iffco aonla unit
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IFFCO AONLA UNIT - ENVIRONMENT
INTRODUCTION
During mid- sixties the Co-operative sector in India was responsible for
distribution of 70 per cent of fertilisersconsumed in the country. This Sector
had adequate infrastructure to distribute fertilisers but had
no productionfacilities of its own and hence dependent on public/private
Sectors for supplies. To overcome this lacuna and to bridge the demand
supply gap in the country, a new cooperative society was conceived to
specifically cater to the requirements of farmers. It was an unique venture
in which the farmers of the country through their ownCo-operative
Societies created this new institution to safeguard their interests. The
number of Co-operative Societies associated with IFFCO have risen from 57
in 1967 to 39,824 at present.
Indian Farmers Fertiliser Co-operative Limited (IFFCO) was registered on
November 3, 1967 as a Multi-unit Co-operative Society. On the enactment
of the Multistate Co-operative Societies act 1984 & 2002, the Society is
deemed to be registered as a Multistate Co-operative Society. The Society is
primarily engaged in production and distribution of fertilisers.
The byelaws of the Society provide a broad frame work for the activities of
IFFCO as a Co-operative Society.
IFFCO commissioned an ammonia - urea complex at Kalol and
the NPK/DAP plant at Kandla both in the state of Gujarat in 1975. Another
ammonia - urea complex was set up at Phulpur in the state of Uttar Pradesh
in 1981. The ammonia - urea unit at Aonla was commissioned in 1988.
In 1993, IFFCO had drawn up a major expansion programme of all the four
plants under overall aegis of IFFCOVISION 2000. The expansion projects at
Aonla, Kalol, Phulpur and Kandla were completed on schedule. All the
projects conceived as part of VISION 2000 had been realised without time
or cost overruns. All the production units of IFFCO have established a
reputation for excellence and quality. Another growth path was chalked out
to realise newer dreams and greater heights through Vision 2010. As part of
this vision, IFFCO has acquired fertiliser unit at Paradeepin Orissa in
September 2005. As a result of these expansion projects and acuisition,
IFFCO's annual capacity has been increased to 3.69 million tonnes of Urea
and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its growth and
development, IFFCO had embarked upon and successfully implemented its
Corporate Plans, ‘Mission 2005’ and ‘Vision 2010’. These plans have
resulted in IFFCO becoming one of the largest producer and marketeer of
Chemical fertilisersby expansion of its existing Units, setting up Joint
Venture Companies Overseas and Diversification into new Sectors.
IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’ which
is presently under implementation.
IFFCO has made strategic investments in several joint ventures. Godavari
Fertilisers and Chemicals Ltd (GFCL) & Indian Potash Ltd (IPL) in India,
Industries Chimiques du Senegal (ICS) in Senegal and Oman India Fertiliser
Company (OMIFCO) in Oman are important fertiliser joint ventures. As part
of strategic diversification, IFFCO has entered into several key
sectors. IFFCO-Tokio General Insurance Ltd (ITGI) is a foray into general
insurance sector. Through ITGI, IFFCO has formulated new services of
benefit to farmers. 'Sankat Haran Bima Yojana' provides free insurance
cover to farmers along with each bag of IFFCO fertiliser purchased. To take
the benefits of emerging concepts like agricultural commodity trading,
IFFCO has taken equity in National Commodity and Derivative Exchange
(NCDEX) and National Collateral Management Services Ltd (NCMSL).
IFFCO Chattisgarh Power Ltd (ICPL) which is under implementation is yet
another foray to move into core area of power. IFFCO is also behind several
other companies with the sole intention of benefitting farmers.
The distribution of IFFCO's fertiliser is undertaken through over 39824 Co-
operative Societies. The entire activities of
Distribution, Sales and Promotion are co-ordinated by Marketing Central
Office (MKCO) at New Delhi assisted by theMarketing offices in the field.
In addition, essential agro-inputs for crop production are made available to
the farmers through a chain of 158 Farmers Service Centre (FSC). IFFCO
has promoted several institutions and organisations to work for the welfare
of farmers, strengthening cooperative movement, improve Indian
agriculture. Indian Farm Forestry Development Cooperative Ltd (IFFDC),
Cooperative Rural Development Trust (CORDET), IFFCO
Foundation,Kisan Sewa Trust belong to this category. An ambitious project
'ICT Initiatives for Farmers and Cooperatives' is launched to promote e-
culture in rural India. IFFCO obsessively nurtures its relations with farmers
and undertakes a large number of agricultural extension activities for their
benefit every year.
At IFFCO, the thirst for ever improving the services to farmers and member
co-operatives is insatiable, commitment to quality is insurmountable and
harnessing of mother earths' bounty to drive hunger away from India in an
ecologically sustainable manner is the prime mission. All that IFFCO
cherishes in exchange is an everlasting smile on the face of Indian Farmer
who form the moving spirit behind this mission.
IFFCO, to day, is a leading player in India's fertiliser industry and is making
substantial contribution to the efforts of Indian Government to increase
foodgrain production in the country.
In 1993, IFFCO had drawn up a major expansion programme of all the four
plants under overall aegis of IFFCO VISION 2000. The expansion projects
at Aonla, Kalol, Phulpur and Kandla were completed on schedule. All the
projects conceived as part of VISION 2000 had been realized without time
or cost overruns. All the production units of IFFCO have established a
reputation for excellence and quality. Another growth path was chalked out
to realise newer dreams and greater heights through Vision 2010. As part of
this vision, IFFCO has acquired fertilizer unit at Paradeep in Orissa in
September 2005. As a result of these expansion projects and acquisition,
IFFCO's annual capacity has been increased to 3.69 million tonnes of Urea
and NPK/DAP equivalent to 1.71 million tonnes. In pursuit of its growth and
development, IFFCO had embarked upon and successfully implemented its
Corporate Plans, ?Mission 2005? and ?Vision 2010?. These plans have
resulted in IFFCO becoming one of the largest producer and marketeer of
Chemical fertilizers by expansion of its existing Units, setting up Joint
Venture Companies Overseas and Diversification into new Sectors.
During mid- sixties the Co-operative sector in India was responsible for
distribution of 70 per cent of fertilizers consumed in the country. This Sector
had adequate infrastructure to distribute fertilizers but had no production
facilities of its own and hence dependent on public/private Sectors for
supplies. To overcome this lacuna and to bridge the demand supply gap in
the country, a new cooperative society was conceived to specifically cater to
the requirements of farmers. It was an unique venture in which the farmers
of the country through their own Co-operative Societies created this new
institution to safeguard their interests. The number of Co-operative Societies
associated with IFFCO have risen from 57 in 1967 to 39,824 at present.
Awards / Recognition
Awards
Aonla wins CII Environmental Best PracticesAward-2011
Safety Innovation Award - 2010
Greentech Gold Award for Training Excellence
IFFCO Aonla Unit has been awarded the 'EDGE' winner prize
ICWAI Award for Excellence in Cost Management - 2009 for IFFCO
IFFCO Shines at Public Relation Society of India, Grabbed 2 prestigious
awards
IFFCO Aonla & Paradeep Unit have won the prestigious FAI awards
presented on 3rd Dec.'2009
IFFCO Aonla Wins "Gold Award“ - 10th Annual Greentech Environment
Excellence Award 2009
IFFCO bagged First ever dotCoop Global Award for Cooperative Excellence
IBM Awards First Prize to IFFCO for Innovation
IFFCO Phulpur Unit-I bagged "First Prize" by FAI.
CIO 100 & IT Awards
Microsoft Felicitates IFFCO
National Energy Conservation 2008 - 1st Award Conferred on Phulpur Unit
Gujarat State Safety Award : 2007 for Kalol Unit
IFFCO bags three FAI Awards
IFFCO bags Energy conservation award
IFFCO Wins PRSI Award
Phulpur Unit Wins National Energy Conservation Award-2006
Aonla Unit wins National Energy Conservation Award-2006
IFFCO's Corporate Film Wins NCUI's Award.
IFFCO Kalol Wins "National Energy Conservation Award: 2006"
Kandla Unit wins FAI Prize
IFFCO Aonla Wins National Safety Award
Kandla Unit Wins - Golden Peacock Environment Management Award
Phulpur Unit bags National Energy Award from Honourable President of
India
Best Managed Work Force Award for IFFCO
IFFCO Aonla Unit Wins National Safety Council of India Safety Award-
2004
Aim / Vision / Mission
Mission
IFFCO's mission is "to enable Indian farmers to prosper through timely
supply of reliable, high quality agricultural inputs and services in an
environmentally sustainable manner and to undertake other activities to
improve their welfare"
-To provide to farmers high quality fertilizers in right time and in adequate
quantities with an objective to increase crop productivity.
-To make plants energy efficient and continually review various schemes to
conserve energy.
-Commitment to health, safety, environment and forestry development to
enrich the quality of community life.
-Commitment to social responsibilities for a strong social fabric.
-To institutionalise core values and create a culture of team building,
empowerment and innovation which would help in incremental growth of
employees and enable achievement of strategic objectives.
-Foster a culture of trust, openness and mutual concern to make working a
stimulating and challenging experience for stake holders.
Vision
To augment the incremental incomes of farmers by helping them to increase
their crop productivity through balanced use of energy efficient fertilizers,
maintain the environmental health and to make cooperative societies
economically & democratically strong for professionalized services to the
farming community to ensure an empowered rural India.
To keep pace with the stringent environmental regulations and to maintain
ecological balance, zero effluent technology for ammonia and urea plants
have been selected at the outset . The quality of liquid effluent discharge
from the factory is monitored continuously and remains much lower than the
norms prescribed by the Uttar Pradesh pollution control board. The lagoons
constructed to store the treated liquid effluent attract a large number of
migratory birds specially during winter seasons. This speaks of the quality of
the environment near the unit. The air quality is constantly monitored by
providing high volume samplers at different locations around the factory
campus. Eighty meter wide green belt has been developed around the factory
and the township to keep the environment clean. Till date more than 15.0
lakhs trees have been planted
Picture of IFFCO Aonla Township Deer Park
METHODOLOGY FOR ENVIRONMENT PROTECTION
Methodology for environment protection starts with identification of all the
activities, which have a substantial environmental impact. These are:
Air emission quality and quantity
Effluent quality and quantity
Hazardous waste generation
Non hazardous waste generation
Consumption & conservation of Natural resources.
Ensure compliances with National Environmental Quality Standards,
Rules & Regulations covered under Environmental Protection Act,
1986.
Compliances with The Kyoto Protocol (GHG reduction)
Recycle and reuse of the wastes generated
Ammonia odor in the plant
Noise
ENVIRONMENTAL MANAGEMENT SYSTEM AT IFFCO AONLA
IFFCO Aonla Unit has sound environmental management system
comprising of following features:-
Afforestation
Zero Effluent Technology
Social Forestry
Monitoring of ambient air and stack emissions
Well Equipped laboratory & E&PC cell to monitor environmental
parameters
Development of all-round awareness regarding environmental issues
ISO-14001:2004 (EMS) Accreditation
AFFORESTATION
Once a wasteland, IFFCO Aonla not only has come up as a hope for millions
of farmers but also a true success story of unstinted and dedicated efforts of
employees who have turned up the desert land to a Lush Green Fertiliser
Complex. The dream of Green-Land comes through IFFCO’s never ending
commitment to the society, dedicated and innovative handwork of its
employees towards Protection of Environment.
Top management while implementing all the plans for afforestation has
taken the philosophy from the Vedas which has been aptly expressed in the
following Sanskrit Shloka :-
“Moolo Bramharoopaya Madhyalo Vishnuroopaiae,
Agarato Shivaroopay Vraksharayay te Namah”
Meaning –
“From root to stem to crown,
Thou art the incarnation of Brahma, Vishnu & Shiva
My salutations to the Oh noble tree”
The eco-friendly environment has attracted a large population of birds of
various species. It is ecstatic to watch peacocks dancing all over the green
belt. It is an oasis of serenity and pollution free environment.
The success story of IFFCO Aonla’s 330 acres of green cover embellished
with around 2 lakh trees of wide variety of about 40 species including some
of the exotic species, verdant lawns and recreational parks reveal excellence
attained through hard work of employees and vision of management.
An 80m wide green belt is developed at the Northern and Eastern sides of
IFFCO Fertiliser Complex and 250 m along with interface of township and
plant. Continuous replantation of dead trees is carried out and overall green
cover is also extended
POLLUTION ABATEMENT SCHEMES IMPLEMENTATED/UNDER
IMPLEMENTATION AT IFFCO AONLA UNIT
Purge Gas recovery unit to recover Hydrogen, which was burnt in
reformer.
Condensates stripper for purification and reuse of Ammonia, CO2 and
Methanol bearing process condensate.
Recycle of contaminated turbine condensate by using Carbon Filter
and Polishers.
Reuse of Boiler Blow down.
Separation and collection of oil by means of Disc Oil separator.
Treatment of Ammonia and Urea bearing waste by Deep Hydrolyser
and Distillation Column in Urea Plants.
Provision of Acidic and Alkaline effluent storage and neutralisation
facilities near ION Exchangers in Plant Battery limit and using them
separately for pH adjustment.
Creation of “centralised strippers and 2 nos. of Guard Ponds for
storage/ equalisation of treated effluent before its utilisation in green
belt development or letting on to river Aril. These guard ponds are attracting
lot of birds especially during winter season.
Provision of dedusting system at Prilling tower top to check dust
emission.
In built Sulphur dioxide, Nitrogen Oxide, Analysers in a flue gas
stacks.
Ammonia, pH, Urea analysers and Auto samplers at different location
in treated effluent line.
Use of Eco-Friendly Non-Chromate treatment for cooling towers
since March, 1999.
Dust collection system at PH Plant.
Developed green belt around factory and township complex. A 50 m
wide green belt throughout the periphery of the plant site and 200 m
deep belt on the Southern side of plant alongwith additional
aforestation in township has been completed.
Environment Management System in accordance with ISO-
14001:2004 has been implemented.
Use of 85 % of treated effluent for irrigation purposes in green belt
SOLID WASTE MANAGEMENT AT IFFCO
CEE North is working with IFFCO’s unit based in Aonla, Bareilly on Solid
Waste Management programme since 2006. The main objective of
programme is to create awareness about the importance of waste
management and to operate the SWM system and to handle household and
horticulture waste generated in the residential colony and plant.
The Solid Waste Management (SWM) system is being implemented by CEE
where waste is being collected from the IFFCO, Aonla Township which
includes around 1100 houses, kitchen gardens, canteens, public places, etc.
A project implementation team is working on the site involving Project
Manager, a Supervisor and 10 waste collectors. The process followed for the
SWM system is collection, transportation, making beds, transferring to pits
and final product packaging. The methodology being followed is the
combination of anaerobic composting and vermi-composting. Segregated
non-biodegradable waste goes under recycling process on weekly basis.
CEE conducts various education and awareness programmes for residents
and school children to sensitize them towards proper disposal of waste. An
awareness and education drive is regularly organized where residents are
told about the SWM process in the area. Training programmes are organized
for the officials and residents of IFFCO Aonla Township. CEE organizes
interactive programme to motivate the maid servants of IFFCO Township
for waste segregation at vermi composting site. Representatives explain the
process of SWM system and emphasize on the need of segregating the waste
properly.
Various school level events are being organized regularly by CEE not only
for the children from the campus but also for the schools of Bareilly.
ZERO EFFLUENT TECHNOLOGY
The environmental management approach adopted at IFFCO Aonla for
pollution abatement is based on following schemes :-
Ammonia and steam/power generation plants utilise the Natural gas from
Bombay High Bassein which contains about 93% methane, 10 ppm (max)
total sulphur as feed and fuel. The two streams Ammonia Plant with a
capacity of 2x1740 MTPD is based on Haldor Topsoe technology. To
achieve zero effluent from the plant, it has Process Condensate Stripper,
Turbine Condensate Polishing unit for recycle of process and turbine
condensates. Boiler blow down is also used as cooling tower make up after
flashing in a flash vessel. The L.P. steam generated is fed to L.P.steam
header.
The Urea Plant is based on Snamprogetti technology having four parallel
streams each with 1515 MTPD capacity each. In this technology, ammonia
acts as a stripping agent and assists in the decomposition of carbamates. The
plant has Waste Water Treatment section, where the Urea bearing waste
containing 0.98% urea and 4.76% ammonia is treated in Deep Urea
Hydrolyser with 37 ata steam which recovers Carbon dioxide and ammonia
from waste-water and recovered materials are recycled in process. There is
one effluent collection pit for collection of floor washings and occasional
waste to be treated separately in “Centralised Effluent Treatment Plant”.
(A) PROCESS CONDENSATE TREATMENT AND RECYCLE
The contaminated process condensate stripping is carried out in the Carbon
dioxide and condensate stripper with L.P.steam. After stripping off the
impurities like CO2, NH3 and CH3OH; the stripped condensate is further
treated in polishing unit before recycling as Boiler Feed Water.
The gaseous overhead product is condensed in overhead condenser for
recycle as reflux and a part is reused in reforming section.
(B) TURBINE CONDENSATE RECYCLE
Turbine condensate coming from the condensers is contaminated with small
quantity of dissolved and undissolved solids. It is treated in the Condensate
Polishing Unit of Ammonia Plant itself. The Polishing Unit comprises of
activated carbon filter to remove organic and undissolved matter and mixed
bed unit to remove dissolved solids.
(C) REUSE OF BOILER BLOW DOWN
The boiler blow-down is flashed in a blow down vessel where flashed
saturated L.P. steam is separated from steam condenste.
(D) SEPARATION AND COLLECTION OF OIL FROM OILY WATER
The spilled oil in the plant is collected through underground PVC pipes to an
oily-water basin. Here oil and water forms two phases with oily layer at the
top. The oil is skimmed off in the oily-water disc unit of Disc-oil separator
and transferred to slop oil tank. From this tank, oil is collected in drums for
disposal. The waste water from slop oil basin is pumped to the neutralisation
pit.
(E) TREATMENT OF AMMONIA AND UREA BEARING WASTE IN
UREA PLANT
The process drainage containing Ammonia and Urea flows to an
underground tank through S.S.piping which inturn is pumped to Waste
Water Tank. The process drainage from waste water tank is pumped to
stripping column of Distillation Tower. The exhaust solution from the
stripping column containing mainly Urea and traces of Ammonia and
Carbon dioxide is fed to Deep Hydrolyser operating at 37 ata pressure. The
hydrolysed solution is fed to the Distillation Tower where in rest of
Ammonia and Carbon dioxide is distilled out by using L.P.steam. The over
head vapours from the top of Stripping Column containing recovered
Ammonia and Carbon dioxide are condensed and reused. The treated water
is used as C.T.make up or Boiler Feed Water.
(F) NEUTRALISATION OF ACIDIC AND ALKALINE WASTE
Ammonia and Water Treatment plants are having ION exchangers for
turbine condensate and D.M.water preparation. During regeneration of ION
exchangers, alkaline and acidic wastes are generated. To neutralise the
acidic and alkaline waste, both the plants are having independent
neutralisation and pumping facilities. Both the neutralisation pits of
Ammonia and Water Treatment Plants are connected to “Centralised
Effluent Treatment Plant”.
(G) TREATMENT OF OCCASIONAL WASTE FROM AMMONIA AND
UREA PLANTS
The Ammonia bearing waste from Urea plant and/or Ammonia plant during
abnormal condition is collected into a contaminated effluent holding pit of
500 M3 capacity the alkaline effluent from Demineralising Plant and lime
solution is added at controlled rate to maintain pH at 11. The effluent after
filtration and preheating is sent to Air Stripper for stripping of free
Ammonia. The air stripped effluent is further heated and residual Ammonia
is further removed by L.P.steam stripping in Steam Stripper. The treated
effluent is sent to “Treated Effluent Lagoons/Guard ponds”. There are two
numbers of Guard Ponds at the terminal end, each having holding capacity
of 85,000 M3. These ponds are quite safe from environmental angles as they
are double lined with P.C.C. and low-density polyethylene (L.D.P.) sheets.
SOCIAL FORESTRY
A local nursery was developed at site (in Township) to grow seedlings of a
wide variety of plants. The different varieties are :-
FAST GROWING TREES
Casurina
Accasia
Eucalyptus
Cassia Siamea
Gulmohar
Kanji
USEFUL TREES
Neem
Arjeun
Peepal
Amaltas
Silver Oak
Mango
Guava
Banana
Pomergranate
Ashok
Trees are distributed free of cost to local residents of IFFCO township and
residents of nearly villages as well as utilised for green belt development at
IFFCO Aonla Fertiliser Complex.
Four ambient air-monitoring stations around the factory have been made in
consultation with U.P.Pollution Control Board for monitoring Sox, Nox,
NH3 & dust. The analysis report of ambient air is being forwarded regularly
to UPPCB.
Stack’s Emission
IFFCO Aonla laboratory monitors following stacks regularly for Sox, Nox
& CO etc. and reports are being sent to UPPCB on monthly/quarterly and
yearly basis :
Name of Stack Height of Stack from G.L.
SG stack (01 no.) 120 m
HRSG stack (02 nos.) 30 m
Urea Prilling tower (02 nos.) 96 m & 98 m
HRU stack 30 m
Flue Gas Stack (02 nos.) 30 m
WELL EQUIPPED LABORATORY AND ENVIRONMENT &
POLLUTION CONTROL CELL TO MONITOR ENVIRONMENTAL
PARAMETERS
A well equipped Environmental Management Laboratory monitors quality
of ambient air samples by analysing suspended particulate matter,
Ammonia, Sulphur dioxide, Nitrogen oxides and Carbon-monoxide
regularly. Anemometer is also installed to know the wind velocity alongwith
wind directions.
One continuous sampler is also installed in the lagoon discharge channel for
composite sampling of treated effluent going to Aril River. River water
analysis are also carried out before and after the point of confluence of
effluent to assess the impact of treated effluent, discharged into river Aril.
IFFCO Aonla Lab is equipped with Gas Chromatograph, U.V.
Spectrophotometer, Plasma Analyser, Flame Photometer, Flue Gas
Analyser, Atomic Absorption Spectrophotometer, Orion analyser etc.
In addition to Env. Management Laboratory, IFFCO Aonla is having an
E&PC cell to fulfil statutory requirements laid down by U.P.P.C.B &
C.P.C.B and co-ordinating activities relating to environment among various
sections.
DEVELOPMENT OF ALL ROUND AWARENESS REGARDING
ENVIRONMENTAL ISSUES
IFFCO Aonla not only operates Pollution Abatement devices successfully
but also provides regular awareness to employees and nearly villagers
regarding environmental issues. Almost all the employees are covered
regularly on various issues like conservation of natural resources, effect of
pollutant on health & various statutory regulations regarding environment.
Moreover nearby villages are also covered by celebrating & participating in
world Environment Day
As no system is contemporary unless standardised against some
internationally approved / adopted system. It is a matter of great pride that
Aonla Unit has been certified for ISO-14001:2004 by M/s BVQI. IFFCO
Aonla Unit is having a well defined environmental policy in line with
corporate SHE (Safety, Health & Environment Policy signed by Managing
Director). The policy states:
IFFCO Aonla Unit is committed for continual improvement and protection
of environment by setting and reviewing the objectives and targets through
Environmental Management Systems focusing at:
- Compliance of applicable legislation at work place and other requirements,
which the organization subscribe.
- Monitoring and conserving natural resources.
- Effluent and waste minimization by way of recycling and reuse.
- Developing awareness and competence amongst Employees, Contractor’s
Staff and Related Agencies on Environmental issues.
- Emergency preparedness for safety of concerned personnel and plant.
ENVIRONMENTAL OBJECTIVES FOR YEAR 2010-11
- To reduce Urea spillage to 250 MT / month.
- To reduce Water consumption below 5.0 M3 / MT of Urea production.
- To plant minimum 15,000 trees in plant and township.
- To bring awareness among Employees, Trainees and contractor’s staff etc.
on environmental issues to minimum 450 participants.
AWARDS RECEIVED FOR ENVIRONMENTAL MANAGEMENT
IFFCO Aonla Unit has received many prestigious awards in the field of
prevention of Pollution and Protection of Environment by implementing
Environmental Management System.
· 10th Greentech Environment Excellence Gold Award-2009 for outstanding
achievement in Environment Management.
· National Award for Prevention of Pollution for the year 2007-08 under
Fertiliser Category from GOI Ministry of environment & forest.
· 2nd Prize for the 8th TERI Corporate Environment Award-2009 for it’s
efforts towards environmental management and innovative
initiatives amongst corporations with a turnover above 1000 crore rupees.
· Golden Peacock Environment Management Award-2008 by World
Environment Foundation, UK for implementation of best
environmental management practices and implementation of CDM project
by the company