JAYPEE REWA PLANT - Jaypee · PDF fileJaypee Rewa Plant is a cement plant of capacity 3.5MTPA...

JAYPEE REWA PLANT (A Unit of Jaiprakash Associates Limited)

JAYPEE NAGAR REWA (M.P.)

2014 – 2015

SUBMITTED TO M.P. POLLUTION CONTROL BOARD

BHOPAL (M.P.)

Jaypee Rewa Plant (A unit of Jaiprakash Associates Limited)

Introduction:

Jaypee Rewa Plant is a cement plant of capacity 3.5MTPA under the division of

Jaiprakash Associates Limited (JAL) groups of Company with Head and Registered

Office at Noida (U.P.), a leading Business House with its presence in Core Industries

like Cement industry, Construction division, Hydropower & Thermal Power, Education,

I.T., Agro based products & a chain of five star hotels in major cities of India ,and

constructed the world class racing track to organized FORMULA – ONE racing

competition first time in India, which has been at the vanguard in generating wealth for

the Nation.

Transforming challenges into opportunities has been the hallmark of the Jaypee Group,

ever since its inception five decades ago. The Group is a diversified infrastructure

conglomerate with business interests in Engineering & Construction, Cement, Power, Real Estate, Expressways, Fertilizer, Hospitality, Healthcare, Sports, Information Technology and Education (not-for-profit). The group produces special

blend of Portland Pozzolana Cement under the brand name ‘Jaypee Cement’ (PPC).

Its cement division currently operates modern, computerized process control cement

plants.The Group is committed towards the safety and health of employees and the

public. The motto of the Group is ‘Work for Safe, Healthy, Clean & Green Environment’. Both Jaypee Rewa & Jaypee Bela Plants of Jaiprakash Associates

Limited at Jaypee Nagar and Jaypeepuram respectively were awarded Five Star

Rating & subsequently prestigious Sword of Honour by the British Safety Council, U.K.

for Safety and Health Management System.

The group produces Ordinary Portland Cement and Portland Pozzolona Cement under

brand name “Jaypee Cement”. Rewa cement complex has three modern,

computerized process control cement plants namely “Jaypee Rewa Cement Plant (02

Nos. Kiln)” & “Jaypee Bela Cement Plant (01 No. Kiln)” with an aggregate production

capacity of 6.0 MTPA cement. JRP Unit-I and Unit-II is located in Huzur Tehsil, Rewa

district of Madhya Pradesh state at an aerial distance of about 15 km North-West of

Rewa Town. Geographically, it is located at latitude 24033’47’’ North and longitude

81011’41’’ East. JRP Unit-I and Unit-II have come into operation in the year 1986 and

year 1992 respectively. The production capacity of both the units was enhanced in the

year 2005. The cement production process is based on dry process. Present

production capacity of Jaypee Rewa plant is 3.50 million tonne Cement per Annum.

“FORM – V” (See rule 14)

ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE

31st MARCH 2015

PART – A

(I)

Name & Address of the

Owner / Occupier of the Industry

Operation or Process

Jaypee Rewa Plant (Unit of Jaiprakash Associates Limited) Jaypee Nagar - 486 450 REWA (M.P.)

(II)

Industry Category

Primary ( STC CODE )

Secondary ( SIC CODE )

Red Category and Large industry

(Primary STC Category)

(III)

Production Capacity Unit-I

Unit-II

1.5 Million TPA Cement

2.0 Million TPA Cement

(IV)

Year of Establishment

Unit-I

Unit-II

Year 1986

Year 1992

(V)

Date of last Environmental Statement

Submitted

15th September, 2014

PART – B

Water & Raw Material Consumption A. Water Consumption - m3/d

(i) Process - 2433

Cooling - 683

Domestic - 1768

Name of the Product

Process (Spraying) Water Consumption per unit of Product Output (m3/MT)

During the Previous Financial Year (2013-14)

During the Current Financial Year (2014-2015)

Cement

0.344 (Only Process)

0.354 (Only Process)

0.453 (Total Water Cooling & Spraying)

(ii). Raw Material Consumption

Name of the Raw Material

Name of Product

Consumption of Raw Material per Unit Product Output

(MT/MT of Cement)



Limestone

Laterite

Iron-ore

Coal

Gypsum

Pozzolona

Pet coke

Cement

1.505

0.022

0.013

0.121

0.025

0.172

0.006

1.548

0.031

0.011

0.124

0.024

0.169

0.010

Total Cement Production (MT)

Name of Product During Previous Financial Year (13-14) MT

During Current Financial Year (14-15) MT

Cement 2309320 2259886

PART - C Pollutant Discharged To Environment / Unit of Output

(Parameters as specified in the consent issued)

S. No. Pollutants

Quantity of Pollutants

Discharged (Mass / day) (tonne/day)

Concentrations of Pollutants in discharged

(Mass / Volume) (mg/Nm3)

Percentage of variation from

prescribed standard

with reasons

(a) Water (i) Domestic Zero discharge is maintained. Treated domestic water is being

used in Horticulture and Plant process (ii) Industrial Zero discharge (b) Air

Monitoring of Ambient Air Quality parameter within limit and report attached as Annexure- I

Stack emission (a) Bag Filters Crusher Bag Filter 0.0120 33.8 (b) ESPs Raw mill / Kiln U-I ESP 0.7246 73.8

Within the standard

permissible limit

Raw mill / Kiln U-II ESP 0.7340 73.5 Cooler U-I ESP 0.2515 63.9 Cooler U-II ESP 0.4078 66.3 Coal Mill U-II ESP 0.1183 58.8 Cement Mill-I Bag House 0.0249 30.7

Cement Mill-II Bag House 0.0265 31.2

Cement Mill-IV Bag House 0.0247 31.7

PART – D

(As specified under [Hazardous Waste (Management, Handling & Transboundary Movement)

Rules 2008)]

Hazardous Waste

Total Quantity (Kg)



(a)

From Process

Used oil Waste oil Used oil Waste oil

24948 10500 45432 Nil

(b) From Pollution Control

Facilities. Nil Nil

PART – E

Solid Wastes

Solid Waste

Total Quantity



(a)

From Process

No solid waste is generated

from the cement

manufacturing process.

No solid waste is generated

from the cement manufacturing

process.

(b)

From Pollution

Control facilities

All the collected material is

recycled in the process.

All the collected material is

recycled in the process.

(c)

(i) Qty. recycled or

reutilised within the unit.

(ii) Sold

(iii) Disposed

All the collected swept Solid

waste is reused in the process.

Nil

Nil

All the collected swept Solid

waste is reused in the process.

Nil

Nil

PART – F PLEASE SPECIFY THE CHARACTERISATIONS (IN TERMS OF COMPOSITION AND QUANTUM) OF HAZARDOUS AS WELL AS SOLID WASTES AND INDICATE DISPOSAL PRACTICE ADOPTED FOR BOTH THESE CATEGORIES OF WASTES. Hazardous waste : All the used oil, waste oil, burnt grease generated from the different

sections of plant is being collected in empty drums and barrels and then sent to store deptt for

proper handling and storage. Collected hazardous waste at specified location as per

Hazardous Waste (Management, Handling & Transboundary Movement) Rule, 2008 from

where the stored hazardous waste is being sold out to authorized recyclers.

Characteristic:

1. Used oil

SN Parameter Result Unit Maximum Permissble

Limit as per HWMH&TM Rules 2008 schedules-

V Part – A 1 Arsenic < 1 PPM 5 2 Cadmium+Chromium+Nickel < 1 PPM 500 3 Lead < 1 PPM 100

4 Poly Chlorinated Biphenyls(PCBs) BDL PPM <2

5 Polyaromatic Hydrocarbons ( PAH) N.D. % 6

Solid waste: The solid waste is generated in the form of MS scrap which is sent to Hi-Tech

casting centre for recycling. Used refractory bricks are collected by Refractory bricks

manufacturer for reuse, used tyres, rejected rubber belts, filter bags, are generated during

cement manufacturing process & these solid wastes are being sold to authorized parties.

PART – G IMPACT OF THE POLLUTION ABATEMENT MEASURES TAKEN ON CONSERVATION OF NATURAL RESOURCES AND ON THE COST OF PRODUCTION.

Following measures have been adopted for abatement of pollution, conservation of natural resources:- 1. Conservation of Limestone a) Utilization of Shale Limestone is being used for manufacturing of cement by proper blending of different grade of

limestone for preparation of proper raw mix to produce a good quality of clinker & cement. The

raw mix design is being prepared in such a way that it reduces the limestone stone saturation

factor by which substantial quality of limestone has been conserved. Almost 7.2 % Shale has

been used in place of Lime Stone for the clinker manufacturing.

b) Utilization of Fly Ash for the manufacturing of cement We have used fly ash up to 28.18% (382142 MT) of total Portland Pozzolonic Cement

manufactured, which directly reduced the extraction of limestone from L/S mines. Reduction in

consumption of limestone in cement manufacturing process leads in reduction of fossil fuel

consumption and ultimately reducing the generation of different pollutant like Suspended

Particulate Matter, emission of SO2 and NOx, fugitive emission from various stages of handling

of limestone (From drilling to grinding stages) & during loading & unloading of coal, laterite &

gypsum. Substantial quantity of electrical and thermal energy has also been saved.

We have 2 nos. of Captive Power Plant (CPP) having capacity of 25 MW and 38.5 MW which

generate approx 485 MT of flyash per day. The flyash generated is being stored in closed steel

silos from where it is pneumatically conveyed to the cement mills for manufacturing of PPC

cement. Additionally, we are also consuming approx 1000 MT flyash for PPC cement

manufacturing which is being sourced from the different thermal power plants and being

transported in closed tankers and directly fed into the cement grinding through pneumatic

feeding system. The percentage of fly ash consumption during last five years is depicted as

under.

2. Conservation of Mineral Gypsum a) Utilization of Chemical Gypsum We have used fertilizer industry byproduct which is waste in nature and its chemical properties

are as good as gypsum. This Chemical gypsum is used for cement manufacturing process;

almost 25092 MT of chemical gypsum (45.71 % of total gypsum i.e 54899 MT) has been

consumed in place of mineral gypsum for cement manufacturing process during the 2014 –

2015.

3. Conservation of Fossil Fuel a) Utilization of Pet Coke The Pet Coke which is petroleum refinery industry byproduct is a waste in nature and having

very high calorific value. This refinery byproduct is used as alternate fuel in cement kiln,

almost 8.38 % (23519 MT) of total fuel consumption during the 2014-2015 was in the form of

pet coke.

Thermal energy Consumption The raw mix quality and process parameters have been

maintained.

4. Water Conservation We have 6.0 km garland canal for rain water harvesting from colony and plant premises. This

harvested rain water is stored in our own abandoned mines reservoirs. We have four mines

reservoirs .The total rain water is collected and stored in these reservoirs and from these

reservoirs, the stored water is used for cement manufacturing process and cooling purpose.

The capacity and quantity of water collected in reservoirs as on March 2015 is as under, Reservoir Total Area

(ha) Total capacity

(Lac m3) Present Status

(Lac m3)

I 18.5 12.78 9.96

II 3.0 1.8 1.08

III 12.187 11.7 9.88

IV 8.0 6.0 3.60

A Glimpse of Reservoir – I, Favorable destination for migratory birds.

5. Water spraying system at Limestone Crusher A dedicated, water pipe line, desired head pump and required nozzles have been placed for

water spraying during unloading of limestone in dump hopper. The water spraying at limestone

dump hopper has substantially reduced the fugitive emission during unloading of limestone at

hopper.

6. Good House keeping practices Following measures have been taken for good housekeeping at Jaypee Rewa Plant:-

a. Laterite is stored in covered sheds. b. Raw Coal is stored in covered shed c. Clinker and cement is being stored in the covered shed and silos. d. Regular road sweeping is being carried out. e. Incorporation of DCL system for extraction of Clinker and Cement bulk loading f. Unloading of Fly ash at covered mechanized unloading tippler and storage in MS bin g. Auto workshop and CPPs treated water is being utilized for the regular road water

spraying & wetting of raw material. h. Internal road concreting

7. Scheduled maintenance and monitoring of Pollution Control Devices.

Maintenance of all Pollution Control Devices are being done as per prescribed schedule by

dedicated environmental management team which comprises of mechanical, electrical and

environment engineers and monitoring of all these are done regularly as per PCB Norms. We

are also certified with ISO-14001 and maintaining all the clauses mentioned therein.

PART – H ADDITONAL MEASURES / INVESTMENT PROPOSALS FOR ENVIRONMENTAL PROTECTION INCLUDING ABATEMENT POLLUTION, PREVENTION OF POLLUTION. Additional measures taken for Environmental Protection are as under 1. Polythene waste incineration in Kiln Polythene waste becomes a big problem before the humanity as well as for our environment.

Jaypee Group is committed for initiating the green activities. For this a system has been

developed for collection and segregation of polythene waste of Jaypee Rewa Plant, colony &

surrounding area. All the polythene waste in segregated form is being transported to our site

for incineration in cement kiln. The required infrastructure / modification have been installed to

carry out the incineration of waste. We have incinerated around 297.18 Tonnes polythene

waste in our kiln till March, 2015. 2. Extensive plantation in and around the Plant. We have a dedicated team of skilled horticulturists for the afforestation and greenery

development program at our plant and mines under the supervision of senior experienced

person. Addition to the horticulture deptt. Environment Cell also does the plantation activity.

The plantation details are given below

Steps taken to protect plantation: 1. Barricading provided for protection of plants.

2. Two numbers of dedicated water tankers having capacity of 1800 liter are provided for

regular watering of plant.

3. Dedicated manpower is provided for regular watering the plants.

4. Tree Guard is provided for protection of the plants.

PLANTATION DETAILS

S. No.

Name of Plant Total Area (Ha.) Plantation (Nos.)

1 Jaypee Rewa Plant 89.752 63530

2 Naubasta Lime Stone Mine 470.941 246307

3 North – North Naubasta Lime Stone Mine 183.937 61595

4 Bankuiyan Lime Stone Mine 541.005 19722

5 Jaypee Rewa Plant (Township) 95.82 159140

PART – I

ANY OTHER PARTICULARS FOR IMPROVING THE QUALITY OF THE ENVIRONMENT.

Details of Improvement Management Program for Environment Protection are as under

S.No. Department/

Plant Details of IMP Environmental Benefits

1 Environment Conversion of Coal Mill U-II ESP to Hybrid Bag House Stack Emission reduction

2 Environment Conversion of Raw Mill U-I ESP to Hybrid System Stack Emission reduction

3 Environment Conversion of Cooler ESP U-I to Hybrid System Stack Emission reduction

4 Environment Reduction of fugitive emission from Clinker Stock Pile Reduction of Fugitive Emission

5 Environment Conversion of Raw Mill U-II ESP to Hybrid System Stack Emission reduction

6 Environment Conversion of Cooler ESP U-II to Hybrid System Stack Emission reduction

CSR Works- JAYPEE GROUP has set up JAIPRAKASH SEWA SANSTHAN with the noble cause of

service to the poor and downtrodden people of the society wherever the Company has its

establishments. Jaiprakash Sewa Sansthan has launched Comprehensive Rural Development

Programme (C.R.D.P.) for overall socio-economic development of the lots of inhabitants in 13

adopted villages initially in year 1996 around Cement Complex at Jaypeenagar, Rewa. These adopted villages have since been increased to 28. The main activities carried out in these villages are below: JACHCHA-BACHCHA MEDICALCAMPS-

The main activities carried out in these villages are below:

JACHCHA-BACHCHA MEDICAL CAMPS

Objective:

To provide basic health and medical care Services closer to home. Camps have been running for 17 years Free consultation & medication Complicated cases referred to hospital for follow up.

YEAR NO. OF PATIENTS

Up to March 2012 26095

April 2012- March13 2134


April 2014-March 15 1775

PULSE POLIO CAMPS

Objective:

To eradicate the disease. Camps have been running for 19 years

200 camps 46,110 children immunized. In collaboration with national programs Camps run twice a year




April 2013- March14 612 April 2014- March15 860

SCHOOL HEALTH CHEACK-UP CAMPS


Up to March 2012 7218 April 2012- March13 499 April 2013 -March14 2425


Objective: To overcome malnutrition, contagious diseases and to identify congenital diseases. The health checks have been running for 13 years. A total of 102 Health Checks have been conducted We’ve checked 12,609 children. The checks and any follow ups or medicines are free. All children are given deworming medicine. In Feb 2014 dental checkup was done for 2793 students.

COMMUNITY HEALTH AWARENESS CAMPS




April 2013 - March14 8905


Objective: Educate on common diseases, their prevention and immediate first-aid measure. These camps have been running for 14 years A total 292 camps held 28,224 people have attended these camps We couple these camps with Parent-Teacher meetings at Balwadi centers held

monthly.

LAPROSCOPIC CAMP

YEAR NO. OF CAMP

Up to March 2012 16


April 2013 -March14 3

April 2014 -March15 19

Objective:

Population control. Camps have been running for 11 years 21 camps 65 men sterilized 729 women ligated Team of doctors and paramedical staff come from government hospital Surgeries conducted at the JSS hospital Patients paid by the government to undergo treatment

VITAMIN A IMMUNISATION





April 2014- March15 `464

Objective:

This programme started in the year 2011-2012. Vitamin A angels, a California based NGO is regularly supplying us with Vitamin A

capsules & Deworming medicines free of cost From 2011-2015 total number of children immunized are 6461. This programme runs every Friday in the Jaypee Hospital & twice a year in Balwadi

playschools. VETERINARY CAMPS

YEAR NO. OF ANIMALTREATMENT




April 2014- March15 1423 Objective:

To educate on breeding methods, feeding and management of the animals. Increase milk production.

The camps have been running for 15 years A total of 196 camps held A total of 41,458 animals treated 15 camps per year Free consultation

Free medication.

VACCINATION OF ANIMALS

YEAR NO. OF ANIMAL VACCINATED





Objective:

To prevent diseases in animals This programs has been running for 10 years A total of 30,596 animals have been vaccinated The program runs from April to March. Free medicines Free consultation HS, BQ, Anthrax, Intro-toxin.

TEACHER’S TRAINING PROGRAMME

Objective:

Teach effective teaching and communication methods. Educate them on personal hygiene and mannerism. The importance of maintaining a clean environment. This program is held twice a year once by an outside consultant and the second at the

Jaypee College of Education.

ADULT EDUCATION

Objective:

To eradicate adult illiteracy. Current results of %age qualified. Stage I: 100 % qualified Stage II: 63 % qualified Stage III: 74 % qualified Currently 5 classes are running

TAILORING CLASSES

Objective:

Women empowerment through self employment. This program has been running for 13 years 1037 women have qualified this program. 54.24 % qualification rate in 2011-2012. These classes run in the afternoons at the Balwadi centres. All tailoring teachers are graduates from M. Gopala Rao Industrial Training Centre,

Jaypee nagar. This program is affiliated with USHA International, a renowned company in the sewing

industry. 207 Sewing machines distributed.

Agriculture awareness camp

Objective: To educate the local farmers on effective agricultural methods to improve quality of produce. This program was introduced in the year 2011.

One camp 200 farmers attended 3 guest speakers Guest speakers are invited from Agriculture Colleges around the region

DRINKING WATER HAND PUMP

Objective:

To provide safe drinking water to the residents. 283 hand pumps, 6 tube wells and 34 bore wells have been installed in total. Maintenance and repair has been stopped since July 2011 by the company.

VILLAGE ROAD CONSTRUCTION

Objective:

To connect all adopted villages to the main arteries. Plain Cement Concrete (PCC) Water Bound Macadam (WBM) A total of 42.3 km completed at a cost of 18 lacs (21176.47 pounds). Concreting of road and beautification of the area in Rewa city at a cost of 62 lacs

(72941.17 pounds)

SULABH COMPLEX CONSTRUCTION

SULABH COMPLEX AT MADHEYPUR

Objective:

Build clean public restrooms and bathrooms. Sulabh complex built: Chijjwar Village (Police Chowki) 18 Toilets + 8 Bathrooms Chijjwar Village (Tri-junction) 18T+12B Sonra Village 15T+8B Total cost of Rs. 17.3 lacs (20353 pounds). Madheypur has 5 complexes consisting of 8 Toilets each. Kachoor Village has 1 complex of 8 Toilets. Total expenditure is Rs. 13 lacs

(15294.11)

BALWADI CONSTRUCTION

RENOVATION OF VETERINARY HOSPITAL AT KACHOOR

TREE PLANTATION

TEMPLE CONSTRUCTION AT KACHOOR

Shiva Temple in Kachoor village is more than 300 years old(1600-1700 AD). It was constructed by the King of Rewa.

It was a dilapidated & neglected structure as shown in the picture. In 1998 Jaypee Group spent Rs 15 Lakhs to reconstruct the old monument to its

original architecture. Every year during Shivratri the local people assemble in great number to solemnize the

festival of Lord Shiva with Parvati.

RANI TALAB TEMPLE, REWA(M.P) DURING CONSTRUCTION

ON COMPLETION

RANI TALAB TEMPLE, REWA(M.P)

In the year 1691 King Bhav Singh made the temple of Goddess Kali(Destroyer of Demons) so that his offspring survives.

His wife was Ajab Kunwar Rani Sahiba, daughter of Maharaja Raj Singh of Chittorgarh.She was a grand daughter of a famous king Maharana Pratap Singh of Chittorgarh who fought & won many battles in the History of India.

Devotees come to pray for the welfare & well being of their children. This is a popular tourist spot.

Jaypee Group has spent 169.91 lakhs for the beautification & development of the surrounding area of this temple.

BABA BHAIRON NATH TEMPLE GURH DISTT. REWA (M.P)

Baba Bhairon Nath Temple was constructed in 1000-1100 AD by Kalchuri Kaleen

Dynasty. It is situated near Gurh,about 42 km from Rewa.

The statue is horizontal where Baba Bhairon Nath is lying down. It is 8.50 meters long & 3.70 meters wide.

There is a big festival celebrations here on Shivratri and Basant Panchami.

For Jaypee Rewa Plant, (A Unit of Jaiprakash Associates Limited)

Jaypee Nagar, REWA (M.P.)

JAYPEE REWA PLANT - Jaypee · PDF fileJaypee Rewa Plant is a cement plant of capacity 3.5MTPA...

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