Environment
environment
With an objective of maintaining the right balance for sustainable development, PPL has taken appropriate measures towards building a safe environment within and outside the plant.

environment
The ISO 14001 certification awarded to PPL in August 2002 for its environmental policy and systems and the upgraded certificate of ISO 9001: 2000 in April 2004 reflect the company’s concern for the environment.

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

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

Compliance of Conditions in Environmental Clearance No-J-11011/370/2009-IA.II (I)
dtd Oct,05-2010 FOR ENHANCED CAPACITY
Specific Conditions :
 Sl No  Conditions  Compliance status
1 The company shall comply with all the conditions stipulated in the environmental clearance issued vide letter no. J -11011/17/86-IA-II dated 23rd July ,1990. Compliance of all the conditions stipulated in the environmental clearance issued letter no. J -11011/17/86-IA-II dated 23rd July, 1990 has been submitted separately.
2 On line SO2, NOx and NH3 analyzer shall be installed to monitor ambient air .The National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. Nom 826(E) dated 16th November, 2009 shall be followed. On line SO2, NOx and NH3 analyzer have been installed to monitor ambient air quality.
3 The gaseous emissions (PM2.5, PM10, SO2, NOx, HCl, and NH3 and urea dust) from various units shall conform to the prescribed standards. At no time, the emission levels shall go beyond the stipulated standards. In the event of failure of pollution control system (s) adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency. We are strictly monitoring the gaseous emissions (PM2.5, PM10, SO2, NOx, and NH3 ) from various units . It is observed that the emission levels are within norms,

Monitoring of parameters like HCL& Urea dust are not applicable to our Industry since we are not manufacturing Urea..
4 As proposed, wet scrubbing system to DAP and Alkali scrubbing system to PAP plant shall be provided to control fluoride and emissions. Cyclones, Venturi scrubbers and mist eliminators along with stack of adequate height shall be provided to DAP plant to control particulate emissions. Alkali scrubber shall be provided to Sap unit to control SO2 and SO3 .V2O5 catalyst and candle filters shall be provided to SAP unit to improve efficiency and reduce emissions. PM2.5,PM10, SO2,NOx, HCl,NH3 and fertilizer dust emissions shall be monitored. Wet scrubbing system to DAP and scrubbing system to PAP have been provided to control fluoride and emissions. Cyclones, Venturi scrubbers and mist eliminators along with stack of adequate height have been provided to DAP plant to control particulate emission. Alkali scrubber has been installed in SAP unit to control SO2 and SO3.
5 Double Contact Double Absorption (DCDA) process shall be adopted in Sulfuric Acid Plant (SAP). Continuous SO2 monitoring system shall be provided in the stack of SAP unit. Fluorine Recovery Unit (FRU) shall be installed for recovering Fluoro- silicic acid and fluoride levels shall be monitored in ambient air. Double Contact Double Absorption (DCDA) process has been adopted in Sulfuric Acid Plant (SAP). Continuous SO2 monitoring system in stack of SAP unit has been provided. . Fluorine Recovery Unit (FRU) installation is going on and the same will be commissioned by January- 2013.
6 Fugitive emissions from different sources shall be controlled, regularly monitored and reports submitted to the Regional Office at Bhubaneswar. To control fugitive emissions, regular monitoring of sub floor environment shall be carried .Leakages in form of gases, liquid and dust emission shall be checked and mitigate measures taken. The company shall provide de-dusting system at all the transfer points in the bagging system. PPL has installed agglomerated dry fog system (ADS) We are controlling fugitive emissions from different sources regularly.
7 The company shall upload the status of compliance of the stipulated environmental clearance conditions including results of monitored data on its web site and shall update the same periodically. It shall simultaneously be sent to the Regional office of MoEF, the respective zonal office of CPCB and the Orissa Pollution Control Board . The levels of RSPM (PM10,PM2.5), NH3 and NOx ( ambient levels) and emissions from the stacks shall be monitored and displayed at a convenient location near the main gate of the company and at important public places. We have uploaded the status of compliance of the stipulated environmental clearance conditions including results of monitored data on our web site and we are also updating the same periodically. The same data has been submitted to Regional office of MoEF, CPCB and the Orissa Pollution Control Board respectively. We are monitoring the levels of RSPM (PM10, PM2.5), NH3 and NOx (ambient levels) and emissions from the stacks. The same data we are displaying at our main gate through electronic display board.
8 Specific energy consumption shall not exceed 5.127G.cal/MT of Urea production. Optimization of cycle of concentration (COC) to 6 and blow down frequency from the cooling towers shall be reduced.. This condition is not applicable to our industry since we are not manufacturing Urea.
9 Steam stripping system shall be installed in the ammonia plant to recover ammonia as well as bottom water from condensate. This condition is not applicable to our industry since we are not manufacturing ammonia
10 Total water requirement from Taladanda Canal shall not exceed 15,000 m3 /day and prior permission shall be obtained for drawl of water fro the competent authority. A copy of permission shall be submitted to the Ministry’s Regional Office at Bhubaneswar within 3 months of issue of environment clearance letter. Applied for renewal agreement
11 All the pond water shall be completely recycled and reused. Zero discharge shall be adopted and no waste water shall be discharged outside the premises. We are recycling all the gypsum pond water to process. Further Effluent Treatment plant has been installed for treatment of water and the treated water is being utilized in plantation.
12 The specific water consumption and waste water generation shall not exceed 5.1m3/MT of urea and 0.9 m3/MT of urea respectively. Accordingly the company shall undertake measures for water conservation. This condition is not applicable to our industry since we are not manufacturing Urea.
13 The waste water from Phosphoric acid Plant (gypsum slurry) shall be sent to gypsum pond. the overflow from PAP,DAP plant ,Offsite and entire effluent from SAP shall be treated in effluent treatment plant (ETP).The waste water from Captive Power Plant (CPP) shall be treated in neutralization tank. Waste water from the existing Gypsum pond shall be pumped to ETP for further treatment. Treated from ETP shall be reused in Ball Mill of PAP .The Sewage and all other effluents shall treated in the Sewage treatment plant (STP) and used for green belt development after meeting the norms specified by CPCB and OSPCB. We are sending the waste water from Phosphoric acid Plant (gypsum slurry) to gypsum pond. The overflow from PAP, DAP plant, Offsite and entire effluent from SAP are being treated in effluent treatment plant (ETP). The waste water from Captive Power Plant (CPP) is being treated in neutralization tank.. STP has been provided for sewage treatment and after treatment & meeting the norms specified by CPCB and OSPCB, the same is being used for green belt development.
14 Ground water shall be monitored in around the project site through peizometer wells as per CPCB guidelines. Presently we are monitoring ground water manually; however procurement of peizometer is under process and the same will be installed on receipt.
15 Another gypsum pond with protective liner shall be constructed as per recommendations of NEERI as per CPCB guidelines. New gypsum pond is being designed and finalized as per guidelines of CPCB/EC conditions. Application for Consent to Establish along with fees have been submitted to OSPCB. Construction will be started after obtaining the said Consent to Establish.
16 Phospho gypsum shall be sold to cement manufacturers or a granulation plant shall be installed as proposed to utilize Phospho gypsum. We have installed 240MT/day capacity Zypmite plant and received Consent to Operate .The plant is under trial run.
17 Spent Catalyst (V2O5) shall be properly stored as per the CPCB guide lines and disposed off to TSDF. Sulfur muck and ETP sludge shall be reused in-house as filler in DAP plant. Spent resin from DM plant shall be sold to authorized agency. Used or spent oil shall be disposed off to authorized reprocessor. Spent Catalyst (V2O5) is being properly stored in a covered area and will be disposed off to TSDF. We are reusing Sulfur muck and ETP sludge in-house as filler in DAP plant. Spent Resin has been disposed in Engineering Landfill area.. Used oil has been disposed off to authorized reprocessor.
18 As proposed green belt shall be developed in 854 acres (37%) out of 2282.4 acres. 854 acres(37%) greenbelt has been developed .
19 Action plan prepared for the complete remediation of the site shall be implemented in consultation with NEERI within 5 years of the issue of this environment clearance and six monthly report submitted to the Ministry and its Regional Office at Bhubaneswar. We are implementing action plan prepared for the complete remediation of the site in consultation with NEERI and the same will be completed before 5 years of the issue of this environment clearance.
20 All recommendation mentioned in the risk assessment report shall be implemented in a time bound manner and an action plan shall be prepared and submitted to the Ministry and its Regional Office at Bhubaneswar. We are implementing all recommendation mentioned in the risk assessment report Action plan will be submitted accordingly.
21 Risk analysis shall be done again after one year and report submitted to the Ministry and its Regional Office at Bhubaneswar. Efforts shall also be made to reduce risk mentioned in the risk assessment report. Risk assessment study for the year 2012 has already been taken up by M/s Ram Safety Consultants, Hyderabad. Action plan will be prepared based on the recommendations.
22 The ammonia unloading arms in the jetty shall be provide with “ Quick release couplings” for automatic disconnection of ships from unloading arm during unloading in case of bad weather. “Quick release coupling” has already been provided in ammonia unloading arms in the jetty .
23 Total quantity of ammonia storage in the plant shall not exceed 40,000Tons at a time. We will not exceed total quantity of ammonia storage in the plant 40,000Tons at a time.
24 The company shall undertake adequate protection measures for handling of ammonia vapor in case of plant upset condition. Safety valve exhaust and drains shall be connected to flare and vent stack. During transfer of materials spillage shall be avoided and garland drains shall be constructed to avoid mixing of accidental spillage with domestic waste and storm drains. Adequate measure has been provided for handling of ammonia vapor in case of plant upset. Safety valve exhaust and drains has been connected to flare and vent stack. Garland drains have been constructed to avoid mixing of accidental spillage with domestic waste and storm drains.
25 The company shall make the arrangement for protection of possible fire hazards as per OISD 117 during manufacturing process in material handling. We have full phase Fire & safety department along will state -of -art equipment, facilities to protect all possible fire hazards as per OISD 117 during manufacturing process in material handling.
26 Occupational health surveillance of the workers shall be carried out on a regular basis and records shall be maintained as per the Factories Act. We are maintaining the record as per the Factories Act. for Occupational health surveillance of the workers on regular basis
27 All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for fertilizer industries shall be implemented. All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for fertilizer industries have been implemented.
28 Provision shall be made for the housing of construction labor within the site with all necessary infrastructure and facilities such as fuel for cooking , mobile toilets, mobile STP ,Safe drinking water , medical health care ,crèche etc. The housing may be in the form of temporary structures to be removed after the completion of the project. All necessary infrastructure and facilities such as fuel for cooking, mobile toilets, mobile STP, Safe drinking water, medical health care, crèche etc. has been provided.
B. GENERAL CONDITIONS:
 Sl No  Conditions  Compliance status
1 The project authority shall strictly adhere to the stipulations of the Orissa Pollution Control Board (OPCB) / State Government or any statutory body. We are strictly adhering to all stipulations of the statutory bodies relevant to our plant.
2 No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. In case of deviations or alteration in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any. We shall not go for any expansion without prior approval of the Ministry.
3 The gaseous emissions (SO2, HCl, NOx, NH3, fertilizer dust) and particulate matter from various process units shall conform to the standards prescribed by the concerned authorities from time to time, Emission data shall be periodically monitored and reports submitted to Ministry’s Regional office at Bhubaneswar, CPCB and OPCB. We are strictly monitoring the gaseous emissions (PM2.5, PM10, SO2, NOx, and NH3 ) from various units . All the time, the emission levels are within norms Monitoring of parameters like HCL& Urea dust are not applicable to our Industry since we are not manufacturing Urea..
4 All the waste waters generated from the various processes shall be recycled/reused in the plant and zero discharge shall be maintained. The domestic waste water shall be treated in septic tanks and treated waste shall be used for irrigation in the green belt All the waste water are treated / recycled / reused as mentioned above under various column of the special conditions.
5 At no time the emissions shall exceed the prescribed limits. In the event of failure of any pollution control system adopted by the unit, the unit shall be immediately put out of operation and shall not be restarted until the desired efficiency has been achieved. We have taken maximum care not to exceed the emission limit as prescribed.
6 The locations of ambient air quality monitoring stations shall be reviewed in consultation with the OPCB and additional stations shall be installed, if required, in the down wind direction as well as where maximum ground level concentrations are anticipated. We have already reviewed those existing locations in consultation with the SPCB officials and continuing the monitoring at those points. Installation of one more station is under process.
7 Dedicated scrubbers and stacks of appropriate height as per the Central Pollution Control Board guidelines shall be provided to control the emissions from various vents. The scrubbed water shall be sent to ETP for further treatment. Scrubber and adequately high stacks are provided as per CPCB guidelines for control of emissions. All scrubbed water is taken to ETP for further treatment.
8 All the storage tanks will be under negative pressure to avoid any leakage. Breather valves, N2 Blanketing and secondary condensers with brine chilling system shall be provided for all the storage tanks to minimize vapor losses. All liquid raw materials shall be stored in Storage Tanks and drums. Tanks are operated and maintained as per design conditions and parameters as provided by the manufacturer.
9 The company shall undertake following Waste Minimization measures :
  • Metering and control of quantities of active ingredients to minimize waste.
  • Reuse of by products from the process as raw materials or as raw material substitute in other processes.
  • Use of automated filling to minimize spillage.
  • Use of closed feed system into batch reactors.
  • Venting equipment through vapor recovery system
  • Use of high pressure hoses for equipment cleaning to reduce waste water generation.
All the solid wastes generated from the process are being taken in the DAP as a filler except spent catalyst, gypsum and spent resin. All these materials are quantified.

Waste Material taken as filler are ;Sulphur Muck Storm water drain sludge ETP sludge Other conditions are also in place to minimize the waste. Other conditions are also in place to minimize the waste.
10 Fugitive emissions in work zone environment, product and raw material storage area shall be regularly monitored. The emissions shall conform to the limits imposed by the State Pollution Control Boards/ Central Pollution Control Board. We are regularly monitoring the fugitive emissions.
11 The project authorities shall strictly comply with the rules and guidelines under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008 as amended time to time. We are abiding by all the rules as mentioned under Manufacture. Storage and Import of Hazardous Chemicals Rules, 1989 and Hazardous Waste (Management, Handling and Trans-boundary Movement) Rules, 2008 as amended time to time.
12 The overall noise levels in and around the plant area shall be kept well within the standards by noise control measures including acoustic hoods , silencers, enclosures etc on all sources of noise generation. The ambient noise level shall conform to the standards prescribed under Environment (Protection) Act , 1986 Rules,1989 viz. 75dBA(day time) and 70 dBA( night time). Ambient noise levels are being measured in 8 locations. Stationary noise levels are being monitored at different locations of the plant.
13 The company shall develop rain water harvesting structures to harvest the run off water for recharge of ground water. The average ground water table in the project area is 2 to 3 meters below ground level. During rainy season almost all open area are submerged. To protect the area from water contamination during rainy season, the following steps are under taken.
  1. All contaminated areas in the plant premises are segregated.
  2. Precipitated water over contaminated areas is diverted to ETP through effluent drain for treatment.
  3. Other non contaminated area water is discharged to river through storm water drain.
  4. Storm drain water is tested for pH, fluoride and phosphate during rainy season before being discharged to the river.
  5. Storm water drain is regularly cleaned before rainy season for free flow of storm water.
  6. PPL has number of open ponds inside PPL Township that naturally receive surface runoff of the township area during rainy season and recharge the ground water.
14 The company shall undertake eco developmental measures including community welfare measures in the project area for the overall improvement of the environment. The eco development plan should be submitted to the SPCB within three months of receipt of this letter for approval. An integrated approach was aimed to ensure eco system restoration for sustainable development.
15 A separate Environment management cell equipped with full fledged laboratory facilities shall be set up to carry out the Environmental Management and monitoring functions. Environment management cell is already in place. It carries out all relevant Environmental Management and monitoring functions.
16 As proposed, Rs 25.02 Crores and Rs 1.24 Crores shall be ear marked towards capital cost and recurring cost / annum for pollution control measures to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State government along with the implementation schedule for all the conditions therein. The funds so provided shall not be diverted for any other purpose. No funds will be diverted. We shall be submitting the expenditure report in next six monthly compliance report.
17 The implementation of the project vis-à-vis environmental action plans shall be monitored by the concerned Regional Office of the Ministry / OPCB/CPCB. A six monthly compliance status report shall be submitted to monitoring agencies and shall be posted on the website of the company. We are submitting a six monthly compliance status report to OSPCB and posting the same data in website of the company.
18 A copy of the clearance letter shall be sent by the proponent to the Panchayat, Zila Parishad/ Municipal Corporation, Urban local Body and the local NGO, if any from whom suggestions / representations, if any were received while processing the proposal. We have sent the copy of the clearance letter to the Panchayat, Zila Parishad/ Municipal Corporation, Urban local Body and the local NGO.
19 The project proponent shall also submit six monthly reports on the status of compliance of the stipulated EC conditions including results of monitored data ( both in hard copies as well as by e mail) to the respective Regional Office of MoEF, the respective zonal office of CPCB and the Orissa Pollution Control Board. We have submitted the six monthly reports on the status of compliance of the stipulated EC conditions including results of monitored data (both in hard copies as well as by e mail) to the respective Regional Office of MoEF, the respective zonal office of CPCB and the Orissa Pollution Control Board..
20 The environmental Statement for each financial year ending 31st March in Form-V as is mandated shall be submitted to the concerned State Pollution Control Board as prescribed under the Environment(Protection) Rules,1986 as amended subsequently shall also be put on the website of the company along with the status of compliance of environmental clearance conditions and shall also be sent to the respective Regional offices of MoEF by e-mail. The environmental Statement for each financial year ending 31st March in Form-V has been submitted to the State Pollution Control Board and the same has been displayed in company website.
21 The project proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the OPCB/Committee and may also be seen at Website of the Ministry at http:/envfor.nic.in. This shall be advertised within seven days from the date of issue of the clearance letter at least in two local news papers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the concerned Regional office of the Ministry. We have informed the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the OPCB/Committee. Advertised has been done within seven days from the date of issue of the clearance letter in two local news papers that are widely circulated in the region of which one is in the vernacular language of the locality concerned and a copy of the same has already forwarded to the concerned Regional office of the Ministry.
22 The project authority shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of start of the project. PPL has already informed the date of financial closure and date of final approval of the project to the Regional Office.MoEF, Bhubaneswar.