Draft Report EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka, Gujarat by M/s Nayara Energy Ltd. (Volume 1) For M/s Nayara Energy Ltd., Jamnagar CSIR-National Environmental Engineering Research Institute (NEERI), Delhi Zonal Centre, Naraina, New Delhi 110028 Head Quarter - Nehru Marg, Nagpur 440 020 (QCI/NABET Accreditation letter no. QCI/NABET/ENV/ACO /18/0592 dated March 15, 2018) February 2019 EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka (Gujarat) by M/s Nayara Energy Ltd. CSIR-NEERI-DZC, Draft Report – February 2019 Foreword M/s Nayara Energy Ltd., erstwhile Essar Oil Ltd., is operating a 20 MMTPA refinery complex at Vadinar, Devbhumi Dwarka, Gujarat. In addition, it has a strong retail network of about 4,900 fuel stations catering to different parts of the country. The network is being further expanded with about 2600 more retail stations in near future. The company, earlier in 2005-06, had planned for expansion of the refinery to 60 MMTPA capacity along with petrochemical project. Environmental Clearance was also obtained from the Ministry of Environment, Forest and Climate Change (MoEF&CC), which was valid upto September 2018. The company has now revisited and revised it’s expansion plan for the optimum total refining capacity of 46 MMTPA along with petro- chemical complex, by addition of another 26 MMTPA crude processing, thereby reducing by 14 MMTPA from the earlier plan of 60 MMTPA. Proposed expansion of refinery and petrochemical complex shall take place at the land available within the existing refinery premises. M/s Nayara Energy Limited proposes to use latest and best available refinery technologies that shall ensure maximum conversion efficiency, production of superior grade clean products and minimum losses shall be selected for the entire expansion project involving refinery and petrochemical complex. With a view to assessing potential impacts arising out of the proposed expansion of refinery with petrochemical complex, M/s Nayara Energy Limited, the project proponent approached CSIR-NEERI to conduct environmental impact and risk assessment (EI&RA) study as a prelude to the preparation of effective environmental management plan (EMP). Baseline data collected for air, noise, water, biological, land and socio-economic components of the environment during Summer 2018 has formed the basis for identification, prediction and evaluation of impacts due to the proposed developments, as also for the delineation of a pragmatic environmental management plan in this EIA Report. The cooperation and assistance rendered by the staff of Nayara Energy Limited in the preparation of this report is gratefully acknowledged. (Rakesh Kumar) Director, CSIR-NEERI Nagpur February, 2019 Draft Report EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka, Gujarat by M/s Nayara Energy Ltd. (Volume 1) For M/s Nayara Energy Ltd., Jamnagar CSIR-National Environmental Engineering Research Institute (NEERI), Delhi Zonal Centre, Naraina, New Delhi 110028 Head Quarter - Nehru Marg, Nagpur 440 020 (QCI/NABET Accreditation letter no. QCI/NABET/ENV/ACO /18/0592 dated March 15, 2018) February 2019 Project Personnel CSIR-NEERI Team Functional Area Expert Team Member/ Component (QCI/NABET) / Project Assistants Scientific Staff Air Environment Meteorology, Air Quality Dr. S.K. Goyal Mr. Amit Kumar Mishra Monitoring & Prediction (AQ) Dr. Sunil Gulia Ms. Pratyushpingita Mishra Air Pollution Monitoring Dr. S.K. Goyal Ms. Prachi Goyal Prevention and Control (AP) Dr. Sunil Gulia Dr. Mamta Prakash Noise Environment Noise & Vibration (NV) Dr. G. L. Bodhe Mr. Mohinder Jain Mr. Satish Lokhande Water Environment Water Pollution Monitoring, Dr. Amit Bansiwal Mr. Amit Kumar Mishra Prevention Control (WP) Dr. Mamta Prakash Ms. Pratyushpingita Dr. Noor A. Khan Mishra Mrs. Priyanka Saxena Mrs. Usha Tripathi Mrs. Neha Yadav Mr. Deep Chand Mr. Sourabh Mr. Ravi Prakash Land Environment Land-use (LU)/ Soil Quality Dr. Ritesh Vijay Mr. Amit Kumar Mishra Dr. Mamta Prakash Ms. Pratyushpingita Solid & Hazardous Waste Dr. M. Suresh Kumar Mishra Management (SHW) Ms. Tridipa Biswas Biological Environment Ecology and Biodiversity (EB) Dr. Kanchan Kumari Ms. Jyoti Tagde Dr. Mamta Prakash Ms. Ruchita Haldar Mrs. Rashmi Dixit Ms. Pratyushpingita Dr. M. Suresh Kumar Mishra Mr. Amit Kumar Mishra Socio-economic Socio-economic Aspects (SE) Mr. Sanjay Bodhale Mr. Amit Kumar Mishra Dr. S.K. Goyal Ms. Pratyushpingita Mishra Geo & HG Dr. Raghuvanshi Ram Ms. Tridipa Biswas Risk Assessment (RA) Dr. Santosh Ghuge Mr. Sagar Karande Ms. Ashoo Kale EIA Coordinator/ Dr. S.K. Goyal Project Leader Dr. M. Suresh Kumar Overall Guidance Dr. Rakesh Kumar Director Project Personnel M/s. Nayara Energy Limited (Formerly Essar Oil Limited) 1) Mr. Shyama Maji, Senior Vice President – Head - Technical 2) Mr. Sudhir Singh, Vice President - Project 3) Mr. Manish Raj, General Manager - Utilities and Offsites 4) Mr. P.R. Dixit, Vice President & Head HSEF 5) Mr. P.K.Srivastava, Vice President – Head – Project, VOTL 6) Mr. Avinash Chaturvedi, Advisor 7) Ms. Asmita Patel, Head - Environment 8) Mr. Nirav Patel, Deputy Manager – Environment DISCLAIMER The information contained in the report is based on the scientific analysis of data/ information / drawings provided by the sponsor as also collected from other sources during the time of the study. While efforts have been made to ensure accuracy of information in the report, CSIR-NEERI shall not own, in any manner, any legal, financial or consequential responsibility for any event of occurrence of any accident/hazard or direct or indirect damage/loss to any third party or to the sponsor due to the use or inability to use the information contained in the report. The sponsor shall exercise due dilligence and make their own decision to implement the contents of the report. The report shall not be construed as any guarantee or warranty from CSIR-NEERI. Contents EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka (Gujarat) by M/s Nayara Energy Ltd. CSIR-NEERI-DZC, Draft Report – February 2019 Contents Item Particulars Page No. List of Tables x-xiv List of Figures xv-xvii List of Plates xviii-xix List of Annexures xx-xxi Acronyms and Abbreviations xxii-xxvii Executive Summery ES.1-ES.24 Chapter 1: Introduction 1.1-1.7 1.0 Background 1.1 1.1 Justification of Proposed Project 1.2 1.1.1 Emerging Refinery Deficit in India 1.2 1.1.2 Growing Petrochemical Deficit in India 1.3 1.2 Objective of Study 1.4 1.3 Scope of the Study 1.4 1.3.1 Details of the Study 1.4 1.3.2 Methodology of the Study 1.5 1.4 Study Area Details 1.5 1.5 Structure of the EIA Report 1.7 Chapter 2: Project Description 2.1-2.34 2.1 Introduction 2.1 2.1.1 Salient Features of the Project 2.1 2.1.2 Project Site Details – Location & Layout 2.3 Products of Existing and Proposed integrated Refinery with 2.2 2.10 Petro-chemical Complex Product Slate of Existing and Proposed integrated Refinery with 2.2.1 2.10 Petro-chemical Complex Product Slate of Proposed 10.75 MMTPA Petro-Chemical 2.2.2 2.11 Complex 2.3 Process Description of Existing and Proposed Refinery 2.12 i Contents EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka (Gujarat) by M/s Nayara Energy Ltd. CSIR-NEERI-DZC, Draft Report – February 2019 2.3.1 Process Units of Existing Refinery 2.12 2.3.2 Process Units under Proposed Refinery Expansion 2.13 Process Unit Capacity of Proposed Refinery and Petrochemical 2.3.3 2.14 Complex 2.3.4 Process Description with Flow Diagram 2.16 2.4 Raw Materials Required, Sources and Mode of Transport 2.16 2.4.1 Crude Oil Slate for Existing and Proposed Refinery 2.16 2.4.2 Crude Receipt and Product Dispatch Facilities 2.16 2.4.2.1 Handling Facilities 2.16 2.4.2.2 Mode of Crude and Product Transport 2.17 Storage Facilities with Capacities for Existing and Proposed 2.4.3 2.19 Refinery 2.5 Infrastructure and Resource Requirements 2.25 2.5.1 Land Requirement 2.25 2.5.2 Water Requirement Details 2.25 2.5.2.1 Water Requirement/Consumption and Source 2.25 2.5.2.2 Sea Water Intake & Discharge System 2.26 2.5.2.3 Cooling Water Facilities (CWF) 2.26 Sweet Water Requirement for the Proposed Refinery with Petro- 2.5.2.4 2.27 Chemical Complex 2.5.2.5 Wastewater Generation, Treatment and Disposal 2.29 2.5.3 Power Requirement 2.30 2.5.4 Manpower 2.30 2.5.5 Fire Protection System 2.31 2.5.6 DM Plant 2.31 2.5.7 Air Separation Unit (ASU)/Nitrogen Generation Unit (NGU) 2.31 2.5.8 Air Generation Unit (AGU) 2. 32 2.5.9 Fuel Gas/Oil Storage and System 2.32 2.6 Emission Control System/ Disposal Mechanism 2.32 Sulphur Balance for the Existing and Proposed Refinery with 2.6.1 2.34 Petro-Chemical Complex ii Contents EIA/EMP Studies for Expansion of Refinery from 20 MMTPA to 46 MMTPA and Petro-chemical Complex at Vadinar, Dist. Devbhumi Dwarka (Gujarat) by M/s Nayara Energy Ltd. CSIR-NEERI-DZC, Draft Report – February 2019 2.6.2 Sulphur Balance for Ultimate Capacity of 46 MMTPA 2.34 Chapter 3: Description of the Environment 3.1-3.138 3.1 Air Environment 3.1 3.1.1 Air Quality Monitoring Details 3.1 3.1.2 Air Quality Status during Summer 2018 3.2 3.1.3 Air Quality Status during 2017-18 3.3 3.1.4 Meteorological Data Analysis 3.3 3.2 Noise Environment 3.14 3.2.1 Noise