Company Profile

Krishak Bharati Cooperative Ltd (KRIBHCO) is a Multi-State Cooperative Society deemed

to be registered under the Multi-State Cooperative Societies (MSCS) Act, 2002. The
Government of India through the Department of Fertilizers was a member of KRIBHCO
but its equity holding was reduced to NIL on 4TH July 2013 under the provisions of the
MSCS Act 2002. KRIBHCO is not owned nor controlled nor financed by the Government
of India / Any State Governments.
KRIBHCO was incorporated on 17th April 1980 as a national level Multi State Cooperative
Society to implement first gas based “state-of-the-art” high capacity Fertilizer Complex
consisting of 2 x 1350 MTPD Ammonia plants and 4 x 1100 MTPD Urea plants each with
annual installed capacity of 8.91 Lakh MT Ammonia and 14.52 lakh MT of Urea at Hazira
District-Surat, Gujarat, India based on natural gas from Bombay High/ South Bassein.
Hazira fertilizer complex was commissioned in 1985 in record time with saving of Rs. 90
crore in project cost.
In an endeavor to make constant improvements, KRIBHCO implemented various
schemes to enhance its capacity and improve the energy consumption. Capacities of
ammonia & urea plants were reassessed to 2x1520 MTPD Ammonia and 4x 1310 MTPD
Urea with annual installed capacity of 10.03 Lakh MT ammonia and 17.29 lakh MT of
urea.
The Hazira Fertilizer Complex was subsequently revamped in 2013 to increase its
production capacity by 4.65 LMTPA of Urea. After the revamp, the rated capacity has
been enhanced to 2x3325 MTPD Urea (21.95 LMTPA) and 2 x 1890 MTPD Ammonia
(12.47 LMTPA). With this, the Hazira fertilizer complex has became largest single location
urea plant in India.We also embrace our responsibility towards the community through
social initiatives in rural development, education and healthcare.
Expansion & Diversifications
KRIBHCO has also made realignment in its corporate strategy and internal operations
revamping to meet the challenges in the liberalized/globalized economy. As a part of
above initiative, KRIBHCO entered into overseas Joint Ventures, diversification into
Power Sector, Logistics Business, etc
 In 2005, KRIBHCO’s Joint Venture project with Oman Oil Company came on
stream in Sultanate of Oman. KRIBHCO holds 25% equity in OMIFCO.
 Kribhco Fertilizer Limited(formerly Kribhco Shyam Fertilizer Ltd) is a 100%
subsidiary of KRIBHCO.
  KRIBHCO has diversified into power sector by investing in Gujarat State Energy
Generation (GSEG).
 KRIBHCO incorporated Kribhco Infrastructure Limited, a 100% subsidiary to
venture into logistics business
 KRIBHCO holds 2.34% equity in Nagarjuna Oil Refinery Limited and 1.84% in
Nagarjuna Fertilizers and Chemicals Ltd
 KRIBHCO holds 5% equity in Indian Commodity Exchange (ICEX)
New products and marketing initiatives
 KRIBHCO has been promoting the use of bio-fertilisers since many years. The
society has three units to manufacture bio-fertilisers at Hazira (Gujarat), Varanasi
(Uttar Pradesh) and Lanjha (Maharashtra).
 Keeping in view importance of the Quality Seeds in enhancing the agricultural
production, KRIBHCO initiated Seed Multiplication Programme in the year 1990-
91 to provide quality certified seeds of the crops.
 KRIBHCO is also marketing high yield Hybrid seeds of various crops like Bt
Cotton.
 KRIBHCO imports and markets other fertiliser like DAP, DAP-Lite and MOP etc
from time to time.
 Organic Agriculture has emerged as a feasible option to address concerns relating
to land degradations. KRIBHCO regularly undertakes marketing of compost made
from city waste.
 In a nut shell KRIBHCO, world’s premier fertilizer producing cooperative has an
outstanding track record to its credit in all spheres of its activities. KRIBHCO has
fully imbibed the cooperative philosophy and has made sustained efforts towards
promoting the cause of modern agriculture and cooperatives in the country.
KRIBHCO stands for commitment, sincerity and high standards of excellence. In
our endeavor towards achieving our goals we are impelled by the ideals set by our
predecessors and the devotion and dedication of our employees. We are ISO
9001, ISO 9002, and ISO 14001 certified organization.
3
4 PROCESS DESCRIPTION:
5
6 M/S. KRIBHCO Hazira plant has two manufacturing Phases: The main plant
consists of Two Ammonia plants, total capacity 3040 MTPD & Four Urea Plants,
total Capacity 5240 MTPD. The company has enhanced the capacities to 3780
MTPD of Ammonia &6650 MTPD of Urea. Subsequently, capacities of the bi-
 products, namely Argon & Bio-Fertilizers have increased to 21,600 NM3/hr. & 25
lakhs liter respectively.

7 The supporting facilities include Raw Water Storage, Water pre -treatment, DM
Water plant, Steam & Power Generation plant, Instrument Air, Plant Air & Inert Gas
plant, Urea Storage, Ammonia and NGL/ Naphtha storage and Product Handling.

8 The plant while on full production consumes everyday 4.3MMSM3 Natural Gas and
9 8.0 million gallons of Water to produce 6650 MT of Urea. Apart from the above
main raw materials varying quantities of chemicals like HCL, NaOH, DEA, H2SO4
Alum, etc will be used in process. Natural Gas and NGL/ARN are received through
pipeline from ONGC located at about 5 km. away from the KRIBHCO site.

10 Total area of the factory is 735 hectares and average no. of employees including
contract workers are 1212 approximately, whereas maximum No. of persons at a
time present inside the factory are 1200 approximately.

11 AMMONIA PLANT
12
13 There are two streams of Ammonia plants each of 1890 MTPD capacity based on
the renowned KBR Purifier technology. The gas obtained from ONGC/GAIL is
preheated and de-sulphurised to remove sulphur. After de-sulphurisation natural
gas mixed with steam and preheated by reformar flue gas and passed through the
catalyst tubes containing Ni catalyst in the primary reformer. To provide the heat
required for endothermic reaction, the tubes are heated externally to maintain the
gas outlet temperature 706 0C. The Hydrocarbons after reforming produces CO,
CO2 , H2 and unconverted CH4 and H2O. This partially reformed gas mixture is
passed on to the secondary reformer wherein excess preheated air is added in
proportion to supply the N2 for purifier process as well as heat required to
complete the reforming. The outlet of secondary reformer process gas at 9000C
contains H2, N2, CO, CO2, unconverted CH4, Argon and H2O.The heat from the
process gas is recovered in
14

15 waste heat boiler and send to high temperature and low temperature shift converter
at 3400C and 1950C respectively to convert CO into CO2 in the process gas. The
exothermic heat generated in shift converter is recovered in waste heat boiler,
gas/gas exchanger and boiler feed water exchanger.

16 To remove the CO2 from the process gas, The process gas is treated in CO2
removal section where CO2 is being absorbed in aMDEA solvent in absorber and
then regenerated in stripper, The heat required for regeneration is supplied from the
process gas in re-boiler, The CO2 produced is send to UREA plant as a raw
material for UREA. The process gas after removal of CO2, mainly contains H2, N2,
CH4, Ar and residual amount of CO and CO2. The CO and CO2 is then converted
to CH4 in the Methanator. The Process gas after methanation mainly contains H2 ,
N2, CH4, Ar and water and traces amount of CO, CO2. The gas mixture containing
H2 and N2 in the ratio 2:1 is then send to drier after cooling in chiller to 40C. The
Drier outlet gas becomes free from moisture, CO2 and NH3 ( Total <1 PPM) is then
send to purifier. In the purifier the excess N2 along with CH4 and Ar is separated
from the process gas and the purifier outlet process gas contains 3:1 H2 /N2 ratio
required for conversion to NH3. The separated liquid mixture of CH4, N2, Ar and
along with saturated H2 in the purifier is send to furnace to use as a fuel. The outlet
process gas from the purifier called as a synthesis gas is then compressed to 180 -
185 Kg/Cm2G in syn gas compressor in four stage and send to ammonia
converter. Part of the gas is converted to ammonia in the converter. The ammonia
produced is separated from the unconverted syn gas by chilling in ammonia chiller.
The unconverted syngas again sends to converter after mixing with fresh make up
gas to convert in to ammonia. The ammonia produced is used as a chilling media
in the refrigeration system and then send to Urea plant as a raw material for UREA
plant. The excess ammonia is send to storage tank at -330C temperature for storing
at atmospheric pressure.

17 The waste heat generated at the various stage of exothermic reaction utilized to
produce steam at 105 Kg/Cm2G pressure. The steam generated from process gas
heat recovery along with Aux Boiler connected with Reformer furnace provides
power for all the drives, driven by high pressure steam and medium pressure steam
at 40 Kg/Cm2G in the Ammonia Plant as well as satisfies the process steam
requirement. The excess steam produced is send to Urea plant and power plant.
18

19 UREA PLANT
20 There are two Phases of Urea Plant ( four streams) each of 3325 MTPD capacity.
The plant is based on the proven “SNAM” Ammonia Stripping process. The
ammonia and CO2 obtained from the Ammonia plant is pressurized and allowed to
react in a Reactor at a pressure of 145 atm and temperature of 1800 C maintaining
a NH3/CO2 mol. Ratio 3:1. The reaction in the Reactor will form a mixture of
Ammonium Carbamate, Urea and water. This mixture flows to a stripper wherein
the excess NH3 helps to strip off the unconverted Carbamate. The urea solution is
furt her concentrated in the vacuum evaporators and urea prills are produced in
Prilling Tower. The unconverted NH 3 and CO 2 are recombined to form Carbamate
and recycled back in the Reactor to achieve further conversion.
21 The Ammonia stripping process enables to strip off and reconvenes most of the
carbamate at the Autoclave pressure itself, facilitating the recycling of Carbamate
from LP Section to the Reactor just by an ejector. The stripping condensing and
recycling of Carbamate solution at high pressure saves lot of energy and enable to
generate LP steam making the Plant energy efficient.

22
23 STEAM & POWER GENERATION
24 The steam generation plant supplied by FOSTER WHEELER POWER PLANT -UK
consists of 3 boilers, 2 running one standby, capable of producing 275 MT S team
per boiler per hour at 105 kg/cm2 pressure and 5100C to supply steam to the
process plants. Two TG Sets of 15 MW capacity each are also installed in this plant.
The boilers are of single drum Monowall Balanced draft type complete with all
accessories and mountings. The boilers can be fired to 100% MCR either with
NGL/ARN or with Gas or of any combination.
25 KRIBHCO installed gas turbine as a new CPP in Year 2014 which is having
capacity of 72 MW power generations & 190 MT/hr steam. Presently this plant is in
operation along with one boiler of old CPP.

26
27 PRODUCT HANDLING PLANT
28 The Product handling plant is having capacity of bagging 6000 MTPD of Urea and is
designed to load trucks and railway wagons. The empty bag storage area is located
on the first floor of the Product handling Plant.
29

30 OFFSITES FACILITIES
31
32 The water requirement of about 7.0 MGD being drawn from the Ukai -Kakarapara
irrigation canal or alternate supply from Kakarapar by dedicated pipeline and
stored at our plant site in a reservoir spread over 50 acres. The raw water thus
stored will be treated in a water pre-treatment plant to bring down the turbidity
level. The Water pre-treatment plant consists of two clarifloculators each of 2000
M3/hr. wherein chemicals like Alum, and Chlorine are added to treat the water. The
treated water is then filtered and used for drinking, servicing as well as cooling.
Part of the treated water is further subjected to process of Ion exchange in the DM.
plant before being used in Boilers.

33 The DM Plant is laid out in four streams each of 180 M3/hr capacities. Each stream
consists of Activated carbon fitters for de-chlorination, caution, exchangers,
degasifies, weak and strong base Anion exchangers and mixed beds.

34
35 OTHER OFF-SITE FACILITIES
36 The other Offsite facilities consist of 5 nos. Instrument Air Compressors; 3 of 25
NM3/min capacity and 2 of 15 NM3/min capacities, 4 nos. Plant Air Compressors of
37 25 NM3/min capacity; 2 nos. of Centrifugal air compressor of capacity 5000 Nm3
each: one no. Inert Gas Plant to produce 1200 NM3/hr. of Nitrogen by Air
Liquefaction, 2 nos. Auxiliary Mains failure Diesel Generators of 1.5 MW each to
supply power in emergency, Urea Upset Plant and a network of Fire Hydrant
System having 6410M3 /Hrs. capacity fire water pumps.

38
39 STORAGE
40 Ammonia Storage tanks, 210000 MT are double walled to store liquid Ammonia
under atmospheric pressure at -330C are available with the necessary refrigeration
system. As a safety measure flare and pressure safety valves are provided.
41 NGL/ ARN is stored in one bulk storage tank of capacity 5600 KL and 3 Day Storage
tank of 400 KL each for alternate fuel for Power plan with necessary handling
facilities and fixed fire protection systems.
42 There are two RCC silos having capacity of 45000 MT each. Urea Silos are
adjoining each other. There is a reclaimer moving on rails by the side of silos to
shift the bulk urea from silos to conveyor belts. Silos are connected with urea
transfer house by means of enclosed RCC conveyor galleries.
 43

44 Raw water reservoir of capacity 15,39,000 M3 out of that 60000 M3 is reserved for fire
protection systems.

6.1 Products, Raw Materials, Hazards & Controls

Sr. Name of the

No. Raw material /
Capacity Hazards Safety Measures provided
By product /
Product

 Water Spray
 Safety Shower
Ammonia  Training
Toxic &
1. Storage in  Area Monitoring
2 X 10,000 MT corrosive in
double walled  SOP
nature  Pr. Safety Valves
tanks
 Non-Respiratory PPEs &
 Breathing Apparatus
 Dyke wall
Caustic Soda in Personnel Injury  Manual Water Spray facility
2 X 114 M3  Separate dyke
2. tanks due to splashing
 Required PPEs available
(CCS/DM) 2 X 82 M3
Corrosive

 Fire Fighting Net Work

3. NG Service Direct supply Flammable in  Pr. Control System
Station from GAIL nature  Isolation on Local & Main
Service Point
 Flame proof installation.
Toxic in nature  Manual Water Spray facility
H2SO4  Separate dyke
4. 2 x 160 MT Hot Burn injury  Required PPEs available
(98 %)
due to splashing  Dyke wall

 Manual Water Spray facility

5. Flammable in  Separate dyke
HSD 1 x 48 KL
nature  Required PPEs available
 Dyke wall
 Fire Fighting Network.
Corrosive  Manual Water Spray facility
6.  Separate dyke
HCl 3 x 105 MT Burn injury due  Required PPEs available
to splashing

7. 2 x 93 KL  Manual Water Spray facility

Liq. Nitrogen Cold Burn  Required PPEs available
(63519 Nm3)
 Auto Control System
2 x 100 M3  Manual Water Spray facility
8. Liq. Argon Cold Burn
(78120 Nm3)  Required PPEs available
 Auto Control System
Sr. Name of the
No. Raw material /
Capacity Hazards Safety Measures provided
By product /
Product

1 X 5500 M3  Flame proof installation

NGL
9. Fire  Fire Fighting Net Work
4 X 400 M3  Trained supervisor
 Dyke wall
6.2 Storage – Hazards & Controls

 Main storage of product and raw materials as mentioned in above 6.1 are hazardous
chemicals. Those chemicals are flammable, corrosive and toxic chemical. Its required
utmost care while handling and storage particularly to avert Fire and Explosion hazards.
Flameproof electrical installation as per Hazard area classification, Earthing and bonding,
Maintenance under PTW system, No smoking zone , spark proof tools etc. are highly
essential and needs to be strictly complied with for area where Flammables are handled /
processed. In case of insufficient ventilation, wear suitable respiratory equipment.
Canister type mask. Avoid contact with skin and eyes. Keep away from incompatibles
materials, combustible materials and other inorganic materials. Keep tightly closed in a
dry, cool and well-ventilated place. Keep away from direct sunlight. Store under incensed
and fenced area.
 Class A petroleum products like NGL, shall be Stored in accordance with local
regulations. Store in a segregated and approved area. Store in original container protected
from direct sunlight in a dry, cool and well-ventilated Area, away from incompatible
materials and food and drink. Eliminate all ignition sources. Separate from oxidizing
materials. Keep container tightly closed and sealed until ready for use. Containers that
have been opened must be carefully resealed and kept upright to prevent leakage. Do
not store in unlabeled containers. Use appropriate containment to avoid environmental
contamination.
6.3 Operational hazards and controls

Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of perimeter
process/operation away, measure
operation storage(Horizontal, s
with their quantity pressure provided
vertical tank, silo, pressure
release,
drum, sphere) temp.
toxic
release,
fire)

Ammonia – I & II

i) Reformer Natural gas Primary reformer T=810 co Fire &  Temp.

+steam (furnace with reforming explosion  monitor
tubes) Secondary P= 36 Ata  Furnace
(157093 kg/hr reformer – vertical high pre.
)Natural gas +steam Trip.
vessel
+ Air(294033 kg/hr) -do -  Safety
T=1300 co valves
 Vent at
P= 34 Ata height 50 m.
 Comb. Gas
detector
ii) Shift N2 + H2+CO + CO2 HT & LT shift T=430 Co  Fire  Temp
Converter + H2O +CH4 + Air converter  Temp control
to 224 Co run-away  High temp.
Vertical vessel  Over trip
P= 32 Ata pressure  Safety
 CO valves
poisoning  Flame
detector
 Continues
CO
monitoring
iii) N2 + H2+CO + CO2 Methanator T=316 Co  Fire  Multi point
Methanation + H2O +CH4  Temp High temp.
(120820 kg/hr) Vertical vessel P= 30 Ata run-away trip
 Over  Temp.
press control
ure  Comb. Gas
detector
 Safety
valves
iv) CO2 N2 + H2+CO + CO2 Absorber- Vertical T=130 Co  Fire  Safety
removal + H2O +CH4 + Air Stripper - vessel  Over valves
(222120 kg/hr) P= 32 Ata pressure  Rupture disc
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

vi) Liquid and vapour Refrigerating flash T= -33 to Over  Safety valve
Refrigerati ammonia drum. pressure & on each
on unit 30 oC toxic gas flash drum
(1890000 kg /day). Horizontal vessel release
P=0.02 to

6 kg/cm2

vii) Ammonia Liquid ammonia 106F ammonia T= -23 to  Over  Pilot

separator +Hydrogen+ separator. Horizontal pressur operated
Nitrogen. (305600 vessel P=210 ization. relief valve
kg/cm2  Fire in synthesis
kg/hr)
and loop
toxic
release
viii) Synthesis NH3 + H2 + N2 Exchangers, chillers. T=330 oC  Over 
loop CH4+Argon. pressur
Horizontal P=210 ization.
(336620 kg/hr) kg/cm2  Fire
and
toxic
release
(ix) Boiler Steam Auxiliary boiler T=313 oC Fire  Flame
system detector
Waste heat boiler P= 105 Over  Pressure
Ata pressure control
Steam drum  7 stage
Safety
Horizontal vessel valves as
per IBR
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

UREA PLANT I & II

(i) Synthesis Urea carbamate Urea reactor T=190 oC Over  Pressure
section pressure control
NH3+CO2+ Stripper P= 160 safety valve
Ata Toxic  Fire water
H2O (vertical vessel) release net-work
with hydrant
(197740) kg/hr and monitor


(ii) Recovery -do- -MP decomposer T= 160oC

(Vertical vessel) P= 18 Ata

-LP decomposer T=138 oC - Do - - Do -

(Vertical vessel) P= 4.5

Ata
-Ammonia receiver
T=35 oC
(Horizontal vessel)
P= 17 Ata
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

POWER PLANT
Steam Steam -Furnace T=313 oC Fire  Flame
generation detector
275 MT/Hr X2 (Vertical Tubes) P= 105 Explosion  Comb. Gas
Ata detector
-Steam drum Over  Pre. &
pressure temp.
(Horizontal vessel) controller
 Furnace trip
system
 Multi-level
safety valves
is as per IBR
 Fire water
net-work
through the
plant

 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

Gas Turbine Air + NG -Gas Turbine- 8.8 -Fire  Flame

+ HRSG Horizontal kg/cm2g, Explosion detector &
648 0C arrestor on
(1 x 72 MW) -Over vent line
pressure  Comb. Gas
-HRSG -boiler- Vertical detector
-5080C,  Pre. &
temp.
103 controller
kg/cm2  HRSG trip
system
-GT chimney-Vertical  Multi-level
safety valves
is as per IBR
 Fire
-HRSG main stack- extinguisher
vertical s/ hydrant
system/MBG
/detectors
1750C through the
plant.
 Zone wise
CO2
flooding
system.

 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

OFFSITE PLANT
Ammonia NH3 liquid (20,000 Storage tank 02 Nos. T=-33.4 Over  Double wall
Storage MT) oC pressure integrated
Ammonia storage area tanks
vertical tanks P=350 Toxic  Pilot
mm wc release operated 02
safety valves
(relief valve
cum
vacuums
breaker)
 4 stage
pressure
control.
 Ammonia.
Vapour
blower
 Refrigeration
unit
 Ammonia
flare system
 Ammonia
gas leak
detectors in
field.
 Fire
hydrants and
monitors.
 Type of hazards
possible
(Exothermi c, run
Name of Name of the Operatin g
away, pressure
hazardo vessel and its perimeter s
Material in release, toxic Control
us location & type of pressure
the release, fire) measure
process storage temp.
process/oper provided
and (Horizontal,
ation with
operatio vertical tank, silo,
their
n drum, sphere)
quantity

Argon Feed gas -Cold box having -Fire Explosion  Continuous N2

contain vertical Column/drum purging in cold
N2+CH4+H2+Ar 1)T=- -Over pressure box with
gon (7000 1) T-301 190.9 indication on
column- 4 to - -Cryogenic liquid DCS.
Nm3/Hr.)
vertical 159.8  21nos.
Process
0 0C
Safety on
2) T-302 process line,
P=1.75
column- Compressor’ s
vertical to 2 & Product line
Kg/c  For Process
m2g. safety by
providing
2) T= - safety
3) T-303 196 instrumented
0C
column- system which
vertical P= trip the plant in
4.08 safe manner.
Kg/c  All electrical
m2g. equipment’s
are explosion
4) D-302 reflux 3) T= - proof.
drum- vertical 196  Fire
0C extinguisher s/
P= 8 hydrant
Kg/c system/
MBG/detect
5) 2 Nos of 100m3 m2g.
ors..
each argon
storage tank TK- 4) T= -
401A/B- 196
0C
Horizontal
P= 8
Kg/c
m2g.

5) T= -
184
0C

P=
0.21
Kg/c
m2g.
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

Nitrogen Plant Feed is Atmospheric A)Cold box has  Continuous

Air 3500 NM3/hr vertical Columns N2 purging in
Fire cold box.
Explosion  Process
Safety
1) C-101:HP Column -Over provision on
1) Temp pressure process line,
: Compressor’s
-Cryogenic & Product line
-165°C to- liquid  For Process
170°C safety by
-Cold Burns providing
Pr.:8 safety
Kg/cm2 -Frost bite instrumented
system which
2) E-105:LP Reboiler: 2) Temp : -Simple trip the plant
in safe
-173°C Asphyxiant
manner.
 Fire
Pr: 4
. extinguisher
Kg/cm2 s/ hydrant
system/
MBG/detect
3) T-101A / T-101 B: ors.
 Use of
Liquid N2 Storage PPEs.
3)LIN  Strict
Tanks.
Tanks: adherence
to SOPs
Tem :-
165°C to -
170°C

Pressure:
8 Kg/cm2
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

WPT  Feed from  Chlorine Toner:  2-3  Tonner  Detectors

Chlorine Toner Horizontal vessel, Kg/cm2 Leakag /Online
(Chlorine 0.9MT liquefied housed inside  Ambient e Breathing air
dosing) Chlorine at chlorinator room. temp.&  Skin mask/
pressure of 9  6 Nos. of Alum Atmosp irritatio  Safety
Kg/cm2 bottle solution heric n& Showers/hyd
pressure. preparation tank pressur allergy rant system/
 Alum dosing e  MBG.
 Chlorine
Absorption
system,
 Chlorine
Neutralizatio
n Pit
 Chlorine Kit,
PVC Suit
 B.A. Set
 Safety
shower
 Type of
hazards
possible
Name of Name of the vessel Operatin
(Exothermi
hazardous and its location & g
Material in the c, run Control
process and type of storage perimeter
process/operation away, measure
operation (Horizontal, vertical s
with their quantity pressure provided
tank, silo, drum, pressure
release,
sphere) temp.
toxic
release,
fire)

Cooling Water  Corrosion  Kept in 200 Kg  Ambien  Precurso  PPE to be

Treatment in Inhibitor, Plastic Drums & t r & used for
ACT/UCT/ST  Scale 50 kg Plastic pressur Bromine prevention.
P & PPCT Inhibitor,H2SO4 Carboys(Vertical), e are  Thorough
 Bio-Dispersant, Located in & ambient Exotherm washing with
 Biocide, respective Cooling temperatu ic in copious
 Dispersant, Towers near re nature. amount of
 Precursor, Cooling tower Skin water in the
 Sodium bromide Basin. burning case of
& Sodium  H2SO4 in Tank, on exposure &
chlorite dosing in CT thru  2-3 contact. follow up
 Chlorine dosing pipe Kg/cm 2  Skin medical
system-Feed  Chlorine Toner: burning treatment.
from Chlorine Horizontal vessel,  Leakage  Safety
Toner 0.9MT housed inside Shower,
liquefied chlorinator room. PVC suit
Chlorine at  Detectors
pressure of 9 /Online
Kg/cm2 bottle Breathing air
pressure. mask/
 Safety
Showers/hyd
rant system/
 MBG
 Chlorine
Neutralizatio
n Pit
 B.A. Set
6.4 Other Hazards & Controls

Loading and unloading of materials, handling of materials, working near D.G. Sets, pumps
and motors, transmission and transportation machinery etc. with use of utilities,
contribute variety of hazards like fire, Explosion, Noise induce hearing Loss, and physical
hazards due to unguarded machineries, hot burns etc. Necessary control measures
depending on the type of hazards are adequately provided and recommend to be
maintained in good working condition. Their proper maintenance and safe working
procedures are available & are expected to be followed on rigorous basis .

Information regarding trade waste generation and disposal are to be maintained by EHS
department as per GPCB guideline.

When entire Plant will be fully operational, following Hazardous waste will be generated
– It’s shown in GPCB Consent.

Sr. Quantity Schedule-

Waste Facility
No (Ton/Annum) Category

Collection, Storage,
1. Used Oil 80 MT/ Year 5.1 Transportation, Disposal by
sealing to Registered recycler

Collection, Storage,
Spent
2. 1 MT/ Year 18.1 Transportation, Disposal by sent
Catalyst
for re-processing