The industry was jointly inspected by the following officials of Central Pollution Control Board, Ministry of Environment & Forests Govt. of India and State Pollution Control Board, Orissa, on 20.2.2002.

1. Sh. N.K. Verma, Additional Director, CPCB
2. Dr. R. Warrier, Additional Director, MoEF, New Delhi
3. Dr. D.K. Behera, Env. Scientist, S.P.C. Board
4. Er. N.R. Sahoo, Env. Engineer, S.P.C.Board
5. Dr. D.K. Rout. Regional Officer, S.P.C.Board, Cuttack

During the inspection, Mr. M. Vishnuprasad, Manager (TS). Mr. R.K. Singh, Vice-President. Mr. Lalit Pal & Mr. Jaggi from M/s Oswal Chemicals & Fertilisers Ltd. accompanied during the visit.

The industry obtained environmental clearance in July 1998 from MoEF under EIA notification, 1994, with specific conditions. The plant started its trial production in April 1999 and obtained consent from Orissa State Pollution Control Board (OSPCB) to operate from 20.01.2000 till 31.03.2000 with specific conditions. OSPCB found that the industry was violating consent conditions. There was a number of public complaints against this unit for polluting air and water. The industry was inspected several times by the officials of the State Pollution Control Board and it was found that the industry has not complied with consent conditions and discharging untreated wastewater to the nearby creek and river Mahanadi. Based on these inspections. Following actions were taken by OSPCB/MoEF:

1. Consent to operate for 2000-01 was refused by OSPCB on 24.11.2000

2. Case was filed on 17.03.2001 under Section 25 of Water (Prevention & Control of Pollution) Act, 1974 by OSPCB

3. Directions were issued by OSPCB on 21.05.2001. u/s 31(A) of Air (Prevention & Control of Pollution) Act, 1981 and u/s 33(A) of Water (Prevention & Control of Pollution) Act, 1974, to take expeditious action to control and mitigate pollution.

4. Direction was issued on 27.07.2000, by MoEF, Govt. of lndia, u/s 5 of EP Act, 1986, to adequate measures.

5. A personal hearing was conducted by OSPCB on 22.11.2001, where the Chairman cum Managing Director of the Industry attended the hearing. It was decided during the personal hearing that the industry shall comply with all the points as per directions issued under Air & Water Acts, and it was decided that a joint inspection by officials of CPCB, MoEF & SPCB will be taken up to verify the compliance.

1. The inspecting team first visited Fishing Jetty at Mahanadi River, Atharbanki Creek near the conveyor belt connecting port area and the factory of M/s Oswal Chemicals. The samples were collected at Fishing Jetty at Mahanadi River (Plate 1) and at Atharbanki Creek (near conveyor belt) (Plate 2), The analysis report of the sample presented in Annexure - I, which indicates that the concentration of various parameters are within the tolerable limit but on inquiry with the fishing people, it was reported that on several occasions floating of dead fishes have been observed possibly due to occasional discharge of acidic effluent from M/s Oswal Chemicals & Fertilisers Ltd. The analysis report of Atharbanki Creek water indicates pH of 2.16, which is highly acidic and high concentration of Fluoride (318 mg/l), and phosphate (589 mg/l). Similarly, the effluent sample collected from the Nallah (Plate 3) leading to river Mahanadi (near the guard pond) indicates pH of 2.47, Fluoride level of 248 mg/l, phosphate of 559 mg/l. This indicates that the industry has been discharging untreated effluent into creek as well as Mahanadi.

2. Sample was also collected of the effluent discharged from new gypsum pond area to nallah leading to river Mahanadi where pH was near neutral (7.13) but having very high fluoride content (793 mg/l). The quality of combined effluent discharged (Plate 4) to river Mahanadi indicate pH of 2.91, phosphate of 143 mg/l and fluoride of 76.8 mg/l.

3. Sample collected of seepage from old gypsum pond discharged to creek, indicates pH 2.21, fluoride of 366 mg/l and phosphate of 2353 mg/l. Similar effluent (seepage from new gypsum pond) discharge to creek was found to have pH of 2.25, fluoride 728 mg/l and phosphate 5714 mg/l. During the visit to dyke of old gypsum pond, the team observed that there has been breach occurred at the gypsum pond (Plate 5) resulting into overflow of gypsum wastewater. At number of places liners were found to be turn off or damaged (Plate 6). Accumulation of highly acidic effluent was also observed around the new gypsum pond (Plate 7).

4. Sampling locations are depicted in layout plan at Annexure-II.

5. Visit to Effluent Treatment Plant

   The team visited the Effluent Treatment Plant (ETP) installed (Plate 7) recently, by the industry for treatment of fluoride bearing wastewater. It was learnt that the wastewater streams coming to ETP are treated with milk of lime. The treated wastewater is reported to be recycled and used in phosphoric acid plant for rock phosphate grinding in ball mill. It appeared that ETP is treating only part of the effluent generated in the industry.

6. Segregation of wastewater and storm water drain

   Though the industry had attempted to segregate the wastewater from the storm water drains, it could not provide layout map indicating such segregation. At places, in the storm water drain, the discharge of effluent was found acidic when tested with pH paper.

7. Storm water collection

   The low-lying area, adjacent to north-west dyke of New Gypsum pond, was shown as collection pond of storm water. It was observed that, the water accumulated is acidic and is discharged to nearby creek. This is also not lined. There is no monitoring device installed, for pH and fluoride, at storm water collection pond.

8. Sulphur Muck Disposal

   The team visited the place of disposal of sulphur muck. Industry has not taken authorization from OSPCB as per the Hazardous Waste (Management & Handling) Rules, 1989 as amended.

9. Visit to the Sulphuric Acid Plant (SAP)

   The online monitoring of SO2 emission through stack in SAP was found in operating condition and continuous recording was done. At the time of visit, Alkali scrubber installed at SAP was not in operation. It was reported that the same is used only during upset conditions and during start-up. When scrubber works, the emission will be discharged at lower height. The recording system, for SO2 monitoring before and after scrubbing system, has not been connected with the control room.

10. Visit to Phosphoric Acid Plant (PAP)

    The hydroflurosilicic acid generated from PAP is not being utilized by the industry and no fluorine recovery system has been installed. As such hydroflurosilicic acid finds way to gypsum pond.

11. Visit to Ambient Monitoring Sites

    It was observed that the industry has installed continuous ambient air quality monitoring equipment with recorder at two locations (one near sewage treatment plant and other at ammonia storage area).

12. Status of Hazardous Waste Management

    The visiting team collected samples of (a) Gypsum cake from phosphoric acid plant, (b) Gypsum slurry discharged to gypsum pond, (c) Gypsum from gypsum pond and (d) Salt deposited outside the embankment of guard pond. The analysis of such samples is given in Annexure-IV, which indicates high content of fluoride ranging from 1.699-5.35 mg/g of fluoride (1699-5350 mg/kg). All the above wastes fall under waste stream no. 18.1 of Schedule-1 of Hazardous Waste (Management & Handling) Rules, 1989 as amended.

    The Sample of sulphur muck was also collected, the analysis of which is given in Annexure-IV. The analysis indicates very high concentration of sulphate i.e. 2.539 mg/g (2539 mg/kg). This waste falls under category 18.3 of Schedule-1 of Hazardous Waste (Management & Handling) Rules, 1989.

    The sample of sediments collected from the drain (leading of river Mahanadi) carrying combined effluent was also collected and analysed. The analysis indicates very high concentration of fluoride (7.10 mg/g or 7100 mg/kg). This is indicative of discharge of untreated effluent containing very high concentration of fluoride.

    Besides above, the industry also generates spent catalyst, oily waste and used batteries, which are designated as hazardous waste under the rules.

    Since the industry does not have adequate facility to handle hazardous waste, authorization has not been granted by Orissa SPCB.

13. Based on above observations, pointwise observations on proceedings of personal hearing held on 20.11.2001 at State Pollution Control Board, Orissa, is presented in Annexure-III.

Action suggested

1. The industry may be issued closure direction till they have full-fledged arrangement for storing of gypsum, proper handling of gypsum, adequate effluent treatment plant and adequate segregation of wastewater from the strom water drains and proper recording facilities of the effluent and strom water discharged and stored in guard pond.

2. The industry should not be allowed to manufacture phosphoric acid; till fluorine recovery unit is installed by the industry.

3. The extent of environmental damage caused due to fluoride contamination may be evaluated by the third party agency like NIO, NEERI etc. for taking remedial measures. The cost of assessment of such damage shall be borne by the industry.

4. Regular monitoring of the Mahanadi river, Atharabanki creek drain(s) leading to creek and effluents from industrial premises is required to be monitored at least once in a month, by OSPCB.

Conclusion

The extremely poor waste water and sludge (gypsum) management in the industry has resulted in pollution of Atharbanki creek and surrounding area. The hazardous waste management is far from satisfactory and the industry has not taken authorization for hazardous waste disposal as per Rules. The industry does not have any monitoring system in place, which is essential to ensure that water surrounding the industry is not contaminated.

(N.K. Verma)            (R. Warrier)         (D.K. Behera)            (D.K. Rout)            (N.R. Sahu)

1. Installation of ETP

   The claim of the industry that there is a negative water balance is not true, as there is considerable amount of contaminated effluent discharged to nearby creek and river. This indicates that there is a need of installing effluent treatment plant of adequate capacity, so as to meet the prescribed standards.

2. Segregation of wastewater & storm water drain

   Action has been taken by the industry to segregate wastewater drain from storm water drains but still untreated effluents find way into storm water drains. No layout map could be provided by the industry to the visiting team to assess the adequacy of segregation.

3. Storm water collection pond

   The low-lying area adjacent to north-west dyke of New Gypsum pond is shown as collection pond of storm water, which is not lined. It was observed that the water accumulated is acidic & there is a discharge to nearby creek. There is no organized storm water collection pond with online monitoring for pH & fluoride.

4. Gypsum pond lining

   The lining of new gypsum pond was observed to be damaged at number of places. The surge pond of gypsum pond No. 2 is not lined. Gypsum pond water was found to be accumulated in proposed expansion area. It is apprehended that pond water is periodically discharged to creek.

   The whole gypsum pond, both new and old one are surrounded with highly acidic water and the vegetation like grass, shrubs weeds are completely burnt and the area has become visibly dry.

   It can be concluded from the above that, the gypsum management in the plant is grossly inadequate and the adverse impact on the nearby water bodies is very alarming. The gypsum handling is far from satisfactory.

5. Sulphur muck disposal

   The industry could not provide the details of the site and also has not taken authorization from the State Pollution Control Board as per the Hazardous Waste (Management & Handling) Rules, 1989 as amended. The industry has not taken up any step in exploring the possibility of locating hazardous waste dump site away from the plant, as stipulated time of two months have already been over.

6. Online Monitoring

   Online monitoring in SAP was found to be operative and continuous recording was done.

7. Arrangement for Stack Monitoring

   Arrangement for stack monitoring both in alkali scrubber as well as main stack of SAP has been made.

8. Scrubber Operation/Routing scrubber emission through main stack

   The industry claimed that as per the design criteria, the scrubber stack cannot be connected to the main stack. For better management, the recording of online monitoring equipment was to be transferred to main SAP control room, which has not been complied.

9. Continuous Ambient Air Quality Monitoring

   Two numbers of continuous ambient air quality monitoring equipment with recorder was found to be installed as against requirement 5.

10. Utilisation Hydroflurosilicic Acid

    The industrial authorities inform that utilization of hydroflurosilicic acid is not commercially viable. The present level of contamination of fluoride and low pH is due to non-utilization of hydroflurosilicic acid and not treating the same for correcting pH before disposal.