 100
30 Carbon Black 100 315
31 Lube Oil Refinery Complex 500 300
32 RPL Refinery 2000 1200
Domestic Consumption / Fire
33 Water Make-Up 1400
34 CT Make-up 6600
Total Water Requirment 14998 5738

5.43
C hapter 6

Environmental Management Plan

The refinery and the petrochemical Special Economic Zone (SEZ), is located near the
existing refinery at Jamnagar and at a distance of 28 kms west from Jamnagar in Gujarat State
of India. The baseline data for various components of environment i.e. air, noise, water, land,
biological and socio-economic aspects has been collected, and the impacts have been
predicted and evaluated due to the proposed SEZ on the various environmental components

The Environmental Management Plan (EMP) provides an essential link between

predicted impacts and mitigation measures during implementation and operational activities.
EMP outlines the mitigation, monitoring and institutional measures to be taken during project
design, implementation and operation to avoid or mitigate adverse environmental impacts, and
the actions needed to implement these measures.

The EMP prepared is in line with the guidelines prescribed by the MOEF / CPCB.
RIL group has got a strong, consistent and committed corporate policy in the Environmental
management in all the complexes. The Environmental parameters are internalized into the
project planning, design, procurement, constructional and operational aspects. The RIL group
as accorded several prestigious environmental management awards for their complexes by
national and international agencies.

The design module for the environmental protection for the process, design,
engineering, procurement and construction will be a set of specific project environmental
specifications for the project planning.

The C1 to C8 petroleum and petrochemical complex the technology providers,

licensors, vendors, EPC contractors and possible JV partners will be instructed to follow and

6.1
implement the project specific project environmental specifications. These are being developed
and will incorporate the applicable standards of Govt of India, State government and pollution
control boards. The IFC /WB standards and the stipulations of environmental stipulations will
also be integrated into the design.

The Environment Management Plan as follows:

• Delineation of mitigation measures for all the identified significant impacts

• Delineation of the unmitigated measures
• Physical planning including work programme and locations for putting mitigation
systems in place
• Delineation of financial plan for implementing the mitigation measures in the form of
budgetary estimates.

The likely impacts on various components of environment due to the project during
developmental activities have been identified and measures for their mitigation are suggested.

Reliance SEZ Jamnagar envisages the following major activities:

• Production of petroleum products such as clean fuels to meet the latest national
and international standards
• Production of downstream petrochemical products C1-C8 based units, Carbon
Black and Lube Oil Cum Refinery Complex.
• Captive power plant, Desalination Plant, Utilities and infrastructure
The EMP lists all the requirements to ensure effective mitigation of every potential
biophysical and socio-economic impact identified in the EIA. For each aspect, or operation,
which could otherwise give rise to impact, the following information is presented:

• A comprehensive listing of the mitigation measures

• Parameters that should be monitored to ensure effective implementation of the

action

• Timing for implementation of the action to ensure that the objectives of mitigation
are fully met

The EMP comprises of a series of components covering direct mitigation plan and
environmental monitoring for air, water, noise etc., an outline on the waste management plan.
The environmental management plan has been prepared for each of the above developmental
activities. M/s Reliance Infrastructure Limited would use the EMP described in the following
sections to develop the standard operating procedures for the SEZ and units therein.

6.2
6.1 EMP during Construction Phase

6.1.1 Site Preparation

Environmental pollution during construction stage will be limited and for temporary
period during the activity.

Directly or indirectly all the environmental components get affected due to construction
activity. The following environmental protection and enhancement measures are suggested for
implementation by the contractor or the project proponent during the construction activities as
applicable.

6.1.2 Air Environment

During the construction phase, the fugitive and gaseous emissions are expected from
the heavy machineries deployed during the construction phase. All the other emission sources
are intermittent and include emissions from materials transport from heavy vehicles. The
gaseous emissions are expected to contribute significantly to the ambient air quality. However,
some generic measures should be taken to reduce fugitive and gaseous pollutants emissions
during the construction phase, which are as follows:

• The storage and handling of soil, sub-soils, top-soils and materials should be
carefully managed to minimize the risk of wind blown material and dust

• Those sections of the working area that are being trafficked over should be
damped by controlled application of water sprays (e.g. by water dowsers) as
conditions dictate.

• Vehicles or equipment should be checked for pollutant emissions against

stipulated norms.

• Transport vehicles and construction machinery should be properly maintained so

as keep air emissions in check. Emphasis should be made on EURO II engines

• Idle running of vehicles should be minimized during transport and handling

activities

• Engines and exhaust systems of all vehicle and equipment should be maintained
so that exhaust emissions do not breach statutory limits (set for that
vehicle/equipment type and mode of operation by CPCB), and that all vehicles
and equipment are maintained in accordance with manufacturers’ guidelines.

• Exhausts of other equipment used for construction (e.g. generators) if any will be
positioned at a sufficient height to ensure dispersal of exhaust emissions and

6.3
 meet the standards set by CPCB.

• Construction material transport to the site should be properly covered to avoid

fugitive emissions.

• Regulate vehicle speed to a maximum limit of 40 km/hr within the premises

• Periodic maintenance of vehicle

• Ensure use of good fuel for vehicle. Gas powered or low sulphur diesel and
unleaded petrol in conventional vehicles should be used within the project area

• Well maintained construction equipments preferably those with lesser emissions

should be preferred.

• During the short period of the site clearing mechanical shovels and earthmovers
should be used for site clearance, cutting and filling and other site leveling
activities. The site clearance activities could generate dust emissions, which can
affect the ambient air quality. The site should be sprayed / sprinkled with water to
suppress the dust emissions. The areas where the soils contain large quantities
of fine sand, which has a tendency to blow in dry conditions. The Contractor
should be made responsible for ensuring that particular attention is paid towards
dust suppression.

• A greenbelt should be initiated along the boundary of the project site for
improvement of ambient air quality as suggested in the Section 6.2.5 of this
Chapter. Past experience for the development of greenbelt by Reliance could
also be utilized.

• Loading/unloading and storage areas should be paved to reduce dust emissions.

All main roads (internal and external) to be used by the project authorities should
be made ‘pucca’ (either with WBM, concrete or bitumen) to suppress the dust
generation along the roads.

• Personnel Protection Equipment (PPE) should be provided to construction

workers. Dust masks should be provided to construction workers, while carrying
out operations that may entail potential for dust inhalation.

• The construction laborers should be prohibited to use the vegetation for fuel
wood.

6.4
6.1.3 Noise Environment

The following measures are recommended to mitigate adverse environment during

construction phase:

• Onsite workers should be provided with noise protection device muffs wherever
necessary.

• Construction activities should be so co-ordinated such that the noise levels

should not exceed the ambient noise levels prescribed by CPCB.

• Engines of all the rotating parts, machineries, vehicles should be thoroughly

maintained (e.g. oiling & greasing of all the moving parts)

• Earth movers and construction machinery with low noise levels should be used.

• Periodic maintenance of construction machinery and vehicles should be

undertaken. Good condition and new machineries should be preferred.

• Green belt should be developed during the construction phase for attenuation of
noise, noise levels in the vicinity of the heavy construction equipment will be high
due to the running of heavy machines and compressors.

• Acoustic laggings, and silencers should be used in equipment wherever

necessary. Either Acoustic barriers / shelter should be developed in noisy
workplaces or acoustic enclosures should be provided for the high noise
generating equipment.

• Use of DG sets should be enclosed type and should conform to the EP rules
prescribed for air and noise emission.

6.1.4 Water Environment

Measures for Supply of Water

• The region being water scarce, the project proponent should not extract water
from any water bodies (surface or groundwater) for the construction phase of
the project. No existing resources fresh water sources (surface/groundwater)
which are currently being used by the villagers for the purpose of obtaining
drinking water for irrigation or other purposes should be tapped into. The water
shall be supplied from the existing water resources of the adjacent Reliance
refinery complex for construction purpose.

• Adequate drinking water of potable quality facilities during the construction

phase should be provided to the contractors. This should be met from the

6.5
 refinery resources to the construction sites.

Mitigation Measures for Prevention of Water Pollution

• The only two credible sources of potential impacts arise from uncontrolled
runoffs from the labour camps and accidental spills of oil etc. into surface and
ground water bodies. The selected contractor should be obligated to follow the
procedures so as not to pollute groundwater.

• Sufficient and appropriate sanitary facilities should be provided in order to

maintain hygienic conditions in the labour camps. Adequate precautions should
be undertaken so as to avoid sewage into any water body, Sasoi tank in
particular. Developmental activities should be in line with the local hydrological
pattern.

• Area for maintenance of vehicles should be so located that contamination of

Surface water (Sasoi tank) by accidental spillage of oil can be prevented.

• These measures will adequately mitigate the possibility of any negative impacts
during construction on terrestrial water quality. The wastes, such as, sanitary
wastes should be treated in sewage treatment plant of appropriate size and
technology existing facilities available in refinery premises should be extended
to construction workers.

• The sludge generated should be collected and disposed in an appropriate

manner either at a landfill site or used as compost for horticultural uses.

• The workshop areas should be used for the maintenance of vehicles and
construction machineries so as to avoid accidental spills of oil/oily wastes.

• Drains and detention basins should be provided to stabilize slopes and collect
run off/sediments

• Storm water management including erosion control and sedimentation measures

at the site should be controlled by erosion control methods (Ponds) for the
construction phase of the project.

• The storm water drainage system should be designed to be commensurate with

the local hydrological pattern of the area. The area being devoid of major
rainfall has limited scope for major flows. However, the storm water drains will
be culminated in the storm water ponds that should collect the water for reuse.
Any excess flow in the ponds will be drained as per the natural hydrological
pattern of the area. The storm water ponds should also act as retention ponds
for sediment transport and erosion control

6.6
 • As stated above, the area is mostly even and will not involve major cutting and
filling. The site grading should not create any open slopes or dips in the
topography that will require slope stabilization. The various storm water ponds
etc should be created with the requisite slope stabilization and stone pitching on
the sides to retain design volumes of storage and collection. The slope
stabilization of storm water pond should also arrest any carrying in or erosion of
banks.

6.1.5 Land Environment

• Workers engaged during construction phase should preferably be provided with

temporary housing facilities at planned labor colonies located nearer to project
site. Haphazard growth of labor camps should be avoided. The labor camps
shall be provided with all the essential facilities.

• Labour camps should not disturb local environment.

• On completion of construction works all temporary structures, surplus materials

and wastes should be completely removed to avoid future land use
incompatibility. Dumping of construction waste should be prohibited on land
covered by natural vegetation and stockpiles should be provided with gentle
slopes.

• The land acquired for the SEZ project is a barren (arid) land, should be
compatible with the surrounding landuse.

• Minimum vegetation should be cleared for the construction activities.

• The solid wastes such as paints, lubricants, oil, diesel containers or any other
non-biodegradable wastes that have leaching characteristics should be
disposed as per the “Authorization” received from GPCB.

• The nutrient content of topsoil should be recovered from different areas during
site grading, prior to construction activities, the topsoil should be placed in the
areas where the greenbelt is earmarked for development. If there is any excess
topsoil, the same should be handled, stored and piled (max. 3 m height) in
demarcated storage area. The storage area should be regularly sprinkled with
water to minimize the risk of dust being blown by the wind.

• Stock piles should not be located in the storm water flows.

• The project location is in an arid barren area, which is devoid of any dense
vegetation. Sparse vegetation in terms of bushes and shrubs are seen on the

6.7
 site. These should be cleared, mulched and used in preparation of compost
material to be utilized for land application in green belt area.
• The area is mostly even and hence will not involve major cutting and filling.
During the site preparation work, the soil from the higher gradient should be
utilized to level the areas with lower gradient. Since the overall area is relatively
flat, the amount of cutting and filling would be well balanced
Construction Waste Management
• Segregation of waste material should be based on the reusability and recycling
potential. Reuse and recycling opportunities shall be systematically investigated.
• Management should ensure that the infrastructure for recycling of construction
and demolition materials is in place and operating at the beginning of the
project. On-site system should be set-up to collect and sort waste for recycling,
or for reuse, and monitor the system consistently throughout all phases of
construction.
• Materials and products should be selected with minimal or no packaging, if
possible.
• Construction debris from the site and any construction debris in the site areas
associated with the projects will be removed on a regular basis by the
contractor.
• Workers should be educated on waste prevention goals and the proper handling
and storage of materials.
• Separation at source should be implemented e.g. by designating a separate
waste disposal area where different types of waste can be brought separated
and stored temporarily prior to disposal.
• The solid waste generated should be collected and disposed in an appropriate
manner either at a landfill site or used as compost for land application. The
existing workshop areas should be used for the maintenance of vehicles and
construction machineries so as to avoid accidental spills of oil/oily wastes. Area
for maintenance of vehicles should be so located that contamination of
groundwater by accidental spillage of oil can be prevented

6.1.6 Biological Environment

The region does not have dense vegetation and landuse suggests agricultural
activities in certain areas, which crops for only one season i.e. during the monsoon season.
The following measures are recommended to mitigate adverse impacts on biological activities
during construction phase:

6.8
 • There should be minimal removal of vegetation and felling of trees.

• Revegetation should commence at the time when site clearing is being

undertaken.

• Reliance should continue with its afforestation programme to replace any

vegetation removed during construction.

• A greenbelt of appropriate width should be developed in and around the

proposed SEZ.

6.1.7 Socio-economic Environment

• The related developments like construction camps should not be dependent on

local resources (power, water), during both construction and operations phase,
the only likely impact on infrastructure would be on the roads, especially SH 25
during the construction phase. However, considering the low traffic emanating
during construction phase, effective traffic management should not pose any
problem. A traffic management scheme should be developed to avoid
congestion on the nearby and local roads.

• It is estimated that about 50,000 construction workers on average will be

involved for a period of 2-3 years. The total employment during the construction
phase will be about 24 lakh man months (both skilled and non-skilled
employment). The manpower required for these activities should preferably be
employed from nearby villages so that avenues of employment will be open to
local people.
• When necessary, it is recommended that the local communities should be
engaged in an on-going dialogue during construction period, with an objective to
build and maintain a good relationship with the project proponent and
contracting companies.
• As an efficient tool for maintaining these good relationships, it is recommended
that a grievance mechanism should be operational during the construction
period. The mechanism aims at receiving and facilitating resolution of the
affected communities concerns and grievances related to the risks and
nuisances created by the project. The efforts should be commensurate to the
potential impacts of the project, ranging from designating a community liaison
officer for maintaining a formal grievance register.

6.9
 Health and Safety

• The movement of heavy equipment should be done with proper precaution to

prevent any accidents on the road.

• Occupational risk should be minimized at the project site through safety

measures. Movement of vehicles with 40 km/hr imposed speed limits on village
roads should reduce risks of accidents or injuries.

• Safety training should be provided to all construction workers on operation of

equipment. Security should also be extended during non-working hours to
ensure there is no uncontrolled access to the machinery and equipment.

• The contractors should also be vigilant to detect workers showing symptoms of

communicable diseases. All illness and incidents should be reported and
recorded.

6.1.8 Energy and Water Use

• Existing Captive Power Plant (CPP) in the adjacent Reliance refinery complex
could meet the power requirement for the construction phase, wherever feasible.
• The source of potable and construction water for expansion project during
construction should be met by the Desalination units in the existing refinery and
storm water collected in the ponds.
• The contractors should be encouraged to conserve the water during the
construction
• The lights should be turned off when work is at a halt. Security lighting can run
on motions sensors.
• Using of natural material in possible areas that require a low-level of processing,
there by reducing energy use and pollution. (Stone, brick Clay tile)

6.2 Environmental Management Plan during Operational Phase

In order to mitigate the impacts due to operation of refinery, power plant and
petrochemical complex on various environmental components, the following measures are
recommended;

6.10
6.2.1 Air Environment

The impact on air quality due to emissions from multiple sources during the continuous
operations has been assessed by use of mathematical models.

The incremental predicted GLCs of major air pollutants viz., SO2 and NOx due to the
proposed SEZ developmental activities over the baseline air quality are within stipulated
standards of CPCB for industrial regions, i.e. 120 μg/m3. However, measures proposed for
mitigating impacts on ambient air quality during the project operations include the following:

• Best Available Control Technology (BACT) should be installed at individual

emission sources to minimize the air pollutant emissions.

• Regular record on sulphur emission should be maintained at SEZ units as part of

the environmental data records.

• Off gases from proposed units should also be treated in amine absorption units
and regeneration unit meant for H2S removal as already in practice for
desulphurization of off gases (fuel gas) in existing Reliance refinery.

• Performance evaluation of Sulfur Recovery Units with Tail Gas Treatment Units
should be done on regular basis (at scheduled intervals) through monitoring off
gas flow rate.

• In case of any failure in sulfur recovery units appropriate steps should be taken to
match the generation with SRU feed

• FCCU should have particulate control systems such as Electrostatic

Precipitators/cyclones/wet scrubbers.

• The measures to reduce the SO2 in furnaces, boilers, gas turbines is by

quantifying the contribution of various sources in order to determine the main
source, increase in the energy efficiency of the plant, heat recovery, vapor
management and change of combustibles.

• All the combustion units should be maintained properly at optimum efficiency.

• All fuel combustion units should be operated with minimum excess air so that fuel
consumption is optimized and emission of NOx is minimized. Low NOx burners
should be implemented in all combustion units of proposed units in SEZ.

• Energy conservation projects/schemes to result into reduction in quantity of fuel

should be implemented.

• Port holes and sampling facilities should be provided at proper location for all the

6.11
 stacks coming up in the SEZ for monitoring of flue gas velocity and flue gas
temperature and also for checking concentration of different pollutants at regular
intervals.

• The SEZ complex should comply with proposed emission standards of CPCB for
stacks located in the SEZ complex.

• Ambient air quality with respect to SPM, SO2, NOx, H2S and CO monitoring shall
be done at minimum 4 locations around the SEZ complex. The monitoring
stations should be set up in consultation with the GPCB.

• A digital weather station for monitoring wind speed, direction, temperature,

relative humidity and rainfall with automatic data logging and analysis facility
should be installed at the SEZ complex. The same should be operated
continuously for maintaining micrometeorological data record at SEZ site.

• Emission from DG stacks, if used should be comply with the emission standards
stipulated by Central Pollution Control Board (CPCB) and GPCB.

• Continuous sources of emissions should be installed with stacks having sufficient

height (CPCB norms) to ensure adequate dispersal of pollutants. Further,
pollution control systems such as low NOx burners and low sulphur fuel should be
used.

• Gas powered or low sulphur diesel and unleaded petrol in conventional vehicles
should be used within the project area and for product evacuation.

• Waste oil should be sold to MoEF /GPCB authorized waste oil recyclers

• Proposed Incinerator design and emissions should be as per the Guidelines of

CPCB as given in details later in the Section 6.2.4.2 of this Chapter.

• Idling of vehicles should also be minimized during transport and handling

activities

• Loading/unloading and storage areas should be paved to reduce dust emissions

• All access roads (internal as well external) to be used by the project authorities
should be made pucca (either with WBM, concrete or bitumen) to suppress the
dust generation along the roads

To control fugitive emissions of VOCs in the SEZ complex, following steps should be
taken along with the requirements / conditions notified by MoEF for oil refineries and
petrochemicals shall be followed:

6.12
 • Provision of internal floating roof tanks with flexible double seal for MS and
intermediate products.
• Provision of mechanical seals in pumps
• Regular inspection of floating roof seals and proper maintenance of floating roof
seals for proposed storage tanks
• Preventive maintenance of valves and other equipment
• Regular skimming of oil from separators/equalization basin in ETP.
• Fugitive VOC emissions should be assessed and minimized whenever possible
(vapor recovery systems, joints, pumps, fittings etc.). They shall also be
monitored at regular intervals
• Fugitive emissions should be controlled through proper maintainance
• It would be a best practice to avoid burning in flaring stacks and to recover these
gases whenever feasible.
• Use of high grade gasket material for packing, provision of motor operated valves
for critical services such as high vapour pressure components and chemicals
• Fuel leaks should be prevented from on land equipment. Further implementation
of Leak Detection and Repair (LDAR) programme using a portable VOC
detection instrument should be done on distribution lines and tanks.
• Inventory of odorous compounds should be maintained and release of such
compounds should be prevented.
The following guidelines should be adopted for the units to be developed in the SEZ
Complex:

• Each plant may prepare a component inventory as per the data reporting formats

• All leaking equipment may be marked by weatherproof identification till repaired

Pumps:
• Visual inspection should be done every week.
• Changeover to spare pump immediately and repair leaks should be attended to
immediately. During the repairs care should be taken to avoid water and soil
contamination.
• Sensors should be provided to detect seal system / barrier fluid leaks and should
be fitted with an alarm.
Compressors:
• Every compressor in VOC service should be equipped with seal & barrier fluid
system to prevent leak to atmosphere.

6.13
• Barrier fluid system should be as under:

- vent/ control system/ fuel systems or back to process

- sensors should be provided to detect seal system / barrier fluid leaks and
should be fitted with an alarm.
• Switch over to leak less / low leak type within next three years.

• The leakages should be attended to immediately

• Compressors having dry sealing systems & having closed vent exhausting
vapour from drive shaft seal to control system may be exempted from monitoring.

Pressure Relief Devices:

• Pressure Relief Devices in gas / VOC service should be operated below leak
threshold except during pressure release

• Monitoring for confirmation within 5 days of pressure release

• Pressure Relief Devices routed to process / fuel gas system or closed vent
system should be exempted from monitoring.

• Pressure Relief devices with upstream rupture disc are exempted from LDAR

• After pressure release, rupture disc should be reinstalled as soon as possible

Sampling Connection Systems:

• Sampling connection system in VOC service should be equipped with closed
purge / closed loop / closed vent system, then gases displaced during filling need
not be collected

• Closed purge/closed loop/ closed vent system should return purged fluid back to
system

• Collect & recycle the purged fluid to process direct or transfer purged fluid to
control device

• In-situ sampling systems & sampling without purge are exempted from LDAR
monitoring requirement

Open Ended Valves or Lines:

• Each open ended valve or line in VOC service should be equipped with a cap /
blind flange / plug or second shut off valve
• Each line equipped with a second valve should be operated so that valve on
process side is closed before closing the shut-off valve.
• Open-ended lines designed to open automatically in emergency shutdown
system should excluded from LDAR

6.14
 • Open-ended lines or valves containing materials which will pose serious
explosion, over-pressure or other safety hazard if capped, should be excluded
from LDAR
Valves:
• Completely closed valves (e.g. bellow seal valves having no external shaft
penetrating valve body) are exempted from monitoring provisions.
• Wherever possible, low leakage valves such as non-rising stem/ diaphragm
valves with tight sealing system (e.g. metal fabric gasket) may be used.
• Repair to a leaking component should be attended immediately. Conduct
monitoring immediately after leak repair as confirmation for satisfactory repair.
• Up to 5% valves may be designated ‘inaccessible’ & may be exempted from
monitoring requirements.
Flanges/Connectors:
• Flanges in organic HAP service should be provided with high quality packing e.g.
metal fabric/graff-oil having low leakage values
• Existing Plants should replace flanges in VOC service with high quality packing
• Up to 5% flanges/connectors maybe declared as inaccessible & maybe
exempted from monitoring requirements.
• The repair of a leaking flange should be attended immediately. Monitoring should
be conducted immediately after leak repair as confirmation for satisfactory repair.
Delay of Repair:
• Conditions under which delay in repair is permissible:
- Repair not feasible without plant shutdown
- If existing seal system are to be changed with better/low leakage system
requiring change is equipment assemble (e.g. single mechanical seal on
pump to be replaced by dual mechanical seal or with a closed vent &
control system or change of valve assembly)

Measures for control of phosgene and Safe Management

Phosgene is a transient intermediate in the manufacturing of Methylene Diphenyl

Diisocyanate (MDA) & Toluene Diphenyl Isocyanate (TDI). The Phosgene Panel under the
American Chemistry Council has delineated the Safe Management Measures for phosgene.
The extract of the above refereed document is attached as Annexure IX. The most suitable
measures for our plant will be selected from those suggested by Phosgene Panel under the
American Chemistry Council based on the configuration and size of the equipments. These will
be selected during the detailed engineering stage through HAZOP & Risk Analysis studies.

6.15
Further, these designs and safety measures will be reviewed by the experts in this field.

Online monitoring of phosgene from the absorber and sensitive detectors would be
installed for detection of phosgene.

6.2.2 Noise Environment

The design of the project should be such that the sound pressure level in the work
area will not exceed 90 dBA. Restricted areas should be those locations where it is not
reasonably practicable to reduce the noise level below the work area limit, Wherever
practicable, attempts should be made to reduce the noise level below 85 dB(A). The equipment
should be chosen in such a way that the above noise limit is not exceeded. The noise levels at
the nearest habitation should be less than the stipulated standards of CPCB. However, as a
good operational procedure, the following generic measures should be implemented in addition
to the existing green belt:

• Similar measures as proposed in the construction phase for noise making

machinery, to ensure practicably low noise levels within the work environment.

• Specification for procuring major noise generating machines/ equipments should

include built in design requirements to have minimum noise levels meeting
CPCB/MOEF requirements. The monitored noise levels at sensitive locations
should be taken to ensure that the impact due to high noise levels is practically
minimized.

• Monitor job and location specific noise levels for compliance with HSE
regulations by verifying acceptability of noise levels caused by the project
activities and comparison with noise criteria

• Conduct periodic audiometric tests for employees working close to high noise
levels, such as compressors, DG sets, the loading, unloading sections etc.

• Provision of PPE’s should be done and their proper usage should be ensured for
eardrum protection of the workers as well as visitors

• It should be ensured that low noise (generating) equipment are procured

wherever feasible

• Acoustic laggings, and silencers should be used in equipment wherever

necessary

• Sound proofing /glass paneling should be provided at critical operating stations,

and control rooms

6.16
 • Either Acoustic barriers / shelter should be developed in noisy workplaces or
acoustic enclosures should be provided for the high noise generating equipment

• Noise generating sources in the plant areas should be monitored regularly.

Monitoring of ambient noise levels should also be carried out regularly both
inside the refinery area as well as outside the greenbelt.

6.2.3 Water Environment

• Since fresh water is a scarce resource in the area, only seawater should be used
for proposed expansion project. Desalination units should be installed to meet
the water requirement of SEZ units. The impact on the ground water/saline
intrusion if any should be monitored through the existing network of monitoring
wells and piezometers.

• An effluent treatment plant based on the raw wastewater quality and required
treated wastewater quality should be designed. However the effluent standards
should be well within the prescribed limits of GPCB & CPCB. The performance of
ETP should be continuously monitored and any deviation in performance should
be corrected on priority

• Reduction in water requirements should be achieved by implementation of closed

circuits within the petroleum and petrochemical complex.

• Use of desalinated water as service water should be minimized

• Reuse of effluent should be attempted

• Recycle of pump gland cooling water should be undertaken

• Condensate recovery should be maximized

• Treated effluent should be used for hydrotesting of vessels/tanks/pipelines

instead of desalinated water. Treated effluent should also be used for cleaning of
columns/vessels during turnaround

• Holding ponds should be provided so that bio-systems of wastewater treatment

system should be prevented against shock load

• Dosing of chlorine or biocides as part of advanced cooling water treatment in the

cooling water system should be done to take care of biological growth

• The detailed record of raw water intake at refinery (for processes, CT makeup,
fire water, green belt development and sanitary and drinking purpose) as well as
township complex and wastewater generation from different sources should be

6.17
 maintained on daily/regular basis w.r.t. flow rates and characteristics. These
details should be useful in preparing comprehensive water balance at project site
and also for identification and implementation of reuse/recycle practice of treated
effluent at project site leading to mitigation of effluent discharges.

• Water flow measurement facilities (metering) should be provided at inlet and

outlets of major process units, which should help in minimizing wastage,
conserving the water as well as maximizing the recycle/reuse of treated effluent

• Regular monitoring of effluent from different treatment units and also combined
final discharge of treated wastewater including outlet of STP at township is
recommended. Performance evaluation of effluent treatment plant as well as
sewage treatment plant should be undertaken at regular intervals for all relevant
parameters covered under this study

• Use of polishing lagoon pond for aquaculture should be explored, where bio-
assay tests could be conducted at regular intervals

• The effluents discharged into the sea should be done through the multipore
diffuser system designed by the National Institute of Oceanography (NIO). The
location of discharge should also be identified by NIO. The diffuser system shall
discharge the wastewater generated by the refinery, power plant and the
petrochemical units.

• The effluents discharged into the surface water or the natural environment, their
physicochemical characteristics after any treatment should comply with the
maximum levels defined by the CPCB.

• Regular monitoring of the discharge of the main pollutants is required to ensure

that the regulatory maximum levels are complies with. Periodic measurements of
the pollutants in the natural environment is considered best practice.

6.2.3.1 Sewerage Management Plan

Following a modular phased development concept in the SEZ, sewerage system

should comprise of an integrated sub-system; each catering to a self-contained park/hub,
collection system of pipe network, lifting stations (LS), terminal sewage pumping stations
(TSPS), sewage treatment plants (STP) and tertiary treatment plant (TTP) before recycling for
non-domestic & industrial usages. The whole SEZ territory should be divided into different
sewerage catchment zones. Each zone shall be serviced by one sewage treatment plant
(STP). Lifting stations should be provided for STPs in order to reduce depth of manholes.
Where necessary, the sewage should be pumped through rising mains to traverse higher

6.18
ground and then flow into the gravity sewer.

Considering the ease of operation and maintenance, power requirement, size of unit,
any one of two processes namely UASB or FAB technology may be appropriate for the SEZ
area. FAB technology requires very less land, which is a precious item in SEZ area; hence, it is
proposed that for secondary treatment of sewage FAB technology (Fluidized Aerobic
Bioreactor) may be used. FAB (Fluidized Aerobic Bioreactor) is a biological treatment process
employing fluidized bed bioreactors operating at elevated pressures, followed by a dissolved air
flotation (DAF) clarifier, which removes suspended solids from the effluent. The DAF unit
produces a clear effluent suitable for direct discharge or further polishing, for example, by
conventional sand filter or membrane filtration, to yield a final effluent of very high quality.

However another alternative, is establishing a Sewage Treatment Plant of high

efficiency aerobic treatment schemes based on extended aeration system using fine bubble
diffused aeration are proposed. These plants are compact, odor free and have an energy
efficient process. STP shall generate water of high quality, suitable for use as process water for
industries / warehouses /transportation / horticulture etc.

6.2.3.2 Drainage

A gridiron patterned integrated Drainage system with the sewerage system, to cater
the surface run off within the SEZ area should be designed by gravity flow. The storm water
discharge points in the form of holding ponds with overflow weirs designed to ensure that
excess water, in extreme circumstances should flow out in a controlled manner. These ponds
shall act as flood retention as well as surface water storage.

The U-drain system should be constructed of reinforced concrete for the surface run
off collection for reasons of easy maintenance and durability. These should be placed along
with the main roads. The entire storm water drainage system should be developed according to
the layout plan of the area showing industries, roads, residential localities, etc. once the
tentative layout is approved. Separate storm water drainage system should be provided to
ensure that there is a quick disposal of storm water so that there is no disruption in normal
activities.

Type of Drains

The SEZ should have drainage along the four types of roads, viz. local street, collector
street, sub-arterial and arterial as drainage is very essential to avoid any water logging which
may result in disruption of normal activities in the area. The surface water should be diverted to
the drain by bell mouth inlet points or gullies.

Drains are to be designed as per design peak discharge governed by the topography

6.19
of the area, duration, amount and frequency of rainfall (with 10 and 25 years return period),
nature of soil, land use, etc.

Size of the main, trunk, branch and lateral drains should be designed according to the
respective area of catchments and design rainfall intensity, as per IRC:50 and CWC flood
estimation report.

6.2.3.3 Wastewater treatment plant

The treatment plant should be designed on the following philosophy

• To treat and recycle the effluents from one process to another and also the
domestic effluent

• To ensure that the treated effluent is within the stipulated standards or statutory
norms of GPCB and CPCB/MOEF.

• Stream wise treatment of wastewater

• To reduce the load on the secondary treatment units

Glycols effluent pre treatment unit

Process effluent like glycol should be kept separately from the other streams because of
high BOD/COD. This is due to the presence of glycol in the effluent, which is biodegradable.
The effluent from MEG plant is received in to equalisation tank and fed equally on the media of
bio tower by rotary distributors. On the surface of the PVC media slime growth takes place and
the outlet of the clarifier is taken to the clarifier for the removal of bio sludge. The overflow from
the clarifier is taken to the waste recirculation, from where part of the effluent is recycle back to
the system and rest is being taken to the equalistion tank II.

Effluent management of mono, di and tri-ethylene glycols

The MEG / DEG / TEG effluent mainly contain corresponding glycols as pollutant. These are
very easily biodegradable. This glycol effluent will be pretreated in a biological pretreatment unit
to reduce the biodegradable load on the central ETP. The details of the pretreatment are given
below.
The effluent from the MEG / DEG / TEG plants will be received in an equalization tank after
primary treatment. The requisite nutrients for bacterial metabolism will be added in the
equalization pond and the effluent will be fed to the bio-tower. Bio-tower will be filled with PVC
media. On the surface of the PVC media slime growth will take place. A rotor distribution arm
will be provided on the top of bio-tower to ensure equal distribution of effluent on the PVC
packing media surface. Outlet of the bio-tower is taken to the clarifier for the removal of bio
sludge from the effluent. Clarifier effluent will then be routed to the Central ETP for further

6.20
treatment with the other effluent streams.

In the MEG / DEG / TEG plant there will be many pumps, which will be handling organic
chemicals like Ethylene Oxide, MEG, DEG, TEG and Poly Glycols. During the maintenance
activity these pumps will be decommissioned. During the decommissioning, contents of pumps
/ suction lines will be drained to separate underground collection pits. These underground pits
will be strategically located at various places in the Glycols Plant.

Instead of diverting the content of the underground pits to the ETP, the content of the
underground pits will be diverted to a Glycol Slop Tank from where the glycols will be sent to
the pretreatment for reprocessing. This system will reduce the organic load on the effluent
treatment plant. During the distillation, MEG, DEG & TEG are obtained and the residual glycols
are left behind which are usually incinerated in an incinerator. However, there is a potential
market for selling this glycol residue, thereby minimizing the generation of waste for disposal.
Since this waste can be treated as a product for sale, the emissions contribution from the usual
incineration of residual glycol will also be less.

The block flow diagram of the Glycol Effluent pre-treatment unit is shown in Fig 6.4.

PTA Effluent
The concentration of the PTA effluent is very high as it contains organic compounds and
acetic acid. The effluent from the PTA is received in to clarifloculator with the aid of poly-
electrolyte, where suspended solids are being removed. The overflow of the clarifloculator is fed
to the anaerobic digester running either parallel or series. These digesters are combination of
up flow sludge blanket and up flow anaerobic filter. The over flow from the digester is taken to
the equalisation tank II.

Details of Effluent Characteristics of PFY unit and Effluent treatment

This effluent does not require any separate pre-treatment and will be pumped directly from
collection sump to the central ETP for treatment with other effluent streams. The schematic flow
diagram of proposed Central Effluent Treatment Plant is shown in fig. 6.1 of the EIA report.
Similar practice is already being followed for PFY effluent at one of our petrochemical complex
located at Hazira, Gujarat.The Effluent characteristic of Polyester filament yarn unit is enclosed
as Table 6.4.

Effluent Treatment Plant

The composite effluent from the rest of the plants mainly consist of oil, grease, organic
matter and suspended solids which should be treated in effluent treatment plant consisting of

6.21
primary, secondary and tertiary facilities.

The primary treatment facilities consist of TPI (Tilted plate inceptor pit) for removal of
free oil, equalisation tank and pH Adjustment tank for pH correction, Flocculator followed by
Dissolved Air Flotation Unit (DAF) for removal of emulsified oils

The secondary treatment is a combination of the attached growth and suspended

growth system consisting of Equalisation tank, Bio tower and Aeration tank and Secondary
clarifier followed by Guard pond and polisher

The tertiary treatment facility consists of clarified water sump, Rapid sand filter and
Activated carbon filter.

The air is continuously blown from the bottom of the tank so that effluent mixed
properly in the tank, due to flowing of air in upward direction it will carry the free oil to the
surface, is taken to the slop oil tank via slop oil sump. There is a provision to removal of water
from the tank. The equalized effluent should be further treated in Dissolved Air Flotation (DAF)
tank for removal of emulsified oils and suspended solids. The oil and scum from the surface
should be removed with the help of mechanical skimmer. The scum and oil should then be
taken to the sludge pump.

The effluent should be taken to the equalisation tank where PTA effluent after
pretreatment. The effluent from the equalisation tank should then pumped into 2 stage
biological system compromising of plastic media bio towers as the first stage and a part of the
effluent should be taken to the fine bubble diffused aeration system as the second stage.

The overflow of the effluent should then taken to the clarifier for removal of biomass
and the overflow from clarifier should be collected in clean clarified sump where chlorine would
be added. Then the effluent should be pumped through dual media filters. Then effluent from
the filter should be send send to the polishing aeration tank. In this DO level will rise and the
effluent from this unit could be used for horticultural purposes and make up water in cooling
towers.

The MoEF sought clarification on details of Common Effluent Treatment plant. Some of the
plants that have typical effluent characteristics that need pre-treatment will have their own
effluent treatment plant within the battery limit of the specific plant. These plant specific ETPs
will treat their respective effluent to the specified standard that would be acceptable at the
Central ETP.
The composite effluent from the all the plants will mainly consist of oil, grease, organic matter
and suspended solids which would be treated in effluent treatment plant consisting of primary,
secondary and tertiary facilities.

6.22
The primary treatment facilities consist of two stage oil removal – the first being free oil removal
and the second would be emulsified oil removal.

The secondary treatment is a combination of the attached growth and suspended growth
biological system consisting of Equalisation tank, Bio tower and Aeration tank and Secondary
clarifier followed by Guard pond and polisher. The tertiary treatment facility consists of clarified
water sump, Rapid sand filter and Activated carbon filter

At the equalisation tank the PTA effluent after pretreatment within the plant will combine.

For further recycle and reuse of the treated wastewater, effluent polishing methods like
RO, Ion Exchange columns etc will be explored and implemented. The Schematic Flow
Diagram of Proposed Central Effluent Treatment Plant in SEZ is shown in Fig. 6.1.

6.2.4 Land Environment

• Soils in the adjoining areas are sandy loam to silty loam with moderate infiltration
rates, amenable to groundwater pollution. Considering this fact, every precaution
should be taken to avoid spillage of oils, petroleum and petrochemical products
on soils to protect groundwater and to avoid any danger to other soil microbial
groups which are sensitive to oil pollution

• Oil is a potential hazardous substance present in wastes generated from refinery

and petrochemical complex. Special care should be taken in all the oil removal
operations. Disposal of Oily sludge generated from effluent treatment plant
through Coker should be practiced.

• The sludge generated from the ETPs’ of the petrochemical complex should be
disposed off in secured landfill / incinerated. The incinerated ash should be send
to the secured landfill.

• The storage, handling, transportation & disposal of the hazardous waste should
comply with the Hazardous Waste Management Rules.

• Greenbelt in and around the SEZ units should be developed.

• A record w.r.t quantity, quality and treatment management of solid hazardous

waste should be maintained at environmental monitoring cell for different process
units (sources)

• Mixers and tank cleaning procedures, which maximize recovery of oil, should be

6.23
 adopted to reduce tank bottom sludge.

• Recovery of oil from oily sludge using techniques such as centrifuging, thickening
and filtration should be undertaken.

The following measures should be practiced at the Coke Storage area by the Reliance:

• Coke piles height should be kept at 3.5 m or less since the wind velocities closer
to the ground is less.

• The piles should be aligned with prevailing wind direction to minimize the carry
over with the wind.

• Regular water sprinkling should be carried out over the piles and truck movement
area. Three / four water tankers should be exclusively used for this purpose
round the clock.

• Rows of Casuarinas trees should be planted on the boundary of the storage area
as windbreakers.

• Storm water channels should be provided around the piles storage area to collect
and route the rainwater to two coke fines settling ponds. Coagulant addition
facilities are also to be provided in these ponds for improving the settling.

• The outlet drains two nos of hay filters should be provided in series.

• Down stream of the hay filters a check dam should be constructed near the
boundary for creating a large water storage area. This will further increase the
residence time for the settling of remaining coke fines.

• It is recommended that above measures should be continued for the project and
take further steps of improving/increasing the hay filters.

6.2.4.1 Hazardous /Solid Waste Management

Solid waste disposal and management is a prime concern in the SEZ as it not only comprises of
the household waste but also the industrial waste. The domestic waste with assumed solid
waste generated of 0.5 kg / capita / day solid waste will be generated in the SEZ township. The
hazardous waste generation from each Unit has been tabulated in Table 5.11 of the EIA report.
However, the catalyst waste generation frequency varies based on the type of catalyst and its
frequency of regeneration. The combined hazardous waste generation and proposed disposal
methodology from the Petroleum and Petrochemical Complex has been tabulated in Table 6.1
of the EIA Report.

6.24
Proposed Solid waste management system

In the short-term, the trash collection areas should be designed for collection of
recyclables and should have a used oil collection tank or a rack on which to store containers of
used oil. In the short-term, this oil should then be exported off-site to a refinery for recycling or
to a facility where it could undergo proper disposal.

This emphasizes the need of on-site recycling of oil, which is an upcoming concept.

There are two main uses for recycled oil:

• It can be re-refined in the refinery and then used in combustion engines and as a
lubricant, or

• It can be burned as fuel, if the proper procedures and equipment are used.

For this facility, the oil collection service transport should collect the oil to an onsite
facility for treatment. Ideally, this facility should be located near or in conjunction with SEZ’s
petroleum, oil, and lubricant facility.

For most of the collected oil, a simple oil separation and storage apparatus should
suffice. The used oil should be emulsified; however, a more advanced system called “ultra
filtration” is required. If high levels of metals or other contaminants are present, a chemical or
reverse osmosis unit may be necessary. In both ultra filtration and osmosis, the waste water
that is removed during separation is clean enough to be used directly for gray water and should
go to the proposed gray water collection area.

Once treated, the oil should be utilized within SEZ industries with oil boilers for use as
a fuel source. The treated oil is actually a preferred fuel source for many industrial facilities.
Many of the industries in the SEZ can be potential candidates for this treated oil.

For the residential township, the effective solid waste management systems are
needed to ensure better human health and safety. They should be safe for workers and
safeguard public health by preventing the spread of disease. In addition to these prerequisites,
an effective system of solid waste management should be both environmentally and
economically sustainable. Clearly it is difficult to minimize the two variables, cost and
environmental impact, simultaneously. There will always be a trade off. The balance that
needs to be struck should reduce the overall environmental impacts of the waste management
system as far as possible, within an acceptable level of cost.

It is proposed that mechanical composting process be adopted, which is eco-friendly

and also some revenue can be generated by the sale of compost.

6.25
 Recycling turns materials that would otherwise become waste into valuable resources.
Materials like glass, metal, plastics and paper are collected, separated and sent to facilities that
can process them into new material.

All biodegradable municipal solid waste should be mixed with sewage sludge to
undergo composting to produce saleable fertilizer. Composting is another form of recycling.
Non-biodegradable waste should be brought together with the industrial waste to the landfill for
ultimate disposal. Although source reduction, reused, recycling and composting can divert large
portions of municipal solid waste from disposal, non-biodegradable waste should be collected
in landfills. Landfills within the SEZ should be well-engineered facilities that are to be located,
designed, operated, monitored, closed, and cared for after closure, cleaned up when necessary
to protect human health and the environment.

Different processes have different catalyst, which have to be replaced at different

intervals. Based on the process, the spent catalyst will be deactivated based on the methods
prescribed by the catalyst suppliers. The spent deactivated catalyst will either be taken back by
the catalyst supplier for regeneration or the catalyst with available activity can be sold to other
processing units. Spent Catalyst containing precious metals can be sold to authorized
processors for precious metal recovery. The management and disposal of catalyst will be in line
with the requirements of the Hazardous Waste (Management and Handling) Rules.

Segregation and Storage at source

It will be necessary to segregate the solid waste generated at every household as well
as in the commercial premises. The segregation will entirely depend upon its source of
generation, it should be segregated as biodegradable as well as non-biodegradable and
accordingly, it should be stored in different containers or bags with different color codes.

There will be another types of solid waste termed as Bio-medical waste, which will be
generated at the medical centre. It will also be of hazardous and non-hazardous type, and
hence required to be segregated and collected in separate containers provided at individual
medical centers.

Control of contamination risk linked to the storage of toxic or hazardous waste:

• Water-proofing and installation of containment system for loading and unloading

area.

• Installation of chemical storage areas which are linked to containment systems, if

possible covered.

• Avoidance of chemical and storage tank drainage systems installed

6.26
 underground.

Collection and transportation

The refuse collector should collect the bags daily from the container placed in
residential areas. Small trucks (dumpers) of capacity 4.5 m3 is suggested for collection of waste.
It should be rear loading type equipped with hydraulic loading and mechanical tipping
mechanism. Truck shall be designed for manual loading of bags and mechanical unloading at
the storage depot.

Waste collected from the litter bins provided at suitable intervals on the street should
be a mixture of biodegradable and non-biodegradable waste. This waste should be emptied in
to the closed truck and transported to storage transfer depot. Road sweeping is proposed to be
done mechanically. Garden waste should be collected once in three days.

Treatment and Disposal Strategies

Several technologies are recommended for processing, treatment and / or disposal of

solid waste. Some of them are Microbial composting, Vermi composting, Incineration, Power
generation, Fuel pelletisation etc. Each waste has a separate destination depending on its
quality. However a general treatment and disposal strategies as out lined in Municipal Solid
wastes (Management and Handling) Rules–2000 that can be adopted is as follows:

• After collection and bringing all the coloured bags at one storage area, the
biodegradable waste from residential, commercial areas can be transported on routine
basis through the authorized contractors to composting plant, whereas non
biodegradable should be disposed off to common land fill site. Due care should be
taken to avoid fly nuisance throughout the cycle of collection, transportation, treatment
and disposal of biodegradable waste from residential and commercial areas
• The recyclables such as metal canes, plastics etc. should be sold to only authorized
vendors.
• Hazardous part of bio-medical wastes should be incinerated at common incineration
facilities and the incinerated ash should be disposed in the on-site secured landfill,
while non-hazardous wastes should be disposed off on pre-identified landfill site in
consultation with local administration body.
• The final designing and modalities may be carried out during construction phase of the
project or a tie-up with local administration should be made for entire solid waste
disposal, after being collected and segregated at township complex.
• The tank truck loading and unloading area should be sealed and linked to containment
facilities.

6.27
 • Hazardous substance storage area should be contained and when possible, covered
to any pollution through run-offs.
• Wastewater and chemical drainage systems must undergo regular inspection for
leaks.
• Chemical drainage systems inside the facility and storage tanks should be above
ground, unless otherwise recommended for reasons of hygiene and safety.
• It is also recommended that a monitoring programme be implemented to check
underground water for any spillage.
• It is the best practice that all necessary measures should be taken in the design and
operation of the facility to ensure proper waste treatment through the definitionof
procedures which aim to:
- limit the quantity and toxicity of waste at source.
- sort, recycle an reuse manufacturing sub-products.
- ensure the treatment or pre-treatment of toxic waste.
- ensure storage of final waste in the best possible condition

Disposal of catalyst used in the different process

Different processes have different catalyst, which have to be replaced at different

intervals. Based on the process, the spent catalyst is deactivated based on the methods
prescribed by the catalyst suppliers. The spent deactivated catalyst is either taken back by the
catalyst supplier for regeneration or the catalyst with available activity is sold to other
processing units. Spent Catalyst containing precious metals will be sold to authorized
processors for precious metal recovery. The management and disposal of catalyst will be in
line with the requirements of the Hazardous Waste (Management and Handling) Rules.

6.2.4.2 Common Incinerator Facility

The incinerator should be designed for capacity more than 200 kg/hr. Incinerator shall
be installed with venturi scrubbing system, which is an air pollution control system. All
incinerators, individual or common will be designed as per the CPCB Criteria. The individual
incinerator will be a process requirement of respective units and the common incinerator will
cater to the incineration of requirement of the complex. The technical details of the common
incinerator is given in Annexure XI

The size of the opening through which the waste is charged should be larger than the
size of the waste bag to be fed. The volume of the primary chamber should be atleast five times
the volume of one batch.

6.28
 The double chamber incinerator should preferably be designed on "controlled-air"
incineration principle, as particulate matter emission is low in such incinerator. Minimum 100%
excess air should be used for overall design. Air supply in the primary and secondary chamber
should be regulated between 30% - 80% and 170% - 120% of stoichiometric amount
respectively. Primary air should be admitted near / at the hearth for better contact. Flow meter /
suitable flow measurement device shall be provided on the primary & secondary air ducting.
The combustion air should be supplied through a separate forced draft fan after accounting for
the air supplied through burners.

A minimum negative draft of 1.27 to 2.54 mm of WC (Water Column) should be

maintained in the primary chamber to avoid leakage of gaseous emissions from the chamber
and for safety reasons. Provision should be made in the primary chamber to measure the
Water Column pressure.

The waste should be fed into the incinerator in small batches after the fixed interval of
time and continuous charging using appropriate feeding mechanism.

The sides and the top portion of the primary and secondary chambers shall preferably
have rounded corner from inside to avoid possibility of formation of black pockets/dead zones.

The size of the secondary chamber should be properly designed so as to facilitate a

minimum of one second of residence time to gas flow. For the estimation of residence time in
the secondary chamber its volume should be calculated starting from the secondary burner tip
to the thermocouple.

The refractory lining of the chamber should be strong enough to sustain minimum
temperature of 1000° C in the primary chamber and 1200° C in the secondary chamber. The
refractory & insulation bricks shall have minimum 115 mm thickness each & conform to IS:8-
1983 & IS:2042-1972 respectively.

The Incinerator shell should be made of mild steel plate of adequate thickness
(minimum 5 mm thick) & painted externally with heat resistant aluminum paint suitable to
withstand temperature of 250°C with proper surface preparation. Refractory lining of the hot
duct should be done with refractory castable (minimum 45 mm thick) & insulating castable
(minimum 80 mm thick). Ceramic wool should be used at hot duct flanges & expansion joints.

The thermocouple location should be as follows:

• In Primary chamber - Before admission of secondary air

• In Secondary chamber - At the end of secondary chamber or before admission of

dilution medium to cool the gas

6.29
 There shall be a separate burner each for the Primary & Secondary chamber. The
heat input capacity of each burner should be sufficient to raise the temperature in the primary
and secondary chambers as 800±50°C and 1050±50°C respectively within maximum of 60
minutes prior to waste charging. The burners should have automatic switching "off/on" control
to avoid the fluctuations of temperatures beyond the required temperature range.

• Each burner should be equipped with spark igniter and main burner.

• Proper flame safeguard of the burner should be installed.

• Provide view ports to observe flame of the burner.

• Flame of the primary burner

- should be pointing towards the centre of the hearth.

- should be having a length such that it touches the waste but does not
impinge directly on the refractory floor or wall

The secondary burner should be positioned in such a way that the flue gas passes
through the flame.

There should not be any manual handling during charging of waste in to the primary
chamber of the incinerator. The waste should be charged in bags through automatic feeding
device at the manufacturer's recommended intervals ensuring no direct exposure of furnace
atmosphere to the operator. The device should prevent leakage of the hot flue gas & any
backfire. The waste should be introduced on the hearth in such a way so as to prevent the
heap formation. Suitable raking arrangement should be provided for uniform spreading of waste
on the hearth.

A tamper-proof PLC(Programmable Logic Control) based control system should be

installed to prevent:

• Wastes charging until the required temperature in the chambers are attained
during beginning of the operation of the incinerator.

• Waste charging unless primary & secondary chambers are maintained at the
specified temperature range.

• Waste charging in case of any unsafe conditions such as - very high temperature
in the primary & secondary chambers; failure of the combustion air fan, ID fan,
recirculation pump; low water pressure & high temperature of the flue gas at the
outlet of air pollution control device.

The incineration system should have an emergency vent. The emergency vent should

6.30
remain closed i.e it shall not emit flue gases during normal operation of the incinerator.

Each incineration system should have graphic or computer recording devices, which
shall automatically and continuously monitor and record dates, time of day, batch sequential
number and operating parameters such as temperatures in both the chambers. CO, CO2, and
O2 in gaseous emission shall also be measured

The possibility of providing heat recovery system/heat exchanger with the incinerator
should also be considered wherever possible.

Structural design of the chimney / stack should be as per IS:6533-1989. The

chimney/stack should be lined from inside with minimum of 3 mm thick natural hard rubber
suitable for the duty conditions and should also conform to IS:4682 Part I-1968 to avoid
corrosion due to oxygen and acids in the flue gas.

The location and specification of porthole, platform ladder etc. should be as per the
Emission Regulations, Part-3 (COINDS/20/1984-85), published by CPCB.

Incinerator room and waste storage room

• The incinerator structure should be built in a room with proper roofing and cross
ventilation. There should be minimum of 1.5 m clear distance in all the directions
from the incinerator structure to the wall of the incinerator room.

• Adjacent to the incinerator room, there should be a waste storage area. It should
be properly ventilated and so designed that waste can be stored in racks and
washing can be done very easily. The waste storage room should be washed
and chemically disinfected daily.

• The floor and inner wall of the incinerator and storage rooms should have outer
covering of impervious and glazed material so as to avoid retention of moisture
and for easy cleaning.

The incineration ash should be stored in a closed sturdy container in a masonry room
to avoid any pilferage. Finally, the ash should be disposed in a secured landfill.

6.2.4.3 Common Secured Landfill Facility

Selection of Landfill Site

The Hazardous Waste Disposal Facility will be designed and constructed as per the
CPCB Guidelines. The ETP sludge, oily sludge, spent clay, incinerator ash etc. should be
disposed in a common captive landfill site proposed to be located in the proposed SEZ. The
landfill site should be chosen based on following considerations:

6.31
 • Minimise health risks

• Minimise adverse environmental impacts

• Minimise costs

• Maximise public acceptability

The site characterization and identification is very important aspect. Prior to

assessment of health and environmental impacts of any landfill site, detailed analysis of
hydrological, atmospheric and chemical features of the site should be carried out. Accordingly,
the selected site for landfill is screened on the basis of following criteria :

• Geology and hydrology of the area

• Soil quality of the region

• Ground water quality

• Ambient air quality

During scrutinizing the selected site, the following areas are eliminated which fail to
meet additional socio-economic and environmental concerns as well as additional geologic and
hydrologic factors:

• Existing zones of development

• Agricultural land preserves

• Areas of mineral development

• Freshwater wetlands

• Visual corridors of scenic rivers

• Riverine and dam-related flood hazard areas

In addition, following features should also be considered for selection of landfill site:

• Easy access to a road system

• Ease in land acquisition

• Beneficial after use

• Outside a military exclusion zone

• Outside a safe buffer distance (100m) from an existing or planned, quarry,

which will undertake blasting with explosives

• Away from areas known to contain collapsing soils

6.32
Specifications for landfill site selection

• Landfill site should be large enough to last for 20-25 years

• Landfill site should be away from habitation clusters, forest areas, water bodies,
monuments, national parks, wetlands and places of important cultural, historical
or religious interest

• A buffer zone of no-development should be maintained around landfill site

Facilities at Landfill Site

The following facilities should be provided at the landfill site:

• Landfill site should be fenced or hedged and provided with proper gate to
monitor incoming vehicles or other modes of transportation

• Landfill site should be well protected to prevent entry of unauthorized persons

and stray animals

• Approach and other internal roads for free movement of vehicles and other
machinery should exist at the landfill site

• Landfill site should have wastes inspection facility to monitor wastes brought in
for landfill, office facility for record keeping and shelter for keeping equipment
and machinery including pollution monitoring equipments

• Provisions like weigh bridge to measure quantity of waste brought and landfill
site, fire protection equipments and other facilities as may be required should
be provided

• Utilities such as drinking water (preferably bathing facilities for workers) and
lighting arrangements for easy landfill operations when carried out in night
hours should be provided

• Safety provisions including health inspections of workers at landfill site should

be periodically made

Specifications for Land Filling

• Wastes subjected to land filling should be compacted in thin layers using landfill
compactors to achieve high density of the wastes.

• Wastes should be covered immediately or at the end of each working day with
minimum 10 cm of soil, inert debris or construction material till such time waste
processing facilities for composting or recycling or energy recovery are set up.

6.33
 • Prior to the commencement of monsoon season, an intermediate cover of 40-
65 cm thickness of soil should be placed on the landfill with proper compaction
and grading to prevent infiltration during monsoon. Proper drainage berms shall
be constructed to divert run-off away from the active cell of the landfill.

• After completion of landfill, a final cover should be designed to minimize

infiltration and erosion. The final cover shall meet the following specifications,
namely :

- Final cover should have a barrier soil layer comprising of 60 cm of clay or

amended soil with permeability coefficient less that 1 x 10-7 cm/sec.

- On top of the barrier soil layer there should be a drainage layer of 15 cm.

- On top of the drainage layer there should be a vegetative layer of 45 cm to

support natural plant growth and to minimize erosion

Leachate Management
When rain water or run-off water gets into the landfill, the chemical compounds
present in the impounded wastes get leached along with water as leachate. The characteristics
of the leachate depend upon both composition of the material and on environmental factors.

Solid/hazardous waste landfills should be provided with a system to collect, contain

and possibly treat leachate. Typically, at a minimum a double-liner system should be placed at
the bottom and side slopes of the facility prior to initial placement of hazardous wastes. This
liner system will contain leachate that later may be generated in the deposited wastes and then
flow downward by gravity. Leachate that accumulates above the liner should be directed to one
or more central collection sumps through a series of perforated plastic collection pipes. From
these sumps, leachate is pumped out for pre-treatment (either on or off-site) and ultimate
treatment in wastewater treatment plant near CPF.

To facilitate removal of leachate from the liner, the bottom of landfill is sloped, and a
sufficient number of drainage pipes are provided so that the leachate depth over the liner does
not exceed 0.3 m (1 ft).

Fig. 6.2 and 6.3 illustrate conceptual design of bottom liner and leachate collection
system configuration.

Leachate generation is also reduced through the placement of a low-permeability cap

over completed portions of the landfill. This cap should have a permeability less than or equal to
the permeability of the bottom-liner system.

In some cases, a hazardous waste landfill can be exempted from double-liner

6.34
requirements for leachate emission control if, among other factors, the hydrogeologic setting
would preclude leachate migration to ground or surface water. For example, some hazardous
wastes may be minimally prone to leaching or migration. Also, hydrogeologic factors at the site
could provide a degree of protection, these include on site soils with a significant attenuative
capacity (e.g. certain clays) and/or a substantial thickness of soil situated between the landfill,
ground and surface water.

Leachate Collection System

The leachate collection and removal system should consists of a network of drains to
collect and remove any accumulation of leachate that might develop in the bottom of the landfill,
and it prevents migration of leachate to the subsurface.

Collection drain layer

• Layer permeability not less than 10-3 meter/sec; minimum thickness 30 cm;
minimum slope 3%

Drain pipe
• Size and hydraulic capacity : large enough to carry-off the collected leachate

• Spacing (as recommended by USEPA)

Surface Water Control

Surface water originating from off-site upstream locations should be directed around
or away from the landfill via half-round corrugated metal pipe (CMP) or ditches lined with
asphaltic concrete (AC). These ditches should be designed such that off-site peak runon from at
least a 25-year storm can be diverted.

On-site surface water should be generally handled as follows:

• Runoff from non-landfilled areas should be diverted directly off-site.

• Runoff from exposed excavation areas should be directed to siltation basins

and then discharged off-site.

• Runoff from the active landfill area should be directed to holding sumps where it
is sampled for contamination. Uncontaminated water should be directed off-site,
and contaminated water should be treated on-site and then discharged off-site
or conveyed by truck or pipe for treatment off-site.

• Runoff from completed landfill surfaces should be directed to holding sumps

(different sumps than used for runoff from active landfill areas since the runoff
volume will be greater and the runoff less likely to be contaminated), where it is

6.35
 sampled for contamination. Uncontaminated water is directed off site and
contaminated water is treated on–or– off–site.

Drainage ditches located on non-landfilled areas are generally earth ditches, half-
round CMP, or AC- or gunite-lined earth ditches.

Temporary earth berms and drainage ditches should be used to divert on-site runoff
away from active landfilling areas. Permanent drainage ditches located on the landfill must be
able to accommodate some differential settlement, and are thus frequently constructed of half-
round or whole CMP or plastic pipes with overlapping flexible joints: riprap-lined earth ditches
are also commonly used.

Ground Water Monitoring

The monitoring of groundwater is the most important tool to test the efficiency of
landfill performance. This is indispensable as it provides detection of the presence of waste
constituents in groundwater in case of leachate migration. In this programme, water samples
are taken at a predetermined interval and analysed for specific pollutant expected to be in the
leachate. However, if any contamination is detected in the existing wells which are located
about 500m away from landfill, it can be concluded that considerable damage has already
occurred in the liner system provided in the landfill site to prevent further damage to
groundwater sources. For early detection of leachate migration, it is suggested to construct
Piezometers around the landfill.

In addition to Piezometers, monitoring wells should be installed to a depth of atleast 3

meters below the maximum historic groundwater depth. Based on assumptions and data about
the characteristics of leachate to be generated, approximate permeability of soils in the zone of
aeration, and direction and velocities of groundwater flow, the maximum probable aerial extent
of contaminant migration can be estimated as a basis for establishing the position of monitoring
wells.

A minimum of two ground monitoring wells should be typically installed at a disposal

facility: one up-gradient well and one down-gradient well. It is suggested to collect water
samples and analyse. Records of analysis should be maintained.

Operation and Maintenance Programme

To achieve effective performance of a landfill disposal facility operation and
maintenance of the landfill form key element.

Factors involved in the operational stage are summarized below:

• Wastes acceptability

6.36
 • Details of wastes arrived at secure landfill facility

• Segregation of wastes according to design methods

• Random checking of waste for its characteristics

• Filling as per specification

In addition to the operational procedures outlined above, following maintenance

schedule should be adhered:

• Proper care should be taken to check for erosion due to rain and vehicular
movements

• Drainage system should be checked periodically for blockage

• A log book should be maintained to account for the quantity of waste

disposed/dumped

• If any vegetative growth on the embankment and near landfill area should be
removed, an equal area should be planted elsewhere in the same area.

Closure and Postclosure

a) Closure
Upon final closure of the landfill or upon completion of a cell, a final cover is applied
that is constructed to:

• Have a permeability less than or equal to the permeability of any bottom liner
system or natural subsoils present in order to minimize long-term migration of
liquids through the closed landfill’s surface

• Function with minimum maintenance

• Promote drainage and minimize erosion abrasion of the cover

• Accommodate settling and subsidence so that the cover’s integrity is

maintained
For lanfills with all or a portion of the wastes in above grade cell, final side slopes are
generally up to 3:1 horizontal to vertical. A 4.6-to 6.1-m wide (15 to 20ft) slope bench is placed
every 7.6 to 9.1 m (25 to 30 ft) of vertical rise to minimize slope erosion and increase slope
stability. Top surface slopes generally are at minimum 5 percent to promote runoff and to
accommodate some degree of future settling of the landfill.

6.37
b) Postclosure
After final closure of a disposal facility, the following postclosure maintenance and
monitoring activities are conducted throughout the postclosure care period:

• Perform routine final cover maintenance. The integrity and effectiveness of the
final cover is regularly maintained by filling and regrading depressions in the
cover and surface as necessary to correct adverse effects such as settling,
subsidence, erosion, and animal burrowing. Also, drainage and flood control
channels should be kept clear of accumulated debris. Dead vegetation should
also be replaced

• Prevent runon and runoff of precipitation from eroding or otherwise damaging

the final cover

• Protect and maintain surveyed benchmarks

• Maintain the environmental monitoring facilities

• Obtain samples from monitoring facilities and analyze and report the results in
accordance with applicable permit requirements

Postclosure monitoring during the first 12 to 18 months will generally involve relatively
frequent site inspections and sampling (e.g. once per month). Monitoring frequencies can
generally be reduced after this period if no problems are encountered during that time.

6.2.5 Biological Environment

Following measures are recommended to mitigate adverse impacts on biological

activities during operation phase:

• Development of green belt with carefully selected plant species is of prime

importance due to their capacity to reduce noise and air pollution impacts by
attenuation/assimilation and for providing food and habitat for local macro and
micro fauna. This not only overcomes the problem but also enhances the
beauty of area that will attract bird and insect species and by this way ecology
of the area will maintain to great extent.

• For developing the greenbelt in and around proposed project site care need to
be taken to plant the evergreen species. The planting of evergreen species may
have certain advantages that may reduce the environmental pollution.

• Survival rate of the planted trees should be closely monitored and the trees
which could not survive should be counted. Equal number of trees should be

6.38
 replaced and their survival should be closely monitored.

• The rainwater harvesting should be done. Treated sewage and effluent in the
best combination should be used for greenbelt development. Water scarcity
should not be the reason for not expanding and strengthening greenbelt.
Provision for irrigation water should be made as part of proposed project

6.2.5.1 Preparation of greenbelt plan keeping in view the selected plant species
The proposed greenbelt development in SEZ should be of a suitable width along the
periphery of SEZ area including residential complex, space between the units located within the
SEZ, along the roads, railway sidings, the hazardous waste disposal facility, storage areas,
loading / unloading areas of products etc.

Criteria for selection of species for greenbelt

The plant species suitable for green belt development should be selected based on
the following characteristics.

− It should have thick canopy cover

− They should be perennial and evergreen

− They should have high sink potential for pollutants

− They should be efficient in absorbing pollutants without significantly affecting

their growth.

6.2.5.2 Guidelines for plantation

The plant species identified for greenbelt development should be planted using pitting
technique. The pit size should be either 45 cm x 45 cm x 45 cm or 60 cm x 60 cm x 60 cm.
Bigger pit size is prepared on marginal and poor quality soil. Soil used for filling the pit should
be mixed with well decomposed farm yard manure or sewage sludge at the rate of 2.5 kg (on
dry weight basis) and 3.6 kg (on dry weight basis) for 45cm x 45 cm x 45 cm and 60 cm x 60 cm
x 60 cm size pits respectively. The filling of soil should be completed at least 5-10 days before
actual plantation. Healthy sappling of identified species should be planted in each pit.

Roadside Plantation
Roadside plantation plays a very important role for greening the area, increasing the
shady area, increasing aesthetic value and for eco-development of the area. The approach
roads to project site, colony, hospitals, etc. should be planted with flowering trees. Reliance
SEZ should encourage plantation outside the plant boundary. Adequate care should be taken
to encourage greenbelt development on the road side, however to uplift the regional ecosystem
of the area by greenbelt development, all the voluntary organizations should take initiative to

6.39
encourage massive plantation along the roadside Trees should be planted to increase aesthetic
value as well as shady area along the roads.

The list of selected evergreen plants species for development of green belt is given in
Table 6.2.

6.2.6 Socio-economic Environment

In order to mitigate the impacts likely to arise out of the proposed project and also to
maintain good will of local people for the proposed project, it is necessary to take steps for
improving the social environment. Necessary social welfare measures by the industry shall be
useful in gaining public confidence depending on local requirement.

The EMP measures are suggested for smooth functioning of the activities are given
below:

• SEZ should continue to undertaken social welfare programes for the betterment
of the Quality of Life of villages around in collaboration with the local bodies.

• Some basic amenities, viz. education, safe drinking water supply to the nearby
villages may be taken up

• Regular medical check up should be continued on routine basis in the villages

around the SEZ and also by providing mobile hospital services

• SEZ shall in collaboration with local government improve the road infrastructure
in the vicinity

• Formal and informal training to provide direct and indirect employment to the
affected villagers due to the project shall be taken up on priority

• Entrepreneurship Development programme (EMP) should be undertaken for both

male and female group irrespective of their age and education, qualification

• Job oriented skill training, courses may be organized. Through

industrial/technical training institutions for educational youth (both for male and
female), like home need appliances, tailoring, plumbing, light & heavy vehicles
driving

6.2.7 Health and Safety

• Personal protective facilities like helmets, safety (gas) mask/safety dress, shoes
etc. be ensured for all workers, engaged in operation of process units within the
refinery complex

• The health checkups (diagnostic) for all regular employees at the refinery
complex at scheduled intervals to be maintained along with the corresponding

6.40
 health records.

6.2.8 A note on Occupational Health and Surveillance and safety measures

The design of the plants will be based on the relevant API, ASTM standards / codes and
the best engineering practices followed internationally. Further, HAZOP studies will be carried
out while detailed engineering is done and P&IDs are developed to ensure that all process
control measures are adequate for safe operation of the plants. In case of chemicals like
phosgene the guidelines issued by American Chemistry Council will be followed and approval
from the concerned agencies will be obtained.
The unit operations manual will include a chapter on HSE issues related to the operation
of the particular unit.
A note on the Safety Management System being followed in the present Refinery
complex is enclosed as Annexure XII .Similar Safety Management System will be developed
for the new complex before its commissioning.
The fire safety measures for the petroleum and petrochemical complex have been
elaborated Chapter 6 & 7 of the Risk assessment Report.

6.3 Capital / Recurring Expenditure on Environmental

Management

The details on proposed refinery expansion project cost and capital / recurring
expenditure on environmental management.

Project Cost : Rs. 60,000 crores

Cost for pollution control facilities : Rs. 1,800 crores
Recurring budget (Annual Maint @ 2%) : Rs. 36.0 crores

6.4 Proposed Environment Monitoring

Since the SEZ Complex is big enough, each industry should have senior executives
who shall report to their respective Site President. The SEZ complex will have an Environment
Cell for the entire SEZ and units therein. The Environment cell should consists of environmental
professionals with experience in various aspects of Environment Management ranging from 7
years to 20 years. This cell should be set up during the construction of the SEZ itself and they
should have adequate expertise and competency in handling and implementing the
Environment Management systems and practices. The Environment Cell should monitor and
measure the environmental performance of each industry in terms of efficiency of pollution
control devices, and conduct regular energy and water audits. The cell should also on a regular
basis also coordinate third party Environmental Audits. Members of the Environment Cell shall
participate in National Task Forces under CREP (Charter for Corporate Responsibility for

6.41
Environmental Protection) and in committees for reviewing National Standards for the
petroleum and petrochemical industry. The Corporate Environment Cell at the Headquarters
shall be an advisory body on all environmental related issues and support the Environment Cell
at the SEZ.

Every industry within the SEZ should in due time aim to be certified for ISO 14001
standards. The Environment cell in each industry should be responsible for implementing and
maintaining environment management systems. These industry should co-ordinate with the
Environmental Management Cell of SEZ for establishing and monitoring the compliance of ISO
14001. The Management Systems should be established in compliance with the ISO 14001
standards which should be audited internally by qualified internal auditors and externally by the
certifying body as per the stipulated frequency.

SEZ - Site President

SEZ - HSEF Chief

Env Managers Safety Doctors Fire Managers

Managers

It is recommended that the parameters as provided in Table 6.3 should be monitored

by strengthening the existing environmental monitoring programme. The frequency of
monitoring is also presented in Table 6.3. In addition, parameters as specified by CPCB,
GPCB, MoEF and in CREP should also be monitored at specified locations with recommended
frequency.

6.42
 Gas
Holder To Boiler

Anaerobic
PTA Digester I
Effluent
Equalization Tank Flash Mixture Clarifloculator

Anaerobic
Digester II

Holding Tank
Holding Tank

Ash for Metal

Recovery
Holding Tank

Effluent fromAcetic MEG

acid + PE plants Emulsified oils
Oil and Grease +Tank farm Polyelectrolyte

Chlorine
Secondary
Bio Aeration Clarifier II
Combined Tower I Tank 1
pH Equalization
Effluent Tilted Plate Equalization Clari Dissolved air
Adjustment Flash Mixture tank II
Cracker,POY,PET, Interceptor tank I Floculator flotation tank
tank
PSF,PP Bio Bio Collection
Tower II Tower II Tank
Secondary
Clarifier II

Sludge
Collection
Chamber

Polisher
For Recycle,
Reuses , Greenbelt
Land Applications and Discharge
Sludge and Disposal
Thickener
Activated Dual
carbon Sand
Refinery ETP
colum Filter

Fig. : 6.1 Schematic Flow Diagram of Proposed Central Effluent Treatment Plant in SEZ
6.43
Fig. 6.2: Schematic Profile of an FML Plus Composite Double Liner System
for a Landfill

6.44
Fig. 6.3 : Schematic of an FML plus Composite Double-liner System for a Landfill

6.45
Fig: 6.4: Block Flow diagram of MEG Effluent Pre Treatment Plant

6.46
 Table 6.1
Hazardous Waste Quantity and Mode of Disposal
Sr. No Waste Qty generated /Yr Mode of Storage and Disposal

A Hazardous waste

1 Oil sludge from ETP 14256 M3 Internal recycle in Delayed Coker unit and Converted into coke.

2 Slop Oil 12000M3 Internal recycle by reprocessing in the process units

Stored In the drums and drums are stored on impermiable concrete

Oil Rags, Oil contaminated platform during storage period. It is praposed to be disposed in the
cotton waste /contaminated secured landfill facility being developed in the SEZ area or
3 packing 450M3 Incinarated using well designed incinarator

Stored in MS drums. MS drums are stored on impermiable concreate

platform during storage period.Waste lubricating oil is sold to certified
4 Waste lubrican oil and Used oil 1500 KL waste lubricating oil processor.

Spent catalyst from other units

like Platformer.isomer and As per the contracts with catalyst suppliers , the catalyst will be taken
5 tatory 2750 tons* back to the suppliers.

As and when these tanks are taken Will be treated through sludge melting pit for the maximum recovery
Oil sludge generated while for cleaning , so Estimation of of hydrocarbon. After that it will be disposed off in the secured
6 cleaning of heavy tanks quantity is not possible landfill..

7 Empty drums 15000 nos Sold after decontamination.

6.47
Sr. No Waste Qty generated /Yr Mode of Storage and Disposal

Throughly purged and made hydrocarbon free and disposed in

8 Spent Clays 5500 Tons landfill area.

9 Incinerator Ash 100 Tons Secured landfill

B Process Related Waste

1 Equilibrium catalyst 14000 tons Sold to other refineries.

2 Biological sludge 250 tons Composting& use as mannure in Greenbelt .

3 Activated Carbon 4800 Tons Mixed with petcoke .

4 Molecular Sieves 4000 tons Sold to firebrick manufacturers.

5 Slag from Coke gasification unit 0.128 to 0.37 MM tons Sold to Cement manufacturing units/ metal recovery

C Non processing waste

1 Scrap metal 7500 tons Sold

2 Wooden and Electrical scrap 3600 tons Sold

3 Plastic Bags 600 tons Sold/Reused after cleaning

4 Scrape carton box and Paper 900 Tons Sold

5 Used Tyres 330 Nos Sold

6 Glass 90 Tons Sold

7 Nylon&Fibre scrap 240 tons Sold

6.48
Sr. No Waste Qty generated /Yr Mode of Storage and Disposal

8 Waste cable Scrap 1200 tons Sold

9 Battary Scrap 330 tons Sold

6.49
 Table 6.2

List of Plant Species suggested for Green belt

Sr. No. Article I. Name of Plants
Species
Trees
1. Acacia auriculoformis (16 m)
2. Acacia nilotica (8 m)
3. Achras sapota(10m)
4. Aegle marmelos (12 m)
5. Annona squamosa (10 m)
6. Annona reticulata (10 m)
7. Albizia moluccana(20 m)
8. Azdirachta indica (20 m)
9. Cassia siamea (10-12m)
10. Casuarina equisetifolia (10 m)
11. Dalbergia sisoo (10 m)
12. Derris indica (10 m)
13. Ficus bengalensis (20 m)
14. Ficus religiosa (20 m)
15. Mangifera indica (15 m)
16. Mimusops elengi (10 m)
17. Peltophorum pterocarpum (10m)
18. Pithecellobium dulce (8 m)
19. Psidium guayava (15 m)
20. Saraca asoka (5 m)
21. Syzygium cumini (20 m)
22. Tamarindus indica (20 m)
23. Zizyphus mauritiana (10 m)
Shrubs
1. Bougainvillea spectabillis (8 m)
2. Citrus lemon (3 m)
3. Hibiscus rosa-sinensis (3 m)
4. Lawsonia inermis (5 m)
5. Nerium indicum (5 m)
6. Sesbania sesban (6 m)
7. Thevetia peruviana ( 6 m)

6.50
 Table 6.3
Post-project Environmental Monitoring Plan
Project Stage
Component

Institutional
Parameters Standard Location Frequency Duration
Responsibility

SPM, RPM, SO2, NAAQS of 6 locations with minimum 1 Once a month 24 hr/day for 2 Agency/
Construction
Air Quality

NOx, CPCB locations in upwind side, more consecutive days In-house

sites in downwind side / impact
zone on land only.

SPM, RPM, SO2, NAAQS of Minimum 6 locations in each Twice a week Consecutive working Agency/
NOx, CO, HC (non- CPCB and field with one on upwind side, days in a week In-house
Air Quality

methane), PPAH two on downwind and one on SPM, RPM, SO2 and
Operation

Mercaptans, (World lateral side. NOx - 24 hrs

benzene, vinyl bank) CO - Grab
chloride, NH3, HC - Grab
1,2-dichloroethane
Particulates, SO2, Emission Each stack Once in 15 As per the Agency/In-house
NOx, CO, HC (non- standards of days recommendations of
Air Quality

Operation

methane), Ni, Va, CPCB/GPCB GPCB for existing stacks

H2S, HCl, Benzene, and PPAH
NH3, 1,2- (World bank)
dichloroethane

6.51
 Institutional

Project Stage
Component
Responsibility
Parameters Standard Location Frequency Duration

Leq day, Leq night, CPCB noise 2 to 4 locations representing Once every 24 hour reading with a Agency/
dB(A) standards different receptors/land use season- frequency of 10 minutes In-house
Summer, every hour for 2 non-
Construction
Noise level

Winter, Post- consecutive days per

monsoon week for 2 weeks per
during season
construction
period
Leq day, Leq night, CPCB noise Near major sources in refinery Once every 24 hour reading with a Agency/
L10, L50, L90 standards complex and along the highway season- frequency of 10 minutes In-house
Noise level

Operation

dB(A) Summer, per hour for 2 non-

Winter, Post- consecutive days per
monsoon week for 2 weeks per
season

6.52
 Physico-chemical Relevant 10-20 groundwater samples Once every One grab samples from Agency/In-house
parameters, water around refinery season – each groundwater
Construction/ Nutrients and quality Summer, source
Water quality

Operation Organic standards of Winter, Post-

parameters, heavy CPCB and monsoon.
metals PPAH
(World
Bank)
Physico-chemical Same as Inlet and outlet of each ETP Once in 15 Composite flow-weighted Agency/
parameters, above units days. sampling In-house
Nutrients and
Organic
parameters, heavy
metals
Water quality

Operation

6.53
 Project Stage
Component
Institutional
Parameters Standard Location Frequency Duration
Responsibility

Particle size Contaminan - At all stockyard locations, At the start Sample every season till Agency/In-house
distribution, t threshold construction machinery and end of construction phase is
Texture, pH, level given parking/refuelling/maintenance construction complete
Construction
Soil Quality

Electrical by USEPA locations activity at the

conductivity, CEC, relevant
Alkali metals, SAR, location
Permeability, Water
holding capacity,
Porosity
Depending on type Contaminan - At accidental spill sites - In the event - One time sample Agency/In-house
Solid/hazardo
us wastes

Operation

of wastes t threshold – Solid waste disposal location of an accident

level given - Once during
by USEPA each season

6.54
 Monitoring of tree Number to At all locations/sections where During tree - Agency/In-house
felling be felled as tree is felled felling
laid out in
Pre-construction
project
detail
Ecology

design

Survival rate of - At locations of compensatory Annually For 3 years after Agency/In-house

Operati
on

plantation plantation and landscaping operation starts

Road Traffic As per At all artery roads leading to 1 day hourly Thrice in a year marking Agency/In-house
Traffic Volume

Construction

volume, relevant construction site counts peak, medium and low

characteristics and IRC construction activity at
speed specification the site
s

6.55
 Table 6.4

Effluent Characteristics of PFY

WATER ANALYSIS REPORT

M/s RELIANCE INDUSTRIES LTD.

Surat, Gujarat
MONTH : April 2009
Date of Sampling : 18-04-09
POY Plant
Sr. No. Parameters
Process Water
1 pH 6.85
2 Suspended Solids, mg/l 22
3 Dissolved Solids, mg/l 356
4 TKN, mg/l 8.96
5 Ammonical Nitrogen, mg/l 6.37
6 BOD (3 days at 270C), mg/l 28
7 COD, mg/l 648
8 Oil and grease, mg/l 2.9
9 Sulphate (as SO4), mg/l 219.38
10 Chloride, mg/l 111.67
11 Sulphide, mg/l <0.1
12 Fluoride (as F), mg/l <0.1
13 Cyanide (as CN), mg/l <0.1
14 Phosphate, mg/l 7.3
15 Phenols (as C6H5OH), mg/l <0.1
16 Copper (as Cu), mg/l <0.01
17 Mercury (as Hg), mg/l <0.01
18 Zinc (as Zn), mg/l 0.033
19 Lead (as Pb), mg/l 1.017
20 Nickel (as Ni), mg/l 0.425
21 Total Chromium (as Cr), mg/l <0.01
22 Chromium (Cr+6), mg/l <0.01
23 Sodium, mg/l 35.07

6.56
Chapter 7

Rehabilitation and
Resettlement Plan

A detailed planning is necessary for the resettlement of project-affected people with a

development strategy and package that may aim at improving or at least restoring the economic
base of the project affected persons (PAPs). Preference must be given to land-based
resettlement strategies for people dislocated from agricultural settings. If suitable land is not
available, non land-based strategies must be planned that may provide opportunities for
employment or self-employment. Resettlement action plan is being prepared according to the
provisions mentioned in National Rehabilitation and Resettlement Policy 2003 in carrying out
resettlement and rehabilitation plans for any developmental project.

7.1 Socio Economic Survey

7.1.1 Demographic Profile of Project affected People

As per the information gathered during the socio-economic survey by NEERI, there
are about five project affected villages namely Navagam, Kanalus, Kana chikari, Dera chikari
and Padana from where land is going to be acquired for the proposed SEZ project. The total
land acquisition for the project is about 4544.76 Hectares out of which 2629.84 hectares of land
is private, 1338.27 hectare is Government land and 576.63 hectare is Lease land. The socio-

7.1
economic survey of the Project Affected Persons (PAPs) was undertaken to know the opinion
and expectations of the project affected people.

Village wise distribution of Land Acquired by SEZ

Sr. Area Acquired

Name of Village
No. Private Govt.
1 Navagam 107-81-76 368-58-97
2 Kanalus 888-62-00 599-25-01
3 Kana Chhikari 439-17-80 321-18-06
4 Dera Chhikari 24-33-19 0-05-06
5 Padana 202-89-96 48-20-83
Total 2629-84-71 1338-27-93
Source: Information provided by Project Authority

Details of Land Acquired

Sr.
Type of Land Ha, Are, Sq. Mtrs
No.
1 Private land 2629-84-71
2 Government Land 1338-27-93
3 Lease land 576-63-59
Total 4544-76-23
Source: Information provided by Project Authority

Navagam

The village has a population of about 1615. The education level of the people of
Navagam is only up to secondary school as there is no higher education facility in the village.
Unemployment level is high in the region, during the survey it was observed that most of the
people were having expectation of being employed by Project Proponents.

Kanalus

Kanalus village is having the population of around 2059. All the required, basic
facilities are available in the village. Sanitation and drainage facilities are poor in the village,
which leads to various diseases. Therefore people are demanding improvement in the
sanitation and drainage facility. From this village, land has already been acquired for the
project. People have high aspirations regarding employment and compensation. People expect
construction of community hall in the villages.

7.2
Dera Chikari

People of Dera chikari village reported that water is polluted and saline and due to
this health status of villages is badly affected. Common health problems like skin itching
gastroenteritis and breathlessness in highly prevalent in the region. People are expecting
mobile health facility at this village. People of Dera Chikari are also expecting that employment
should be given to the local population by SEZ authorities. People are expecting that SEZ
authorities must construct Radhakrishna temple in the village. People are complaining about the
air pollution problem in the region.

Kana Chikari

Most of the project affected people of Kana Chikari village are aware about the
project and have favorable opinion towards the project; but people are expecting that SEZ
authorities must provide job opportunities to the local population and are also demanding that
technical training institute must be introduced for the local people so that it may help to create
employment opportunities. Villagers are mainly facing the problem of water and electricity.
People opined that SEZ authorities should extend welfare activities in the villages

Padana

The village has a population of around 3364. The common diseases reported are
gastroenteritis, malaria, skin infection and common fever particularly during rainy season.
Frequent power failure and power shut down for 16 hours is reported in the village that hampers
the irrigation facility in the region. Agricultural land from Padana village was earlier acquired for
the different project operating in the study area. People were unsatisfied with the compensation
given to them for the acquisition of the land and are demanding adequate compensation from
SEZ and they have high aspirations regarding employment and compensation. People are
expecting that SEZ authorities must develop certain infrastructure facilities like school, medical
center, community hall, temple etc. in the village. As the village is near to the SEZ people have
common complain of air and non availability of potable water.

During the survey it was observed that the quality of life of the surveyed villages is
satisfactory. People opined that the implementation of social welfare schemes should be based
on priority need of the local people and these needs must be considered after the consultation
with the villagers.

7.3
7.1.2 Recommendations from National Rehabilitation and Resettlement Plan
Resettlement and Rehabilitation Strategy

The Gujarat government has no specific R&R policy at state level; however they have
adopted National Policy on Resettlement and Rehabilitation for Project Affected Families –
2003. The National Policy does not cover any R&R plan in the form of purely cash
compensation to project affected people. It addresses only compensatory land allotment and
some additional financial assistance as part of compensation for shifting to new location and the
transit period losses. The summary of R&R plans based on the provisions under the National
Policy on Resettlement and Rehabilitation of Project Affected Persons (PAPs), without affecting
their social and economic life have been described below:

♦ Each PAF owning agricultural land in the affected zone and whose entire land
has been acquired may be allotted agricultural land or cultivable wasteland to the
extent of actual land loss subject to a maximum of one hectare of irrigated land or
two hectares of un-irrigated land/cultivable wasteland subject to availability of
Government land in the districts.

♦ Each PAF owning agricultural land in the affected zone and whose entire land
has been acquired shall get one-time financial assistance equivalent to 750 days
minimum agricultural wages for “loss of livelihood” where neither agricultural land
nor regular employment to one member of the PAF has been provided.

♦ Each PAF owning agricultural land in the affected zone and whose entire land
has not been acquired and consequently he becomes a marginal farmer shall get
one time financial assistance equivalent to 500 days minimum agricultural wages.

♦ Stamp duty and other fees payable for registration shall be borne by the requiring
body.

♦ The Land allotted shall be free from all encumbrances. The Land allotted may be
in the joint names of wife and husband of PAF.

♦ In case of allotment of wasteland/degraded land in lieu of acquired land, each

PAF shall get financial assistance of Rs. 10000/- per hectare for land
development. In case of allotment of agricultural land, a one-time financial
assistance of Rs. 5000/- per PAF for agricultural production shall be given.

♦ The state government should provide irrigation facilities to the irrigable land at the
relocation sites

7.4
 ♦ According to the government resolutions on R&R policy, each landed oustee shall
be entitled to be allotted irrigable land in the state which they choose to resettle,
of equal size to that type which they own prior to their resettlement provided,
however that in those cases where the oustees owned less than 2 hectares of
land, such oustee shall be entitled to at least 2 hectares of irrigable land
acceptable to them

♦ Each PAF belonging to the category of ‘agricultural labourer’, or ‘non-agricultural

labourer’ shall be provided a one time financial assistance equivalent to 625 days
of the minimum agricultural wages.

♦ The Project Affected Families shall be provided necessary training facilities for
development of entrepreneurship to take up self-employment projects at the
resettlement zone as part of R&R benefits.

♦ Only those oustee who own land shall be considered eligible for the allotment of
agriculture land of their own choice

♦ For the loss of trees, crops, perennials and Sharecroppers compensation should
be given at the market value

R&R benefits for project affected families of scheduled tribes

♦ Each Project Affected Family of ST category shall be given preference in

allotment of land.

♦ Each tribal PAF shall be entitled to get R&R benefits mentioned in above Paras
under the Policy.

♦ Each Tribal PAF shall get additional financial assistance equivalent to 500 days
minimum agriculture wages for loss of customary rights/usages of forest produce.

♦ The Tribal Land alienated in violation of the laws and regulations in force on the
subject would be treated as null and void and the R&R benefits would be
available only to the original tribal landowner.

♦ The Tribals families residing in the Project Affected Areas having fishing rights in
the river/pond/dam shall be given fishing rights in the reservoir area.

♦ Tribal PAFs enjoying reservation benefits in the affected zone shall be entitled to
get the reservation benefits at the resettlement zone.

Estimation of Cost of Land

♦ Aspects to be considered while preparing R & R Plan

7.5
 - Total land to be acquired
- Nature of the land and cropping pattern
- Market value of the land
- Net annual productions of the land
- Net profit from the land

The resettlement plan must include land allocation or culturally acceptable alternative
income- earning strategies to protect the livelihood of the landless, semi-landless and
households headed by females.

7.2 Recommendations
The recommendations for smooth implementation of the Resettlement and
Rehabilitation Plan are delineated below :

♦ Compensation should be provided earlier enough before commencement of

project construction to the PAP, for the loss of their agricultural land

♦ Project authorities should ensure frequent meetings with the implementation and
monitoring committee and also with the local project affected people and teams
for the smooth implementation of all relief measures

♦ Project authorities should seek advice and help of local administration sarpanch,
Block development officer and other local leaders] in the area. Their participation
and involvement in the proposed development schemes shall be helpful in
confidence building. This would also help in conflict resolution if any such,
situation arises.

♦ The quality of the land must be considered as it may not hinder the economic
status of the project affected people and affects their quality of life

♦ If the desirable quality of land required is not available, then the net annual
income of the project affected people and the net profit from the land income
must be considered and that amount of money is to be provided to the project
affected people

♦ At the time of land acquisition, compensation must also be given for the standing
crops, perennials to the PAP

♦ Essential cash compensation must be given for the existing infrastructures on the
agricultural land like well, small huts etc. for the reconstruction of the
infrastructure

7.6
Access to Training, Employment and Credit

a) Employment

The Project Authorities should provide preference in employment for project-affected

families in the category of unskilled and skilled workmen as per the need of the project. Every
affected family must be helped in starting some gainful occupation/getting training to facilitate
secondary employment in the region. The project authorities must construct shopping
complexes in which a limited number of small shops/stalls will be earmarked. Eligible persons
must be allotted employment after considering their skills and capabilities and wages should be
provided to them as fixed by the corporation. Some members of the project-affected families
may qualify to go for vocational training courses, like ITI etc.

b) Training
Majority of household have small landholdings and their occupation is agriculture.
Special training must be imparted to the affected people for supporting their economic activities
in various forms. The oustee must be given training on dairy farming, carpet weaving, carpentry
etc. Promotional activities for improvement of agricultural and horticulture yields in the area will
be encouraged by providing training to the project affected people.

c) Financial Assistance
For starting an income generation scheme/self employment the Project Authority
should provide financial grant in the case of shops allotted to the land PAFs. Certain financial
assistance must be given to the eligible project affected families for generating self
employment.

The Project authorities must consider awarding petty contracts to the Co-operatives
of eligible families on preferential basis so that some of them may be engaged in such jobs
also.

7.3 R&R Programme Monitoring and Reporting Procedure

R&R committee meetings should be held in every three months in order to ensure
incorporation of preference of the PAFs and resolve logistic problems in implementation of R&R
Plans. The project co-ordinator with team members must meet every PAF to ensure the
implementation of project from time to time. Six-month progress reports must be submitted to
project proponent. Planning Department, for evaluation and disbursement of finance. The
Potential Evaluation Indicators for monitoring would be:

7.7
♦ Task completion as per schedule

♦ Identification of conflict among stakeholders, and its resolution

♦ Awareness of PAFs and their involvement in overall development and

improvement in their quality of life

7.8
 References
1. The SEZ policy introduced in the Export Import (EXIM) Policy, Govt. of India,
April 1, 2000

2. Draft Policy and Guidelines issued by the Ministry of Commerce (“MoC”),

Govt. of India (2005)

3. Amendment in the EIA Notification of 7th July, 2004, Ministry of Environment

and Forests (MoEF), New Delhi

4. EIA Notification of 14th September, 2006, Ministry of Environmnet and Forests

(MoEF), New Delhi

5. National Ambient Air Quality Standards Notification, April 11, 1994, Ministry
of Environment and Forests (MoEF), New Delhi

6. The Noise Pollution (Regulation and Control) Rules, 2000, Notified by Ministry
of Environment and Forests, New Delhi, February 14, 2000

7. Soil Chemical Analysis by M.L. Jackson, Prentice Hall of India Pvt. Ltd., New
Delhi (1967)

8. Methods of Soil Analysis Part-I, Black C. A., Ames Iowa, 555 (1964)

9. IRS P6 LISS III Scenes (Path 94, Row 59) available in CD format from
National Remote Sensing Agency (NRSA), Department of Space, Government
of India were used along with collateral data

10. National Policy on Resettlement and Rehabilitation (R&R) of project affected

families (2003)

11. Gujarat Policy on Special Economic Zone

12. Analysis Monitoring and Surveying Air Pollution, Stern, A.C, (1968)

13. Measuring and Monitoring of Air Pollutants, Strauss W, Air Pollution Control
III, Wiley Interscience Publications (1978)

14. a. ISO/TR 4227 : 1989 Planning of Ambient Air Quality Monitoring

b. ISO 8756 : 1994 Air Quality – Handling of Temperature; Pressure and
Humidity Data
c. ISO 6879 : 1983 Air Quality – Performance Characteristics and Related
Concepts for Air Quality Measuring Methods
d. IS 5182 (Part-II), 1989, Sulfur dioxide estimation procedure, Methods for
measurement of air pollutants.
e. IS 5182 (Part-IV), 1987, Suspended solids estimation procedure, Methods
for measurement of air pollutants.
 f. IS 5182 (Part-VI), 1992, Nitrogen oxide estimation procedure, Methods
for measurement of air pollutants.
g. IS 5182 (Part-X), 1982, Carbon monoxide estimation procedure, Methods
for measurement of air pollutants.

15. Non-methane hydrocarbon air quality measurements, J. Air Pollut. Contrl.

Assoc. Altshuller, A.P., Lonneman W.A. and Kopczynski S.L., 23 : 597 (1973)

16. Climatological Tables of Observatories in India (1951-1980), published by the

India Meteorological Department, Govt. of India, issued by The Director
General of Meteorology, New Delhi, 5th edition (1999)

17. Standard Methods for Examination of Water & Wastewater, 19th Edition, 1995,
Edited by Andrew Eaton, et.al.

18. ISO/DIS – 11464 – Soil Quality – Pretreatment of Sample for Physico-chemical

Analysis (1993)

19. SEE Soil Class 2.0 version based on United States Department of Agriculture
(USDA)

20. Soil methods, Keen, B.A and Raczkowski, H.J. Agric. Sci., 11 : 441-449 (1921)

21. Soil and plant testing as a basis of fertilizer, FAO Soils Bulletin, 38/2, Rome
(1980)

22. Course Manual on Soil Sampling Analysis, NEERI, Nagpur (1986)

23. Studies in Ecology, Quantitative Plant Ecology, P. Greig Smith (Third edition),
vol. 9, 1983

24. A Revised Survey of the Forest Types of India, Champion, H.G. &
Seth, S.K., Manager of Publication, Delhi (1968)

25. Working Plan for Jamnagar Division , Forest Department, Govt. of Gujarat

26. Simpson, E.H., Measurement of Diversity, Nature, London, 163,pp 688 (1949)

27. Red Data Book of Indian Plants, M.P. Wayar & A.R.K. Sastry, by Botanical
Survey of India (1998)

28. Primary Census Abstract, Jamnagar District, Gujarat State, CD - 2001

29. National Health Policy, Govt. of India (1983)

30. Statistical Handbook, Jamnagar District, Gujarat State (2001)

31. Report on Doing Better Business Through Effective Public Consultation and
 Disclosure by International Finance Corporation (IFC) (1998)

32. Socio-economic Environmental Studies Series, Studies in Environment, vol. II –

“Quality of Life”, EPA – 600/5-72-012b (1974)

33. Christopher Wood, Environmental Impact Assessment, A Comparative

Review,(Second edition) Published by Pearson Education LTD., England
pp125-1399 (2003)

34. Categorization of Industry based on Pollution Potential by CPCB

35. EIA for Proposed Special Economic Zone (SEZ) for Positra, Gujrat by NEERI
(2001)

36. Environmental Impact Assessment for Proposed Development of Navi Mumbai

Special Economic Zone, Maharashtra, India by NEERI (2005)

37. Manual on Water Supply and Treatment’ published by CPHEEO (Central

Public Health and Environmental Engineering Organisation), Ministry of Urban
Development, New Delhi, (1991)

38. Municipal Solid Waste (Management and Handling) Rules-2000, Ministry of

Environment and Forests Notification, New Delhi The Gazette of India, pp. 1-
22, (2000)

39. Guidelines for Developing Greenbelts, CPCB, Ministry of Environment and

Forests (MoEF), New Delhi, Govt. of India, Probes 75 (1999-2000)

40. a. ISO 5667 – 1 : 1980 Water Quality Sampling Part 1 : Guidance on the
Design of Sampling Program
b. ISO 5667 – 2 : 1991 Water Quality Sampling Part 2 : Guidance Sampling
Techniques
c. ISO 5667 – 3 : 1985 Water Quality Sampling Part 3 : Guidance on the
Preservation and Handling of Samples
d. ISO 5667 – 4 : 1987 Water Quality Sampling Part 4 : Guidance on the
Sampling from lakes natural & man made
e. ISO 5667 – 5 : 1991 Water Quality Sampling Part 5 : Guidance on the
Sampling of drinking water & water used for food & beverage processing
f. ISO 5667 – 6 : 1990 Water Quality Sampling Part 6 : Guidance on the
Sampling of rivers and streams
g. ISO 5667 – 8 : 1993 Water Quality Sampling Part 8 : Guidance on the
Sampling of Wet Deposition
h. ISO 5667 – 9 : 1992 Water Quality Sampling Part 9 : Guidance on the
Sampling from marine waters
i. ISO 5667 – 10 : 1992 Water Quality Sampling Part 10 : Guidance on the
Sampling of wastewater
 j. ISO 5667 – 11 : 1993 Water Quality Sampling Part 11 : Guidance on the
Sampling of groundwater
k. ISO 5667 – 15 : 1989 Water Quality Determination of Biochemical Oxygen
Demand after 5 days (BOD5) – Dilution & Seeding Method

41. Book on “Water and Wastewater Analysis” by D.S. Ramteke,

C.A. Moghe, R. Sarin of Daya Publishing House, New Delhi (2002)

42. World bank Group Pollution Prevention and Abatement Handbook for
Petrochemicals Manufacturing, (July 1998)

43. Proposed Air Emission Regulation For Petrochemical Plants by CPCB, New
Delhi

44. Coface Environmental Guidelines for Oil and Gas –Petrochemical Plants
(July 2003)

45. Additional TOR Letter from the MoEF

46. Proceedings of the Public Consultation Process

47. Clarifications and additional information submitted to MoEF

 Annexure - I

National Ambient Air Quality Standards (NAAQS)

(1994, 1998)

Concentration in ambient air

Pollutant Time weighted --------------------------------------------------------- Method of
average Industrial Residential, Sensitive measurement
area Rural & other area
areas

1 2 3 4 5 6

Sulphur Annual average* 80 µg/m3 60 µg/m3 15 µg/m3 - Improved West

dioxide 24 hours** 120 µg/m3 80 µg/m3 30 µg/m3 & Geake method
(SO2) - Ultraviolet
fluorescence

Oxides of Annual average* 80 µg/m3 60 µg/m3 15 µg/m3 - Jacob & Hochheiser

Nitrogen 24 hours** 120 µg/m3 80 µg/m3 30 µg/m3 (Na-Arsenite) method
(as NO2) - Gas phase
chemiluminescence

Suspended Annual average* 360 µg/m3 140 µg/m3 70 µg/m3 - High volume sampling
Particulate 24 hours** 500 µg/m3 200 µg/m3 100 µg/m3 (average flow rate
Matter (SPM) not less than 1.1 m3/min)

Respirable Annual average* 120 µg/m3 60 µg/m3 50 µg/m3 - Respirable particulate

Particulate 24 hours** 150 µg/m3 100 µg/m3 75 µg/m3 matter sampler
Matter (size
less than
10 µm) (RPM)

Lead (Pb) Annual average* 1.0 µg/m3 0.75 µg/m3 0.50 µg/m3 - AAS method after
24 hours** 1.5 µg/m3 1.00 µg/m3 0.75 µg/m3 sampling using EPM
2000 or equivalent
filter paper

Carbon 8 hours** 5.0 mg/m3 2.0 mg/m3 1.00 mg/m3 - Non-dispersive infrared
Monoxide 1 hour 10.0 mg/m3 4.0 mg/m3 2.00 mg/m3 spectroscopy
(CO)

Ammonia Annual average* -- 100 µg/m3 -- - --

(NH3) 24 hours** -- 400 µg/m3 --

* Annual arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at uniform
interval.
** 24 hourly/8 hourly values should be met 98% of the time in a year. However, 2% of the time it may exceed
but not on two consecutive days
NOTE
1. National Ambient Air Quality Standard : The levels of air quality necessary with an adequate margin of
safety, to protect the public health, vegetation and property.
2. Whenever and wherever two consecutive values exceeds the limit specified above for the respective
category, it would be considered adequate reason to institute regular/continuous monitoring and further
investigations.
3. The State Government/State Board shall notify the sensitive and other areas in the respective states within
a period of six months from the date of Notification of National Ambient Air Quality Standards.

i
 Annexure - II

Damage Risk Criteria for Hearing Loss

Occupational Safety & Health Administration (OSHA)

Maximum Allowable Noise Level

Duration Per Day, h dBA (Slow Response)

8 90

6 92

4 95

3 97

2 100

1.5 102

1 105

0.5 110

0.25 or less 115

ii
 Annexure – III

Ambient Air Quality Standards in Respect of Noise

Area Code Category of Area/Zone Limits in dB(A) Leq*

Day Time Night Time

(A) Industrial Area 75 70

(B) Commercial Area 65 55

(C) Residential Area 55 45

(D) Silence Zone 50 40

Notes :

1. Day time shall mean from 6.00 a.m. to 10.00 p.m.

2. Night time shall mean from 10.00 p.m. to 6.00 a.m.
3. Silence zone is defined as an area comprising not less than 100 meters around Hospitals,
Educational Institutions and courts. The silence zones are zones which are declared as
such by the competent authority.
4. Mixed categories of areas may be declared as one of the four abovementioned
categories by the Component Authority.

* dB(A) Leq denotes the time weighted average of the level of sound in decibels on scale A
which is related to human hearing

"A", in dB(A) Leq, denotes the frequency weighting in the measurement of noise and
corresponds to frequency response characteristics of human ear

Leq : It is an energy mean of the noise level over a specified period

iii
 Annexure - IV

Classification of Inland Surface Water

(CPCB Standards)

Characteristics A@ B@ C@ D@ E@

1. Dissolved oxygen, mg/l,Min 6 5 4 4 -

2. Biochemical oxygen demand, 2 3 3 - -
mg/l. Max
3. Total Coliform organisms,* 50 500 5000 - -
MPN/100 ml, max
4. Total Dissolved Solids,mg/l, Max. 500 - 1500 - 2100
5. Chlorides(as Cl), mg/l, Max. 250 - 600 - 600
6. Colour, Hazen units, Max. 10 300 300 - -
7. Sodium absorption ratio, Max. - - - - 26
8. Boron (as B) \, mg/l, Max. - - - - 2
9. Sulphates (as SO4),mg/l, Max 400 - 400 - 1000
10. Nitrates ( as NO3),mg/l, Max. 20 - 50 - -
11. Free Ammonia (as N), mg/l, Max. - - - 1.2 -
o
12. Conductivity at 25 C, - - - 1.0 2.25
micromhos/cm, Max.
13. pH value 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5 6.0-8.0
14. Arsenic (as As),mg/l, Max. 0.05 0.2 0.2 - -
15. Iron (as Fe) mg/l, Max. 0.3 - 50.0 - -
16. Fluorides (as F), Mg/l, Max. 1.5 1.5 1.5 - -
17. Lead (as Pb),mg/l, Max. 0.1 - 0.1 - -
18. Copper (as Cu), mg/l, Max. 1.5 - 1.5 - -
19. Zinc (as Zn), mg/l, Max. 15.0 - 15.0 - -

’ If the coliform count is found to be more than the prescribed tolerance limits, the criteria for coliforms shall be
satisfied if not more than 20 percent of samples show more than the tolerance limits specified, and not more than
5 percent of samples show values more than 4 times the tolerance limits. Further, the fecal coliform should not
be more than 20 percent of the coliform. Source: Indian Standard (IS:229 - 1982).
@ A - Drinking water source without conventional treatment but after disinfection
B - Outdoor bathing (organised)
C - Drinking water source with conventional treatment followed by disinfection
D - Propagation of Wildlife, Fisheries
E - Irrigation, Industrial cooling, Controlled waste disposal

iv
 Annexure - V

General Standards for Discharge of Environmental Pollutants - Effluents

(Gazette Notification of MoEF, May 1993)
_____________________________________________________________________________
S. Parameter Standards
No. -----------------------------------------------------------------------------------------
Inland surface Public Land for Marine coastal
water sewers irrigation areas
---------------------------------------------------------------------------------------------------------------------------------
(a) (b) (c) (d)

1. Colour and odour --- ---- --- ---

2. Suspended solids 100 600 200 a) For process waste

mg/l, Max. water-100
b) For cooling water
effluent 10 percent
above total sus-
pended matter of
influent

3. Particular size of Shall pass 850 --- a) Floatable solids,

suspended solids micron IS Sieve max. 3 mm

b) Settleable solids,
max 850 microns

4. *** * --- *** ---

5. pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0

6. Temperature Shall not exceed 5oC --- --- Shall not exceed 5oC
above the receiving above the receiving
water temperature water temperature

7. Oil and grease mg/l 10 20 10 20

Max.

8. Total residual chlorine 1.0 --- --- 1.0

mg/l Max.

9. Ammonical nitrogen 50 50 --- 50

(as N), mg/l Max.
_____________________________________________________________________________
1. Schedule : VI inserted by Rule 2(d) of the Environment (Protection), Second Amendment
Rules, 1993 notified vide G.S.R. 422(E) dated 19.05.1993, published in the Gazette No. 174
dated 19.05.1993.

v
_____________________________________________________________________________
S. Parameter Standards
No. -----------------------------------------------------------------------------------------
Inland surface Public Land for Marine coastal
water sewers irrigation areas
(a) (b) (c) (d)

10. Total Kjeldahl nitrogen 100 - - 100

(as NH3) mg/l, Max

11. Free ammonia (as 5.0 - - 5.0

NH3 ) mg/l, Max

12. Biochemical Oxygen 30 350 100 100

demand (5 days at
20oC) mg/l Max.

13. Chemical Oxygen 250 - - 250

demand, mg/l Max.

14. Arsenic (as As), 0.2 0.2 0.2 0.2

mg/l Max.

15. Mercury (As Hg.) 0.01 0.01 - 0.01

mg/l Max.

16. Lead (as Pb) mg/l, 0.1 1.0 - 2.0

Max.

17. Cadmium (as Cd) 2.0 1.0 - 2.0

mg/l, Max.

18. Hexavalent chro- 0.1 2.0 - 2.0

mium (as Cr+6),
mg/l, Max.

19. Total chromium (as 2.0 2.0 - 2.0

Cr) mg/l, Max.

20. Copper (as Cu) 3.0 3.0 - 3.0

mg/l, Max.

21. Zinc (as Zn.) mg/l 5.0 15 - 15

Max.
22. Selenium (as Se.) 0.05 0.05 - 0.05
mg/l, Max.
_____________________________________________________________________________

vi
____________________________________________________________________________
S. Parameter Standards
No. -----------------------------------------------------------------------------------------
Inland surface Public Land for Marine coastal
water sewers irrigation areas
---------------------------------------------------------------------------------------------------------------------------------
(a) (b) (c) (d)
_____________________________________________________________________________

23. Nickel (as Ni) 3.0 3.0 - 5.0

mg/l, Max.
2
24. *** * * * *
2
25. *** * * * *
2
26. *** * * * *

27. Cyanide (as CN) 0.2 2.0 0.2 0.2

mg/l Max.
2
28. *** * * * *

29. Fluoride (as F) 2.0 15 - 15

mg/l Max.

30. Dissolved phosphates 5.0 - - -

(as P), mg/l Max.
2
31. *** * * * *

32. Sulphide (as S) mg/l 2.0 - - 5.0

Max.

33. Phenolic compounds 1.0 5.0 - 5.0

(as C6H5OH)
mg/l Max.

34. Radioactive materials

(a) Alpha emitter 10-7 10-7 10-8 10-7
micro curie/ml

(b) Beta emitter 10-6 10-6 10-7 10-6

micro curie/ml

35. Bio-assay test 90%survival 90%survival 90%survival 90%survival

of fish after of fish after of fish after of fish after
96 hours in 96 hours in 96 hours in 96 hours in
100% effluent 100% effluent 100% effluent 100% effluent
_____________________________________________________________________________

vii
_____________________________________________________________________________

S. Parameter Standards
No. -----------------------------------------------------------------------------------------
Inland surface Public Land for Marine coastal
water sewers irrigation areas
---------------------------------------------------------------------------------------------------------------------------------
(a) (b) (c) (d)
_____________________________________________________________________________

36. Manganese (as Mn.) 2 2 - 2

mg/l

37. Iron (as Fe) mg/l 3 3 - 3

38. Vanadium ( as V) 0.2 0.2 - 0.2

39. Nitrate Nitrogen mg/l 10 - - 20

2
40. *** * * * *
_____________________________________________________________________________

2. Omitted by Rule 2(d)(i) of the Environment (Protection) Third Amendment Rules, 1993 vide
Notification No. G.S.R. 801 (E) dated 31.12.1993

viii
 Annexure VI

Procedure for Environmental Clearance of the project

The Ministry of Environment and Forests (MoEF), Government of India, is the governing body
that issues the Environmental Clearance (EC) for a project. The procedures for obtaining the
EC for a project is specified in Figure 1.

The EC process will compromise of a maximum of four stages, of which screening may not
apply for cases such as i.e. refinery, petrochemical complex, SEZ, etc. These four stages in
sequential order are given below:

1. Screening
2. Scoping
3. Public Consultation
4. Appraisal

Scoping
The applicant has to submit an application seeking prior EC made in the prescribed format,
pre feasibility report and a comprehensive Terms of Reference (TOR) of the proposed project
addressing all the environmental concerns for the preparation of the Environment Impact
Assessment (EIA) & Risk Assessment (RA) to the Expert Appraisal Committee (EAC) under
the MoEF. The EAC shall determine and convey to the applicant the TOR within 60 days of
the receipt of the documents. This TOR will be on the basis of information furnished by the
applicant including the TOR proposed by the applicant, site visit by EAC (if required) and the
other information available. These TOR shall be deemed as the final TOR for EIA, which will
be displayed on the MoEF website.

The applicant/ third party shall prepare the Draft EIA and RA study report in line with the final
TOR for the proposed project.

Public Consultation
Once the draft EIA and RA is ready, the applicant shall make a request for Public Hearing
(PH) to State Pollution Control Board (SPCB). The SPCB shall advertise the same in one
national daily and one regional vernacular daily intimating the date, time, venue, the offices
where the public could access the Draft EIA Report and the Summary of the EIA report before
the PH. The SPCB shall arrange to video film the entire proceedings. Once the public hearing
is completed, a Final EIA is prepared by incorporating the public hearing comments before
submission for Appraisal.

On completion of the PH, the SPCB representatives will prepare the minutes of the meeting
and compile the documentation pertaining to the PH which will include the press notice,
queries, responses, attendance sheets and comments/suggestions made at the PH, which will
be submitted to the MoEF.
No Objection Certificate (NOC) / Consent for Establishment (CFE)

As per the requirements of the Air Act and Water Act, the project proponent will file an
application with the respective State Pollution Control Board for the Consent for
Establishment. The project will be appraised by the technical committee of the SPCB wherein
the project proponent has to respond to all the queries based on the documentation submitted
and furnish any additional information, as required. On satisfactory completion of the technical
committee review, the SPCB issues the No Objection Certificate (Consent for Establishment)
of the project.
Appraisal by EAC
The draft EIA will be finalized incorporating the comments of the Public Consultation process.
The final EIA will be submitted to the MoEF along with the outcome of the public consultations.
The MoEF will then scrutinize the documents (EIA Report, video tape of the PH, final layout
plan, Project feasibility report) with reference to the TOR and the inadequacies noted shall be
communicated to the EAC enclosing a copy of the EIA documents, the PH proceedings, public
responses along with Form – I and scheduled dated of the EAC meeting for considering the
proposal. The appraisal of an application (EIA report and other documents) shall be completed
by the EAC and the recommendation on grant of EC shall be conveyed to the MoEF. The
MoEF shall consider the decision of recommendations of the EAC and convey its decision on
EC to the applicant.

Post Environmental Clearance Monitoring

The Project management shall submit half yearly compliance reports in respect to the
stipulated EC terms and conditions in hard and soft copies to the regulatory authorities.

Transferability of the EC

A prior EC granted for a specific project to an applicant may be transferred during its validity to
another legal person entitled to undertake the project on application by the transferor or by the
transferee with a written ‘no objection’ by the transferor, to, and by the regulatory authority
concerned, on the same terms and conditions under which the prior EC was initially granted.

Consent to Operate, Environmental Action Plan and Monitoring

Prior to the commissioning of the project, the project proponent shall apply to the SPCB for
Consent to Operate in the prescribed format. All the operational details based on the final
design of the project are mentioned on this application and after ensuring compliance to all the
conditions specified by the SPCB in the CFE and the conditions specified in the EC. The
SPCB will issue consent to operate.

The compliance to various conditions that are specified in the statutory approvals is monitored
by the SPCB and MOEF. The post project environmental plan as specified in EIA is to be
practiced and periodic reports are to be sent to the MOEF and SPCB of monitoring division.
Further an annual environmental audit report is to be submitted to the relevant statutory
authorities.
 EIA & RA Scope
Process For Environmental Approvals

Start Project Definition S

C
Agency Selection for EIA & O
RA P
Form 1 + Pre-feasibility I
report + Terms of Reference N
(TOR) to EAC G
Draft EIA and RA report

Approved TOR for EIA and

RA Studies

P
Application to SPCB for U
Draft EIA and RA report Public Hearing and NOC B
L
I
C
Public hearing notice
Public Hearing publication and documents C
for public review during O
mandatory notice period N
S
Incorporation of Public Hearing U
Final EIA & RA L
comments in Draft EIA SPCB Appraisal T
A
A T
P Final EIA to be submitted to I
P NOC
MOEF O
R N
A
I
S MOEF to scrutinize the Final
A EIA with reference to TOR.
L

C
E 60 ( 315 ) of
EAC’s recommendation
N EC to MOEF
T
R
A
L Comprehensive EIA study or
Environmental
15Clearance
( 345 ) any other studies as stipulated
(EC)
G in the MOEF EC
O
V
T
Preparation of Specs for
environmental requirement & Preparation of detailed EAP
systems incorporating the for Construction and
stipulated conditions of Operation
environmental clearance
E
A
P
Review and feed back during
& Design, Construction and
Commissioning
M
O
N Liaison with Govt and
I statutory bodies and obtain
T operational approvals/
O consents
R
I
N
Establish monitoring &
G
regulatory compliance norms
for steady state operation.

Periodic monitoring of
compliance and assistance to
plant on specific issue.

Project Management to
submit compliance report in
respect of EC to MOEF
Annexure - VII
 Annexure VIII
Resettlement & Rehabilitation Plan

Instructions of Government of India (Ministry of Industry) 1988

Thus, “land for land” was the only objective of human resettlement. But there was no
clearcut guidelines in achieving this objective. Government of India, in the Ministry of
Industry, Department of Public Enterprises, Bureau of Public Enterprises in their Office
Memorandum No. 15/13/84 B.P.E (C) dt. 3.2.1986 issued a set of instructions on land
acquisition and rehabilitation aspects involved in major projects and alleviation of the
difficulties faced by the dispossessed persons. Ministry of Water Resources in their letter
No. 6/71/84-P.H dt. 27.5.1986 impressed upon all State Governments to follow the
instructions contained in the aforesaid Office Memorandum of Ministry of Industry,
Department of Public Enterprises, while formulating projects. The salient features of the
Office-Memorandum are the following :

(a) There should be a Rehabilitation Cell in each and every project to identify the
persons who are dispossessed of their land following acquisition of their land

(b) Rehabilitation assistance should be given to those who are dispossessed of their
land and homestead and provided they were themselves cultivating those lands.
Absentee landlords will not be entitled for any rehabilitation assistance

(c) Considering the educational attainment of the oustees, arrangements at project cost
will be made to impart suitable-vocational training in available training institutes for
employment in the project, subject to availability of vacancy. If suitable training
disciplines are not available in existing institutes, such training courses which would
equip the candidates for employment should be started and funded by the project.
But there will be no started and funded by the project. But there will be no
commitment by the project authorities that such training arranged for by the project
will ultimately provide employment to the oustee in the project itself or anywhere else.
The idea behind such training is only to equip the oustee with necessary ability to
compete for employment alongwith others

(d) There will be no assurance for any employment opportunities in the project. But the
projects will assist the State, Governments in organising and financing the oustees in
taking to useful avocations like poultry, animal husbandry, etc. The basis
 responsibility of initiating such activities will be that of the State Government ; not the
project

(e) The Rehabilitation Cell will monitor the progress of rehabilitation activities

(f) The entire cost of rehabilitation will be a part of the project cost

Eligibility
(a) In fully submerged villages, displaced families losing land and/or houses will get land
in rehabilitation area provided they do not have three acres or more land in any
adjoining area

(b) Landless and homeless families belonging to the fully submerged villages will also
get land

Rehabilitation Policy Relating to Other Projects in the State

1. Training in I.T.I

2. Allotment of shops adjacent to plant approaches and inside township

3. Engagement in agro-based industries

4. Unskilled job in the plant

Determination of Market Value of Land

(a) Preparation of Land Acquisition estimate is not an easy task. For this, the market
value of the land proposed to be acquired is to be determined. Normally this is
determined after taking into account the sale transactions at the date of publication of
notification U/S 4(1) of the L.A. Act. In the event of non-availability of such data, the
market value of the land prevailing on or close to the date of submission of the
proposal may be taken into consideration

(b) If no such sale transaction data are available, sales of such quality of land in the
vicinity within a fairly recent date can be taken into account

(c) If no such statistics as contemplated in (b) above are available, the net annual
produce of the land can be taken into account for valuation
 (d) Value awarded in previous land acquisition proceedings is also relevant evidence on
the question of market value

(e) For determination of market value of agricultural land, the annual letting value is also
taken into account. The net profit the tenant derives from the land over a certain
number of years is taken as the letting value

(f) While determining the market value of the land, value of trees, houses, wells, tanks,
crops, etc., that are standing on the land shall be taken into account

Source : Environmental Impact of Large Reservoir Project on Human Settlement : A.K. Dalua 1993
Annexure IX
SAFE MANAGEMENT
MEASURES
FOR
PHOSGENE
 Contents

Section Topic Pg.

No. No

1.0 Introduction 1
1.1 Preface and Legal Notice 1
1.2 Company Goals 1
2.0 Training and Job Safety
2.1 Employee Education and Training 1
2.2 Safety review 4
3.0 Health Factors, Industrial Hygiene, Medical Management, 5
First Aid and Protective Equipment
3.1 General 5
3.2 Air Monitoring 6
3.3 Medical Management 9
3.4 Personal Protective Equipment 15
3.4.1 General 15
3.4.2 Availability and Use 17
3.4.3 Training 17
3.4.4 Personal Protective Equipment 17
4.0 Emergency Response 18
4.1 Emergency Response Plan 18
4.1.1 General 18
4.2 Fire 21
4.3 Gaseous Leak 22
4.4 Liquid Spills 25
4.5 Mutual Aid 25
4.6 Public Departments 25
5.0 Design of Facilities 26
5.1 Plant Layout and Siting 26
5.2 Materials of Construction 28
5.2.1 General Design Considerations 28
Section Topic Pg.
No. No

5.3 Piping Items and Valves 30

5.3.1 Piping 30
5.3.2 Valves 32
5.3.3 Other Components 32
5.3.4 Piping Layout and Design 33
5.3.5 Preparation for Use 36
5.3.6 Leak testing 36
5.3.7 Drying 36
5.3.8 Preventative Inspection and Maintenance 37
5.4 Pumps 39
5.4.1 General Guidelines 39
5.4.2 Mechanically Sealed Pumps 40
5.4.3 Differential Pressure 41
5.5 Instruments 41
5.5.1 Introduction 41
5.5.2 General Description 42
5.5.3 General Design Installation Issues 43
5.6 Relief Devices 44
5.6.1 Introduction 44
5.7 Secondary Containment 45
5.7.1 Introduction 45
5.7.2 Double Walled Construction 46
5.7.3 Structural Enclosures 46
5.7.4 Dump Tanks 47
5.7.5 Containment Vaults 47
5.8 Mitigation Systems 48
5.8.1 Fugitive Collection Systems 49
5.8.1.1 Vacuum Systems 49
5.8.1.1.1 Spot Ventilation Systems 49
5.8.1.1.2 Permanent Ventilation Systems 50
5.8.2 Phosgene Neutralization Systems 50
Section Topic Pg.
No. No

5.8.2.1 Caustic Scrubbers 50

5.8.2.1.2 Dispersion Stacks 51
5.8.2.1.3 Emissions and Controls 51
5.9 Inspection and Testing 53
5.9.1 Inspection & Testing During Operation 53
5.9.2 Inspection & Testing During Maintenance / Turnarounds 57
5.9.3 Commissioning Equipment 62
5.9.4 Certification & Training Requirements for Non Destructive 67
Testing (NDT) Inspectors
5.9.5 Record keeping 67
6.0 Equipment Cleaning and Repair 68
6.1 General 68
6.2 Preparation for Inspection or Repair 68
6.3 Equipment Repairs 71
6.4 Preparation of Service 72
 SAFE MANAGEMENT PRACTICES FOR PHOSGENE

1.0 Introduction

1.1 Preface and Legal Notice

The information on Phosgene Safe Practice Guidelines Document is a presented

in this document. The information provided in the document is a guideline to be
adopted or followed. The information is intended to provide helpful guidance that
the Project Proponent has to consider.

1.2 Company Goals

Continuous improvement in phosgene production process with respect to

safety, health and environmental protection.

Comply with the ‘Chemical Weapons Convention’ to which India is a

signatory.

Precautionary information, such as is presented here, should be provided to

all persons who will use, handle or otherwise be exposed to phosgene.

2.0 Training and Job Safety

2.1 Employee Education and Training

Phosgene boils at 7.56oC (approximately 46oF) at atmospheric pressure so it is

normally in a gaseous state. As a gas, phosgene is poisonous. However, it may
be in a liquid state under certain pressure and temperature conditions. Liquid
phosgene can cause skin and eye burns. Liquid phosgene will usually have a
sufficiently high vapor pressure that handling it presents the same toxicity
concerns as handling the gas. The toxicity of phosgene depends on the degree
of exposure or dose. The hazards associated with the use and handling of
phosgene (that is, the likelihood of significant exposure) can be minimized by
proper education and training of employees and contractors before their
assignment to operating responsibilities in areas handling this material, as well
as by observing proper engineering practice.

Safe handling of phosgene depends to a great extent upon the effectiveness of

employee education, proper training in safe practices, the use of safety
equipment, and the proper application from the employee of the knowledge and
skills learned. Knowledgeable supervision and management support is required
to assess and improve on this process.

Before undertaking any employee training on the handling or processing of

phosgene, the trainer should be thoroughly familiar with the properties and
characteristics of the chemical. While reviewing the information provided in this
document to be helpful, users to help ensure that all appropriate
recommendations and precautions are followed. Consider whether the training
materials include up-to-date information and are presented in a format that is
easily understood by all employees. Verification that the employee has
understood the material, and documentation of the testing procedure, may be
needed. Frequently Material Safety Data Sheets (MSDS) are relied upon to
provide up-to-date information on phosgene safety and handling. The National
Institute of Occupational Safety and Health’s (NIOSH) Criteria Document on
phosgene also provides information.

Employee and contractor education and training programs should be thorough

and accurate training program covering topics and information are important and
beneficial include:

Exposure symptoms and exposure signs with emphasis on possible delayed

effects.

Phosgene handling training that includes line-breaking practices.

Phosgene neutralization practices.

2
Qualification of workers authorized to approach and contain phosgene leaks.

Instructions and periodic drills or quizzes regarding items such as:

• potential emergency scenarios

• physical characteristics of phosgene

• health hazards associated with exposure and overexposure to phosgene

• first response measures

• personal protective equipment (PPE)

• occupational exposure limits

• fire and explosion information

• gas detection equipment, gas alarms and emergency shutdown

equipment such as valves and switches

• spill and disposal procedures

• emergency procedures

• review of previous incidents (if any)

Instructions on reporting to the proper authority all incidents involving either

the inhalation of the vapors of phosgene or direct contact with the liquid, as
well as all signs of illness, particularly respiratory distress.

Instructions on reporting all cases of personal protection equipment failure to

the proper authority.

3
 In addition to initial training, periodic re-training of phosgene workers should be
carried out on a regular basis to reinforce and update important information. The
Company shall also provide training and education programs for maintenance
and emergency personnel who may frequent a phosgene area. Informing
workers in neighboring areas (villages) of emergency procedures, in the event of
phosgene releases or spills can help provide for appropriate actions should an
event occur.

Company will find it useful and this may be required by law to maintain a record
of those personnel who are instructed, retrained and tested.

2.2 Safety Review

The users must consult the applicable regulatory norms and review all the
requirements in their entirety (and to learn of potential updates). After becoming
thoroughly familiar with the properties and hazardous characteristics of
phosgene, operating procedures must be written and reviewed by appropriate
personnel. Once the procedures have been finalized, they should be reviewed
by appropriate personnel, especially workers who will be handling phosgene.
During the hazard evaluation, the hazards of the process, past incidents,
engineering controls, failure consequences, mechanical integrity and facility
siting must be considered. The review should not only be concerned with the
hazards of contact with or exposure to phosgene, but also with hazards that may
be involved in handling containers and using the operating equipment. Other
hazards associated with the work should be noted. The need for personal
protective equipment, its maintenance and its proper use, as well as its
limitations should be determined. Procedures for all reasonably foreseeable
emergencies should be established, including determining suitable locations for
and the operation of safety showers, fire extinguishers, alarms etc. Both routine
and non-routine operations must be considered including the startup and
shutdown of a process. Emergency planning and response procedures must be
considered.

4
 During safety review of the operations, it may become apparent that some
danger points can be eliminated. However, process changes should not be
made without following the ‘Management of Change’ procedures. In chemical
processing, even a slight deviation might cause disastrous results.

To increase training effectiveness, all significant hazards can be explained

together with precautions to be followed in the standard operating procedures.
Safety precautions can be an integral part of the operating instructions.

For example, if specific-level personal protective equipment is required while line-

breaking, the standard operating procedure which describes the line-breaking
can also make it clear that the specific personal protective equipment is required
for that operation. Since each aspect of operation has elements of safety, it is
helpful if the manuals and operations documents incorporate safety information
for all steps.

Periodic audits are required at least every 3 years. This duration however can be
increased or decreased based on the requirements. Periodically checking the
employees helps make certain that they are following instructions and
precautions as directed. Complete standard operating procedures that embody
safety information can help prevent injuries and accidents.

3.0 Health Factors, Industrial Hygiene, Medical Management, First Aid and
Protective Equipment

3.1 General

Phosgene is a poisonous gas at atmospheric pressure and room temperature. (It

may, however, be in a liquid state under certain temperature and pressure
conditions.) However, the hazards of phosgene are greatly reduced if workers
follow safe working procedures and are provided with proper safeguards.

The harmful effects of low-level exposure to phosgene are primarily due to

irritation but this action may not be immediately apparent in a relatively mild

5
 exposure. An exposed person may even breathe the gas deeply into the lungs
without being aware of the hazard. This may result in minor and brief irritation to
the upper respiratory system with more serious effects in the alveolar portion of
the lungs. In heavy exposures, irritation may be apparent at once but even so,
because the gas causes little spasm of the air passages, immediate symptoms
may subside. However, the effects to the areas of the lung where gas exchange
is taking place will continue to occur over the next few hours. Pulmonary edema,
indicated by excessive amounts of fluid in the lungs, is the result of
overexposure.

Phosgene exposure may also produce irritation of the eyes and headache.
Nausea, vomiting and abdominal pain may occur. The important site of action is
in the finer air passages of the lungs and the pulmonary capillaries.

3.2 Air Monitoring

Early methods for the detection of phosgene utilizes absorption into a solution
which changes color (25% 4(4-nitrobenzyl pyridine) and stabilizes the color
(0.5% N-Phenylbenzene). The absorbance is then read on a spectrophotometer.
Early colorimetric methods give rise to development of diffusion badges.

Badges that change color upon exposure to phosgene are commercially

available. Color change is white to pink (red) or white to blue. Extremely high
concentrations (percent not ppm levels) may cause the color to change back to
white again. Badge readings may vary depending on the manufacturer of the
badge, the reader of the badge, and other conditions and factors. Manufacturers
may provide additional details for inclusion in employee training.

Dose is estimated by matching the intensity of color on a badge reader or color

wheel (graduated color intensities that correspond to dose (ppm-minutes). The
potential for individuals color blindness to reds is a factor that can be addressed
in the development of a badge program.

6
Users can develop written programs including a log of exposures or possibly lack
of exposures. Documentation of dose can include details of the event leading to
the exposure as well as details of any respiratory protection used. Useful
information may include the name of the individual who wears the badge, the
person entering the information, and the circumstances of the event in case it
should be necessary to provide this information later. During training on the use
of the badges, it may be important to stress that all exposures be reported
immediately. In most cases, exposures warrant an incident investigation and
accompanying documentation of that investigation.

Placement of badges can be an important element in a badge program. More

useful and reliable results can be achieved if the badge is placed in the breathing
zone of the individual. Badges that are affected by ultraviolet (UV) light and
water may be adhered under the front brim of the hard-hat. Alternately, clips can
attach the badge to the collar to better secure the badge and still provide
representative breathing zone concentration. Wearing badges under additional
personal protective equipment (PPE) (slicker suits, bunker gear, etc.) and
badges worn on the back of the hard-hat can hinder the badges effectiveness.

Users may also consider including the written program on ‘Standard Operating
Procedures’ or ‘Job Safety Information’ regarding instructions on the proper use
of badges and medical reporting procedures. The badge manufacturer’s
recommendations for use are also relevant. Since a dose of 48 ppm-min is
equivalent to 480 minutes times the TLV of 0.1 ppm, values less than 48 ppm-
min do not necessarily constitute an overexposure. This information may be
helpful when considering the definition of “first aid” and “recordable injury.” A
dose of 48 ppm-min can be chosen as reporting through the medical facility; or
use a lesser value. It must be emphasized again, however, any phosgene
exposure should be given due consideration keeping in mind the TLV and the
hazard potential of phosgene.

Badges are also used as leak detection devices, especially in open-air

environments where tiny leaks may escape detection using handheld monitors,
area monitors or ammonia sprays. Badges may be placed and left for long

7
periods of time (subject to the manufacturer’s recommendations for maximum
sampling time) to identify low concentrations of phosgene. The lower detectable
limit of instrumentation that gives immediate concentration readout (usually 0.01
ppm) may be insufficient for very small leaks.

Other types of portable and fixed monitoring systems also are available which
use either electrochemical cell detectors or a version of the color chemistry
mentioned above. Instrumentation utilizing paper tape chemistries is usually very
specific to phosgene. Electrochemical cell detectors may have cross-sensitivity
to a number of contaminants typically found in industrial settings (e.g., sulphur
compounds and hydrochloric acid (HCl) gas). Filters can help minimize the
problem. It is beneficial to discuss this matter with manufacturers of all these
devices, especially where false indication of phosgene could cause harm to
employees, neighboring industries or the community.

In some circumstances, it may be necessary to employ instrumentation in the

event phosgene is released in areas where it could enter a building (e.g. intake
through the heating, ventilating and air-conditioning (HVAC) system, conduit path
openings, etc.). Detection of trapped phosgene vapors after a release is
important because vapors could pose a threat to building occupants in the vicinity
or person downwind of a release.

Remote optical sensing systems can monitor for phosgene down a long path,
rather than detecting its presence at a single point. Fourier Transform Infrared
(FTIR) systems may be quite useful. Rapid improvements in this technology
make this technique state-of-the-art, but therefore may lack of field reliability over
time.

8
3.3 Medical Management

Clinical Procedures

• Adequate self- protection should be ensured before rescuers attempt to aid

casualties. Rescuers should wear appropriate protective clothing including
respiratory and eye protection. Self contained breathing apparatus and
impermeable suits are required to protect against high concentrations.

• The priority is to remove the casualty from further exposure and maintain vital
functions. Management of acute phosgene inhalation is symptomatic and
supportive.

• Phosgene is a volatile gas and contamination from individuals exposed to gas

alone is unlikely. However, in cold environment/weather, phosgene gas can
condense and contaminate others dermally, unless they are protected.
Exposure to liquid agent will result in off-gassing and a secondary hazard.

• Remove contact lenses if present and easily removable. Irritate eyes with
lukewarm water or sodium chloride 0.9% solution. Patients with eye injuries
should be referred to an ophthalmologist. If eye tissue is frozen seek urgent
specialist advice.

• All clothing should be removed unless covering an area of frostbite.

Whenever possible the affected individual should remove contaminated
clothing for him/herself

• Phosgene does not remain liquid for long, except in cold climates. Skin
decontamination is therefore not usually required following exposure to gas
alone. If required, this should be carried out using a rinse-wipe-rinse regime
with dilute detergent (10 ml washing up liquid to a 10 litre bucket of water).

9
• Contaminated clothing should be placed in clear, labeled sealed bags to
prevent further contamination. It should be stored in a secure area away from
staff and patients.

• Establish and maintain a clear airway and administer supplemental oxygen

as required.

Sample collection and monitoring

• There is no analysis available to measure blood phosgene concentrations.

Concentration in air may be measured.

• Clinical samples will be required according to patients condition. Consider

obtaining arterial blood gases and chest X-rays. These may need to be
repeated.

Treatment

In the event of and incident causing release of phosgene, additional resuscitation

equipment will be available. This should be requested EARLY in the course of
the incident. The ‘trigger’ for obtaining it will be released separately.

The severity or duration of the initial phases does not reliably indicate the
potential for sever clinical effects.

If exposure is suspected the patient should be observed for 24 hours.

Those exposed should undertake no exercise – remaining on bed rest as

exercise may precipitate oedema and collapse.

10
Inhalation Management

• Treatment is symptomatic and supportive. Give oxygen for dyspnoea and

bronchodilators (e.g. inhaled sulbutamol) for bronchospasm.

• Monitor arterial blood gases and pulmonary function and obtain a chest x-ray.

• Mechanical ventilation with positive end-expiratory pressure may be

necessary if non-cardiogenic pulmonary oedema develops.

• Monitor for the development of secondary infection and ARDS.

• The role of prophylactic corticosteriods (inhaled or systemic) is unproven.

Antibiotics will be required if pneumonia is unproven.

• Follow up lung function testes should be obtained following recovery from the
acute illness.

Dermal Management

• Dermal features usually occur only after exposure to concentrated phosgene

gas or contact with liquid phosgene.

• If frostbite has occurred; remove clothing carefully; these may need to be

soaked off with tepid water; irrigate the area. Surgical referral may be
necessary.

• If frostbite has not occurred; remove any remaining contaminated clothing.

Irrigate with copious amounts of water.

• Treat burns symptotically.

• Place any contaminated clothes in double, sealed, clear bags, label and store
in a secure area away from patients and staff.

11
Eye Management

• Remove contact lenses if required. Irrigate eyes immediately. Stain with

fluorescein and refer to an ophthalmologist if there is any uptake of the stain.

Oral Management

• Not applicable.

Admission criteria

• If exposure is suspected, the patients must be observed for 24 hours due to

the possibility of delayed, potentially fatal, pulmonary oedema occurring.
Patients should undertake no exercise and should be placed on strict bed as
soon as possible.

Protection of health workers

• All medical staff should wear full personal protective equipment when
decontaminating patients.

Laboratory procedures

• There is no analysis available to measure phosgene concentrations. Air

sampling at the site of exposure may confirm the nature of exposure. Clinical
samples, including blood gases should be taken according to the patients
clinical condition.

12
Public health procedures

Surveillance and detection of deliberate release

• A deliberate release should be considered in the event of any cases where

there is no clear history of occupational or other exposure to phosgene. The
likelihood of a deliberate release increases with the number of cases, which
are linked in time and place.

• Expert advice may be required in order to confirm the occurrence of a covert

release and epidemiological investigations may be required to defined
exposed zone in time and space.

Case definition

• A record should be kept of all patients attending as the result of phosgene

release.

Possible case

• Patient reporting possible exposure with or without mild symptoms, probably

not admitted for continuing medical care.

Probable case

• Patient reporting exposure, with some symptoms consistent with exposure,

likely to have continuing medical care.

Confirmed case

• Patients reporting exposure, with some symptoms consistent with exposure,

likely to have require hospital care.

13
Confirmed case

• Characteristically symptomatic patient, with history of exposure require

hospital care.

Public Health Action

Removal from exposure

• Minimization of harm by removal from exposure is probably the most

important public health measure. Evacuation from contaminated area is
essential and is likely to be undertaken by the emergency services (or by self
evacuation).

Decontamination

• Adequate self-protection should be ensured before rescuers attempt to aid

causalities. Rescuers should wear appropriate clothing including respiratory
and eye protection. Self-contained breathing apparatus and impermeable
suits are required to protect against high concentrations.

• Phosgene is a volatile gas and secondary contamination from exposed

individuals is unlikely, though liquid phosgene can contaminate others
dermally, unless they are adequately protected. Off-gassing from liquid agent
may pose a secondary vapor hazard.

• All clothing should be removed. Phosgene evaporates quickly except in cold

weather and therefore tends not to remain liquid for long, except in very cold
climates. Skin decontamination may not be required. If required, it should be
carried out using a rinse-wipe-rinse regime with dilute detergent (10 ml
washing up liquid to a 10-litre bucket of water.

• Contaminated clothing should be placed in clear, labeled, sealed bags to

prevent further contamination.

14
 Epidemiological investigation

• It is vitally important to try and obtain epidemiological data on this patient

group. A draft questionnaire has been provided to hospital trusts (Hospital
Chemical Incident Response) and further advice may be issued. Health
authorities may wish to collaborate with acute trusts in collating these data.

Environmental hazard summary

• Phosgene is denser than air and may accumulate in low-lying areas.

• It has a vapor pressure (vapor pressure 1418 mm Hg at 25C).
• Phosgene degrades slowly in atmosphere
• In water phosgene in hydrolyzed and is rapidly lost by volatisation.
• If released into damp soil phosgene will hydrolyze and be lost by
volatilization. It has a high Kco and is expected to be highly mobile.
• Drinking Water Standards: no data available. Immiscible with water.
• Soil Guidelines: no data available.
• Air Quality: no data available.

3.4 Personal Protective Equipment (PPE)

3.4.1 General

Because the odor of phosgene may not be noticed and is not unpleasant,
establishment of engineering controls and work practices helps protect
against potential risks. Phosgene fatalities have occurred from
overexposure, sometimes with few, if any, initial symptoms.

Handling phosgene in completely closed processing systems helps

minimize exposure. In the event of a release of phosgene, the immediate
evacuation of the area, and entering the area only with the use of
appropriate respiratory protective equipment reduces potential concerns.

15
It is beneficial to have several sets of protective equipment available at all
times stored outside of, but near to, the area where phosgene is used.

Workers can benefit from instructions on how to avoid or minimize

breathing phosgene in areas where they may be exposed to the gas.
Other items may include: equipping and instructing in the use of positive
pressure self-contained breathing equipment when it is known that
phosgene may escape; familiarizing workers with the location, operation
and limitations on the duration of use of respiratory protective equipment;
and reporting immediately any episode in which the gas was breathed or
of contact of the skin or eyes with liquid phosgene.

Personal protective equipment serves to compliment but not substitute for

safe working conditions, adequate process control, ventilation and proper
conduct by employees working with phosgene (engineering controls).
However, in some instances, it is the only practical means of protecting
the worker in emergency situations and while performing tasks where
engineering controls are not feasible.

An appropriate choice in selection and use of personal protective

equipment will normally be dictated by the total situation, rather than by
the toxic properties of phosgene alone. These situations may also
involve other hazardous materials or normally innocuous materials that
can magnify potential concerns associated with phosgene. Therefore, the
following information on equipment is to be considered as a potential
reference point for general guidance. Users need to select appropriate
personal protective equipment based on their specific needs and
circumstances. Other chemicals or factors may require the use of
additional protection. Except in extreme emergencies, no one should be
given personal protective equipment without suitable training in its use.

CAUTION : It is important to consider all the chemicals potentially

present with phosgene when selecting PPE.

16
3.4.2 Availability and Use

Location, care and selection of appropriate PPE are dictated by the

proposed use of the equipment. Personnel, facilities and programs have
to be assigned for suitable care, decontamination and repair of all
equipment.

3.4.3 Training

Provide training so that employees using PPE in phosgene service are

extensively experienced in the use of the relevant PPE prior to its use in
phosgene service. Consult the manufacturer recommendations where
provided.

3.4.4 Personal Protective Equipment

Some of the Personal Protective Equipment to be provided will be as

follows:

Protective clothing
Foot protection
Hand protection
Eye protection
Respiratory protection
Head protection
Storage of PPE for phosgene service
Maintenance of PPE for phosgene service
Decontamination of contaminated clothing

17
4.0 Emergency Response

4.1 Emergency Response Plan

4.1.1 General

Elements of an emergency response plan. The requirements dictate that

the employer develop an emergency response plan that shall address, as
a minimum, the following items to the extent that they are not addressed
elsewhere:

a. Pre-emergency planning and coordination with outside parties.

b. Personal roles, lines of authority, training and communication
c. Emergency recognition and prevention
d. Safe distances and places of refuge
e. Site security and control
f. Evacuation routes and procedures
g. Decontamination
h. Emergency medical treatment and first aid
i. Emergency alerting and response procedures.
j. Critique of response and follow-up.
k. PPE and emergency equipment

Additional items for Emergency Response Plans

The following items may also be included or considered as part of

emergency response planning. Depending on specific circumstances,
alternative or additional items may be required for emergency response
plan development

• Key company personnel evaluate the feasibility of including alternate

personnel and how to contact those individuals if the need arose (e.g.
phone, pager). Automatic pager calls and phone ring-down systems

18
 are available and may be helpful especially where large numbers of
people must be contacted quickly.

• Key outside personnel may be contacted directly or by automatic ring-

down, and messaging systems may be incorporated to speed the
process and document that the calls were made.

• Titles of individuals as they function in Emergency Response activities

and their associated duties before, during and after the emergency
can be explained in the plan.

• A description of the facility, layout and chemical inventory will aid in

communicating with outside agencies and mutual aid groups.

• Preplanning the location and staffing of the incident command team,

management and staging areas, including a possible location offsite
should a catastrophic emergency arise, can facilitate response
actions.

• It is beneficial to have training and drills simulate real situations and

have personnel trained to act as if the activity was not a mere
preparation exercise. Drills should include the actual use of
respirators including escape respirators. Smoke bombs to be used to
make drills more or realistic and to display air patterns.

• Alarm systems such as directional sirens, strobes or public

announcement systems to be included. Evaluate whether alarm
systems have sufficient volume to reach all affected personnel.

• Evacuation/Shelter-in-Place: Establishing procedures that include

communication equipment inside the safe shelter in the event it
becomes necessary for persons to evacuate the safe shelter or for
occupants to communicate information back to the On Scene Incident
Commander (OSIC)

19
• Downwind or perimeter monitoring has been used to better draw
boundaries for personnel protection. Detection instruments help to
determine when concentrations have dropped and the “all clear” can
be safely given. Consideration may be given to any structures
downwind that are or could be occupied by personnel. Phosgene can
be “trapped” in buildings where it dissipates slowly. Keep in mind that
IDLH conditions will affect the staffing requirements for the
downwind/perimeter monitoring person.

• Personnel and PPE decontamination procedures have to be included

in emergency plans. Before wearing PPE, the use of badges or direct
reading phosgene analyzers help evaluate whether phosgene is
present.

• Given the frequency of personnel turnover at hospital emergency

rooms, addressing medical procedures for offsite personnel can be
useful.

• The incident and drill critiques generate action items that can be
resolved in a timely manner.

• When developing written plans consider past incidents, near misses

and credible emergency situations that could arise. A detailed plan
for phosgene may be incorporated into the general site emergency
plan. Other practices that benefit response plants include:
familiarizing all employees in the phosgene process with the plan;
reviewing the plan on a periodic basis; and training the plant
emergency responders to handle phosgene emergencies.

20
Emergency Response Plan

a. The owner or operator shall develop and implement an emergency

response program for the purpose of protecting public health and the
environment. Such programs shall include the following elements:

1. An emergency response plan which shall be maintained at the

stationary source and contain at least the following elements:

(i) Procedures for informing the public and local emergency

response agencies about accidental releases;

(ii) Documentation of proper first-aid and emergency medical

treatment necessary to treat accidental human exposures; and

(iii) Procedures and measures for emergency response after an

accidental release of a regulated substance.

2. Procedures for the use of emergency response equipment and for

its inspection, testing and maintenance;

3. Training for all employees in relevant procedures; and

4. Procedures to review and update, as appropriate, the emergency

response plans to reflect changes at the stationary source and
ensure that employees are informed of changes.

b. A written plan that complies with other contingency plan regulations or

is consistent with the approach in the National Response Team’s
Integrated Contingency Plan Guidance (“One Plan”)

21
4.2 Fire

Phosgene is nonflammable. At temperatures above 250oC (482oF), phosgene

decomposes to form mixtures of carbon monoxide (CO), chlorine (Cl2), carbon
dioxide (CO2) and carbon tetrachloride (CCl4). In the presence of oxygen, the
carbon monoxide may burn to form carbon dioxide.

In case of fire and in the absence of phosgene leaks, the removal of cylinders
from the fire zone and immediately shutting off phosgene sources reduces some
potential risks. When containers cannot be moved and if no phosgene is
escaping , water has been sprayed on containers and piping to keep them cool.

Vessels and piping containing phosgene can be cooled with water spray. In such
cases, cooling may be imperative because boiling of the phosgene and
subsequent explosion of the vessel could create an extremely hazardous
situation.

The selection of sprinkler systems, firewater monitors or portable firewater

supplies is based on factors including the quantity of phosgene and the
requirements of the insurer and local fire marshal. Structural fireproofing where
phosgene is stored, piped and used may affect the requirements.

In case of fire associated with phosgene, it may critical to keep all authorized
persons upwind a safe distance from the phosgene area and all other personnel
evacuated from the area. Firefighting personnel may need respiratory protection
available.

4.3 Gaseous Leaks

As soon as there is any indication of phosgene present in the environment,

immediate steps to evaluate include stopping the release of gas/liquid and
simultaneously protecting personnel downwind including the community.
Indication of phosgene’s presence in the environment may come from personnel
or area monitoring systems, process control indicators or other sources.

22
 Authorized, trained personnel equipped with suitable protective equipment
should conduct the investigation. It is prudent to assume that Immediately
Dangerous to Life and Health (IDLH) conditions exist when responding to
emergencies.

Procedures for IDLH atmospheres. For all IDLH atmospheres, the employer
shall ensure that:

i. One employee or when needed, more than one employee is located outside
the IDLH atmosphere.

ii. Visual, voice or, signal line communication is maintained between the
employee(s) in the IDLH atmosphere and the employee(s) located outside
the IDLH atmosphere.

iii. The employee(s) located outside the IDLH atmosphere are trained and
equipped to provide effective emergency rescue.

iv. The employer or designee authorized to do so by the employer, once notified,

provides necessary assistance appropriate to the situation.

v. Employee(s) located outside the IDLH atmospheres are equipped with:

(A) Pressure demand or other positive pressure SCBA’s or a pressure

demand or other positive pressure supplied-air respirator with auxiliary
SCBA and either

(B) Appropriate retrieval equipment for removing the employee(s) who

enter(s) these hazardous atmospheres where retrieval equipment would
contribute to the rescue of the employee(s) and would not increase the
overall risk resulting from entry or

(C) Equivalent means for rescue where retrieval equipment is not required.

23
If the leak or spill is extensive or uncontained, sounding an evacuation alarm and
warning all persons in the path of the gas helps prevent further concerns. Pre-
arranged meeting points, crosswind or upwind, can be planned and used in
practice to help ensure everyone is accounted for. Gaseous phosgene often lies
close to the ground because it is heavier than air. Wind socks and
instrumentation indicating wind speed and direction can provide important
information for communication to those in the immediate area.

Relevant regulatory and community organizations should be notified as

appropriate.

The use of Safe Shelters sometimes provides a safer alternative to evacuation.

These designated buildings can provide greater safety by constructing them to
be relatively air-tight and under positive pressure, assuming the air intake is in a
phosgene-free area or can be filtered. These locations may be labeled, and
direction given to the occupants about procedures to follow when the Safe
Shelter is downwind as well as upwind. Persons entering a Safe Shelter
downwind of a release have been known to contaminate the building with
phosgene.

Anyone critical to the orderly shutdown of a process system that could be

downwind of the release, may require respiratory protection.

In case of fire and if only gaseous phosgene is leaking, water can be sprayed on
containers and piping to keep them cool. Water applied to the point of leak may
cause enlargement of the leaking opening because of corrosion. Consider
removing cylinders from the fire zone if possible and shutting off phosgene
sources immediately. Water fog may not be very effective in neutralizing
phosgene vapor, but can help reduce concentration in the air. Aqueous
ammonia spray may be more effective in neutralizing phosgene vapor, but
should be used with caution due to hazards associated with breathing high
concentrations of ammonia.

24
4.4 Liquid Spills

In case of fire and if liquid phosgene is leaking, firefighting foams have to be

used to cover the liquid spill until disposal. Water for firefighting should be used
with caution so as to avoid adding water to the liquid pool if at all possible. Liquid
phosgene reacts slowly with water to form carbon dioxide and hydrochloric acid.
The heat of reaction increases the vaporization rate of the liquid phosgene and
therefore may increase the potential hazard to personnel. Subject to such issues
and depending on overall circumstances, it still may be useful to spray containers
with water to keep them cool.

All of the requirements and considerations for handling gaseous phosgene leaks
also apply for liquid phosgene spills.

4.5 Mutual Aid.

Industrial plants in vicinity can help one another by establishing plans and an
organization for rendering mutual aid in the event of an emergency or disaster
such as phosgene spill or fire. As part of these efforts, making mutual aid
organizations thoroughly aware of the presence of phosgene in a facility
facilitates proper response and training. Staging areas (including alternates) may
be designated during the planning stage.

Phosgene emergency procedures that may involve persons outside the plant can
be incorporated in Mutual Aid Instructions and Public Department Procedures.

Written provisions may be included in the Mutual Aid-Private Industry Agreement

to allow for reimbursement for damages to equipment, manpower, etc.

4.6 Public Departments

In the absence of a structured Mutual Aid Organization or where local emergency

responders do not participate, including local emergency groups in any

25
 emergency plan may provide useful assistance. This inclusion would become
especially critical during a catastrophic event.

5.0 Design of Facilities

5.1 Plant Layout & Siting

The design layout of the phosgene plant is an important factor to be considered

for new construction. Aspects relevant to design layout include being located
near populated buildings, other operations and off site populations.

“Siting” means conducting a review of the location of equipment and piping with
regards to: 1) possible impact on human or environmental receptors, or 2) where
other plant operations could have impact on the phosgene equipment. In case
one, for example, design layout might consider such items as predominant wind
direction and populated areas down wind. In case two, the considerations might
include items such as any flammable or potential explosive processes, which – if
an event occurred – could have impact on the phosgene equipment.

The following section on Plant Siting and Layout Guidelines provides information
relevant to the design and layout of new or revised facilities. It is important to
note that the following criteria represent considerations often used by facilities
handling hazardous materials. However, given the highly toxic nature of
phosgene, during the construction of new phosgene handling facilities, or
significant modifications to existing facilities, facilities should also consider what
secondary mitigation measures may also be necessary or appropriate to address
the potential risk to local populations resulting from significant loss of
containment.

26
Items to consider may include:

A) Plant Siting

• Locating phosgene containing units with consideration of prevailing wind

direction as far as possible from the general community outside the site
boundaries.

• Protecting on-site buildings occupied by a large number of people through

a combination of engineering controls, administrative procedures and/or
distance.

• Locating phosgene generating and processing plants close together

within a site to minimize the spread of phosgene containing areas.

• Locating phosgene containing units away from other processes which

have potential for explosion of fire, or events which may impact or
damage equipment containing phosgene.

• Incorporating additional safety and loss prevention precautions if

phosgene must be transported across plant boundaries either by pipeline
or in pressurized container.

B) Plant Layout

• Providing that all sections of the plant are easily accessible for
maintenance and emergency response purposes.

• Locating phosgene generating or processing sections in plant areas with

low traffic density whenever possible and minimizing phosgene containing
pipelines.

• Having additional engineering controls for prevention and mitigation of

leaks from the equipment where plant sections have special process

27
 conditions, or where because of the surrounding situation, other controls
may be needed. Refer to those parts for additional information. Designs
that incorporate “layers of protection” rather than relying on a single
method of control are relevant in this capacity.

• Selecting the location of the control buildings in relation to the phosgene

containing sections and with considerations of the prevailing wind
direction. The selected location, having an elevated fresh air intake in the
control building and maintaining the building under positive pressure have
been used to minimize infiltration of phosgene in the event of a release.

5.2 Materials of Construction

Carbon steel is often used. Austenitic stainless steel, duplex stainless steel, and
high nickel alloys have also been used.

5.2.1 General Design Considerations

In this section, the design of process equipment for pure phosgene is

discussed. Unless otherwise specified, the information provided below
applies to the design of storage and non-storage vessels.

Phosgene processing equipment has been sited earlier above or below

ground depending on local conditions. Influencing factors include:

• Consequence of a major spill on the locality (e.g., the local population

and the weather conditions).

• Venting, draining, etc. of the immediate area if a major spill occurs.

• Risk from falling objects and accidental damage from other sources
(e.g., traffic).

28
• Risks from external vessel corrosion, (e.g., environment and ground
conditions if sited in a buried storage).

• Accessibility for vessel inspection (external as well as internal).

• Approachability to the vessel from all directions to allow access during

emergency conditions.

Above ground vessels may, however, be a desirable choice for future

installations unless special environmental conditions dictate otherwise.

Containment of Spills

Development of a containment area around phosgene processing

equipment can be used to help prevent an uncontrollable spread should a
leak occur. This area might be bounded by retaining walls with facilities
for the addition of absorbing chemicals, or be fitted with special drains
leading to vessels containing neutralization facilities and fume extraction
or any other measure that addresses potential conditions. The area
might also be fitted with a storm water drainage system that could be
manually controlled to lift water out of the containment area. The purpose
of this arrangement is to keep inadvertently released chemicals out of the
effluent system.

Trenches and Drains

To help prevent the spread of fire into a phosgene process area, maintain
an appropriate distance between the equipment and a service trench. A
similar distance should be considered between a drain and the
processing equipment unless the drain system is completely isolated from
any other drains that could transport flammable liquids.

29
 Vessel Design

Consider required pressure rating, operating temperature, and absolute

vacuum conditions within the vessel during design. A corrosion
allowance may also be incorporated into the design.

Users can take steps to help ensure that the vessels are protected
against over pressurization. High-pressure alarms serve in this capacity.
Set the alarm approximately mid-way between normal operating and the
burst disc failure pressure to give warning of a potentially dangerous
occurrence.

Extra protective devices may be required as a function of the site chosen

for the vessel. For example, the vessel may be double walled to reduce
the risk of damage from falling objects, corrosion and subsequent leaks.

5.3 Piping Items and Valves

5.3.1 Piping

Particular consideration should be provided with regard to the following

activities.

• Thoroughly purging all piping of phosgene prior to any welding. Dry

phosgene can support combustion of carbon steel and other metals,
and may pose a safety risk to personnel performing the welding.

• Protecting piping (and valves and instruments) from over

pressurization when liquid phosgene can be trapped between closed
valves.

• Protecting phosgene systems from the intrusion of moisture. Moisture

can react with phosgene and cause severe corrosion and failure.

30
• Taking measures so that the phosgene systems are thoroughly
cleaned, dried, and devoid of all oils, greases and other materials that
would react with phosgene to cause fire, corrosion, pressure increase
or harmful deposits.

• Inspecting all phosgene-piping systems at regular intervals for signs

of leakage, internal or external corrosion, and insulation failure. Note
that because piping supports can be subject to corrosion and can
create opportunity for other system integrity problems, including piping
supports within the inspection plan helps reduce risk.

• Where stainless steel materials are employed, inspections and testing

may include an assessment of stress corrosion cracking caused by
exposure to chlorides. Atmospheric exposure from the outside, as
well as process exposure from the inside can cause stress corrosion
cracking.

• Considering fugitive emission issues when designing piping systems

for phosgene.

• Adequately protecting liquid phosgene piping from liquid hammer

damage. Phosgene liquid has a high density that can result in large
hydraulic shock forces.

Selection

When making design decisions, the designer should consider such

items as variable operating conditions, including start-ups, upsets,
shutdowns and system evacuation.

The use of threaded joints in piping systems creates increased

potential for leaks, and the fittings are necessarily thinner because of
the requirement to taper the joints for threading. As a result, threaded
fittings tend to be generally avoided, if possible, but where threaded

31
 connections cannot be avoided, the use of a chemically compatible
thread sealant helps reduce some risks of leakage. Employ
fluoropolymer-based thread sealants in phosgene service.

5.3.2 Valves

Types of Valves

Valves commonly employed in dry phosgene service are the globe, ball,
plug and butterfly types. Each valve is available in several basic body
patterns, employing different design features often suited to a particular
service and/or specific application.

5.3.3 Other Components

Other components such as instrument items, relief devices,

decontamination hoses, temporary items, cylinders and expansion
chambers are described in their respective sections.

Expansion Joints

It is important to consider whether phosgene piping systems have

sufficient flexibility to prevent failure of the piping system due to thermal
expansion or contraction. When flexibility cannot be introduced into the
system through pipe routing, bellows expansion joints have been
employed to absorb the differential expansion while containing the system
pressure.

Hoses

It is not often that either metallic or non-metallic hoses are used in

permanent piping systems, and their use in permanent piping connections
may increase opportunity for leakage. When hoses are required for
temporary connections, give due consideration to the design, fabrication,

32
 testing and certification of all the components. British Standard BS6501
Flexible Metallic Hose Assemblies is one available source for additional
information regarding the hoses.

One approach has been to adopt using a hose that is consistent with
Chlorine Institute criteria, for phosgene cylinder connections to rigid
piping with a PTFE liner. These hoses are typically used in well
ventilated areas due to the potential permeability of the fluoropolymer
liner. Non-reconstituted (virgin) PTFE reduces the likelihood of
permeability. Contact the Chlorine Institute for further information on its
approval specification.

5.3.4 Piping Layout and Design

Good piping layout will enhance safety, reduce maintenance costs and
provide an efficient operation.

General Layout Considerations

• It is important to avoid trapping liquid phosgene between valves and
to provide expansion chambers or pressure relief.

• Arrange and support piping to permit removal of process equipment

and components.

• Installing phosgene lines next to steam lines, acid lines, etc. can
increase risk of corrosion. Protect phosgene piping from risks of
excessive heat or fire.

• Consider limiting the use of vent and drain connections in a phosgene

pipeline to the minimum strictly necessary for removal of dirt, liquid or
gas. However, company may wish to provide that all sections that
can be blocked in have sufficient connections for clearing the
phosgene.

33
• Consider providing for linear thermal expansion by routing or pipe
loops.

• Piping design can incorporate a means to minimize the possibility of

liquid hammer. Phosgene liquid has a high density that can result in
large hydraulic shock forces.

• It may be desirable to blind all dead-ended valves/openings.

• Layout of both process equipment and piping should consider

potential safety benefits resulting from minimizing the length and
diameter of piping in phosgene service and reduced phosgene
inventory

Clearances

Road and walkway clearances can be set to minimize the potential for
impact damages. Barriers or guardrails may be useful. Railroad and
roadway clearances may be regulated by state or local laws. If phosgene
piping must pass through a wall or bulkhead, the maintenance of proper
side clearances is important.

Supports

Use supports to prevent pipe sagging. It may be necessary to avoid

hanging other piping from phosgene lines and conversely, to avoid
hanging phosgene lines from other piping. Piping has been supported
with hangers, pipe shoes or other items that do not allow metal to wear or
corrode. If located in an area where seismic activity can be significant,
local codes may require special design considerations.

34
Routing
Route phosgene piping for the shortest distance practical with
consideration given to the flexibility, line expansion and good engineering
practice. Piping can be designed to avoid pocketing.

Valving

• Locate valves and controls in areas with adequate accessibility.

• Consider locating block valves as close to equipment as possible,

also in branch lines at the main header and, where practical, to allow
lines to drain away from the valves.

• Minimizing the use of valving can reduce some potential risks.

Tracing

Condensation can occur in gas lines when the temperature drops below
the pressure-temperature equilibrium. To help prevent this action, the
lines can be traced. Installation of tracing can be such so as to minimize
corrosion or decomposition of the piping system.

Electric tracing is a useful tracing method. Care must be taken to monitor

the condition of the electric tracing system to ensure localized hotspots do
not develop in the event of a wiring or control system failure.

Insulation

A key function of insulation is to provide a sufficient moisture barrier to

prevent corrosion under the insulation. Engineered access methods,
which do not compromise the system moisture barrier, have been used to
accommodate thickness testing or external inspection.

35
 Miscellaneous

• Connectors have been used in lieu of flange joints.

• Confusion can be reduced by readily identifying phosgene lines.
• Consider keeping the use of flange joints to a minimum.
• Elastomers, which have been used in piping components, should be
selected based on factors including relevant service and service
conditions.

5.3.5 Preparation For Use

Cleaning

Since phosgene can react with foreign materials, clean all portions of
phosgene systems before use. Care must be taken in cleaning
procedures to remove all residues because phosgene also reacts with
water. To this end, any equipment received in an oily condition should be
appropriately cleaned and thoroughly dried before use.

5.3.6 Leak Testing

Develop leak-testing procedures tailored to a particular need and

circumstance. Additional information on leak testing, such as ASME
B31.3, is available.

5.3.7 Drying

It is important to consider whether the phosgene piping systems are

adequately dried before being placed in service. Even if water has not
been purposely introduced into the system for hydrostatic testing or
cleaning, moisture may enter the system from the atmosphere or other
sources. Where steam has been used for cleaning, introduce nitrogen or
dry air directly after steaming. Heating the purge gas aids considerably in
the drying process. The temperature must be limited based on the

36
 equipment and insulation type, but for general reference purposes, 200oF
(93oC) has been a temperature previously used in some situations.

Vacuum dehydration can also be considered after the majority of phased

water has been purged from the system. This may be particularly
effective following the steam heating / nitrogen purge step, and can also
be used for leak checking the system.

Valves

Valves require special attention. Consideration should be given to valve

removal for disassembly and drying if water has entered the piping
system. Most valves, regardless of style, have pockets where water can
be trapped, especially if the valve is fully open. It can be important that
valves left in the piping system are fixed in the half-open position when
the system is being dried. To help ensure that water or moisture is not
trapped in a cavity,a check can be run on valves removed temporarily
from the system during the drying operation. These valves are thoroughly
dried prior to replacement in the piping system if they are not dried with
the rest of the system. Personal responsible for drying the system should
be familiar with valve construction and aware of places where water or
moisture can be trapped.

5.3.8 Preventative Inspection & Maintenance

Preventative Maintenance

As part of an over-all preventative maintenance program, consider

whether items, such as the following have been checked periodically and
corrected as needed.

• flange bolt condition and tightness

• valve packing leaks
• valve bonnet leaks

37
• valve operation
• threaded joints
• insulation condition
• tubing connections
• paint condition
• condition of supports
• external corrosion

Repainting on a regular basis will help maximize pipe life and minimize
leaks by reducing external corrosion. Timing for this activity is
determined by individual site conditions.

Periodic Inspections

Inspecting phosgene-piping systems on a regular basis reduces potential

risks. Methods include those such as visual inspections, ultrasonic
thickness checks and non-destructive radiography checks. In many
situations, the visual inspection is by far the most important inspection
that can be done with other methods used to supplement. Documenting
the results of all inspections helps provide for a thorough and consistent
maintenance program.

Visual

Part of a visual inspection may encompass a leak check of all flanges,

valves and other fittings and attachments. Particular areas of concern
may include items such as pipe supports and areas with paint or
insulation damage. Where insulation is damaged, further inspection is
often warranted. Special note may be taken of weld areas as these areas
corrode more quickly. Any significant observed pitting or wall loss merits
further investigation and correction as necessary.

38
 Non-Destructive Testing

Non-destructive testing methods measure pipe walls thickness, pit

depths, and internal and external erosion/corrosion. These methods
include ultrasonic thickness measurements and radiographic
measurements.

Routine testing will indicate corrosion rates typical for the system so that
the timing of major reports can be estimated. Consideration should be
given to checking areas of high fluid velocity more frequently due to
possible internal erosion.

Radiographic techniques are available to check pipe wall thickness

through insulation. This approach permits checking piping systems
without breaking the vapor barrier of the insulation. If test methods are
used which require the removal of insulation, care must be taken to
address whether the insulation vapor barrier integrity has been properly
restored.

5.4 Pumps

5.4.1 General Guidelines

All pumping equipment should be designed to provide reliable operation

and a high certainty of containment. The information set out in the
following identified sections also provides general guidelines relevant to
the specification and design of the pumping system: 5.2 Materials of
Construction; 5.3 Piping Items and Valves; and 5.5 Instruments.
Additional information is included in Section 5.4.5.

Several common options available to pump phosgene are addressed

here. As with other sections of the Manual, users have an independent
obligation to conduct their own analysis for their specific circumstances as
alternative or additional considerations may be required.

39
5.4.2 Mechanically Sealed Pumps

Where mechanical seals are employed for containment, a double seal

with some type of pressurized barrier fluid should be considered. The
use of protective systems helps ensure that the seal and pump function
correctly. Local and remote indications are more useful than no
monitoring or local monitoring only.

Evaluate whether all gasket and O-ring materials are compatible with the
process fluids. Concerns have been raised over graphite being more
permeable than other gasket materials. The resulting leakage over time
combined with atmospheric moisture has caused corrosion to take place
on bolts where it is difficult to monitor.

Screwed connections are more prone to leaks. They also appear weaker
in resisting pipe strain and external forces because of concentrated
stresses in their thread roots. Threaded connections in phosgene service
may be undesirable.

Casing drains can reduce or eliminate trapped phosgene in equipment

that must be serviced. Installing a sufficient quantity at the proper
location can allow almost complete draining of the pump prior to
decontamination and maintenance.

Many manufacturers offer hydro testing as a method of testing their

casings, and pumps to be used in phosgene service can use this service.
Vessels have been tested to 1.5 times their working pressure and this
reference may offer a useful pressure for these pump parts as well.
Documentation of the hydro test, for record keeping, can reduce potential
difficulties. Additional inspections to help ensure the integrity of the
casing include dye penetrant, x-ray or helium leak tests. Other casting
specifications can be added that will also require additional testing.

40
 Pumps function most efficiently and reliably if they are operated near their
design flow.

For pump protection, instruments are available that measure, monitor or

indicate some of or all of the following:

• Suction pressure
• Discharge pressure
• Seal fluid pressure
• Seal fluid flow
• Seal fluid level
• Vibration
• Minimum flow protection
• Supply level trip
• Power level

5.4.3 Differential Pressure

Where practical, phosgene can be moved via differential pressure.

When possible, as with a new design, a combination of differential

pressure, and gas only, may reduce the possibility of leaks, save
maintenance efforts, and reduce the quantity that can be released.

5.5 Instruments

5.5.1 Introduction

The Instruments section provides a general description of

instruments and control systems utilized in phosgene service. It
also provides tips regarding operation and maintenance, as well
as information regarding less than successful applications
employed in the past.

41
5.5.2 General Description

Phosgene producing or phosgene processing units should be operated in

a manner that provides protection for personnel and the environment.
Instrumentation complements piping and mechanical systems to help
provide for safe and reliable operation.

It is expected that the process will be controlled and remain within the
vessels, equipment, piping, instruments and/or analyzer systems. A goal
of the instrument design effort is to eliminate or minimize potential
leakage points. This is often accomplished by minimizing leak paths in
instrument installations, frequently with the use of inline instrument
devices.

Other goal of instrument design efforts for phosgene service include

providing for the reliability of instrument systems and devices, utilizing
reliable technologies and methods, and providing for safe access and
maintainability of the instrument system and devices to minimize
personnel exposure to phosgene.

The goal of providing safe access for maintainability of the instrument

system may sometimes create inconsistencies with the goal of minimizing
leak paths. Maintainability is often enhanced with the use of flush/purge
fittings or devices. These installations tend to add more valves and
fittings, and hence possible leak paths. “Minimizing leak paths” without
maintainability will often require removal of an instrument device with a
small “controlled” release to a recovery system. Individual company
policies and/or practices will provide guidance for achieving these
seemingly conflicting goals.

The design/application of inline instrument devices or hardware utilized in

phosgene service should consider all the process conditions and other
materials in the process stream in selecting the most suitable/appropriate

42
 materials of construction for the instrument device or hardware. Material
selection for instruments in contact with phosgene varies depending on
overall process stream requirements and other specific factors.

5.5.3 General Design Installation Issues

As part of evaluation the following have to be considered:

Evaluation the use of inline devices whenever possible.

Eliminating (minimizing) leakage points to the atmosphere for

instruments in phosgene service.

Minimizing screwed (national pipe thread, NPT) process connections

and tubing and fittings in contact with phosgene or its reactants as
non-threaded process connections provide less potential for leaks (i.e.
evaluate the use of welded or flanged connections whenever
possible).

Evaluating common Mode Failure possibilities and taking steps to

eliminate as many as possible.

Utilizing “fail-safe” components and methods whenever possible to

drive the process to a safe on loss of energy.

The use of a process isolation valve for all instrument devices in

phosgene service that are not of inline design may allow for safe
removal of instruments for maintenance.

Histories of reliability should be reviewed in technology selection. The

use of smart transmitters, valves with smart positioners, etc., may
assist online diagnostics and maintenance.

43
 Instrument devices are often installed to allow flushing and
decontamination, purging and/or venting before removal of equipment
for calibration and/or repair.

Redundant systems, when used, often include redundant elements

from sensor to control processing to final control elements.

Support for instrument devices and their auxiliaries are designed to

protect against mechanical damage. One example is a small bore
extended branch trees with extended moment arms.

Incorporating self-monitoring and/or error reporting elements (“smart

instruments”) into phosgene indication, control, interlocking, and/or
alarming strategies can help identify some potential problems.

Periodic checks, calibration procedures (including function check),

and reporting methods have been used for instrument devices
deemed critical to safety to the process (as identified by PHA analysis
or other method).

Instrument devices are often specified and installed with consideration

given to maintenance, calibration and testing requirements, both on
line and off line.

Transmitter specified for phosgene applications can be designed to

handle vacuum service required for equipment evacuation.

5.6 Relief Devices

5.6.1 Introduction

Relief devices are used to help prevent a catastrophic failure of

equipment and/or minimize the effects of any unanticipated or
uncontrolled events. As such, relief devices generally serve as

44
 emergency devices not used for normal process control. Relief devices
are used for individualized equipment as well as equipment assembled as
part of a chemical process. Relief devices are designed to protect a
vessel or system from excess pressure by removing or relieving fluid from
that vessel or system. Relief devices however are not the only method
for over-pressure protection. Equipment and/or process designers also
consider the causes of over-pressure as well as the appropriate pressure
disposal system during the process design stage. Some considerations
during this stage may include:

• Design of process equipment such that there are no credible

scenarios, which exceed the maximum allowable working pressure of
the equipment, possibly eliminating the need for an over-pressure
protection device.

• Design of process equipment to minimize the venting / relief rate

through the over-pressure protection device, possibly reducing the
size of both the relief device and the connected disposal system.

• Design of process equipment such that a single common over-

pressure protection device protects several pieces of equipment,
possibly reducing the number of relief devices.

5.7 Secondary Containment

5.7.1 Introduction

Proper design and installation of phosgene handling equipment is

essential in preventing phosgene leaks and accidents. Proper design
installation, along with an effective maintenance program and operator
training, enhances the safety of phosgene operations.

However, to further increase the safety level of the operation, employ

“secondary containment” systems. The purpose of these secondary

45
 systems is to provide a “safety net” in order to prevent chemical releases
to the open atmosphere. Examples of secondary containment include
double walled construction, structural airtight enclosures, dump tanks and
containment vaults. A description of each type follows:

5.7.2 Double Walled Construction

These types of systems are often called a “pipe within a pipe” or “wall
within a wall”. The design concept is essentially a two-layer approach
where the inside layer or inside wall is in contact with the chemical and
the outside layer and the outside layer or outside wall surrounds the inner
layer. The void or plenum area between the walls is often monitored for
chemical leakage. Sometimes this area is filled with a gas such as
nitrogen to prevent moisture build-up.

Double walled systems also provide protection against foreign object

impingement or contact. The same principle is sometimes used in the
transportation industry for railcars and barges.

5.7.3 Structural Enclosures

Structural enclosures can be described as a sealed building or box. From

the outside, these enclosures may appear similar to other buildings in the
operational process. However, they will normally have special features,
such as an air tight seal, possibly maintained under vacuum with
ventilation to a scrubber, controlled access, and dedicated leak detection
monitors.

The material of construction can vary from standard concrete blocks to

special “cocoon” sealed corrugated metal to fully welded steel sheets. No
matter what the materials of construction, the success of the enclosure or
box depends upon its ability to fully contain any phosgene leaks and
direct them to a safe neutralization system.

46
 Some cautions when using enclosures involve the possible containment
of process flammables such as carbon monoxide or hydrocarbons and
the possible need to use of PPE when entering a sealed enclosure.
These factors are considered in the design of the enclosure as well as in
development of procedures and special steps for maintenance activities
inside an enclosure.

5.7.4 Dump Tanks

Dump tanks can be used to transfer a liquid mixture from the process
vessel to an emergency holding or containment vessel. In most cases,
dump tanks are not used for any other purpose. They are sized to
contain the largest applicable operating volume and normally remain
empty. Transfer to the dump tank can be either manual or automatic and
by either process pressure or with nitrogen pressure. Due to the special
nature of most phosgene processes, dump tanks are not routinely used.

5.7.5 Containment Vaults

A vault can be described as an underground pit designed to contain a

liquid spill. The spill would be directed into the valve vault where it would
be contained and vented or purged to a neutralization unit. Most vaults
remain water or moisture free. Also vaults have limitations are not usually
effective for gas release containment.

Because of the special nature of most phosgene processes, vaults are

not routinely used.

Pluses Minuses
Double Excellent impact Sometimes extremely
Walled protection difficult to locate point of
Easy to maintain leak
Reliability of Difficult to repair internal
containment wall

47
 Capable of continuous Focused secondary
leak monitoring of containment
plenum area
Enclosures Reliability of Operational &
containment maintenance cost
Can encompass large Special personnel
processing sections procedures used
Quick detection of leaks Extends maintenance
possible duration

Dump Provide focused Dedicated for liquid

Tanks containment processes
Limited purpose.

Vaults Provide focused Underground

containment Limited purpose
Must remain moisture
free

5.8 Mitigation Systems

Mitigation methods are used to reduce the overall impact of an accidental

release. The methods listed below provide varying degrees of mitigation success
from complete mitigation to unquantified partial mitigation methods. Mitigation of
phosgene is difficult because of the chemical properties of phosgene

In relative terms, phosgene is slow to hydrolyze when exposed to water whereas

other halogen compounds tend to react very quickly with water. This
characteristics represents a key understanding for emergency response and
HAZMAT personnel’s awareness.

Another concern is that hazardous concentrations of phosgene may not be

visible because the vapor tends to be transparent unless the concentration is

48
very high. This issue depends on the atmospheric conditions at the time of the
release.

Phosgene also tends to accumulate in low-lying areas. For instance, phosgene

will often be found in drainage systems located in affected areas of release.

5.8.1 Fugitive Collection Systems

5.8.1.1 Vacuum Systems

Generally, there are two different types of vacuum systems

employed for handling of fugitive phosgene emissions

5.8.1.1.1 Spot Ventilation Systems

A spot ventilation system typically consists of a circuit or

header of “elephant trunk” drops connected to a large
volume-blower and discharges to a phosgene mitigation
device. The flexible hose of an elephant trunk drop is
positioned near the fugitive source, pulling the emission
away to a mitigation device. This type of system can serve
the following purposes:

Capture, contain, and mitigate low levels of fugitive

phosgene resulting from a minor loss of containment
event (e.g., a small valve-packing leak).

Capture, contain, and mitigate low levels of fugitive

phosgene which may result during the process of
verifying equipment is clear prior to any maintenance
breaking and entering activity.

49
 5.8.1.1.2 Permanent Ventilation Systems

The second vacuum system is typically associated with

clearing contaminated process equipment prior to any
maintenance disassembly activities. This vacuum system
has consisted of either temporary or permanent piping
connected to process equipment, with a vacuum pump
capable of pulling deeper vacuum. As part of the overall
strategy for clearing and maintenance preparation,
phosgene and other contaminants are vaporized under a
deep vacuum, captured in the vacuum system and
discharged to a phosgene mitigation device.

5.8.2 Phosgene Neutralization Systems

5.8.2.1 Caustic Scrubbers

Caustic scrubbers provide a method for mitigation of a phosgene

release. Within the category of caustic scrubbers, there are
several different types of scrubbing towers.

The basic caustic scrubbing system is comprised of a caustic

source feeding a scrubbing tower. The tower is either an open
contact type tower or a packed tower.

Key operating parameters for operation of a caustic scrubber

include: the maximum flow rate of phosgene expected from the
process; the maximum duration of the release to the scrubber;
the concentration of caustic available for scrubbing; and the
circulation or flow rate of caustic into the scrubbing tower.

50
5.8.2.1.2 Dispersion Stacks

A robust phosgene destruction system design, installation,

and operating procedures represent the primary option of
controlling phosgene emissions. However, an elevated
dispersion stack may be used to provide an additional
layer of defense in the event of phosgene breakthrough
from the primary phosgene destruction system. In the
event the destruction system is unable to completely
neutralize the phosgene, the exit gas can be dispersed at
an elevated location with the intention of reducing the risk
to personnel in the general vicinity. A high volume air
blower can be used to elevate the gas velocity through the
stack, enhancing the dispersion capability. Dispersion
modeling software can be employed to estimate any
potential impact of a fugitive phosgene emission, taking
into consideration the environmental conditions, such as
wind speed and direction. Materials capable of
withstanding corrosion resulting from mixing phosgene with
moisture in the air are available for dispersion stacks and
related equipment.

In addition, an online phosgene analyzer can be used to

help ensure appropriate regulatory limits are not exceeded.

5.8.2.1.3 Emissions and Controls

Potential process emissions from the production of

isocyanate include phosgene, hydrogen chloride, aromatic
and aliphatic solvents, aromatic amines, aromatic nitrogen
compounds, isocyanates, nitrogen oxides and sulphur
oxides. Because these emissions include a number of toxic

51
 and corrosive chemicals, controls are necessary (as shown
in figure given below) would include:

1. A water scrubber to remove and recover hydrogen-

chloride.
2. A caustic scrubber to provide removal of VOC and
CoCl2 from the water scrubber as well as to remove
VOC from the nitration and distillation processes.
3. An incinerator for volatile organic compound
4. A second caustic scrubber for treatment of the
incinerator exhaust to remove residues from the
combustion of chlorinated hydrocarbons.

HCl, VOC, Stack

COCl2 Exhaust

Caustic Caustic
Water
Scrubber Incinerator Scrubber
Scrubber
A B

Recovered Spent Caustic Spent

Water Caustic Fuel Air
HCl Caustic Caustic

52
5.9 Inspection & Testing

Maintaining the integrity of phosgene handling systems is of the utmost

importance. This section outlines common practices for inspecting and testing
phosgene system equipment, piping and vessels. The objective of inspection
and testing practices is to eliminate phosgene releases by preventing failures in
these components.

5.9.1 Inspection & Testing During Operation

This section outlines techniques commonly used to inspect and test

phosgene-containing process equipment while in operation. The
methodologies and frequencies listed are to be considered only as
references for additional consideration. Users must develop their own
inspection methodologies and frequencies based on their specific needs
and circumstances. Local regulations, design codes, and plant history
are among the factors that must also be considered in developing
appropriate inspection methodologies and frequencies.

Inspection Methodologies and Frequencies

During Operation
Equipment Sample Methodology Sample
Type Frequency

Process Visual inspection has to be used for Annually

Equipment observing the signs of corrosion,
leaks, condition of paint, and condition
of structural support (e.g., pipe
hangers, I-beams, etc.)

Rotating Testing that has to be performed: Vibration –

Equipment Vibration measurement Monthly to semi-

53
 Inspection Methodologies and Frequencies
During Operation
Equipment Sample Methodology Sample
Type Frequency

annual

Fugitive emission testing of seals, Emissions

tubing, and flanged connections Quarterly to
Yearly

Piping Thickness measurements (TMs) have Thickness

to be performed to check integrity and measurements –
estimate corrosion rates. The intervals from 1
thickness measurements have to be to 5 years, based
done using ultrasonic or radiographic on remaining life
methods. Areas frequently checked and corrosion
for thickness include elbows, rates
downstream of valves and welds,
branches, turbulent areas, dead legs,
injection points and the small end of
reducers

Piping including connections and Visual - Annually

flanges, has to be visually inspected
for installation of the correct gasket,
gasket condition, signs of leakage,
paint condition, and the presence of
corrosion under insulation (CUI).
Profile radiography has to be used to
identify corrosion insulation without
having to remove the insulation.
Suspect areas for corrosion under
insulation have included low points on

54
 Inspection Methodologies and Frequencies
During Operation
Equipment Sample Methodology Sample
Type Frequency

vertical piping runs, areas where

insulation is altered to fit valves,
branches, fittings or areas where
insulation is damaged/uncovered.
Areas of operating temperatures
between 140oF to 280oF (60oC to
137.7oC) and intermittent operation
have also warranted focus.

Relief Visual inspection has to be used to Annually

Devices inspect for signs of leakage or
corrosion of bolts, holders, etc.
Vessels, Thickness measurements have to be Thickness
Pressure & used to check integrity and estimate measurements –
Low/No corrosion rates. The thickness based on
Pressure measurements have to be done using remaining life
ultrasonic or radiographic methods.
(Note: Be sure that the diameter size
of the vessel does not exceed the
capability of the radiographic
methodology. Consider appropriate
locations for establishing specific
thickness measurements)
Visual – Annually
Visual inspections and profile
radiography (on small vessels) have
to be used to identify corrosion under
insulation. Suspect areas for
corrosion under insulation have to be

55
 Inspection Methodologies and Frequencies
During Operation
Equipment Sample Methodology Sample
Type Frequency

included vessel skirts, insulation

support rings, and areas where
insulation is altered to fit valves,
fittings etc. Areas of operating
temperatures between 140oF to 280oF
(60oC to 137.7oC) and intermittent
operation have also warranted focus.

The seam between tank bottom and

support pad has also to be visually
inspected for damage to the sealer
Valves, Visual inspections have to be used for Visual – Annually
Flanges, the following:
Fittings, & Gasket and bolt condition
Tubing Packing condition
Paint condition
Support condition
Abrasion and crimping (tubing)
Sign of leakage

Connections, flanges, fittings, and Emission -

valve packing have also to be tested Quarterly
for fugitive emissions.

Profile radiography has to be used on

certain valves to determine if there is
erosion or corrosion. This can help
identify items to repair prior to
turnarounds. (Note check whether the

56
 Inspection Methodologies and Frequencies
During Operation
Equipment Sample Methodology Sample
Type Frequency

size of the valve exceeds the

capability of the radiography
methodology

5.9.2 Inspection & Testing During Maintenance / Turnarounds

This section outlines commonly used techniques to inspect and test

phosgene-containing process equipment during maintenance and
turnarounds. The methodologies and frequencies listed are to be
considered only as references for additional consideration and are based
on historical data from major phosgene manufacturers. Users must
develop their own inspection methodologies and frequencies based on
their specific needs and circumstances. Local regulations, design codes,
and plant history are among the factors that must also be considered in
developing appropriate inspection methodologies and frequencies.

Inspection Methodologies and Frequencies

During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

All process Visual inspection to be used At each repair or

Equipment observing for signs of corrosion, turnaround
leaks, condition of paint, and condition
of structural support (e.g., pipe
hangers, I-beams, etc).

Rotating Testing that has to be performed: At each repair or

Equipment Coupling inspection & alignment turnaround

57
 Inspection Methodologies and Frequencies
During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

Leak testing of seals, tubing and

flanged connections
Internal inspection for casing
erosion and corrosion

Piping Thickness measurements have to be At each repair or

performed to check integrity and turnaround
estimate corrosion rates. The
thickness measurements have to be
done using ultrasonic or radiographic
methods. Common areas checked for
thickness have included elbows,
downstream of valves and welds,
branches, turbulent areas, dead legs,
injection points and the small end of
reducers.

Piping including connections and

flanges, has to be visually inspected
for installation of the correct gasket,
gasket condition, signs of leakage,
paint condition, and the presence of
corrosion under insulation (CUI).
Profile radiography has to be used to
identify corrosion insulation without
having to remove the insulation.
Suspect areas for corrosion under
insulation have included low points on
vertical piping runs, areas where

58
 Inspection Methodologies and Frequencies
During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

insulation is altered to fit valves,

branches, fittings or areas where
insulation is damaged/uncovered.
Areas of operating temperatures
between 140oF to 280oF (60oC to
137.7oC) and intermittent operation
have also warranted focus.

Inspection tools such as a boroscope

have to be used to internally inspect
piping for signs or corrosion or erosion

Welds have to be inspected for stress

cracking using dye penetrant or eddy
current. Areas of concern have
included welds that experience high
loading or high vibration.

Relief Activities of rupture disks have to be 1 to 2 year

Devices included: intervals
(including Inspect holder & bolts for corrosion
rupture Inspect disk for corrosion or other
disks and mechanical defects to check
pressure / correct material selection
vacuum Check piping for blockage
relief Replace disk
valves)
Activities for pressure or vacuum relief
valves have been included:

59
 Inspection Methodologies and Frequencies
During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

Tested set pressure (not while

installed)
Inspected packing, seats, bolts,
and gasket surfaces for corrosion
or other mechanical defects
Checked piping for blockage
Looked for signs of leakage

Vessels, Thickness measurements have to be External – ¼ of

Pressure & performed to check integrity and remaining
Low/No estimate corrosion rates. The
Pressure thickness measurements have to be
done using ultrasonic or radiographic
methods. Consider appropriate
locations for establishing specific
thickness measurements. Eddy
current has to be used to check
integrity of tubes.

Visual inspections and profile

radiography (on small vessels) have
to be used to identify corrosion under
insulation. Suspect areas for
corrosion under insulation have to be
included for vessel skirts, insulation
support rings, and areas where
insulation is altered to fit valves,
fittings etc. Areas of operating
temperatures between 140oF to 280oF

60
 Inspection Methodologies and Frequencies
During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

(60oC to 137.7oC) and intermittent

operation have also warranted focus.

Internal inspections have to be used

to visually identify pitting of the base
metal and condition of the welds.
Stainless steel alloy welds have to be
inspected to dye penetrate or eddy
current to identify stress corrosion
cracking. Welds that experience high
loading or high vibration have often to
be areas of concern. Examples
include piping connections, seam
welds, and tray supports.

The internal inspection has also to be

used to check the integrity of tank
bottoms that cannot be externally
inspected. Thickness measurements
have been taken to identify areas of
thinning or corrosion between the tank
bottom and tank pad.

Valves, Critical isolation valves and valves in As with other

Flanges, solids or high velocity service have to timetables,
Fittings, & be internally inspected to check for frequency varies
Tubing corrosion/erosion and seat condition. with previous
These isolation valves have also to be experience.
pressure-tested to check sealing Areas of high

61
 Inspection Methodologies and Frequencies
During Maintenance / Turnarounds
Equipment Sample Methodology Sample
Type Frequency

integrity. solids or erosion

may be checked
Profile radiography has to be used on more frequently.
certain valves to determine if there is
erosion or corrosion. This can help
identify items to repair prior to
turnarounds. Check whether the size
of the valve exceeds the capability of
the radiography methodology.

5.9.3 Commissioning Equipment

This section includes common techniques for checking system integrity

prior to and following installation, repair, or turnaround of equipment and
systems. Local regulations may require a combination of several of these
techniques or alternative methods.

An inspection of equipment and valves prior to installation can help

prevent future failures and leaks. This inspection frequently consists of
verifying appropriate materials of construction, gasket material, and
lubricants. During the installation or assembly process, proper bolt
torquing is important to ensure the integrity of connections.

Once installation or repair work is complete, a visual inspection can be

used to help verify system integrity. This visual inspection evaluates that
correct gaskets are used, all flanges and connections are tight,
instrumentation is installed, and that no open connections or drains exist.
The visual inspection is often followed by cleaning or flushing to remove
trash and debris. This cleaning has been done with compressed gas

62
(e.g. nitrogen or air) or with a fluid. One benefit to using a fluid wash is
that some instrumentation can be functionally tested. An acid flush may
be necessary for carbon steel equipment to reduce iron content in the
product. Draining and blowing the system clear following a fluid wash
removes free-standing liquid and minimizes corrosion.

The procedures described above help prepare the system for a rigorous
integrity test. The integrity tests are commonly referred to as “pressure
tests” or “ leak tests.” Available integrity tests for piping and equipment
systems include: (a) hydrostatic tests, (b) pneumatic tests, and (c)
sensitive leak tests. Generally, a hydrostatic or pneumatic test is
performed on repaired or new piping and vessels, and then a sensitive
leak test is performed on equipment that was opened or repaired during
the maintenance / turnaround. Each test method will be described in
more detail below.

Hydrostatic Testing

A hydrostatic test is frequently performed on new or repaired piping and

vessels. In this test method, the vessel and/or piping is pressurized with
a fluid (e.g. water) up to or slightly above design pressure. A hydrostatic
test helps verify that the repaired or new vessels and piping can withstand
the design pressures.

A hydrostatic test does not provide many clues as to the actual condition
of the vessel. Unknown factors such as flaws, corrosion, metal loss in
heat affected zones of the welds, poor weld fusion or lack of penetration,
cracks in weld seams, or de-lamination of plates are, for the most part,
undetected by hydrostatic testing.

Repeated hydrostatic testing can shorten the fatigue life of the vessel
because it applies close to yield level stresses to small cracks or flaws
that may be developed over time by cyclic stresses. Thus, the hydrostatic
test method is not often used for routine inspections. As discussed

63
above, in many cases, it is only performed on new or repaired piping and
vessels to help ensure the integrity of welds and connections.

Also, careful development of the test procedure helps prevent damaging

equipment due to over pressure. American Society of Mechanical
Engineers Code B31.3 provides further information relating to the test
parameters. Questions often considered include:

Is other equipment to be tested at the same time or to be included in

the same test? If no, then has the equipment been properly isolated
for the test?
Will the testing exceed the maximum allowable working pressure
(MAWP) of the equipment?
What are the test-acceptance criteria, including duration and gauge
errors?
Who needs to witness the test?
Is overpressure protection required?
Are redundant gauges installed?
What measures are in place to ensure that all air is purged through
high point vents to prevent equipment damage or personal injury?

Note: The chemistry of the fluid used in the hydrostatic test is

important in preventing corrosion of carbon steel and stress
cracking of stainless steel.

Pneumatic Testing

The use of pneumatic testing requires special consideration because of

the potential dangers associated with the stored energy of the
compressed gas involved in the test. Pneumatic testing is often only
used when hydrostatic test is undesirable because of concerns over
moisture in the piping and vessels. A pneumatic test involves pressuring
the vessel and/or piping with a compressed gas up to or slightly above
design pressures.

64
Like hydrostatic testing, pneumatic testing can shorten fatigue life, or
damage equipment and injure people if performed improperly. Thus, it is
often only performed on new or repaired equipment to help verify the
integrity of welds and connections. The precautions listed in the
Hydrostatic Testing discussion above are commonly considered in
pneumatic testing a well.

Sensitive Leak Testing

Sensitive leak tests are commonly used in phosgene services because

they can detect very small leaks that may go undetected during
hydrostatic or pneumatic leak tests. Examples of sensitive leak tests
include helium leak tests, ultrasonic leak tests, and anhydrous
hydrochloric acid (HCl) tests.

Helium leak testing consists of adding a small volume of helium to the

system, followed by a larger quantity of nitrogen. A helium mass
spectrometer is then used to detect for leaks.

Advantages of helium testing:

Very little fatigue on the equipment.
Helium testing is a more sensitive test. It can identify more leaks than
water or air.
The equipment is portable
Decreased risk to health or environment

Disadvantages of helium testing:

Operators must be properly trained.
The test can be very slow, as you must wait for helium to travel
through the vessel.
Equipment and/or contractors can be costly.

65
Ultrasonic testing consists of pressuring up the system with nitrogen or
compressed air and then using a high frequency sonic leak detection
device to detect leaks. The sonic leak detector is used to detect leaks at
welds, seams, joints, and any other areas of possible leakage. Sonic leak
detectors with a detection frequency range of 20 kHz to 100 kHz have
been used previously.

Advantages of ultrasonic testing:

Simplicity.
Little fatigue on the equipment.
High sensitivity relative to hydrostatic or pneumatic tests.
Low costs.

Disadvantages of ultrasonic testing:

Not as effective in finding leaks in large systems.
Sensitive to environmental conditions, especially wind.

Anhydrous HCl testing consists of adding bottled anhydrous HCl into the
piping/equipment to a low pressure. Once this is complete, the system
pressure is raised using a solution of ammonia water. This should create
smoke at the connection if the HCl is leaking from the pressurized
system.

Advantages of HCl testing:

Little fatigue on the equipment
HCl testing is a sensitive test and provides visual indication of the
leak.
The bottled HCl is portable

Disadvantages with HCl testing:

Operators must be properly trained.
Hazardous properties of anhydrous HCl.

66
 Before Startup

After testing, it is important to dry the equipment before returning to

service. If the equipment is not dried, HCl will be formed and corrosion
may occur.

5.9.4 Certification & Training Requirements for Non Destructive Testing

(NDT) Inspectors.

It is important to consider training and qualifications when selecting an

inspector. Properly qualified inspectors can help in developing an
inspection plan and interpreting the results. The American Society for
Nondestructive Testing (ANST) offers information on testing personnel
qualifications and certifications. Local regulations may also define
specific requirements.

5.9.5 Record keeping

Maintaining accurate inspection records for vessels, piping, and

equipment facilitates inspection and testing operations, and is often
required by local regulations. These records can be used to determine
future inspection intervals and repair methods. Information often kept in
these records includes:

Original design details of the equipment (e.g., design code, fabrication

drawings, materials of construction, capacity, chemical service,
operating conditions)

Procedures for safely and effectively performing external and internal

inspections, including preferred inspection methods.

Results of previous inspections and corresponding repair

recommendations.

67
 Procedures and details of any vessel repairs or changes of chemical
service.

Local regulation may define record retention rules. Frequently, these

records are retained for the life of the equipment or longer.

6.0 Equipment Cleaning and Repair

6.1 General

Because phosgene is a highly toxic material, extraordinary caution is required

when working on or entering equipment used in phosgene service. Cleaning and
maintenance are potentially hazardous activities that should be performed only
by workers who are thoroughly familiar with the dangers involved and the
precautions necessary for safe performance of the work. For this reason, the
importance of proper training, an understanding of hazard recognition, and a
soundly planned approach to each job cannot be overemphasized.

The following sections provide an overview of procedures and techniques used

to prepare phosgene equipment for maintenance and return the equipment to
service, and offer information on issues that might arise during the repair work
itself.

6.2 Preparation for Inspection or Repair

When a phosgene system is to be cleaned or repaired, empty the system of

process liquids and gases containing phosgene. Following equipment shutdown,
remaining liquids and gases should be transferred to other process equipment in
the plant either by pumping or by pressuring off with a dry, inert gas, such as
nitrogen, supplied at a pressure higher than that on the equipment to be cleared.
Once this has been accomplished, it is useful to valve the system and vent the
remaining pressure to a destruction or decomposition device, such as a caustic
scrubber. During depressurization, the frosting of piping, etc., which has been in

68
 liquid phosgene service, indicates it still contains liquid. External application of
heat can expedite the clearing process and may be a necessity when cold
weather retards or even prevents evaporation of phosgene at atmospheric
pressure. However, heating a closed system containing liquid phosgene may
produce excessive pressure so close monitoring helps protect against potential
risks.

After the equipment has been depressurized and is liquid-free, pull the
equipment under vacuum and install steel slip blinds at the isolation points to
prevent phosgene from leaking back through the blocked valves from other parts
of the system (note: if plans call for the use of purging for clearing purposes, the
vent line would be left unblended). Consider locating the blinds as close as
possible to the isolating block valves because a leaking valve may fill the space
between the blind and the valve with liquid phosgene, which will then be released
when the blind is removed. It may be advantageous to connect the vacuum to a
high point on the system, but not at a drain valve if at all possible, because low
points are prone to pluggage. When removing full face blinds or plugs located on
bleed valves where the vacuum connection would be made, exercise appropriate
caution because liquid phosgene can be trapped behind them. Before installing
blinds, it may be important to verify that the system is under vacuum by reading
an appropriately ranged pressure gauge or by cracking open a bleed valve.

` After blinds are installed, use a dry, inert gas to purge the remaining phosgene
vapors to the vent system. For larger systems, which are solid-free, the use of
heated inert gas can sometimes be more effective at purging. Once the system
is clear, the vent line itself can be blinded to help complete the isolation. For
difficult-to-clear equipment, additional options for consideration include flushing
with water, weak aqueous ammonia, caustic or anhydrous ammonia (only done
after the blinds have been installed and the system vented). Water flushing,
following the use of ammonia or caustic, serves an important function to help
eliminate those contaminants. Dispose of the resulting vent or waste stream in
an environmentally responsible manner consistent with relevant requirements.

69
Safety should always be the primary consideration when clearing phosgene
process equipment. The use of air-supplied respiratory protection is necessary
for any activity where exposure to phosgene is a concern. Clear appropriate
areas of unprotected personnel whenever performing work requiring breathing
air.

Prior to beginning maintenance work, plant operations personnel can help verify
that the equipment has been cleared of phosgene by cracking open a bleed
valve and checking for the presence of phosgene using a detection badge or
other hand-held detection device. The system may need a slight positive
pressure in order to check for the presence of phosgene. It is important that the
system is depressurized completely before maintenance loosens the first bolt.

As part of the evaluation, keep in mind that process solids that come into contact
with, or are suspected of coming into contact with, phosgene may contain
trapped phosgene. When solids are agitated, crushed, or blasted, there is
potential for phosgene to be released.

The preceding information on clearing relates to equipment being removed from

service for relatively major repairs expected to take a considerable amount of
time. Aspects of the information may be useful to address minor repairs, such as
gasket replacements, instrument replacements, leaking plugs and valve packing,
as well as some valve replacements. Even after the equipment has been cleared
of liquid, depressurized, and pulled under vacuum, use appropriate precautions
during the performance of repair work.

If phosgene equipment requires welding or burning, evaluate use of special

preparation procedures because phosgene impregnated into the surface of the
metal can be liberated by the high localized temperatures produced. This
process can involve washing out the equipment with hot water and/or steaming it
out to remove the residual vapors.

In preparation for vessel entry, clear the inert gas used for purging by flushing
with atmospheric air. For example, an air horn or similar air-moving device has

70
 been used. Flexible ducts connected to a vacuum source discharging to a
destruct system may be useful if the existing air is contaminated.

6.3 Equipment Repairs

The repair of equipment that has been in phosgene service merits special
precautions to avoid accidental exposure. Due to the increased possibility of
accidental releases, it is beneficial to avoid attempting repairs while the
equipment is still in operation unless authorized to do so using appropriate safe
work procedures. Even after clearing, it is possible for phosgene vapors or liquid
to remain trapped in gaskets and valve packing, behind pluggage in piping,
inside damaged level displacers or agitator gearboxes, etc. This phosgene can
be released during disassembly for repairs or, for example, simply by operating a
valve. For this reason, performing repairs using appropriate PPE even on
“cleared” equipment reduces potential risks.

At times, equipment that is still contaminated must be transported from the unit to
another location for decontamination. In such cases, consider the feasibility of
blinding off or plugging all process-exposed sections. If this is not possible,
another option is to transport the equipment by a person wearing appropriate
PPE and clearing all other personnel from the route.

If equipment must be taken to the facility’s shop or sent out of the plant for repair,
consider decontaminating the equipment as soon as possible using special
procedures to eliminate the possibility of an unexpected release. The
procedures may require disassembly and cleaning using steam, hot water or
other cleaning agents as appropriate. Vendors who handle such equipment must
be thoroughly knowledgeable of the hazards of handling phosgene and with the
decontamination procedures used.

Sometimes welding on phosgene equipment has to be done in the field without

benefit of complete decontamination. If so, review whether the welder has air-
supplied respiratory protection and whether the area has been cleared of
unprotected personnel.

71
 After welding on piping or equipment in phosgene service, risks can be reduced
by evaluating whether the work was done properly and will not result in
premature or unexpected failures. To this end, all welds can be tested prior to
placing the piping or equipment in service.

All parts and materials to be used in phosgene service are designed and
specifically approved for such use. A detailed procedure for cleaning and
packaging repaired valves for phosgene service serves an important function
because failure of these valves to properly seal when required could have
significant consequences.

Threaded fittings used in phosgene service (e.g. plugs, pressure gauge nipples)
create increased potential for leaks and are necessarily thinner because of the
requirement to taper the joints for threading. As a result , threaded fittings tend
to be generally avoided if at all possible, but when they must be used, some
risks can be reduced by coating the threaded fitting with approved pipe sealant
before being installed in order help avoid leakage. As one example, employ
fluoropolymer-based thread sealants in the phosgene service.

If a vessel used in phosgene service must be inspected or repaired internally,

OSHA guidelines for vessel entry are available. If the vessel has been cleared
by dry-gas purging only and has not been washed out, evaluate appropriate PPE
to protect against the possible presence of ferric chloride and hydrochloric acid
coating the interior surfaces.

6.4 Preparation for Service

A phosgene system that has been open to the atmosphere needs to be

extensively dried before being returned to service. Severe internal corrosion to
steel piping and other equipment can result if significant moisture is allowed to
remain inside the system. Drying the system’s return to practice helps prevent
this possibility. Drying has been done using a purge of dry inert gas, such as
nitrogen. Heating the purge gas will facilitate the procedure. If a steam
exchanger is used, consider whether the gas pressure is higher than the steam

72
pressure on the exchanger. This action will help prevent moisture from
contaminating the purge gas if the exchanger leaks. To aid evaporation,
consider keeping the phosgene system maintained as close to atmospheric
pressure as possible (or slight vacuum) during the drying process. External
heating of the equipment being dried can help aid in the drying process.
Nitrogen bleeds have been established at dead legs, including instruments such
as pressure transmitters and differential pressure flow transmitters. Dew points
can be taken at a number of different locations to help ensure the entire system
has reached the desired dew point.

Equipment that has undergone minor repairs using the vacuum method
described in the previous sections may contain a small amount of atmospheric
moisture. It may not be practical or possible to purge this moisture from the
system or, if it can be purged, to obtain a dew point due to contamination with
phosgene. Such equipment can sometimes be returned to service without
problems. However, to keep the frequency of this type of repair to a minimum
and to do whatever drying is possible under the circumstances because some
corrosion and sludging are likely.

Small sections of piping which need to be dried before installation have for
example been flushed with acetone and then nitrogen purged. Another method
has been to steam purge internally until the piping is very hot then purge
immediately with nitrogen.

Note the importance of removing grease, oil and other foreign material from lines
and equipment before returning to service. Piping components contaminated
with oil, grease, or other hydrocarbons are potentially reactive with phosgene.
Products of reaction could lead to unexpected pressure buildup in a closed
system.

When drying is complete, consider whether all atmospheric bleeds have been
plugged, capped or blinded to prevent phosgene leakage or a release due to
accidental valve operation. To reduce risks, the system can be checked for
leaks (after removing any blinds) by first pressurizing it with a dry, inert gas to

73
operating pressure, blocking it in, and watching for a pressure drop. This
process will help indicate any large leaks, but small leaks might only be found
through other methods. Options that have been used include those such as
checking each flange, etc. with a soap and water solution and watching for
bubbles or by charging the system with a sensitive gas such as helium or
helium/nitrogen combination and then leak detection device. After all leaks have
been repaired and the equipment passes pressure tests, it can typically be
depressurized and returned to service.

It is possible for leaks to occur after equipment has been returned to service,
especially if the equipment is in liquid phosgene service. Frequent equipment
checks (using phosgene badges or handheld phosgene monitors for example) for
several hours after startup help identify such leaks. The use of special washers
such as disk spring to prevent loosening of bolting due to thermal cycles on the
equipment can be helpful in preventing leakage. A desirable attribute of an
appropriate disc spring is that it should apply clamping pressure along a
continuous arc pattern, rather than concentrating it at one point.

74
Annexure X
point. A slipstream of hot quench oil will be fed by USC recycle furnace quench fittings
and the combined stream will flow into the Heavy fuel oil stripper.

The cracked gas overhead from Quench Oil Tower will be further cooled in the Quench
Water Tower by direct contact with circulating quench water, condensing much of the
cracked gasoline and most of the dilution steam. The gasoline and process water are
separated in the oil/water separator at the bottom of the tower. A portion of the gasoline
will be used to reflux the Quench Oil Tower, and the net product gasoline will be
Debutanized in the Distillate Stripper and sent to the gas hydrogenation unit (GHU).

The separated quench water will be used for various process heating service and returned
to the top of the Quench Tower. Net condensate, representing condensed dilution steam,
which was fed in the furnace along with the feed, is sent to the dilution steam generation
system.

Dilution Steam Strippers (DSS)

Solids and entrained hydrocarbons are removed from the quench water in a
filter/coalescer system. Dissolved light hydrocarbons are stripped from the process water
by dilution steam in the LP water stripper. After pumping and preheating, the water is
sent to the dilution steam generators for vaporization by quench oil and low medium
pressure (LMP) steam in DSS reboilers. Phenols, styrenes and other contaminants are
stripped from the water cooled, resulting in an environmentally acceptable blowdown.
Additional DSS with steam reboilers are provided to meet excess requirements.

Cracked Gas Compression

The cracked gas from the Quench Water Tower is compressed in a four stage centrifugal
compressor. The effluent from each stage passes through an aftercooler and then to a
separator drum. Liquid condensate is flashed back to the previous drum, with the vapour
going to the next stage of compression. The hydrocarbon condensate from the second
stage suction drum is pumped to the distillate stripper. The process water from this drum
flows to 1st stage suction drum from where it is pumped to Quench water tower.

Acid gases are removed between the third and fourth stages of compression in Caustic
wash tower with non-fouling ripple trays. A water wash section at the top of this tower
removes any caustic entertainment.

Cracked gas from the fourth stage discharge is water cooled and sent to a separator drum.
Vapor from this drum is sent to the cracked gas rectifier, which fractionates the heavy
ends from the feed gas flowing to the demethanizer system. Reflux for this tower is
condensed against high-level propylene refrigeration. The cracked gas rectifier
effectively reduces cracked gas compressor interstage recycle, minimizing compressor
horsepower and further reducing fouling. Wash water is injected into the compressor
blades to reduce fouling of blades with polymers during compression.

Acid Gas Removal

Cracked gas from the third stage discharge drum is fed to the caustic tower where it is
washed with circulating weak and strong caustic solutions and finally with water. The
bottom circulating weak caustic solution is heated by quench water to ensure that
hydrocarbons do not condense in the tower. The strong caustic solution is maintained at
10% NaOH with fresh caustic solution make-up. The strength of the weak caustic
solution is maintained by letdown from the more concentrated solution.

Spent caustic from the base of the tower of 1% concentration is routed to the spent
caustic deoiling drum where it is contacted with aromatic gasoline to remove
hydrocarbons and polymers. The spent caustic is sent to the degassing drum. After
degassing spent caustic is stripped with steam to remove hydrocarbons like benzene,
before entering the spent caustic oxidation unit for further treatment.

Spent Caustic Oxidation

Spent Caustic from Stripper flows to SCO fed surge from where it is pumped to the first
reactor after preheating against reactor vent gas. There are three reactors operating in
series. These reactors are fed with air from air compressor after filtration.

Each reactor operates nearly full of liquid at 130°C and is divided into two zones by a
perforated plate. The spent caustic flows slowly upward in contact with a stream of fine
air bubbles. The reactor pressures are individually controlled to allow the flow of spent
caustic through each reactor under level control. On the spent caustic stream from each
reactor a filter is provided for removal of possible agglomerated polymer. The residence
time in each reactor is approximately 4 hours at the maximum design rate.

Oxidized spent caustic from last reactor is filtered, cooled and diverted to effluent surge
drum. From this drum spent caustic is pumped to the effluent treatment plant. During
this process, COD of the spent caustic is reduced to acceptable limits for treatments in
ETP.

Condensate Stripper
Liquid hydrocarbon bottoms from the cracked gas rectifier are flashed into fourth stage
suction drum. Liquid hydrocarbon from this drum is warmed against quench water and
flashed into the condensate stripper. This tower function as a deethanizer, further
reducing compressor recycle and allowing much of the C3 and heavier hydrocarbons to
bypass the cold fractionation system, with a savings in refrigeration horsepower. Also
this ensures that the C2 spec. in the bottom stream is satisfied.

Cracked Gas Dehydration

The cracked gas from the rectifier reflux drum is dried in the cracked gas dehydrators.
Two vessels are provided, one operating, the other regenerating or on standby. Molecular
sieve desiccant is utilized with a moisture analyzer strategically placed to monitor for
water breakthrough. The desiccant is regenerated with residue gas from the demethanizer
overhead system. The regeneration gas is heated in a feed/effluent exchanger followed
by a high-pressure steam heater. Saturated regeneration gas is cooled before feeding a
separator drum. The condensed water is sent to the quench water tower and the residue
gas flows to the fuel gas system.
Demethanizer System
The dried cracked gas is cooled against propylene refrigerant and demethanizer bottoms
before separating vapor and liquid in the prestripper feed drums. The liquid is sent to the
demethanizer prestripper, while the vapor is further cooled against recycle ethane and
propylene refrigerant. Liquid from the second prestripper feed drums is sent to the
demethanizer prestripper.

The prestripper is a demethanizing tower, which reduces the energy requirements of the
fractionation system. The overhead vapor is the bottom feed to the demethanizer. The
prestripper bottoms are sent to the deethanizer. Reboil heat is provided by quench water.

The vapor from demethanizer feed drum No. 1 is cooled in stages against demethanizer
overhead streams and ethylene refrigerant. The vapor from demethanizer parallel feed
drum No. 1 is cooled against stages of ethylene refrigerant. Liquid vapor provides liquid
for the second and third demethanizer feeds.

Vapor from the last demethanizer feed drum is cooled against demethanizer overhead
streams and sent to the residue gas rectifier. This small tower effectively eliminates
ethylene loss in the residue gas. The rectifier bottom stream is reheated and enters the
demethanizer as the top feed. The rectifier overhead vapor is further chilled against
residue gas and sent to the overhead separator. Liquid from the separator is returned to
the rectifier as reflux.

The net rectifier vapor from the reflux drum is further chilled against the coldest residue
gas and sent to the hydrogen drum. Net vapor from this drum of 95-mol percent
minimum hydrogen purity is reheated and sent to the PSA system for CO removal.
Liquid from this drum is normally flashed to low pressure, reheated and compressed back
to fuel gas pressure using fuel gas compressor. If fuel gas compressor is down, hydrogen
is injected into the methane stream to achieve low temperature by reducing methane
partial pressure.

A standard Pressure Swing Adsorption (PSA) system is used to remove carbon

monoxide, which would poison the hydrogenation catalyst. The demethanizer overhead is
condensed against lowest level ethylene refrigerant to provide tower reflux. The net
tower overhead after partial reheat is sent to the methane expander-recompressor system
for cooling the incoming CG feed beds and then to the fuel gas system after regenerating
the CG dehydrator.

Reboil heat for condensing intermediate level propylene refrigerant provides the
demethanizer. Additional chilling of the CG is performed in the parallel chilling train.

Deethanizer
The dual-feed deethanizer separates the demethanizer and demethanizer prestripper
bottom streams into C2 overhead and C3 and heavier bottom streams. The bottom stream
is sent to the depropanizer. The net vapor overhead stream feeds the acetylene
hydrogenation system. Reboil heat is provided by circulating quench water.
Acetylene Hydrogenation System
The acetylene is catalytically hydrogenated to ethane and ethylene over palladium
catalyst. The deethanizer vapor overhead stream is heated to reaction temperature and
sent to the primary C2 hydrogenation reactor. Two primary reactors with intermediate
cooling are provided, one operating, the second for regeneration or on standby.

The effluent from the primary reactor is cooled and enters the first secondary adiabatic
reactor. The effluent from this reactor is cooled and sent to the second guard adiabatic
reactor. A third adiabatic reactor is either on regeneration or standby.

The acetylene - free effluent from the secondary adiabatic reactors is cooled and sent to
the green oil knockout drum. The separated green oil is sent to the primary fractionator.
The gas flows to the secondary dehydrator where molecular sieve desiccant removes
traces of water.

Ethylene Fractionation
The ethylene - ethane vapor from the secondary dehydrator feeds the ethylene tower.
Reflux is condensed against low level propylene refrigerant. The ethylene product is
withdrawn as a liquid a few trays below the top of the tower. Light impurities are
eliminated by pasteurization with a small vent stream from the reflux drum recycling to
the cracked gas compressor system. Condensing propylene refrigerant vapor provides
bottom reboiler heat. Condensing ethylene refrigerant compressor discharge vapors
provides the side reboiler load.

Provision is made to send a low pressure and high pressure ambient temperature ethylene
vapor product to battery limits by pumping vaporizing and superheating the side draw -
off liquid product stored in OSBL spheres. Provision is also made to sub - cool this
liquid to approximately - 100°C for transfer to atmospheric storage.

Depropanizer
The deethanizer and condensate stripper bottom streams feed the depropanizer. The C3
fraction is totally condensed against propylene refrigerant, producing reflux and a liquid
overhead stream, which is pumped into the C3 bydrogenaton system. The bottom stream
flows to the debutanizer.

C3 Hydrogenation
Methylactylene and propadiene are catalytically converted to propylene and propane in
two liquid - phase reactors in parallel with after cooling. A separator drum after the
cooler vents gas to the cracked gas compression system. MAPD concentration in the
feed is controlled by recycling reactors is being regenerated. Third reactor is kept as
standby.

Secondary and Tertiary Deethanizers

The effluent from the C3 hydrogenation system feeds the secondary and tertiary
deethanizers operating in series. These towers remove traces of C2's, carbon dioxide
water which are recycled to the cracked gas compression system. These towers are
reboiled with quench water. Reflux is condensed with cooling water.
Propylene Fractionation System
The bottom stream from the seondary/tertiary deethanizer feeds the propylene
fractionation system, which consists of the propylene stripper and rectifier, in series. The
overhead stream from the rectifier is totally condensed against cooling water, producing
reflux and a liquid propylene product. The bottom stream, which is primarily propane, is
vaporized and is recycled to the cracking furnaces.

Debutanizer
The debutanizer produces a mixed C4 distillate product. The bottom stream is combined
with the distillate stripper bottoms and sent to raw pyrolysis gasoline unit. The
Debutanizer is reboiled with L.P. steam and condensed with cooling water.

Refrigeration
The cascaded refrigeration system has three levels of ethylene refrigeration and four
levels of propylene refrigeration. The ethylene refrigerant is condensed against various
levels of propylene refrigeration. The propylene refrigerant is condensed with cooling
water. Refrigerant makeup is supplied by propylene/ethylene product.

C4 Hydrogenation
The C4 hydrogenation system is a liquid - phase catalytic process. The butadiene in the
debutanizer net overhead - is selectively converted to n-butanes. Recycled back for
cracking or used for separating various C4 components in C4 complex.

Gasoline Hydrogenation Unit (GHU)

The GHU consists of two stages. This process produces a feedstock for downstream
aromatic recovery by selectively hydrogenating the diolefins in the first stage and the
olefins in the second stage. The feedstock hydrodesulfurization also takes place during
second stage.

The liquid feed from debutanizer bottoms is pumped under flow control to the unit and
mixed with fresh makeup hydrogen. The mixed stream enters the 1st stage reactor after
heating. The reactions (diolefins and styrene hydrogenation) occur in a mixed phase on
the fixed bed type of reactor with two beds. Quench liquid injection between the bed
limits the temperature increase.

The reactor effluent enters 1st stage hot separator. The vapor phase from the hot separator
is cooled and partly condensed and then it enters the cold separator drum. The liquid
from this drum with liquid from hot separator drum flows to the Depentaniser. The
purpose of depentaiser is to stabilize the reaction liquid products by eliminating the light
components, which have been dissolved under pressure. The second purpose is to
separate C5 cut from C6 + cut.

C5 cut is drawn as a side stream from the column and sent to battery limits after cooling.
This C5 stream is recycled back to furnace for further cracking with Naphtha/NGL. C6 -
stream flows to deoctaniser, which operates at slight vacuum, created by LMP steam
ejector. Overheads from this column are partly condensed and fed to second stage
hydrogenation reactor. Wash oil is drawn as a side product and sent to wash oil tank after
condensation and cooling for internal consumption. Bottoms from the column is C9 +
steam, which is sent to Battery Limits.
The feed to second stage is mixed with hydrogen from 2nd stage recycle compressor &
vaporized to reaction temperature prior to reactor entry. The reactions (hydrogenation of
olefins and desulfurization) occur in the vapor phase on a fixed bed type reactor.

Ni - Mo type catalyst is used for hydrogenation and Co - Mo catalyst is used for

desulfurization. The quench is provided between the two stages for temperature control
of second bed. The effluents from the reactor are flashed in the second stage separator
after cooling. The net liquid from separator is sent to stripper.

The stripper eliminates H2S and light components dissolved at high pressure in the C6 -
C8 cut. The bottoms are sent to battery limits after cooling as C6 - C8 cut product, which
is further pumped for aromatics, recovery.
Annexure XI
minutes prior to waste charging. The burners will have automatic switching "off/on"
control to avoid the fluctuations of temperatures beyond the required temperature range.
• Each burner will be equipped with spark igniter and main burner.
• Proper flame safeguard of the burner will be installed.
• Provide view ports to observe flame of the burner.
• Flame of the primary burner
- will be pointing towards the centre of the hearth.
- will be having a length such that it touches the waste but does not impinge directly
on the refractory floor or wall

The secondary burner will be positioned in such a way that the flue gas passes through
the flame.

The waste will be charged in bags through automatic feeding device at the manufacturer's
recommended intervals ensuring no direct exposure of furnace atmosphere to the
operator. The device will prevent leakage of the hot flue gas & any backfire. The waste
will be introduced on the hearth in such a way so as to prevent the heap formation.
Suitable raking arrangement will be provided for uniform spreading of waste on the
hearth.

A tamper-proof PLC (Programmable Logic Controller) based control system will be

installed to prevent:
• Wastes charging until the required temperature in the chambers are attained during
beginning of the operation of the incinerator.
• Waste charging unless primary & secondary chambers are maintained at the
specified temperature range.
• Waste charging in case of any unsafe conditions such as - very high temperature in
the primary & secondary chambers; failure of the combustion air fan, ID fan,
recirculation pump; low water pressure & high temperature of the flue gas at the
outlet of air pollution control device.

The incineration system will have an emergency vent. The emergency vent will remain
closed i.e it shall not emit flue gases during normal operation of the incinerator.

Structural design of the chimney / stack will be as per IS:6533-1989. The chimney/stack
will be lined from inside with minimum of 3 mm thick natural hard rubber suitable for
the duty conditions and will also conform to IS:4682 Part I-1968 to avoid corrosion due
to oxygen and acids in the flue gas.

The location and specification of porthole, platform ladder etc. will be as per the
Emission Regulations, Part-3 (COINDS/20/1984-85), published by CPCB. The
incineration ash will be disposed in a secured landfill.
Annexure XII
 ™ Titmus Vision Tester for eye checking.
™ Laboratory services: with Randox auto analyser for bio-chemistry, Cell Dyne for
hematology, Gas chromatography for urine phenol monitoring. Laboratory tests
for all including blood sugar estimation, lipid profiles, liver and kidney profiles
etc. can be performed with state-of-the-art equipment like Automatic Blood cell
counter & Auto-analyzer.
™ Other facilities: X-Ray, TMT (Tread Meal Test), 4D-USG with Colour Doppler
for Sonography and 2-D Echo, ECG, Spirometer for Pulmonary function test,
Audiometry booth and audiometer (for evaluating hearing loss), 24 hrs chemist
and Fully equipped ICU ambulance, Nebuliser, Defibrillator-cum Cardiac
Monitor, Pulse Oxymeter, Minor Operation Theatre, Ventilator, Separate
decontamination room and observation beds with facility of online oxygen for
each bed.
™ Industrial Hygiene Cell: - To bridge a link between safety, health and
environment, a separate industrial hygiene cell is established. A qualified
industrial hygienist looks after personal monitoring of various health hazards, by
walk through surveys, quantitative analysis etc. Various instruments to measure
the same are procured, e.g. Wet Bulb Globe Temperature(WBGT) meter, noise
level meter, noise dosimeter, air sampler, indoor air quality monitoring
equipment, and illumination meter etc.

3. Occupational Health Monitoring

The main purpose of health monitoring is to detect possible onset of an occupational
disease, to identify as early as possible any adverse health effects caused by work practices
or exposure to potential hazards, to monitor personal exposure with the help of biological
monitoring, for checking the effectiveness of preventive and control measures, for
identifying possible health effects of changes in the working practices, technology or
substances used in the refinery, to ensure right man for the right job, to prevent spread of
communicable diseases through food handlers. Health examinations helps to identify
conditions, which may make workers more susceptible to the effects of hazardous agents
and to detect the early signs of health impairment caused by these agents.
Medical Monitoring at Reliance includes:-

Pre-employment Medical Examination

Periodic Medical Examination
Special Medical Examination

3.1 Pre-Employment Medical Examination

Pre-employment medical examination is a statutory requirement and its conduction is an
important function of an occupational health service. The purpose of pre-employment
assessment is to ensure that a person has no pre-existing ill health or disability that may
make the performance in the proposed job difficult or unsafe for the individual, co-workers,
other employees and for the third parties like the visitors or customers, also to ensure that
the proposed job does not cause a danger to health of the person himself/herself by
aggravating his/her pre-existing health condition. The assessment is also used to provide
baseline data for future comparison during Periodic Medical Examinations (PMEs). All
prospective candidates are called to OH&FWC for pre-employment medical examination.
Based on all reports, his/her fitness certificate is prepared and sent to HR.

3.2 Periodic Medical Examination

The purpose of periodic medical examination is to monitor the health of employees during
the course of their employment. It aims at verifying fitness in relation to their jobs and
early detection of any signs of ill health. It will be supplemented by other examinations in
accordance with the nature of hazards observed for e.g. persons working in hazardous
processes undergo half yearly medical examination; annual audiometry test is performed to
those who are exposed to high noise areas. Periodic medical examination of all employees
joined or transferred to site on or before 31st March is done irrespective of their cadre or
type of job. A separate mail of PME Observation & Recommendation is sent to employees
with their findings. A Health Card with brief details of PME is sent to individual employee
through internal courier to their residential address
3.3 Special Medical Examination
Those employees who are exposed to either hazardous chemicals or processes will require
more frequent medical examination than the others, with specific attention to certain
parameters. Similarly some specific groups like food handlers, bus drivers and paramedical
staff will also need more frequent medical examination. Special Medical examinations are
carried out for following groups:-

3.3.1 Persons exposed to Hazardous Chemicals

Some persons may be exposed to hazardous substances (liquid/gaseous) like hydrogen

sulfide, benzene, methanol, petroleum coke, crude oil etc during different processes in
refinery. In addition to periodic medical examination they will be subjected to special
examination of target organs like Respiratory system, Nervous system, Gastro-intestinal
system, Optic nerve & Retina, Skin, Lungs, Bladder, and Hemophiliac etc depending upon
the type of chemical exposure. Frequency of this check-up will be six monthly. Every six
months data generated will be reviewed and appropriate steps will be taken. For e.g. all
personnel handling benzene are monitored for benzene exposure. Based on shift schedule, a
monthly schedule is made for urine sample collection by medical center and their urine
samples are collected at the end of week shift. Urine phenol estimation and tt-MA (Trans,
trans-Muconic Acid test) is done at medical laboratory.

3.3.2 Persons working in Noisy areas

In refinery there are certain areas where personnel are exposed to continuous noise. Though
different measures have been taken during designing of the plant, and various protective
devices are issued, occupational health hazards due to noise cannot be completely ruled
out. In addition to periodic medical examination, employees exposed to continuous noise
are subjected to audiometry test every year.
3.3.3 Employees >45 years of age

The likelihood of cardiac problems, hypertension, diabetes, increases progressively with

age, hence special attention, including a more detailed investigation is required in this age
group. More emphasis is given to: Eye sight and its problems, Status of heart, Stress test,
Audiometry. Frequency will be once a year.

3.3.4 Food-Handlers

This group of workers is catering to a large number of employees. They may be one of the
prime sources for spreading different communicable diseases, especially those food or
water borne. The Health-card will be issued to the workers found fit. The worker will keep
the card with him while on duty and will have to display it as and when required.

3.3.5 Drivers of Company Owned Cars / Hired Vehicles

This specific group of workers drives vehicles for the organization (both passenger and
goods). Accidents put the employees and property at risk. To avoid such untoward
incidents, their medical examination is done. Emphasis is given to vision (Colour &
distant), hearing, history or signs of Heart Diseases, epilepsy, and any drug addiction.
Crane operators also undergo task specific annual medical examination.

3.3.6 Paramedical Staff

While discharging their duties this group of workers is exposed to different communicable
diseases, similarly if they are suffering from communicable disease they may pass it to the
patient. Hence it is utmost important to screen them at regular intervals.

4.0 Curative Medical Care

Health Care during Construction
The construction of new Refinery complex is in progress where in thousands of workers
are involved. It is of upmost importance to render medical services – both emergency and
routine to take care of health of construction workers. All construction workers are
examined for communicable diseases before assigning the job at the site as well as
providing the accommodation in labour camps. The First Aid medical centres are provided
in all labour camps and at the site with necessary required facility, 24 hrs a day. Dust masks
are provided to construction workers, while carrying out operations that may entail
potential for dust inhalation.

4.1 Project Medical Centre (PMC):

PMC is manned round the clock with availability of doctor, male nurse and an ambulance.
PMC is equipped with emergency medical equipment and medicines to give primary
medical treatment for any type of injury /acute illness. All medical data are entered in
MDMS (Medical Data Management System). 3 additional ambulances are stationed at
different locations at construction site to minimize the response time to an emergency call.
These ambulances are equipped with basic life saving instruments and medicines. One
male nurse along with walkie-talkie is deployed round the clock in these ambulances.

Pre- Placement screening

Contractor supervisors bring / direct new contract workers to Medical Inspection (MI)
room, located at Shramik Swagat Kendra & before proceeding for safety induction.
Contract workers are screened for any major communicable disease and referred to Moti
Khavadi Medical Centre (MKMC) /Project Medical Centre (PMC) for further examination
to determine his fitness by doctor. Based on doctor’s fitness certificate, security pass is
issued. Contractor’s supervisor also ensures that such workers are seen by Labour Colony
Medial Center (LCMC) medical officer before allocating him a room in labour colony.
Workers free from communicable disease, are certified for the same by putting a stamp on
a format submitted by contract agency and will proceed for further formalities.

4.2 Labour Colony Medical Center (LCMC)

Sufficient number of labour colonies is provided for workers and each labour colony have
one medical centre with doctor, paramedic and necessary equipments. In addition to this,
there is one medical centre at project site. It is important to provide medical services to all
workers during their stay at labour colony as well as while on the job.
Facilities Available

• All routine medicines

• All emergency injections

• Treatment room: dressing table, oxygen cylinder, suction machine, laryngoscope with

tube, autoclave machine, dressing material, suture material etc.

• Observation beds – nos. of bed will depend on strength of labour colony.

• Round the clock availability of paramedics

• Part time/Full time doctor

• Ambulance with necessary equipment (Major colonies will have their own ambulance.

Smaller colonies will have Camp vehicle to shift patient)

5.0 Health Awareness & Training

CASHe (Change Agents for Safety, Health & Environment)
Reliance Management is always striving for excellence in each and every field. Hence to
fulfill this dream, the CASHe Project (Change Agents for Safety, Health & Environment)
was initiated as amongst many other initiatives to strengthen the HSE management system
and culture. CASHe activities are in place since 2003. The biggest gain by the project was
inculcating strong occupational health culture in the plant working area.

Various innovative ideas have come up from the shop floor workers in process design
change, modification in PPE’s etc. Implementation of various engineering controls and
administrative controls have helped in reduction in exposure to majority of occupational
health hazards like noise, heat, dust, chemical, vibration, illumination as well as
ergonomics. Training and awareness drive is reflected in attitudinal change among workers
regarding occupational health, safety and environment. CASHe activities at Jamnagar
complex are recognized globally in terms of presentations in conferences and publication in
international journal. Swedish experts on OS&H from the National Institute for Working
Life (Stockholm) visited the CASHe Project areas. They appreciated the high level of OSH
awareness and commended our achievements. Jamnagar site has won “Dhirubhai Ambani
Trophy for Excellence in Occupational Health” for consecutive two years in a row. Won
“Golden Peacock Award for Occupational Health and Safety Award” instituted by
World Environment Foundation
First aid
A two days training under basic first aid training is given every month in which employees
are taught on basics of emergency first aid and basic life support. Aim is to train all
employees in basic first aid. Almost 500 employees are trained in a calendar year.
Members of auxiliary fire squad are also trained in basic first aid. One day refresher
training is given after 3 years. All electrical personnel are also trained for Cardio-
pulmonary Resuscitation (CPR). A volunteers’ group from first aiders – Auxiliary Medical
Squad - is given practical training at medical centre.

Ergonomics
Ergonomics training is given to employees and contract workers wherein how to identify
symptoms, workstation design & various exercises are taught to them.

Other Training
Life style management, stress management, understanding of health card, awareness of
occupational health hazards etc. are some of training modules in which participants are
informed about the specific subject. Health tips are published on intranet, house magazines.
Every year in month of July, occupational health week is observed in which various health
related activities are carried out for a week

Hygiene and Sanitation

The main objective for hygiene and sanitation is to protect employees, their dependants and
labour from different water/ food borne diseases, to prevent epidemics of communicable
diseases, to keep all workers healthy, to monitor potability of drinking water all over the
project and the township. Pest control measures are taken at different places in Refinery
and Township. For effective control of water-borne diseases, sanitary Inspector will
randomly collect water samples every month for biological and chemical analysis. All
canteens are also inspected once in a month.

6.0 Community Services

The Reliance, Jamnagar Complex processes as much as 30 million tons of Crude and
associated Hydrocarbon products per annum. It employs several hundred personnel to work
in various capacities in the plant. As a part of corporate social responsibility services, a
community medical centre was established in nearby village – Moti Khavdi during the pre-
commissioning stage of refinery well back in 1995. This Community Medical Centre caters
free of cost, round the clock, comprehensive health services. All the above services will
continue for proposed SEZ and the same will be augmented as and when required.

Mobile Van Clinic

The health centre operates “Health on wheels” through Mobile van clinic. One doctor
accompanied by one nurse visits five villages namely Nani Khavdi, Meghpar, Gagva,
Gagva gate & Padana – each twice a week. Patients are examined & free of cost medicines
is dispensed. A step ahead health centre contributes in various national health programmes
in its own way. Following is a summary of activities carried out.

REPRODUCTIVE & CHILD HEALTH ACTIVITIES

Family planning clinic
Target couples are advised to adopt either temporary or permanent family planning
methods. Free distribution of condoms, oral pills & copper-T insertion is carried out here.
Antenatal clinic
On 1st Thursdays of every month antenatal mothers are examined thoroughly. Iron,
calcium & folic acid are supplemented. Inj. Tetanus Toxoid is given & laboratory tests are
done. All antenatal mothers having pregnancy of more than 5 months screened for
gestational diabetes. To prevent neonatal tetanus in new born, safe delivery kit is given to
all expecting mothers in case of home delivery. Health quiz for village ladies are organized
time to time
Postnatal clinic
Postnatal mothers are given iron & calcium supplementation, pre-vaginal examination done
for stitches. Breast feeding is promoted to lactating mothers.
Vaccination clinic
First Wednesdays of every month is fixed for vaccination in children against Vaccine
Preventable Diseases like TB, polio, diphtheria, whooping cough, measles & tetanus. To
prevent night blindness in children, syrup Vitamin –A is given to all children from 9
months to 5 yrs. of age
Pulse Polio Drive
Under National Pulse Polio Immunization programme, all children staying at Moti Khavdi
Village, nearby villages, labour colonies, Township and surrounding vicinity are
immunized with polio drops. With help of mass awareness campaign, group meetings,
posters, audio- visual aids etc. 100% target (approx. 3500 eligible children in each round) is
achieved for all the rounds.

Other
To be fathers are counseled (Couple counseling) to take care of their better half to restrict
physical activities & dietary supplementation during antenatal & postnatal periods. “Saas
Bahu samelan” (Mother in law & Daughter in law meeting), are organized to reduce barrier
between two generations regarding gender bias & family planning.

CAMPS & OTHER ACTIVITIES

Blindness prevention programme.

Vitamin A supplementation is given to all children in age group of 9 months to 5 yrs 6

monthly.
Started cataract surgery to the patients free of cost.
Eye care clinic is started in which renowned eye specialist renders her services.

School health check up camp

Every year school children are examined for refractive eye error, congenital defects, night
blindness, etc.
Community Reproductive Child Health (RCH) Clinic.
A weekly clinic is started at nearby Primary health centre (PHC) at Village Padana, where
eminent gynecologist and pediatrician give medical services to the village women and
children. Medicines are also distributed free of cost.
Multi-diagnostic camp
Every year one multi-disciplinary diagnostic & treatment camp is organized for community
people in which large no. of patients are treated. Eye camps, dental camp, Thallassemia
screening camp are also done regularly in which free diagnosis, treatment, cataract surgery,
spectacles are provided.
Audiovisual camps
On various topics e.g. Hygiene, diarrhea & diet, antenatal care, family planning, AIDS,
Tuberculosis etc. are carried out.
De-addiction camp
Tobacco, panmasala is an addiction in school going children & villagers.
First aid training
The programme is designed to create awareness among the villagers & to make them aware
of actions to be taken during emergency situations. Till date villagers from Moti Khavdi,
Sikka, Padana, Meghpar and Setalus are trained in safety and first aid.

Directly Observed Therapy (DOT) & HIV / AIDS CENTRE, Motikhavdi

At Moti Khavdi Community Medical Centre (MKMC), DOT & HIV/AIDS centre has
became functional from 1st October, 2004 Since inception of DOT center (Oct 2004) and
HIV/AIDS awareness Drive (Sep 2004), more than 23,000 people are contacted one to one.
Total 26 street plays, 231 group meetings are conducted till date. By rapid method, 367
persons are examined for HIV, of which 5 are found positive. They are directed to Guru
GovindSingh Hospital (GGH) for further management. In the clinic, 569 patients are
treated for Sexually Transmitted Diseases. Of 2423 patient examined for sputum, 32 were
detected for TB. Total 33 (including from transferred from other DOTs) have already
completed the treatment. The center has organized lectures, seminars, and street plays for
the migrant labor, truck drivers etc. Large quantities of condoms and literature have been
distributed.

7.0 Emergency and Admission Services

Emergency Department at Occupational Health & Family Welfare Centre is one with
facilities of international standards. The emergency department is staffed round the clock
medical officers and registered nurses. They provide care using state-of-the-art equipments
and advanced patient monitoring systems to respond to any medical situation.
Emergency Services are applicable to:-

• All work related accidents involving employees, agency staff, contractors and

company’s guests.
• All domestic accidents and non-accidental medical emergencies like- cardiac, acute

abdomen, Heart Attack, surgical emergencies, Status Asthmaticus (severe form of

Bronchial asthma), etc. of employees, their dependents, their relatives, and residents of
township other than employees.
• As a part of community service, Reliance provides emergency medical care to the

victims of roadside accidents occurring in the neighbourhood of the refinery, where the
other hospitals/ medical facilities may be far-off.

8.0 Proposed Occupational Health Surveillance for SEZ

As can be seen a well established infrastructure with experienced doctors, paramedics,

occupational health personnel and systems are already in place to cater to the existing
refinery complex and the new refinery complex under construction. The same approach
and systems will be used for occupational health surveillance in the proposed
petrochemical SEZ also. This will call for suitable augmentation of the existing
infrastructure and manpower. As the expertise is already available with Reliance in this
area, augmentation can be carried out to remain best in the industry.
Annexure XIII
 Process technology / information
Process hazards analysis
Operating procedures
Work permit system
Management of change
Personnel training and validation
Contractor safety
Incident investigation and communication
Emergency planning and response
Auditing
Pre - startup safety review
Risk Assessment

Documents developed by HSEF Department

Various procedures, plans and policies concerning health, safety, environment and fire
protection activities prepared for complex are documented in the HSE manual which
consists of four parts,

- Management Systems & Plans

- Occupational Health and Environment
- Safety
- Fire Protection

In addition to the above four parts of HSEF Manual, Major Emergency Management Plan
(Onsite Emergency Plan) Oil Spill Response Plan and Emergency Plan for War or
Warlike Situations have also been prepared. Some of the procedures prepared are listed
below:

Management Systems and Plans

HSE Management System HSE - S 101

HSE Training Plan HSE - S 104
Environment Management Plan
HSE - E 101
HSE – S 105
HSE Awards Policy

Safety

Basic safety rules for Employees, Contractors &Visitors HSE - S 103

Safety Districts and Committees HSE - S 106
Safe Work Permit System HSE - S 201
Pre-start up safety review HSE - S 202
Safety Audits HSE - S 203
 Safe Transportation of Hazardous Materials by Road HSE – S 204
Personal protective equipment HSE - S 205
Safe handling of hazardous substances HSE - S 206
Management of plant changes HSE - S 210
Procedure for PHA / HAZOP HSE - S 211
Incident reporting & Investigation HSE – S 213
Safe use of Hoses HSE – S 216
Electrical safety HSE – S 220
Ionization Radiation safety HSE – S 221
Traffic safety HSE – S 222
Safety of Contractor Personnel HSE – S 223

Emergency Plans

Emergency Response and Control Procedure HSE – S 229

( On-site Emergency Plan )
Oil Spill Response Plan HSE – E 102
Emergency Plan for War or Warlike Situation HSE – S 240

HSEF Audits
Periodically, Health, Safety, Environmental programs and Fire Protection including
management systems, require a thorough audit to exercise proper control. Audits are
conducted periodically on the systems, procedures, and operational aspects to ensure that
a desired level of health, safety and environmental standards are maintained as per the
requirements of company policy and statutory norms.
Major objectives of the audits are:
• Ensure that all statutory requirements are met fully and extended to new facilities
and changes.
• Ensure that set procedures are complete, up-to-date and compliant with applicable
standards, codes, company policies, good engineering, and process safety
practices.
• Ensure that the management systems in place are effective in assuring that the
company and plant policies and procedures are being implemented.
• Identify opportunities where the systems and procedures can be strengthened.
• To check on training and preparedness for handling emergencies
• Cater to public opinion and concern for safe environment.

Various safety audits like two member and Procedure Compliance audits are conducted
by an independent two member and three member teams in all plants in order to verify
the compliance to Work Permit system, Contractor Safety, Scaffoldings, Portable
electrical tools, Personal Protective Equipment and Housekeeping. Mobile crane safety
audit also started as a part of the procedure compliance audit. The ratings in the audits are
counted for quarterly safety performance competitions.
HSE Committees
Committees are excellent forums to promote health, safety and environment in any type
of organization. These committees play a vital role in making health, safety and
environment activities an integral part of operating policies and practices. HSE
committees help the employees to recognize that their co-operation is essential for safe
operation of the complex.
Considering the nature and magnitude of the operations, three tier HSE committees have
been set up in our organization. These are:
• Apex Committee
• Central Safety Committee
• District Safety Committees (24 nos.)

The objective of these committees is to promote co-operation among the employees and
the management in maintaining proper safety, health and environment at work and to
review periodically the measures taken for improving the same. Document HSE - S 106,
'Safety districts and committees', provides the guidelines on formation, scope,
composition, responsibilities and functioning of these committees.
Apex Committee

Apex Committee is the highest body of the management of Reliance Industries Limited.
Daily Apex meetings in Management Control Cockpit (MCC) are started with review of
previous day’s HSEF incidents, Fire & Gas alarms, reliability issues, etc. The meeting is
chaired by the Site President, coordinated by Site Shift Manager and is attended by Chief
of HSEF.
Central Safety Committee
Central Safety committee is the body consisting of senior management personnel from
Operations, Manufacturing Services and Support Services which advises the management
on all aspects of Health, Safety, Environment and Fire Protection. Regular meetings are
held to review the Health, Safety Environment and Fire Protection performances in the
whole complex.
District Safety Committees
Each safety district shall have a District Safety Committee which consists of
representatives from both management and employees. The District Safety Committee is
an advisory body on the safety, health and environmental issues related to the particular
district. This committee also fulfils the goal of employee’s participation in safety
management as envisioned in Factories (Amendment) Act; 1987.These committees play a
vital role in highlighting the problems that are specific to the respective districts.

HSEF Promotional activities

Health, Safety Environment and Fire Protection promotion activities are planned to
improve the awareness of Health, Safety, Environment and Fire Protection programs
among the employees and to clearly exhibit management's commitment and concern
towards Health, Safety, Environment and Fire Protection issues. Following are the few
activities that are carried out on a regular basis to promote awareness on health, safety
and environment issues.
• Celebration of National Safety Day - 4th March
• Celebration of Fire Services Day - 14th - 17th April
• Celebration of World Environment Day - 5th June
• Celebration of Traffic Safety Week - 2nd Week of March
• Celebration of World AIDS prevention Day
• Safety Competitions like, Slogan writing, Poster painting, Essay writing, Case
Study Presentation, etc.
• Health and fitness camps / campaigns.
Special HSEF learning Programmes / Self Development Modules

Self Development Module is the concept to identify and improve the individuals learning
needs and upgrade their knowledge in various elements. Some of the HSEF knowledge
elements have been identified for each job position under this system. The individual
employees will identify their learning needs of HSEF elements. Therefore to enhance the
knowledge of the employees under the SDM system and also to give focus on special
issues need based Learning programmes have been identified and made.
Safety Initiatives

• In line with the Reliance Commitment, “Reliance shall strive to be a leader in

the field of management of Health, Safety and Environment”, Jamnagar site
has taken several initiatives to improve its safety performance to move towards
the adoption of the best practices and the ultimate achievement of a zero incident
safety performance. The Safety management improvement program is one of such
initiatives which is focused on improving the procedures and culture of the
organization. A prioritized schedule has been prepared which, to begin with,
focuses on the key areas of Incident investigation, corrective actions tracking,
contractor safety management, major hazard management and safety audit.

• Reliance group has engaged DuPont Safety Resources as a strategic partner in

our pursuit of excellence in Health, Safety and Environment. As a part of this
engagement for creating World class Safety Culture, restructuring of the Central
HSEF Committee was being done through formation of various Sub-committees
which focuses on specific safety functions/aspects.

• A project titled “Change Agents for Safety, Health and Environment

(CASHe)” was initiated in all the units of Jamnagar refinery complex. This pilot
project is meant to promote a culture of addressing all occupational health issues
(i.e. noise, heat stress, ergonomics and dust) at the plant level by plant personnel
themselves.
• HSEF training remains a major forte at Reliance, Jamnagar to further the cause
of safety. All personnel joining the Jamnagar Refinery Complex undergo
intensive fire & safety training. Regular refresher training is also conducted for all
employees every year. Continuous, systematic education of Company's
contractors and transporters personnel is done for ensuring safe work practices.
Special awareness and training programs are also conducted before taking up a
major shutdown, in the areas of job specific risk assessment, hazards of toxic
gases and pyrophoric material, mechanical isolation and scaffolding. Work permit
workshop which was started last year was continued for permit issuers /
acceptors. External faculty is also invited to give specialized inputs in Process
Safety, Noise Monitoring and Traffic Safety.

• To ensure all critical factors involved in an incident are determined through

scientific investigation and key factors are identified to derive the corrective steps
which will eliminate recurrences. With a special focus that all incidents are
reported and investigated within the stipulated time at RIL Jamnagar on- line
system named as “iRIL” has been developed and made effective for reporting
incidents including near misses from April 2008.

• Developed and implemented structured Reliance Safety observation Process

(ReSOP) with intent of capturing the safe and unsafe observations. ReSOP Portal
was developed which enables tracking of all such observations with effective
from Feb 2008.

• A document driven Process Technology Portal (PT) portal has been developed
for easy retrieval and tracking of process safety documents from June 2008. This
portal covers major areas of process Safety viz. Hazards, Process Design and
Equipment Design etc.

• In order to enhance the safety skills within the management executives, two
batches of HSE line management workshop was organized. Several senior
management personnel attended the program which was conducted by Shell
Safety expert.

• Control Of Substances hazardous to health (COSHH)- In bid to help

employees to effectively control exposure of hazardous substances in the work
places, COSHH assessment for various chemicals has been carried out. Simple
advice in form of Do’s & Don’ts in the workplace has been displayed at all
location where chemical is being handled.

An intranet portal titled “CHIP”-Chemical Hazard Information Portal has been

developed in-house and launched. This portal is readily accessible to all Reliance
Jamnagar site employees & other Reliance group companies. It contains various
safety information for over 400 hazardous chemical handled at Jamnagar. This
includes one page MSDS, standard MSDS, COSHH assessment sheet, First Aid,
 Do’s and Don’ts, TREM Card, COSHH risk Criteria etc., for ready reference and
use.
• Safety issues are continuously communicated to all employees at all levels
through the use of printed news letters and electronic media in the form of HSE
flash, HSE vision, Reliance News, What Went Wrong, Learning from incidents ,
Chemical Incident Report Centre, etc.

• Community awareness programs are conducted regularly in nearby villages,

covering topics such as, safety in LPG cylinder handling; basic fire fighting &
first aid; actions to be taken in case of a gas leak etc. More than 500 persons were
have benefited form the training so far.

AWARDS

ƒ British Safety Council Five Star Audit was conducted in the year 2003. The site was
conferred with prestigious “Five Star " rating for its Health and Safety Management
System.

ƒ The Baroda Productivity Council also conferred the “Best House Keeping Trophy”
for the excellent house keeping efforts for the year 2002-03, 2004-05 and 2006-07.

ƒ British Safety Council awarded the “International Safety Award 2004” to Reliance,
Jamnagar for its firm & demonstrated commitment to health & safety plans for
making safety an important feature of every day work practice.

ƒ Reliance Jamnagar site recertified for OHSAS-18001 by LRQA for its Occupational
health and Safety management system compliance in Sept’2008.

ƒ Greentech Golden Safety Award 2005-06 by Greentech Foundation, New Delhi

ƒ Golden Peacock Award for Occupational Health and Safety by World Environment
Foundation, New Delhi for Year 2007
 Abbreviations
EIA Environmental Impact Assessment

SEZ Special Economic Zone

PVA Poly Vinyl Acetate

JERP Jamnagar Export Refinery Project

MEG Mono Ethylene Glycol

DEG Di Ethylene Glycol

TEG Tri Ethylene Glycol

LLDPE Linear Low Density Polyethylene

SAP Super Absorbent Polymer

PP Polypropylene

SBR Styrene Butadiene Rubber

PBR Poly Butadiene Rubber

MA Maleic Anhydride

PX Paraxylene

OX Orthoxylene

PTA Putrefied Teraphthalic acid

PET Polyethylene Tera-phthalate

POY Polyesters Complex Polyester Oriented Yarn

PSF Polyester Stable Fiber

HRSG Heat recovery steam generation

AAQM Ambient Air Quality Monitoring

SPM Single Point Mooring

ATF Aviation Turbine Fuel

MMTPA Million Tons per Annum

FCC Fluid Catalytic Cracker

CCR Continuous Catalytic Regeneration

SWS Sour Water Stripper

STGs Steam turbine generators

MTF Marine Tank Farm

NMHC non-methane hydrocarbons

HTDS High Total Dissolved Solids

LTDS Low Total Dissolved Solids

VLCC Very Large Crude Carriers

GPCB Gujarat Pollution Control Board

MoEF Ministry of Environment and Forests

IEA International Energy Association

MoPNG Ministry of Petroleum and Natural Gas

MBPD Million Barrel Per Day

APM Administered Price Mechanism

GSFC Gujarat State Fertilizer Corporation

GEB Gujarat Electricity Board

RCO Reduced Crude Oil

GAIL Gas Authority of India Limited

TIS Tank Information System

BOSS Blending, Optimisation and Supervisory System

DCS Digital Control Systems

LRS Lloyds Register of Shipping

TAC Tariff Advisory Committee

EMP Environmental Management Plan

GT Gas Turbines

OMIS Oil Movement Information System

CPCB Central Pollution Control Board

ii
NMHC Non-Methane Hydrocarbons

CBDS Closed Blow Down System

IRS Indian Remote Sensing

NOAA National Oceanic and Atmospheric Administration

UNEP United Nations Environmental Programme

USGS United States Geological Survey

LISS Linear Imaging Self Scanner

FAO Food and Agriculture Organization of United Nations

IAS Image Analysis System

GIS Geographic Information System

UNEP/EAP-AP) UNEP Environmental Assessment Programme for Asia and the Pacific

NRSA National Remote Sensing Agency

SOI Survey of India

DIP Digital Image Processing

NIR Near Infra Red

SWIR Short Wave Infra Red

NEERI National Environmental Engineering Research Institute

SMML Sulakshani Mines and Minerals Limited

GPS Global Positioning System

CSIR Council of Scientific and Industrial Research

EIRA Environmental Impact and Risk Assessment

ITDA Integrated Tribal Development Authority

RJIL Reliance Jamnagar Infrastructure Limited

JERP Jamnagar Export Refinery Project

iii