GOVERNMENT OF INDIA - Orient Cement...3600 TPD Rotary Kiln – I & Raw Mill – 59.75I 80 2800 TPD...
Transcript of GOVERNMENT OF INDIA - Orient Cement...3600 TPD Rotary Kiln – I & Raw Mill – 59.75I 80 2800 TPD...
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CONTENTS
Contents 2
List of Tables 2
List of Figures 3
1. Compliance Report 4
2. INTRODUCTION 17
2.1 Location and Accessibility 19
3. PROCESS DESCRIPTION 20
4. ENVIRONMENTAL BASELINE STATUS 23
5. ENVIRONMENTAL MANAGEMENT PLAN 36
6. CONCLUSIONS 40
LIST OF TABLES
1.1 Average Values of online Stack Monitoring Data 5
1.2 Average Values of online Stack Monitoring Data 9
1.3 Average Values Ambient Air Monitoring Data 10
1.4 Average Values of Noise level Data 11
1.5 Average Values of Fugitive Emissions Data 13
1.6 Average Values of Noise level Data 14
2.1Salient features of expansion project 18
4.1 Soil Analysis 24
4.2- 4.4 Water Analysis 25-26
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4.5 Weather Monitoring Data-Temperature & Relative Humidity 27
4.6 Average Values Ambient Air quality data 29
4.7 Details of Stack Emissions 30
4.8 Average Values of Stack Monitoring Data (SPM) 31
4.9 Average Values of Stack Monitoring Data (SO2
&NO2
) 32
4.10 Average Values of Noise level Data 33
LIST OF FIGURES
1. Process flow diagram of cement manufacturing 22
4.6 Ambient air quality data – Particulate Matter – PM10
29
4.6 Ambient air quality data – Particulate Matter – PM2.5
29
4.6 Ambient air quality data – (SOx
) & (NOx) 29
4.8 Stack Monitoring Data – Suspended particulate matter 31
4.9 Stack Monitoring Data – Sulphur dioxide 32
4.9 Stack Monitoring Data – Oxides of nitrogen 32
4.10 Noise Level Data 33
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1. COMPLIANCE REPORT: MoEF ENVIRONMENTAL CLEARANCE
Environmental clearances accorded by Ministry of Environment & Forest vide Letter
F. No. J -11011/266/2007-IA II (I) Dated 6th September 2007 for expansion of cement
plant (Cement 3600 to 8900 TPD and clinker 5550 to 10600 TPD) and installation of
Captive Power Plant (50 MW) at Devapur, Adilabad, A.P. by M/s. Orient Cement
Ltd.,The project has been completed and production activities are going on.
A. Specific conditions
(i) On-line continuous stack monitoring facilities for all the stacks and adequate air
pollution control systems shall be provided to keep emission levels below 50
mg/Nm3 and data submitted to the APPCB and CPCB regularly. ESP to kiln / raw
mill, clinker and CPP shall be provided to control air emissions.
Online continuous monitoring facility for process stacks have been provided along
with main equipments. Online connectivity is given to CPCB and TSPCB Server.
Latest Pollution Control Equipments were installed, which are controlling the
emissions within the stipulated levels, data is presented in Table 1.1.
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Table 1.1
AVERAGE VALUES OF STACK MONITORING DATA
(Apr’16 - Sep’16)
Parameters
Particulate Matter (mg/Nm3)
Location of Online Continuous
Stack Monitoring Equipment
PCB Limit as
per Consent
(mg/Nm3)
Avg.
(mg/Nm3)
3600 TPD Rotary Kiln – I & Raw Mill – I 80 59.75
2800 TPD Rotary Kiln – II & Raw Mill – II 80 32.25
4200 TPD Rotary Kiln –III & Raw mill – III 50 21.33
Clinker Cooler – Line 1 80 33.75
Clinker Cooler – Line 2 80 23.25
Clinker Cooler – Line 3 50 19.83
FBC Boilers of Capacity 2 X 115 115 90.17
(ii) Total water requirement from the reservoir of abandoned mine pit shall not
exceed 1,895 m3/day. No water from other surface or ground water sources
shall be used. All the treated wastewater shall be recycled and reused in the
process and/or for ash quenching, dust suppression, green belt development
and other plant related activities etc. No process wastewater shall be
discharged outside the factory premises and ‘zero’ discharge shall be adopted.
Treated domestic effluent shall be used for green belt development within the
plant premises.
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Mines reservoir gets filled with rainwater. Water consumption is well within
the permissible limits.
STP is in operation for domestic sewage water from which the treated water
is being used for green belt development in the colony.
Zero wastewater discharge concepts are adopted.
(iii) The fly ash from the power plant shall be stored in silos and pneumatically
transferred to the cement plant and used in the process itself for manufacturing
Pozollona Portland Cement (PPC). Bottom ash shall be disposed off in
abandoned mines or utilized in road making or given to brick kiln
manufacturers. All the cement dust collected from pollution control devices
shall be recycled and reused in the process and used for cement
manufacturing. Sludge from domestic sources shall be used as manure for
green belt development. Waste oil shall be sold to authorized recyclers/
re-processors only.
Fly ash from the Power Plant is being stored in silos and pneumatically
transferred to cement plant and it is completely utilized in the cement
manufacturing process.
Bottom ash is also meeting the quality parameters and it is completely
utilized in the cement manufacturing process.
The Cement & other raw material dust are collected through Pollution
Control Equipments and are being recycled in the Process.
Sludge from STP (domestic sources) is used as manure in township for
colony plantation.
Waste oil is being sold to Authorize Recyclers/Re-processors only.
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(iv) High calorific value hazardous waste shall be utilized in the cement kiln from
Ranga Reddy, Medak and Patancheru Districts.
Alternate & Biomass fuels (Rice Husk, Cotton Stalk, Black Carbon, Pet coke) are
being used in the plant.
(v) Out of total 425.89 acre, green belt shall be developed in 216.09 acres (51%) as
per the CPCB guidelines to mitigate the effects of air emissions in consultation
with local DFO.
Green belt was further increased during this financial year. About 5020 saplings
were planted till September 2016 including mines.
(vi) Green Belt shall be developed along the boundary of the cement plant.
Green belt is already developed as per the guidelines. About 5020 saplings were
planted till September 2016 including mines.
(vii) Regular annual medical examination of all the employees shall be carried out
from the occupational health point of view and records should be maintained.
Annual Medical Examination for all the employees and contract workmen was
done we will continue to do the same annually.
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B. General Conditions
(i) The project authority shall adhere to the stipulations made by A.P. Pollution
Control Board (APPCB) and State Government.
The stipulations made by various state government departments including
TSPCB will be adhered strictly.
(ii) No further expansion or modification of the plant shall be carried out without
prior approval of this Ministry.
No expansion/ modification will be carried out without permission from MoEF.
(iii) The gaseous and particulate matter emissions from various units shall conform
to the standards prescribed by the A.P.Pollution Control Board. At no time, the
particulate emissions from the cement plant shall exceed APPCB limit.
Interlocking facility shall be provided in the pollution control equipment, so that
in the event of the pollution control equipment not working, the respective unit(s)
is shut down automatically.
SPM Standards prescribed by the Telangana State Pollution Control Board are
being followed and automatic tripping system of equipment is installed and
data is presented in table1.2.
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Table 1.2
AVERAGE VALUES OF STACK MONITORING DATA
(Apr’16 to Sep’16)
Parameters
Particulate Matter (mg/Nm3)
Stack attached to
PCB Limit as
per Consent
(mg/Nm3)
Avg.
(mg/Nm3)
3600 TPD Rotary Kiln – I & Raw Mill – I 80 59.75
2800 TPD Rotary Kiln – II & Raw Mill – II 80 32.25
4200 TPD Rotary Kiln –III & Raw mill – III 50 21.33
Clinker Cooler – Line 1 80 33.75
Clinker Cooler – Line 2 80 23.25
Clinker Cooler – Line 3 50 19.83
FBC Boilers of Capacity 2 X 115 115 90.17
All Results are within the limit.
(iv) One Ambient Air Quality Monitoring Station shall be installed in downwind
direction. Ambient air quality including ambient noise levels shall not exceed the
standards stipulated under EPA or by the State authorities. Monitoring of
Ambient Air Quality and Stack Emissions shall be carried out regularly in
consultation with APPCB and report submitted to the APPCB quarterly and to the
Ministry’s Regional Office at Bangalore half-yearly.
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Two Online Ambient Air Quality Monitoring Stations are installed and connected
to Central and State Pollution Control Boards. We are also getting it done once in
a month by MoEF approved third party. The same are submitted to RO MoEF&CC
in half yearly reports.
Table 1.3
AMBIENT AIR QUALITY DATA
(Apr’16 to Sep’16)
Parameter
Location
Particulate Matter –
PM10
(µg/m3)
Particulate Matter –
PM2.5
(µg/m3)
Sulphur dioxide
(µg/m3)
Nitrogen Dioxide
(µg/m3)
Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg.
Near Time
office.
49 63 54.67
15 27 19.50
6 13 9.33 15 23 17.50
Near Mines
Office
44 68 54.00 6 10 7.83 19 24 21.33
Near D.G.
Set
51 64 58.33 7 11 9.17 16 22 18.67
Near Guest
House
41 51 46 7 11 9.17 16 23 19.83
All Results are within the Limit.
Noise level: Noise in general is sound which, is composed of many frequency
components of various loudness distributed over the audible frequency range. The
most common and heavily favored of these scales is the A-weighted decibel [dB (A)].
This scale has been designed to weigh the various components of noise according to
the response of the human ear; loud noise may damage hearing or health; interfere
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with work tasks, speech communication and sleep; affect inter-room privacy; cause
annoyance. The impact of noise depends on its characteristics (instantaneous,
intermittent or continuous in nature), time of day (day or night) and location of noise
source. The noise levels at various locations in and around plant area were measured
and tabulated in table 1.4.
Table 1.4
AVERAGE VALUES OF NOISE LEVEL DATA
(Apr’16 to Sep’16)
Location NOISE LEVEL in Leq dB(A)
Day Time Night Time
Min Max Avg Min Max Avg
Near Kiln 68.50 69.20 68.85 63.10 64.20 63.65
Near Raw Mill 70.80 71.50 71.15 65.40 66.40 65.90
Near Compressor House 72.50 73.10 72.80 67.30 68.70 68.00
Near Cement Mill 67.60 69.70 68.65 62.50 64.70 63.60
Near D.G.Set 72.70 73.60 73.15 67.90 68.10 68.00
Near Limestone Crusher 70.90 71.30 71.10 65.20 66.30 65.75
Near Work Shop 65.70 66.90 66.30 60.80 61.60 61.20
Near Line-III 68.20 69.40 68.80 63.90 64.80 64.35
All the Values are within the Range
All the equipment is being operated from Central Control Room. Exposure of the employees
near the machines is limited. If at all required to be weighting, they are using ear plugs / ear
muffs.
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Monitoring of Ambient Air Quality and Stack Emissions are carried out regularly and
report is submitted to the TSPCB Monthly and to the Ministry’s Regional Office at
Chennai half-yearly.
(V) The company shall install adequate dust collection and extraction system to
control fugitive dust emissions at various transfer points, raw mill handling
(unloading, conveying, transporting, stacking), vehicular movement, bagging and
packing areas, etc. Asphalting/concreting of road and water spray all around the
stockyard and loading / unloading areas shall be carried out to control fugitive
emissions. Covered sheds for storage of raw materials and pneumatic conveying
system for fly ash and bed ash for conveying ash from boiler shall be provided.
Coal, cement, fly ash and clinker shall be stored in silos.
We have adequate number of bag filters. Total Number of Pollution Control
Equipments is as follows: ESPs – 7, Bag Filters – 99.
All the transfer points equipped with bag filters.
Dump hoppers are equipped with water sprinkler system.
Venting systems are available for pneumatic Conveying System.
All the circuits are having venting system.
Truck mounted Water Spraying system arranged in the plant to control fugitive
emissions.
Concrete roads were laid down.
Covered Sheds are available for storing raw materials & fuel.
Pneumatic conveying system provided for fly ash from CPP to Fly ash Silo.
Storage silos are available for in process materials and finished products.
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(v) Secondary fugitive emissions shall be controlled and regularly monitored as per
guidelines issued by the CPCB.
Concrete Roads are available, which minimizes the fugitive emissions.
Road sweeping machine is used for roads cleaning inside the plant.
Regular water spray is being carried out to control the secondary fugitive
emissions.
Fugitive emissions analysis data is presented in table 1.5
Table 1.5
AVERAGE VALUES OF FUGITIVE EMISSIONS DATA
(Apr’16 to Sep’16)
Parameter
Location
(PM10)
Average (µg/m3)
(PM2.5 )
Average (µg/m3)
Min. Max Avg. Min. Max. Avg.
On top of
Technical
building
50 61 55.50 18 26 22.17
PCB Limit: PM10 – 100 (µg/m3): PM2.5 - 60(µg/m3).
All Values are Within the Range.
(vi) The company must harvest the rainwater from the rooftops and storm water
drains to recharge the ground water and use the same water for the various
activities of the project to conserve fresh water.
Rain water is stored in a reservoir and is utilized for various activities in the
plant thus reducing the consumption of ground water.
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(vii) The company shall undertake eco-development measures including community
welfare measures in the project area.
Various welfare schemes are being adopted for the development of the
surrounding village people & area under CSR.
(viii) The overall noise levels in and around the plant area shall be kept well within the
standards (85 dBA) by providing noise control measures including acoustic
hoods, silencers, enclosures, etc. on all sources of noise generation. The
ambient noise levels shall conform to the standards prescribed under
Environmental (Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) 70 dBA
(night time).
The values are recorded and are well within the limits.
Table 1.6
AVERAGE VALUES OF NOISE LEVEL DATA
(Apr’16 to Sep’16)
Location NOISE LEVEL in Leq dB(A)
Day Time Night Time
Min Max Avg Min Max Avg
Near Kiln 68.50 69.20 68.85 63.10 64.20 63.65
Near Raw Mill 70.80 71.50 71.15 65.40 66.40 65.90
Near Compressor House 72.50 73.10 72.80 67.30 68.70 68.00
Near Cement Mill 67.60 69.70 68.65 62.50 64.70 63.60
Near D.G.Set 72.70 73.60 73.15 67.90 68.10 68.00
Near Limestone Crusher 70.90 71.30 71.10 65.20 66.30 65.75
Near Work Shop 65.70 66.90 66.30 60.80 61.60 61.20
Near Line-III 68.20 69.40 68.80 63.90 64.80 64.35
All the Values are within the limits.
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(ix) All recommendations made in the ‘Corporate Responsibility for Environment
Protection (CREP) for cement plants shall be implemented.
We are complying with the CREP Guidelines.
(x) Proper housekeeping and adequate occupational health programmes shall be
taken up.
Housekeeping is maintained in all areas of the plant with better management
Road sweeping machine has been provided for maintaining good Housekeeping
Regular health checkups, awareness programs are continued.
(xi) A separate environmental management cell to carry out various management and
monitoring functions shall be set up under the control of Senior Executive.
Environmental management cell is formed with a team of qualified engineers
& chemists to carry out various management and monitoring functions under
the control of senior executive.
(xii) As proposed in EIA/EMP, Rs.24.50 Crores and Rs.1.86 Crores earmarked towards
the capital cost and recurring cost/annum for environmental pollution control
measures shall be suitably used to implement the conditions stipulated by the
Ministry of Environment and Forests as well as the State Government. The funds
so provided shall not be diverted for any other purpose.
a. Major control equipments installed in the Up gradation of the plant. The funds
have been utilized for installing and maintenance of Pollution Control
Equipments & to keep up the green belt and an amount of Rs. 2756 Lakhs has
been spent for construction of limestone stockpile and CPP coal storage
sheds. All pollution control equipments will be in operation during running of
the plant. In order to comply with new emission norms of less than 30
mg/Nm3 for stacks, all existing single phase transformers are replaced with
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three phase transformers, procured bags and accessories for Bag House/Bag
Filters.
(xiii) The Regional Office of this Ministry at Bangalore / CPCB / APPCB shall monitor
the stipulated conditions. A six monthly compliance report and the monitored
data along with statistical interpretation shall be submitted to them regularly.
Six monthly compliance report and the monitored data along with statistical
Interpretation is being submitted to RO, Ministry at Chennai regularly.
(i) The Project Authorities 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 commencing the land development work.
The project work was completed in the month of August 2010.
(ii) 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 A.P. Pollution Control Board / Committee and may also be seen
at Website of the Ministry of Environment and Forests at http:/envfor.nic.in. This
should be advertised within seven days from the date of issue of the clearance
letter at least in two local newspapers 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 Regional office at Bangalore.
Environmental clearance was advertised in local newspaper with in the
stipulated time during proposal of the line three project (2007-08).
For ORIENT CEMENTLIMITED
R.V.R. MURTY
Vice President – operations
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2. INTRODUCTION
M/s. ORIENT CEMENT LIMITED has expanded the cement unit and also 50MW coal
based Captive Power Plant (CPP). The total cost of the project is Rs.531.72 Crores.
These units are located in existing Cement Plant premises of M/s. ORIENT CEMENT
LIMITED at Village: Devapur, Mandal: Kasipet, District: Adilabad of State: Telangana.
The salient features of the expansion project are presented.
At present we have three production lines (Line-1 & Line-2 & Line-3) with a installed
capacity of 10,600 TPD Clinker. Cement production capacity is 8,900 TPD. The
modifications & retrofitting was carried in Raw Mills, Kilns & Cement Grinding line 1 &
2.
A 50 MW Coal based power plant is installed to meet the power requirement of the
plant operations.
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Table2.1
SALIENT FEATURES OF THE EXPANSION PROJECT
Built-up area includes buildings, utilities like roads, storage yards, water
tanks etc.
Existing Plant
Total
Cement Unit
1. Clinker Production (TPD)
a) Line – 1
b) Line – 2
c) Line – 3
d) Overall production
1. Cement Production (TPD)
2. Built-up Area (Acres)
3.Project Cost (Rs. in
Crores)
3600 TPD
2800 TPD
4200 TPD
10,600
8,900
54.42
- - -
Captive Power Plant
1. Power Production (MW)
2. Built-up Area (Acres)
3. Project Cost
(Rs. in Crores)
- - -
- - -
- - -
50
11.06
213
50
11.06
- - -
1. Plant Area (Area in acres)
a) Built-up Area
b) Green belt Area
2. Town Ship
a) Built-up Area
b) Green belt Area
3. Total Project Area
a) Total Built-up Area
b) Greenbelt Area
c) % Greenbelt Area
4. Total Project Cost (Rs. in
Crores)
168.56
45.56
67.74
257.35
20.07
148.35
425.89
65.63
216.09
50.74
- - -
No Change
19.92
3.50
No Change
No Change
7.5
No Change
19.92
11.00
- - -
531.72
168.56
65.48
71.24
257.35
20.07
155.85
425.89
85.55
227.09
53.32
- - -
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2.1 Location and Accessibility
M/s. Orient Cement Ltd is located in Devapur (V), Kasipet (M), Adilabad (Dist) of
Telangana. The area is between 19°00’15” - 19°03’16” North Latitude and
between 79°18’30”-79°21’44” East Longitude. Fig2.1 shows location map. Mean
sea level of the place is in between 240 – 260 m.
The site can be reached from the State Highway between Mancherial and
Bellampalli using a connecting tar road via Kasipet. The plant area is about 35
km from Mancherial and 22 km from Bellampalli.
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3. PROCESS DESCRIPTION
MANUFACTURING PROCESS:
Materials:
Lime stone + Additives → Raw meal
95% 5%
Raw meal (1.48 Ts) → Clinker (1.00 T) (Burning with Coal at 14000C - 14500C)
Clinker + Gypsum → Ordinary Portland cement (OPC) 97% 3% Clinker + Fly Ash + Gypsum → Portland Pozzolana Cement (PPC)
Stage wise Operations:
Limestone Mining: Mechanized mining of limestone is done by deep hole drilling, blasting, excavation and hauling. The blasted limestone of size less than 1000 mm will be transported to Limestone Crusher for crushing.
Limestone Crushing: Limestone crushing is done in Hazemag type Double rotor impact crusher (1200 TPH capacity). The size reduction in crusher will take place from 1000 mm to less than 40 mm.
Stacking & Reclamation: Crushed limestone will be stacked with Stacker (CIMMCO Birla make – 1500 TPH capacity) as per the required quality. Capacity of the stockpile is 50000 Ts. After forming the stocking (with the required quality as well as quantity), the reclamation (Reclaimer – CIMMCO Birla make – 800 TPH capacity) will be started. The total process of stacking and reclamation is called Chevron method.
Raw material grinding: Blended Limestone will be reclaimed and will be filled into raw material hopper in the respective raw mill section. Laterite -1 and Alumina Laterite (out sourced material) will be filled into respective Laterite hoppers. Lime stone with Laterite -1 and Alumina Laterite in required ratios will be conveyed through weigh feeders and belt conveyor to Polycom, HIC, Roller Press, where grinding will take place. The product, called raw meal, is entrained with air/gases to Electrostatic precipitator, Bag House where the total raw meal is collected and further conveyed to Continuous Flow Silo’s.
Coal Crushing & Grinding: Raw coal, received from Singareni collieries, is crushed in coal crushers, where the size reduction of coal from 100 mm to 30 mm size takes place; this is conveyed to Raw Coal hoppers. Ball Mill, VRM will grind raw coal to fine powder and will be collected in bag filter. The fine coal will be further conveyed mechanically to fine coal bins.
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Pyro-processing: The system consists of Rotary Kilns (3600 TPD, 2800 TPD, 4200 TPD) with 5, 6 stage suspension pre-heater and in-line calciners. Raw meal from respective CF silo will be conveyed to Preheater. Fine coal will be fired through burner pipe in kiln and through nozzles in precalcinator. The material will be 90% calcined at kiln inlet and balance Calcination, pre burning and sintering reactions will take place in kilns. Temperature of 1400 - 14500C will be maintained in kiln for the completing the reactions. Clinker will be formed and is cooled in Clinker coolers. The clinker after cooling will be transported mechanically to CSP, Silo’s.
Cement grinding: Clinker from CSP, Silo’s will be conveyed to clinker hopper. Gypsum (out source material) will be filled into gypsum hopper. Closed circuit ball mill with dynamic separator and Pregrinding Roller Press System will grind clinker and gypsum fed to it in fixed ratios. The product, called Ordinary Portland Cement, is conveyed mechanically to OPC storage silos.
Similarly clinker, flyash and gypsum at a fixed ratio will be ground in the Roller Press and ball
mill system. The product, called Portland Pozzolana Cement, will be conveyed mechanically to
PPC storage silos.
Cement Packing: Six packers (Electronic packers) are available for packing of cement in to bags and dispatching.
Plant (Raw Mills to Cement Grinding section) is operated from CCR based on PLC systems.
Captive Power Plant: Two boilers with 25 MW capacities are installed within the Cement
Plant premises to cater the Power requirement of the Plant.
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4. ENVIRONMENTAL BASELINE STATUS
The base line data for Soil, Water, Micrometeorology, Ambient air quality; Stack
monitoring Data and Noise levels in and around plant area was generated from
April’16 to September’16.
4.1 Soil Environment
During plant operations top soil is removed. Presently topsoil whenever removed
is being spread on the mined out areas for reclamation & plantation. Soil samples
were collected from various locations and analyzed for different parameters,
which are presented. The soils in the plant area are mostly varying between silty
clay to mixed soil (Loamy sand) analysis data is presented in table 4.1.
4.2 Water requirement
Water is drawn from Bore wells in the company area and Jack wells in the nearby
for different utilities. At present 2,070 m3/day of water is used for gas
conditioning for ESP’s and for cooling of bearings, gearboxes and dust
suppression at raw material etc. Additional 430 m3/day of water is required for
up-gradation and another 450 m3/day is required for proposed expansion as
makeup water for cooling of bearings, gearboxes and dust suppression etc. After
proposed expansion the total water requirement for plant will be 2,950 m3/day.
About 641 m3/day of water is used for domestic purposes (township) at present,
which will increase, by 20m3/day after the expansion. The water quality data &
drinking water data is presented in tables 4.2 & 4.3 and drinking water data is
presented in table 4.4.
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Table4.1
SOIL ANALYSIS (Apr’16 – Sep’16)
Location
1 2 3 4
pH 7.59 7.73 7.37 7.81
E.C. µ mhos/cm 292 277.50 253.50 238.50
Calcium as Ca m eq/100g 65 42.50 35.50 23
Magnesium as Mg m eq/100g 17.1 15.83 10.50 11.38
Sodium as Na m eq/100g 54 45.50 23 22
Potassium as K Kg/ha 67.4 53 107.50 127
Phosphorous as P Kg/ha 15 10.50 15.50 11
Nitrogen as N Kg/ha 105.5 144 207.50 232.50
Organic Carbon % 0.35 0.50 0.61 0.55
Sulphates as So4 m eq/100g 0.64 0.58 0.22 0.25
Chlorides as Cl m eq/100g 0.55 0.64 0.39 0.54
Silt & Clay % 62 60.50 65.50 63.50
Sand % 34 37.50 33 34.50
Textural Class m eq/100g Loamy Sand
Loamy Sand
Loamy Sand Loamy Sand
Physical Appearance m eq/100g Mixed Soil Mixed Soil Mixed Soil Mixed Soil
Note: a. Soil Sample collected at a depth of 45 cm.
b. Soil sampling locations
1. Near Crusher site,
2. Near Mines Office,
3. Agriculture land Devapur
4. Near colony.
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25 Orient Cement Limited
Table 4.2
WATER ANALYSIS
Date of Sample Collection : 30-06-2016, 09-09-2016.
Date of Sample Analysis : 01-07-2016, 10-09-2016.
Locations 1 2 3 4 5
Colour (Hazen units) 0 0 0 12.5 5
Turbidity (NTU) 0.2 0.60 0.9 1.77 0.585
pH 7.86 7.45 7.6 7.50 7.80
E.C. (Micromhos/cm) 350.5 1233 629.5 855.50 1041
Total dissolved solids 202.5 830 389.5 555.00 650.5
Phenolphthalein alkalinity as CaCo3 0 0 0.0 0.00 0
Methyl orange alkalinity as CaCo3 94 296 118.5 253.50 339.5
Total hardness as CaCo3 131.5 367.5 269.5 332.00 381
Calcium as Ca 31.5 110 85.0 94.00 121.5
Magnesium as Mg 12.82 22.49 13.9 23.81 18.775
Sodium as Na 19 122 35.5 53.00 40.5
Potassium as K 1.075 1543 1.3 2.10 1.22
Chloride as Cl 35.5 181.5 61.0 94.00 65
Sulphate as So4 27 66.5 47.0 48.00 56
Nitrate as NO3 7.985 23.5 15.5 20.00 26
Carbonates as CaCO3 0 0 0.0 0.00 0
Bicarbonates as CaCO3 114 361 201.5 311.50 413
Residual Chlorine 0 0 0.0 0.42 0
Copper as Cu <0.05 0.055 <0.05 0.17 <0.05
Manganese as Mn <0.02 <0.05 <0.02 0.09 <0.02
Iron as Fe 0.145 0.17 0.2 0.27 0.22
Fluoride as F 0.45 0.58 0.5 0.68 1.06
1. Bore well (Near Crusher) 2. Bore well (Maddimadugu Village)
3. Bore well (Factory Premises) 4. Open well (Devapur village)
5. Bore well Water (Devapur Village)
Note: All the values except pH are expressed in mg/L.
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Table 4.4
DRINKING WATER ANALYSIS DATA
(Apr’16 – Sep’16)
S.NO PARAMETERS min max AVERAGE
1 Turbidity (NTU) 0 0 0.00
2 pH 7.67 8.02 7.86
3 E.C (micromhos/cm) 116 166 137.33
4 Total dissolved solids 71 101 81.67
5 phenolpthalene alkalinity as CaCO3 0 0 0.00
6 Methylorange alkalinity as CaCO3 46 65 54.00
7 Total alkalinity as CaCO3 46 65 54.00
8 Total hardness as CaCO3 37 56 44.83
9 Calcium as Ca 7.13 11 8.78
10 Magnesium as Mg 4.69 7042 1178.00
11 Sodium as Na 0.83 16 10.51
12 Potassium as K 0.65 0.95 0.77
13 Copper as Cu 0.08 0.08 0.08
14 Iron as Fe 0.05 0.1 0.07
15 Managanese as Mn 2.72 2.72 2.72
16 Chlorides as Cl 10.45 16 12.74
17 Sulphates as SO4 2.16 3.1 2.56
18 Flourides as F 0 0 0
19 Phenolic compounds as c6h5OH 0.18 0.77 0.53
20 Mercury as Hg <0.001 <0.001 <0.001
21 Cadmium as Cd <0.001 <0.001 <0.001
22 Selenium as Se <0.001 <0.001 <0.001
23 Cyanide as CN <0.01 <0.01 <0.01
24 Lead as Pb <0.01 <0.01 <0.01
25 Zine as Zn <0.01 <0.01 <0.01
26 Resifual chlorine 0.01 1.01 0.177
27 Silver as Ag 0 0
28 Mineral Oil <0.04 <0.04 <0.04
29 Hexavalent chromium as Cr+6 0 0 0
Note: All the values except pH, Turbidity and E.C. are expressed in mg/L
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27 Orient Cement Limited
4.2.1 Water pollution
There is no wastewater generated from cement plant. Different effluents except
DM plant regeneration water generated from utilities of power plant will be
diverted into cooling water tank of cement plant. DM plant regeneration water is
separately collected, neutralized and used for ash quenching. Sewage from
township etc. is to be treated in the proposed sewage treatment plant and used
for green belt.
4.2.2 Solid waste management
There are no prominent solid wastes generated from cement plant. Fly ash from
power plant will be safely collected and used in cement manufacturing. Bed ash
from power plant will be used for reclamation of abandoned mine pits
Table 4.5
WEATHER MONITORING DATA
(Temperature & Relative Humidity)
Date Temperature (0C) Relative Humidity (%)
Min. Max. Avg. Min. Max.
29-06-2016 26.10 29.50 27.80 60 68
08-09-2016 25.40 31.90 28.60 65 72
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28 Orient Cement Limited
4.3 Air Environment
The pollutant emissions from sources and atmospheric interactions determine
the quality of air at a receptor (any object affected adversely by the quality of air
to which it is exposed and include human beings, vegetation and materials), is
determined by the type and amount of pollutants emitted upwind and the extent
of atmospheric interaction.
The base line data for major pollutants like particulate matter (PM10), Particulate
Matter (PM2.5), Sulphur dioxide (SO2), Nitrogen Dioxide (NOX) and Carbon
Monoxide were collected by judiciously designed ambient air quality stations
network in and around the plant area.
Note: The Ministry of Environment and Forests (MOEF) New Delhi has given
amendment on 16th November 2009 for revised standards for Ambient Air
Quality Standards. M/s. Orient Cement has following the same Standards.
At each station 24 hr continuous sampling in every month was carried out. From
August 2010 onwards they are following as per MOEF Notification i.e. Particulate
Matter (PM10), Particulate Matter (PM2.5), SO2 & NO2 were monitored on 24 hourly
basis. The method of sampling and analysis were carried out vis-a-vis following
the Central Pollution Control Board guidelines. The average values of ambient air
quality data is presented in table 4.6 and graphical data are presented in figs.4.7
to 4.10.
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29 Orient Cement Limited
Table 4.6
AVERAGE VALUES OF AMBIENT AIR QUALITY DATA
(Apr’16 – Sep’16)
Parameter
Location
Particulate Matter –
PM10
(µg/m3)
Particulate Matter –
PM2.5
(µg/m3)
Sulphur dioxide
(µg/m3)
Nitrogen Dioxide
(µg/m3)
Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg.
Near D.G.
Set
49 63 54.67
15 27 19.50
6 13 9.33 15 23 17.50
Near Time
Office
44 68 54.00 6 10 7.83 19 24 21.33
Near Guest
House
51 64 58.33 7 11 9.17 16 22 18.67
Near Mines
Office
41 51 46 7 11 9.17 16 23 19.83
4.3.2 Air Pollution Sources and Control Measures
The sources of air emissions are from Kiln with Raw Mill, Cement Mill, Coal Mill
and Cooler. The stack details are furnished in Stack emissions monitoring are
carried out once in a month for the parameter Particulate matter (PM). It is
noticed from the collected emissions data that the parameters monitored are
within the limits prescribed by TSPCB. The stack details are furnished in table 4.7
and results are presented in tables 4.8 to 4.9.
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30 Orient Cement Limited
Table 4.7
DETAILS OF STACK EMISSIONS
(Apr’16 – Sep’16)
SI.N
O.
Stack attached to Height
(Meters)
Dia
(Meters)
Flow rate
(Nm3/hr)
Concentration
of particulate
matter
(mg/Nm3)
1. Kiln –I & Raw
mill – I 85.0 3.34 230676 59.75
2. Kiln-II & Raw mill – II 82.5 3.00 194973.50 32.25
3. Kiln – III & Raw mill – III -- 3.76 454134 21.33
4. Cooler –I 30 3.00 119886 33.75
5. Cooler-II 31 3.80 170820 23.25
6. Cooler – III -- 3.50 256200 19.83
7. Coal Mill-I 36.0 0.85 13164 56.50
8. Coal Mill-II 45.5 1.00 18402 52.50
9. Coal Mill – III -- 1.80 89970 33
10. Cement Mill-I 39.0 1.00 16656 20
11. Cement Mill-II 38.7 1.50 44754 21
12. Crusher -- 1.20 38310 60.50
13. Packing Plant-I -- 0.75 6444 63.5
14. Packing Plant-II -- 0.75 10830 59.5
15. Packing Plant-III -- 0.75 8322 60.67
16. Packing Plant-IV -- 0.75 55.68 63.50
17. CPP 90.0 5.00 418380 90.17
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Table 4.8
AVERAGE VALUES OF STACK MONITORING DATA
(Apr’16 – Sep’16)
S.No Parameters
PCB Norms
(In mg/Nm3)
Particulate Matter
(mg/N m3)
Location
Min Max Avg.
1 3600 TPD Rotary Kiln – I & Raw Mill – I 80 57 63 59.75
2 2800 TPD Rotary Kiln – II & Raw Mill – II 80 25 42 32.25
3 4200 TPD Rotary Kiln –III & Raw mill – III 50 16 30 21.33
4 FBC Boilers of Capacity 2 X 115 115 82 96 90.17
5 Cement mill – Line 1 80 15 51 25
6 Cement mill – Line 2 80 11 46 21
8 Coal mill – Line 1 50 46 62 56.50
9 Coal mill VRM – Line 1 80 39 65 47.75
10 Coal mill – Line 2 80 47 56 52.50
11 Coal mill – Line 3 50 30 35 33
12 Clinker Cooler – Line 1 80 28 37 33.75
13 Clinker Cooler – Line 2 80 17 36 23.25
14 Clinker Cooler – Line 3 50 13 27 19.83
15 Packing plants - 5 Nos. 80 59.5 63.5 61.79
16 Attached to 4 X 4. 2 MW &1 x 4.0 MW
D.G.sets
115 Not Running
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32 Orient Cement Limited
Table 4.9
AVERAGE VALUES OF STACK MONITORING DATA
(Apr’16 – Sep’16)
Parameter
Location
Sulphur dioxide
(mg/N m3)
Oxides of Nitrogen
(mg/N m3)
Min. Max. Avg. Min. Max. Avg.
Kiln – I
4.80 27.0 19.45 622 678 652
Kiln – II 2.30 29.0 20.58 613 654 632.75
Kiln – III 3.90 26.0 16.73 605 652 628.17
4.4 Noise Environment
Noise in general is sound which, is composed of many frequency components of
various loudness distributed over the audible frequency range. The most
common and heavily favored of these scales is the A-weighted decibel [dB (A)].
This scale has been designed to weigh the various components of noise
according to the response of the human ear; loud noise may damage hearing or
health; interfere with work tasks, speech communication and sleep; affect inter-
room privacy; cause annoyance. The impact of noise depends on its
characteristics (instantaneous, intermittent or continuous in nature), time of day
(day or night) and location of noise source. The noise levels at various locations
in and around plant area were measured and tabulated in table 4.10.
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Table 4.10
AVERAGE VALUES OF NOISE LEVEL DATA
(Apr’16 to Sep’16)
Location NOISE LEVEL in Leq dB(A)
Day Time Night Time
Min Max Avg Min Max Avg
Near Kiln 68.50 69.20 68.85 63.10 64.20 63.65
Near Raw Mill 70.80 71.50 71.15 65.40 66.40 65.90
Near Compressor House 72.50 73.10 72.80 67.30 68.70 68.00
Near Cement Mill 67.60 69.70 68.65 62.50 64.70 63.60
Near D.G.Set 72.70 73.60 73.15 67.90 68.10 68.00
Near Limestone Crusher 70.90 71.30 71.10 65.20 66.30 65.75
Near Work Shop 65.70 66.90 66.30 60.80 61.60 61.20
Near Line-III 68.20 69.40 68.80 63.90 64.80 64.35
4.5 Green belt development:
Development of water bunds in the plant water drains and reuse of wastewater
for maintaining green belt commenced. Further it is planned to build bunds
upstream of the drains to meet additional requirement for new green belt area in
the plant.
The already developed greenbelt enhances environmental quality through:
Mitigation of fugitive emissions including odor
Attenuation of noise levels
Creation of aesthetic environment
Balancing Eco-environment
Prevention of soil erosion
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34 Orient Cement Limited
Recharging oxygen into environment
Spatial and compositional design of greenbelt for environmental management is
done after considering the topography, climate, soil quality of the area and flora
spread over the area.
4.5.1 Township
For township wastewater treatment plant is proposed for reuse of treated
wastewater for maintaining large green belt developed in colony. This will also
cater to propose green belt in the township.
4.5.2 Other measures
Further construction of water reservoir in township in an area of 23,600
sq. m with a volume of 87,000 m3 was developed for storage of water.
Water is used for watering the plantation & improves ground water
recharge.
Development of water bunds in the plant water drains and reuse of
wastewater for green belt development will be undertaken.
STP Provided in colony along with water filtration system for use in
Green Belt development.
Higher No. of air-cooling fans for cooler installed to reduce water
consumption.
High Pressure water spray system installed for process cooling to
reduce the water consumption.
Reservoir in the mines pit will also add to increasing ground water table
economizing the water intake.
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35 Orient Cement Limited
4.6 Land Environment and Solid Waste Management
There is no generation of solid wastes from cement manufacturing process, as all
the dust collected in air pollution control systems is continuously recycled into
process. Different types of solid wastes are generated from the non-process
activities in the unit. They include waste packaging materials, steel scrap, and
empty oil/grease drums, used tyres, used batteries etc. All the non-process solid
waste materials are disposed for further processing as per the directions of TS
Pollution Control Board.
4.7 Waste Management
The used oil is used as fuel in the Kiln calcining system. The Precalciner is
designed to use waste fluids from the plant for utilizing the heat value of the
waste. The required feeding system shall be part of the main equipment.
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36 Orient Cement Limited
5.ENVIRONMENTAL MANAGEMENT PLAN
Effective pollution control measures, greenbelt development and adequate safety
measures and post project monitoring facilities for pollution, implementation of the
same form the strategy for Environmental Management Plan. The environmental
management plan is prepared for operation phases.
5.1 Operation phase
Effective pollution control measures to abate various types of pollution generated in
the plant are installed. Major pollution after up gradation and expansion (3rd line) of
Cement plant and new captive power plant is air pollution in the form of flue gas and
dust emissions from kiln, crushers, material handling systems etc., of cement plant
and boilers, coal crusher and coal and ash handling systems of power plant. Waste
water generated from DM Plant, RO Plant & other waste water and solid waste in the
form of ash due to coal burning from power plant.
5.2 Air Environment:
Different types of air pollution control equipment are installed/modified along with
up gradation/new plant installation in concurrence with installation of other process
equipment and control equipment is commissioned simultaneously along with process
plant.
5.3 Water Environment:
There is no wastewater generation from the cement plant except domestic discharge.
From power plant waste water generated from blow-downs of cooling tower & boiler,
DM plant regeneration, RO plant reject and sanitary effluent. The blow-down from
boiler & cooling tower is sent to cement plant’s cooling water tank. The DM Plant re-
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37 Orient Cement Limited
generation water about 100 m3/day collected separately collected and neutralized
effluent is directly used for quenching of ash. The above waste water management
facilities created along with process plant installation and the same functions from the
day of commissioning of plants.
About 550 m3/day of sanitary effluent is generated from township and industry. In the
expansion program sewage treatment plant to treat the sewage and use the same for
green belt is installed.
5.4 Land Environment and solid waste Management:
There is no generation of solid wastes from cement manufacturing process as all the
dust collected in air pollution control systems is continuously recycled into process.
Different types of solid wastes are generated from the non-process activities in the
unit. They include waste packaging materials, steel scrap, and empty oil/grease drums,
used tyres, used batteries etc. All the non-process solid waste materials are disposed
to scrap vendors for further processing. The present disposal and management
practices are continued.
Solid waste generation is ash from the boilers of CPP. All the Fly ash that is generated
is used to produce Pozollona Portland Cement.
5.5Noise Environment:
The noise generating equipment is covered with sound proof enclosures. The noise
generating sources in captive power plant is Turbine generator, high pressure boiler
and compressor. The noise generating equipment is covered and acoustic noise
suppression measures implemented under the guidance of equipment manufactures.
Personnel safety equipment like earmuffs provided to the staff working near high noise
generating sources. There are no human habitations in the vicinity of the unit so there
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38 Orient Cement Limited
no impact on the surroundings. The greenbelt help in the reduction of noise levels
outside the plant.
5.6 Hazardous Materials Management
There are no hazardous materials used in the process. Used lead acid batteries at
present are sent to suppliers on buy back basis. Non-ferrous metal scrap is disposed
to nonferrous metal scrap recyclers authorized by TSPCB. Waste oil generated from
various manufacturing equipment is disposed to agencies authorized by TSPCB. The
additional waste generated after up gradation/expansion is disposed in the same
manner.
5.7 Safety Systems
The company maintains safety of the equipment as well as the employees with well-
defined procedures, which is also spelt out in ISO-14000 and OHAS-18000. For
emergency control fire hydrant system is available along with maintenance
Schedule for the firefighting equipments. We have mobile fire hydrant also. A well-
defined on site emergency plan is also made and regular monitories are conducted.
Mock drills are conducted regularly Ambulance is available of the plant.
Water spraying system is provided for coal yard to control coal burning. Flame proof
motors are installed wherever required. Electric sub-stations are sufficiently ventilated.
Electrical fittings like switches, lamps, starters etc. are provided with flameproof
components. Smoking is strictly prohibited and vehicles are to be allowed only near
storage yards and utility places in the industry premises.
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39 Orient Cement Limited
a) Fire Hydrant System:
The fire protection system provided is capable of achieving a non-combustible
atmosphere in less than one minute, which meets the requirements of National Fire
Protection Association (NFPA). This system shall include sprinkler systems and CO2
based fire suppression equipment. Fire hoses & tools cabinet, Fire alarm and required
Fire pumps are provided as part of fire safety system.
b) Fire Extinguishers:
Fire extinguishers are provided wherever necessary. 158 no. DCP fire extinguishers, 94
no. CO2 fire extinguishers, 48 no. Mechanical Foam type extinguishers and 7 no. ABC
type extinguishers are provided at various locations throughout the plant. Additional
fire extinguishers are procured and provided wherever required.
Necessary safety and preventive measures avert any possible hazards and fire
accidents which may cause human suffering, property loss/ damage to equipment and
detrimental effect on environment.
5.8 House Keeping:
Proper housekeeping and cleanliness is being maintained both inside and outside the
industry. The process areas are cleaned regularly. Internal roads are water sprayed to
avoid dust emissions. Signboards are provided in the work areas and all the road and
building highlighting the safety and occupational aspects.
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40 Orient Cement Limited
6. CONCLUSIONS
The compliance report is enclosed. The monitoring data generated is presented
and critical analysis is carried out. Necessary control equipments have been
added in the up gradation of clinker transportation belt & Cement Storage silo’s
For the new 3rd Line all control equipments have been installed and well
maintained. We have installed 2 No’s of Online Ambient Air Quality Monitoring
Stations, 7 No’s of stack monitoring Stations and these are connected to TSPCB
AND CPCB Servers. The Emission levels are found to be in the specified limits.
There is no wastewater generation in the process. Sewage treatment plant is
provided to treat the sewage water. STP is maintained in good condition.
Adequate green belt has been developed and every year we are planning 2000-
4000 new saplings. Two new rose gardens were developed inside the plant.
Adequate measures are taken to maintain the Environmental conditions
stipulated by MoEF and Telangana State Pollution Control Board.
Environmental Monitoring facilities:
The industry already procured AAQ samplers - 2 Nos. PM10 and PM 2.5 each, stack
monitoring kit 1 no. and noise level meter - 1 no., Continuous ambient air quality
monitoring stations – 2 Nos. and stack emission monitoring – 7 Nos. are installed.