Cement Grinding Plant, Madhukunda P.O. Sunuri Dist. - Purulia West Bengal

Transcription

1 ENVIIRONMENTAL AUDIIT STATEMENT M//s.. ACC LIIMIITED Damodhar Cement Works Cement Grinding Plant, Madhukunda P.O. Sunuri Dist. - Purulia West Bengal FOR THE YEAR

2 L I S T O F C O N T E N T S Sl. No. Item Page No. 1. Preamble 1 2. Concept of environmental audit 1 3. Audit procedures should describe Audit procedure for the present company Scope of the present project Background of the Present Report Brief Description of the Plant Details of Cement Manufacturing Process Water Requirement and Generation of wastewater 6 7. Pollution load testing Stack Emission Characteristics of the Plant Ambient Air Characteristics of the Plant Fugitive Air Characteristics of the Plant Waste Water Characteristics of the Plant 7 8. Environmental Management Plan: Pollution Prevention 7 2

3 8.2 Measures for Industrial Safety 8 9. Auditor s Comments Recommendation 8 Annexure I : Environmental Statement (Form V) L I S T O F T A B L E S Table No. Item Page No. 1 Raw Material Consumption 9 2 List of Machines ( Major ) 9 3 Stack Air Monitoring Report of the Factory 10 4 Ambient Air Characteristics of the Factory 11 5 Fugitive Air Characteristics of the Factory 12 6 Waste Water Analysis Report of the Factory 12 7 Stack Fitted with Control Device 13 8 Measures for Industrial Safety 14 3

4 1. PREAMBLE : Environmental audit can be defined as a measure of environmental risks, and an assessment of environmental opportunities. It is a wide concern in the last decades. This Audit program verifies the policy of an industry and performance of its environmental management program, which ascertain and regulate pollution control and environmental abatement. It is an environmental management tool for measuring the effects of certain activities on the environment against standards. Now a day a global need is that, products produced by industries generate less amount of waste and lead to a sustainable development. For which green products are manufacture in environmentally compatible process. People are found in more numbers in registering courts and appellate authorities against the industries which violate different obligations regarding environmental protection. In order to keep continuous control on the environmental performance, it is necessary to carry out Environmental Audit at regular interval. As per the current status, the occupants of the industries are required to submit yearly environmental statement to the State Pollution Control Board. Environmental Auditing is based on the data supplied by plant personnel and verification and generation of data regarding status of environment of the industry by a competent authority. 2. CONCEPT OF ENVIRONMENTAL AUDIT : A proper and systematic audit possesses some benefits includes : Control and reduce wastage Initiate preventive action and avoid risk factors Ensure compliance with environmental legislation Enhance corporate image of organisation Increase confidence of customer or client Making the working environment safer and healthier 4

5 3. AUDIT PROCEDURES SHOULD DESCRIBE : Audit planning - discussed about the planning of an audit. Audit scope (areas and activities covered) To identify the level of pollution and control the same by means of installed the new control device or modify the existing control system. Audit frequency - mentioned in what interval an audit is done. Audit methods - consists of how the audit should done. Key responsibilities for the audits - discussed about the responsibility of the person concern. For any type of loss or damage of products in store, it is informed by Store Manager. For safety of products in store, it is informed by Safety Manager. For any type of production problem it should be informed by production manager. Reporting mechanisms for the audits Record keeping for audit results - records of audit should keep in form of hardcopy and/or softcopy. 4. AUDIT PROCEDURE FOR THE PRESENT COMPANY : Audit planning The company prepared its audit for the financial year focused on betterment of environmental condition by reducing pollution. Audit scope Under this, company works on to control and prevention of environmental pollution in respect to Air, Water and Noise. Audit frequency Under this, company prepares its audit each and every year for the previous financial year as per Environmental Protection Rule. 5

6 Audit Methods Under this, company has monitored the pollution load for air, water and noise with respect to consumptions of raw materials and production and find out the loss of materials for manufacturing in terms of pollution generated. Key responsibility for the audits This company deals with various responsible persons for different departments For any kind of loss or damage of raw materials in store, it should be informed by Store Manager. For the question of any type of safety of the material it should be informed by Safety Manager. For any type of problem in production, it should be informed by production manager. Reporting mechanism of the audit Reports of audit should be scientific and in proper elaborate manner. It is focused mainly on controlling the environmental pollution. For this, this company works on Ambient monitoring air, Fugitive monitoring air, Stack emission, Waste water, Drinking water and noise intensity monitoring level. Record keeping for audit result This company keeps records of every audit details of each and every financial year in forms of hardcopy as well as softcopy. 5. SCOPE OF THE PRESENT PROJECT : The present project, encompasses studies on environmental quality status followed by preparation of environmental audit statement of M/s. ACC Limited, Damodhar Cement Works, Cement grinding Plant, Madhukunda, P.O. Sunuri Dist. Purulia, West Bengal. 6

7 (i) Pollution Audit covering air, water pollution as well as pollution with respect to solid and hazardous wastes This section also includes the compliance status of the company to various statutory norms set by pollution control agencies in India. (ii) The pollution prevention and waste management audit This section includes scanning of the efforts taken up by the company to prevent pollution with respect to generation and handling of wastes. (iii) Management policy of the company with respect to welfare, occupational health of the employees, industrial safety and environmental abatement This portion describes the social responsibilities of the company with respect to the industrial safety and with respect to the abatement of environment in general in its broader perspective. The socio-economic environment created by the company and the company s responsibility towards the welfare of the workers are also described in this portion. Auditor s comments : In this part the auditor will provide his independent views regarding the industrial pollution created by the company, whether the concentration of different pollutants generated by the company are within the statutory norms and whether sound environmental management plan do exist in the company and whether the company authorities are aware of the statutory obligations binding upon them. Some independent suggestions are also given by the auditor if necessary in the above mentioned aspects for pollution control and abatement of environment as a whole. 6. BACKGROUND OF THE PRESENT REPORT : 6.1 Brief Description of the Plant: M/s. ACC Ltd., Damodhar Cement Works, Cement Grinding Plant, manufactures Portland Slag Cement and Portland Puzzolana Cement; and was established in October The plant is located at distance of 1.5 kms East of 7

8 Madhukunda Railway Station (SE Rly.) in Purulia District West Bengal. Address of the firm is M/s. ACC Limited, Damodhar Cement Works, Madhukunda, P.O. Sunuri Dist. Purulia, West Bengal and the registered office is situated at Cement House, 121, Maharshi Karve Road, Mumbai Its capacity is 6 lakhs tons per annum. The raw material consumption and the amount of production during one complete year along with the production capacities are given Table 1. Table 2 represents the list of machines (major) of the plant. At present there are three shifts (6 a.m. 2 p.m., 2 p.m. 10 p.m. and 10 p.m. 6 a.m.) each of eight hours duration and one general shift from 7.30 a.m. to 4 p.m. Total no. of employees employed in the firm are 157 which includes 112 permanent staff and workers, of which 45 belong to managerial and officer grade. The number of working days in the year is Details of Cement Manufacturing Process: The cement-grinding unit essentially consists of the following processes; Wet Slag Storage Handling and Drying: Wet slag is received at the Cement Grinding Plant via wagon rake. It is stored in open stockyard. It is fed to the hopper of kiln type Rotary Slag Dryer for drying. With a counter flow of pulverized coal (as fuel) firing, the wet slag is dried up to moisture content 1-3 %. Clinker, Gypsum, Dry Slag and Fly ash - Handling & Storage: Gypsum and Clinker rakes are unloaded in wagon tippler which is conveyed and stored in covered gantry (Stock pile), Dry slag from Slag Dryer section is also stored in stock pile. The clinker, gypsum and dry slag are transported in required quantities via underground conveyor belts of stockpile to cement mill hoppers for cement grinding. The Fly ash from bulkers is unloaded to Fly ash Silo. 8

9 Cement Grinding: Clinker, Dry Slag, Fly ash and Gypsum are fed through weigh feeders to individual mills in required proportion and ground in mills to desired fineness, to produce Portland Slag Cement and Portland Pozzolana Cement. The ground Cement is stored in 3 cement silos, from where it is pneumatically conveyed to packing plant. Packing: Cement is packed in two rotary packers into 50 Kg bags. The bags are then loaded on to the truck by truck loaders for dispatch. 6.3 Water Requirement and Generation of waste water: On an average 305 m 3 /day and m 3 /day of water is required for domestic (residential colony and office buildings) and Industrial use respectively. However, m 3 /day of water used for industrial cooling is totally recycled and about 200 m 3 /day of wastewater is generated from domestic use. Company has constructed a sewage treatment plant and all the five parameters are within the permissible limit. 7. POLLUTION LOAD TESTING: 7.1 Stack Emission Characteristics of the Plant: The stack emission characteristics of the plant are tabulated in Table Ambient Air Characteristics of the Plant: The ambient air characteristics of the plant were studied at three stations inside the factory premises; like 9

10 Near Administrative Buildings Near Laboratory Near Guest House The ambient air characteristics of the plant were studied with respect to the concentrations of Sulphur dioxide (SO 2 ), Oxides of nitrogen (NO X ), PM 2.5 and PM 10. The results are shown in Table Fugitive Air Characteristics of the Plant: A fugitive air characteristic of the plant is presented in Table - 5. The fugitive air characteristics of the plant were studied under the shed in the following stations;- Inside the Mill House Inside the packing plant Inside Slag Yard The fugitive air characteristics of the plant were studied for SPM. 7.4 Waste Water Characteristics of the Plant: Waste water characteristic of the Plant (after treatment) is presented in Table - 6. The wastewater samples of the plant were analyzed for ph, Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD), Total Suspended Solids (TSS) and Oil & Grease. 8. ENVIRONMENTAL MANAGEMENT PLAN: 8.1 Pollution Prevention: Types of pollution control devices are attached to stacks are mentioned in Table

11 8.2 Measures for Industrial Safety: Overall Management Policy of the industry with Respect to Welfare and Occupational Health of the Employees, Industrial Safety and Environment were mentioned in Table AUDITOR S COMMENTS: Most of the major equipments, namely, cement mills, silos, hoppers, feeders, slag dryer etc. have been provided with adequate emission control devices. Almost no water is required in the cement manufacturing process. The water used for industrial cooling is totally recycled. The plant authorities have installed facilities for treatment of domestic water. The management of the plant is conscious about the safety, health and environment as evident the results of various analysis undertaken throughout the year. 10. RECOMMENDATIONS: The work zone environment should be improved after proper evaluation by approved authorized person. Special attention is required in packing section and coal yard. Audit has been carried out by M/S Pollution Analyzer Consultant. Impetus should be given to new green belt development apart from maintaining the existing green belts. 11

12 Sl. No. Items Table - 1 Raw Material Consumption Raw Material consumption in the financial year (MT) Raw Material consumption in the financial year (MT) 1. Clinker Slag Gypsum Fly ash Total : Fuel consumption : 1. Coal Table - 2 List of Machines (Major) Sl. List of Machines No. 1. Weigh Bridge 60 Ton & 100 Ton 2. Packing Plant 2 No. Packer (Rotary) a) 8 Nozzles Roto Packer 120 Ton /hrs. b) 8 Nozzles Roto Packer 120 Ton /hrs. 3. Cement Mill 3 Nos. Cement Grinding Mills a) 44 Ton/hr. Close Circuit Mill b) 16 Ton/hr. Close Circuit Mill c) 15 Ton/hr. Close Circuit Mill 4. Slag Dryer - a) 60 Ton/hr. Rotary Kiln type Slag Dryer b) 3 Ton/hr Coal Mill 5. Ropeway 135 Ton/hr. Ropeway 6. Wagon Tippler 600 Ton/hr. material Conveying Capacity 7. Payloaders 3 Nos. 8. Dumper 1 No. 12

13 Sl. No. Location Table 3 Stack Air Monitoring Report of the Factory Concentration of Parameters PM (mg/nm³) Quantity of Gas Flow (Nm³/hr) 1. Packing Plant No Cement Mill No.2 & 3 Feeder Cement Mill 2 & 3( Hopper) Packing Plant No Cement Mill No.2 & 3 (Bag Filter) Cement Silo Mill (No. 1) Cement Mill No-1 (After ESP) Cement Mill No. 1(Hopper) Wagon Tippler Hopper Stock Pile Tunnel (Front) Wagon Tippler Tunnel Diesel Generator (750 KVA) Slag Drier Coal Mill Furnace Stock Pile Back CM-1 Turbo Separator Fly Ash Silo(Bucket Elevator Bin) Fly Ash Silo ( Bag Filter)

14 Table - 4 Ambient Air Characteristics of the Factory Parameter Near Administrative Building Near Laboratory Near Guest House Particulate Matter (PM10)(µg/m3) Particulate Matter (PM2.5) (µg/m3) Ammonia (NH3) (µg/m3) Ozone(O3) (µg/m3) (µg/m3) BDL(DL:10) BDL(DL:10 ) BDL(DL:10) Benzo(alpha) Pyrene (ng/m3) BDL(DL:2.0) BDL(DL:2. 0) BDL(DL:2.0) Benzene(as C6H6) (µg/m3) BDL(DL:2.0) BDL(DL:2. 0) BDL(DL:2.0) Nitrogen Dioxide(NO2) (µg/m3) Sulphur Dioxide(SO2) (µg/m3) Carbon Monoxide(CO) BDL(DL:2.0) BDL(DL:2. 0) BDL(DL:2.0) (mg/m3) Arsenic(as As) (ng/m3) BDL(DL:2) BDL(DL:2) BDL(DL:2) Nickel (as Ni) (ng/m3) BDL(DL:2) BDL(DL:2) BDL(DL:2) Lead (as Pb) (µg/m3) BDL(DL:0.01) BDL(DL:0. 01)

15 Table- 5 Fugitive Air Characteristics of the Plant (Fugitive emissions are measured only for suspended particulate matter) Sl. No. Location Concentration of Parameters SPM (µg/m³) 1 Inside the Mill House Inside the Packing Plant Inside Slag Yard Table- 6 Waste Water Analysis Report of the Factory Sl. No. Location ph Concentration of Parameters Total Suspended Solids (mg/1) Oil & Grease (mg/1) COD (mg/1) BOD 3 days, 27 C (mg/1) 1. S.T.P Outlet

16 Table - 7 Stack Fitted with Control Device Sl. Stack Connected To Device No. 1. Cement Mill 1 ( After ESP) ESP 2. Cement Mill 1 Hopper Pulse Jet Bag Filter 3. Cement Mill 2 & 3 Hopper Pulse Jet Bag Filter 4. Cement Mill 2 & 3 Feeder Pulse Jet Bag Filter 5. Wagon Tippler Hopper Pulse Jet Bag Filter 6. Wagon Tippler Tunnel Pulse Jet Bag Filter 7. Stock Pile Front Pulse Jet Bag Filter 8. Slag Dryer Pulse Jet Bag Filter 9. Coal Mill Furnace No Device 10. Diesel Generator( 750 KVA) - do Packing Plant-1 Pulse Jet Bag Filter 12. Cement Silo Mill 1 Pulse Jet Bag Filter 13. Packing Plant -2 Pulse Jet Bag Filter 14. Cement Mill 2 & 3 ( Bag Filter) Pulse Jet Bag Filter 15 Stock Pile Back Pulse Jet Bag Filter 16 CM-1 Turbo Separator Pulse Jet Bag Filter 17 Fly Ash Silo(Bucket Elevator Bin) Pulse Jet Bag Filter 18 Fly Ash Silo Pulse Jet Bag Filter 16

17 Table - 8 Measures for Industrial Safety * Safety Gate Meeting Every 1 st. working day of the Month * Training programme of safety to all employees (With Training Calendar) * Safety Patrolling System * Periodical medical checkup for all employees * Monthly safety committee meeting. * Regularization of contract workers with Medical, Insurance and safety training * Pre-commission check by safety engineer * Standardization of Machine Guarding * Internal housekeeping audit * Colour codification of pipeline, guards, structures etc. * Computation of Accident Cost (Direct & Indirect) * Safety work at system by top management * Inspection of Tools & Tackles, Pressure Vessels etc. * Cable identification, labeling and re-arranging * Constructions of internal road * Budget and expenditure accordingly to maintain greenway * Identification of unsafe conditions * Fire fighting Training Periodically * Checking of Personal Protective Equipments of all employees * Stability certificate for Building & Structure * Safe work instruction to all section of the plant * First aid training by internal & external agencies * Work permit from Electrical Dept. for any maintenance / repairing job. * Safety week celebration * Internal Safety Audit * Annual external Safety Audit by National Safety Council. * Implementation of Contractor Safety Management (CSM) * Celebration of World Environment Day * Job Safety Analysis 17

18 Annexure I F O R M - V (See Rule - 14) ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR P A R T A i) Name and Address of the Owner/Occupier of the industry operation or process : Mr. BISWAJEET PRAFULLAKANTI Mallik Director Plant M/s. ACC Ltd. Damodhar Cement Works. Madhukunda, P.O. Sunuri Dist. Purulia, West Bengal ii) Industry Category : Red Primary Secondary - (STC Code) - (SIC Code) : : iii) Production Capacity - Units : 0.6 MTPA iv) Year of establishment : October, 1989 v) Year of the last environmental statement submitted :

19 P A R T B Water & Material Consumption 1. Water Consumption m 3 /day : Process m 3 /day : Domestic m 3 /day : Name of the Products Portland Slag Cement and Portland Pozzolana Cement Process water consumption per unit of product output During the Previous During the Current Financial year Financial Year m 3 /Ton m3/ton 2. Raw Material Consumption Name of Raw Materials Clinker, Slag & Gypsum Name of Products Portland Slag Cement Consumption of Raw Material per unit of output During the Previous Financial Year During the Current Financial Year 1 MT/MT 1 MT/MT Clinker, Fly ash & Gypsum Portland Pozzolana Cement 1 MT/MT 1 MT/ MT Industry may use codes if details of raw material would violate contractual obligations otherwise all industries have to name the raw materials used. 19

20 P A R T C Pollutant discharged to environment/unit of output (Parameters as specified in the consent issued) a) W A T E R Pollutants Quantity of Pollutants discharged (mass/day) kg/day Concentration of Pollutants discharged (mass/vol) mg/l Prescribed emission limits (mg/l) Variation from prescribed standard with reason (%) * C O D B O D T S S Oil & Grease * Industry and colony disposes wastewater = 200 m 3 /day. 20

21 b) A I R Sl. No. Pollutants Quantity of Pollutants discharged (mass/day) kg/hr * Concentration of Pollutants discharged (mass/vol) mg/nm 3 Prescribed Emission Limits (mg/nm3) Variation from prescribed standard with reason (%) *** 1. Packing Plant No Cement Mill No.2 & 3 Feeder Cement Mill 2 & 3( Hopper) Packing Plant No Cement Mill No.2 & 3 (Bag Filter) Cement Silo Mill (No. 1) Cement Mill No-1 (After ESP) Cement Mill No. 1(Hopper) Wagon Tippler Hopper Stock Pile Tunnel (Front) Wagon Tippler Tunnel Diesel Generator (750 KVA) Slag Drier Coal Mill Furnace Stock Pile Tunnel (Back) CM-1 Turbo Separator Fly Ash Silo(Bucket Elevator Bin) Fly Ash Silo

22 P A R T D HAZARDOUS WASTES (As specified under Hazardous Wastes/Management and Handling Rules, 1989) Hazardous Wastes Total Quantity During the Previous Financial Year During the Current Financial Year a) From different machine (used liquid lubricating oil and used grease) Used oil 1000 kg Used grease 1370 kg Sold to authorized recyclers. Used oil 2950 kg Used grease 1840 kg Sold to authorized recyclers. b) From Process Nil Nil c) From Pollution Control facilities. Nil Nil P A R T E SOLID WASTES SOLID WASTES During the Previous Financial Year Total Quantity During the Current Financial Year a) From process Nil Nil b) From Pollution Control facility Quantity recycled or re-utilised within the unit Sold Disposed Nil Nil 4. Stored

23 P A R T F Please specify the characterization (in terms of composition and quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes. For Hazardous Wastes please refer Part D. Not applicable for Solid Wastes. P A R T G Impact of the pollution abatement measures taken on conservation of natural resources on the cost of the production. There is little impact of pollution abatement measures taken on the cost of production. Natural resources are hardly affected by the activities of the company. P A R T H Additional measures investment proposal for environmental protection including abatement of pollution, prevention of pollution. As may be required and suggested by Pollution Control Board. P A R T I Any other particulars for improving the quality of the environment. The company is aware of its responsibility for creating green belt inside the factory premises. 23