Environmental Data-Plant

Transcription

1 2 Orient Cement Limited

2 CONTENTS Contents 2 List of Tables 2 List of Figures 3 1. Compliance Report 4 2. INTRODUCTION Location and Accessibility PROCESS DESCRIPTION ENVIRONMENTAL BASELINE STATUS ENVIRONMENTAL MANAGEMENT PLAN CONCLUSIONS 40 LIST OF TABLES 1.1 Average Values of online Stack Monitoring Data Average Values of online Stack Monitoring Data Average Values Ambient Air Monitoring Data Average Values of Noise level Data Average Values of Fugitive Emissions Data Average Values of Noise level Data Salient features of expansion project Soil Analysis Water Analysis Orient Cement Limited

3 4.5 Weather Monitoring Data-Temperature & Relative Humidity Average Values Ambient Air quality data Details of Stack Emissions Average Values of Stack Monitoring Data (SPM) Average Values of Stack Monitoring Data (SO 2 &NO 2 ) Average Values of Noise level Data 33 LIST OF FIGURES 1. Process flow diagram of cement manufacturing Ambient air quality data Particulate Matter PM Ambient air quality data Particulate Matter PM Ambient air quality data (SO x ) & (NOx) Stack Monitoring Data Suspended particulate matter Stack Monitoring Data Sulphur dioxide Stack Monitoring Data Oxides of nitrogen Noise Level Data 33 4 Orient Cement Limited

4 1. COMPLIANCE REPORT: MoEF ENVIRONMENTAL CLEARANCE Environmental clearances accorded by Ministry of Environment & Forest vide Letter F. No. J /266/2007-IA II (I) Dated 6 th September 2007 for expansion of cement plant (Cement 3600 to 8900 TPD and clinker 5550 to 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/nm 3 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 viz Baghouse (RABH), ESP S are equipped with three phase transformers were installed, which are controlling the emissions within the stipulated levels, data is presented in Table Orient Cement Limited

5 Table 1.1 AVERAGE VALUES OF STACK MONITORING DATA (October-16 to March-17) Parameters Particulate Matter (mg/nm 3 ) Location of Online Continuous Stack Monitoring Equipment PCB Limit as per Consent (mg/nm 3 ) Avg. (mg/nm 3 ) 3600 TPD Rotary Kiln I & Raw Mill I TPD Rotary Kiln II & Raw Mill II TPD Rotary Kiln III & Raw mill III Clinker Cooler Line Clinker Cooler Line Clinker Cooler Line FBC Boilers of Capacity 2 X (ii) Total water requirement from the reservoir of abandoned mine pit shall not exceed 1,895 m 3 /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. 6 Orient Cement Limited

6 Treated domestic effluent shall be used for green belt development within the plant premises. Mines reservoir is replenished with rainwater. Water consumption is well within the permissible limits. STP is in operation for treatment of i.e domestic sewage water from which the treated water is being used for green belt development in the colony. Zero liquid 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. 7 Orient Cement Limited

7 (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. We have applied for co-processing Permission of various hazarders waste at TSPCB, Hyderabad. (v) Out of total acre, green belt shall be developed in 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 March including mines. We have developed green belt in plant & Colony areas which is well above 51% as prescribed by TSPCB, Hyderabad (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. 8 Orient Cement Limited

8 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 table Orient Cement Limited

9 Table 1.2 AVERAGE VALUES OF STACK MONITORING DATA (October-16 to March-17) Parameters Particulate Matter (mg/nm 3 ) Stack attached to PCB Limit as per Consent (mg/nm 3 ) Avg. (mg/nm 3 ) 3600 TPD Rotary Kiln I & Raw Mill I TPD Rotary Kiln II & Raw Mill II TPD Rotary Kiln III & Raw mill III Clinker Cooler Line Clinker Cooler Line Clinker Cooler Line FBC Boilers of Capacity 2 X 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 10 Orient Cement Limited

10 Ambient Air Quality and Stack Emissions shall be carried out regularly in consultation with APPCB and report submitted to the TSPCB quarterly and to the Ministry s Regional Office at Bangalore half-yearly. 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 (October16 to March-17) Parameter Particulate Matter PM 10 Particulate Matter PM 2.5 Sulphur dioxide (µg/m 3 ) Nitrogen Dioxide (µg/m 3 ) (µg/m 3 ) (µg/m 3 ) Location Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg. Near Time office Near Mines Office Near Stores Near Guest House 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)]. 11 Orient Cement Limited

11 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 1.4. Table 1.4 AVERAGE VALUES OF NOISE LEVEL DATA (October-16 to March-17) Location NOISE LEVEL in Leq db(a) Day Time Night Time Min Max Avg Min Max Avg Near Kiln Near Raw Mill Near Compressor House Near Cement Mill Near D.G.Set Near Limestone Crusher Near Work Shop Near Line-III All the Values are within the Range All the equipment are being operated from Central Control Room. Exposure of the employees near the machines is limited. If at all required to be exposed, they are using ear plugs / ear muffs. 12 Orient Cement Limited

12 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 installed number of bag filters. Total Number of Pollution Control Equipments is as follows: ESPs 7, Bag Filters 99. All the transfer points are 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. 13 Orient Cement Limited

13 (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 (October to March-17) Parameter (PM 10) Average (µg/m 3 ) (PM 2.5 ) Average (µg/m 3 ) Location Min. Max Avg. Min. Max. Avg. On top of Technical building PCB Limit: PM (µg/m 3 ): PM2.5-60(µg/m 3 ). 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 mines abandoned reservoir and is utilized for various activities in the plant thus reducing the consumption of ground water. 14 Orient Cement Limited

14 (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). We have Provided various noise control measures like acoustic enclosure in CPP, Silencers and low noise old blower and compressor The values are recorded and are well within the limits. Table 1.6 AVERAGE VALUES OF NOISE LEVEL DATA (October-16 to March-17) Location NOISE LEVEL in Leq db(a) Day Time Night Time Min Max Avg Min Max Avg Near Kiln Near Raw Mill Near Compressor House Near Cement Mill Near D.G.Set Near Limestone Crusher Near Work Shop Near Line-III Orient Cement Limited

15 All the Values are within the limits. (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. (xi) Good 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. 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 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 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/nm 3 for stacks, all existing single phase transformers are replaced with 16 Orient Cement Limited

16 17 Orient Cement Limited

17 b. 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 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. 18 Orient Cement Limited

18 Table2.1 SALIENT FEATURES OF THE EXPANSION PROJECT Existing Plant Total Cement Unit 1. Clinker Production (TPD) a) Line TPD b) Line TPD c) Line TPD d) Overall production 10, Cement Production (TPD) 8, Built-up Area (Acres) Project Cost (Rs. in Crores) Captive Power Plant 1. Power Production (MW) Built-up Area (Acres) Project Cost (Rs. in Crores) 1. Plant Area (Area in acres) No Change a) Built-up Area b) Green belt Area Town Ship No Change a) Built-up Area No Change b) Green belt Area Total Project Area No Change a) Total Built-up Area b) Greenbelt Area c) % Greenbelt Area Total Project Cost (Rs. in Crores) Built-up area includes buildings, utilities like roads, storage yards, water tanks etc. 18 Orient Cement Limited

19 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 North Latitude and between East Longitude. Fig2.1 shows location map. Mean sea level of the place is in between 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. 19 Orient Cement Limited

20 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 C C) 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 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. 20 Orient Cement Limited

21 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 C 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. 21 Orient Cement Limited

22 22 Orient Cement Limited

23 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 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 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 m 3 /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 m 3 /day of water is required for up-gradation and another 450 m 3 /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 m 3 /day. About 641 m 3 /day of water is used for domestic purposes (township) at present, which will increase, by 20m 3 /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 Orient Cement Limited

24 Table4.1 SOIL ANALYSIS (October-16 to March-17) Location ph E.C. µ mhos/cm Calcium as Ca m eq/100g Magnesium as Mg m eq/100g Sodium as Na m eq/100g Potassium as K Kg/ha Phosphorous as P Kg/ha Nitrogen as N Kg/ha Organic Carbon % Sulphates as So4 m eq/100g Chlorides as Cl m eq/100g Silt & Clay % Sand % m eq/100g Loamy Loamy Sand Loamy Loamy Sand Textural Class Sand 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. 24 Orient Cement Limited

25 Table 4.2 WATER ANALYSIS Date of Sample Collection : , Date of Sample Analysis : , Locations Colour (Hazen units) Turbidity (NTU) ph E.C. (Micromhos/cm) Total dissolved solids Phenolphthalein alkalinity as CaCo Methyl orange alkalinity as CaCo Total hardness as CaCo Calcium as Ca Magnesium as Mg Sodium as Na Potassium as K Chloride as Cl Sulphate as So Nitrate as NO Carbonates as CaCO Bicarbonates as CaCO Residual Chlorine Copper as Cu < < <0.05 Manganese as Mn <0.02 <0.05 < <0.02 Iron as Fe Fluoride as F 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. 25 Orient Cement Limited

26 Table 4.4 DRINKING WATER ANALYSIS DATA (October -16 to March-17) S.NO PARAMETERS min max AVERAGE 1 Turbidity (NTU) ph E.C (micromhos/cm) Total dissolved solids phenolpthalene alkalinity as CaCO Methylorange alkalinity as CaCO Total alkalinity as CaCO Total hardness as CaCO Calcium as Ca Magnesium as Mg Sodium as Na Potassium as K Copper as Cu Iron as Fe Managanese as Mn Chlorides as Cl Sulphates as SO Flourides as F Phenolic compounds as c6h5oh <0.001 <0.001 < Mercury as Hg <0.001 <0.001 < Cadmium as Cd <0.001 <0.001 < Selenium as Se <0.01 <0.01 < Cyanide as CN <0.01 <0.01 < Lead as Pb <0.01 <0.01 < Zine as Zn Resifual chlorine <0.04 <0.04 < Silver as Ag <0.01 <0.01 < Mineral Oil <0.01 <0.01 < Hexavalent chromium as Cr+6 <0.01 <0.01 <0.01 Note: All the values except ph, Turbidity and E.C. are expressed in mg/l 26 Orient Cement Limited

27 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 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 ( 0 C) Relative Humidity (%) Min. Max. Avg. Min. Max Orient Cement Limited

28 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 (PM 10), Particulate Matter (PM 2.5), Sulphur dioxide (SO 2), Nitrogen Dioxide (NO X) 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 16 th 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 Orient Cement Limited

29 Table 4.6 AVERAGE VALUES OF AMBIENT AIR QUALITY DATA (October-16 to March-17) Parameter Particulate Matter PM 10 Particulate Matter PM 2.5 Sulphur dioxide (µg/m 3 ) Nitrogen Dioxide (µg/m 3 ) (µg/m 3 ) (µg/m 3 ) Location Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg. Near D.G. Set Near Time Office Near Guest House Near Mines Office 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 Orient Cement Limited

30 Table 4.7 DETAILS OF STACK EMISSIONS (October 16 to March-17) SI.N O. Stack attached to Height (Meters) Dia (Meters) Flow rate (Nm 3 /hr) Concentration of particulate matter (mg/nm 3 ) 1. Kiln I & Raw mill I Kiln-II & Raw mill II Kiln III & Raw mill III Cooler I Cooler-II Cooler III Coal Mill-I Coal Mill-II Coal Mill III Cement Mill-I Cement Mill-II Crusher Packing Plant-I Packing Plant-II Packing Plant-III Packing Plant-IV CPP Orient Cement Limited

31 Table 4.8 AVERAGE VALUES OF STACK MONITORING DATA (October-16 to March-17) S.No Parameters PCB Norms (In mg/nm 3 ) Particulate Matter (mg/n m 3 ) Location Min Max Avg TPD Rotary Kiln I & Raw Mill I TPD Rotary Kiln II & Raw Mill II TPD Rotary Kiln III & Raw mill III FBC Boilers of Capacity 2 X Cement mill Line Cement mill Line Coal mill Line Coal mill VRM Line Coal mill Line Coal mill Line Clinker Cooler Line Clinker Cooler Line Clinker Cooler Line Packing plants - 5 Nos Attached to 4 X 4. 2 MW &1 x 4.0 MW D.G.sets 115 Not Running 31 Orient Cement Limited

32 Table 4.9 AVERAGE VALUES OF STACK MONITORING DATA (October to March-2017) Parameter Sulphur dioxide (mg/n m 3 ) Oxides of Nitrogen (mg/n m 3 ) Location Min. Max. Avg. Min. Max. Avg. Kiln I Kiln II Kiln III 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 interroom 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 Orient Cement Limited

33 Table 4.10 AVERAGE VALUES OF NOISE LEVEL DATA (October-2016 to March-2017) Location NOISE LEVEL in Leq db(a) Day Time Night Time Min Max Avg Min Max Avg Near Kiln Near Raw Mill Near Compressor House Near Cement Mill Near D.G.Set Near Limestone Crusher Near Work Shop Near Line-III 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 33 Orient Cement Limited

34 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 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 Other measures Further construction of water reservoir in township in an area of 23,600 sq. m with a volume of 87,000 m 3 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. 34 Orient Cement Limited

35 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. 35 Orient Cement Limited

36 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 (3 rd 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- 36 Orient Cement Limited

37 generation water about 100 m 3 /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 m 3 /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 37 Orient Cement Limited

38 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 welldefined procedures, which is also spelt out in ISO and OHAS For emergency control fire hydrant system is available along with maintenance Schedule for the firefighting equipments. We have mobile fire hydrant also. A welldefined 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. 38 Orient Cement Limited

39 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 C O2 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. 39 Orient Cement Limited

40 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. 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 3 rd 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 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. 40 Orient Cement Limited