1 ENVIRONMENTAL MANAGEMENT PLAN Of 0.66 MTPA CEMENT GRINDING UNIT At BHUPDEOPUR VILLAGE, KHARSIA TAHSIL, RAIGARH DISTRICT, CHHATTISGARH STATE. By M/s. CALCAR PRODUCTS PVT., LTD Prepared By B.S. ENVI-TECH (P) LTD Secunderabad
2 TABLE OF CONTENTS S.no Contents Page no. 1.0 Introduction Present proposal Project cost Location of the plant Requirements of the project Raw material Land Water Power Man power Infrastructure Production Details Plant and machinery Environmental impacts and management plan for controlling the impact 7.1 Environmental impacts and management plan - construction phase 7.2 Environmental impacts and management plan during operational phase Air environment Noise environment Water environment Land environment Solid waste generation Hazardous waste management rules Transportation Green belt development Socio economic environment Occupational safety & health management Budget for EMP
3 LIST OF TABLES TABLE No Title Page No Table 1 Salient Features Of the Plant Site 6 Table 2 Budget for environment management plan 17 LIST OF FIGURES Fig No Title Page No Fig 1 Location Map 2 Fig 2 Key Map 4 Fig 3 Topographical Map showing 10 km Radius 5 Fig 4 Layout of the Grinding unit 8
4 ENVIRONMENTAL MANAGEMENT PLAN 1.0 INTRODUCTION Calcar Products Pvt. Ltd (CPPL) is a Private incorporated on 23 June It is classified as Non-Govt. company and is registered at Registrar of Companies, Kolkata. CPPL proposes to setup a Cement Grinding Unit of 0.66 MTPA at Survey No. 26/1 of Bhupdeopur Village, Kharsia Tehsil, Raigarh District, Chhattishgarh State. The project will be located in an area of 3.5 Ha on the land which was earlier put to industrial use the activities of which are now abandoned. The existing infrastructure will be removed. This new cement grinding unit would be setup in the same location. 2.0 PRESENT PROPOSAL Calcar Products Pvt. Ltd (CPPL) proposes to setup a 0.66 MTPA Cement Grinding Unit in Bhupdeopur Village, Kharsia Tehsil, Raigarh District, Chhattishgarh State. 3.0 PROJECT COST The estimated capital cost is Rs. 75 Crores (Rs. 42 crores - Phase-I & Rs. 33 crore for Phase-II). 4.0 LOCATION OF THE PLANT The proposed site of Cement Grinding Unit is located at Bhupdeopur Village, Kharsia Tehsil, Raigarh District, Chhattishgarh State. The Plant Site is a part of the Survey of India Toposheet No. 64/O/5. The site falls between B15) 21 58'24.90"N B11) 21 58'9.90"E, B12) 83 16'10.10"N B2) 83 16'19.70"E, North latitude and East Longitude with an average altitude of 245 m above MSL. The location map of the Plant site is shown in Fig 1. 1 B.S. Envi-Tech (P) Ltd., Secbad.
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6 Nearest railway line connecting Champa junction railway station - Raigarh of South Central Railway line is at a distance of 0.2 km to South direction from the Proposed Cement Grinding Unit. Lop line will be laid into the premises from here. Key map showing the location of various features around the Plant site is shown in Fig 2. Raigarh is major town is located at a distance of 15.0 km in SE direction. The National Highway (NH-49) connecting Raigarh Sarangarh is located at a distance of about 16 km in SE direction. The nearest railway station is located at Bhupdeopur RS which is 1.1 km in W direction. There are no wild life sanctuaries, national parks, elephant/tiger reserves within 10-km radius of the study area. Bilaspur and Belari are the Nearest Settlements from the Plant site at 0.6 Km NNW direction & 0.5 KM W direction respectively. Rabo and Urdana RF are the Nearest Reserve Forests from the Plant site at 0.2 Km N & 4.4 Km E respectively. Salient features of Plant site are given in Table 1 and Fig - 3 shows the study area of 10 km radius around the Plant site. 5.0 REQUIREMENTS OF THE PROJECT 5.1 RAW MATERIAL Clinker is transported by the railway wagons from the major clinkerisation units of Ambuja and Shree cement situated 191 Km to the above proposed grinding unit and from the clinkerisation units situated in Chhattisgarh. RAW MATERIAL (MTPA) Phase I Phase II Total Source Mode of Transport 100% PSC 100% PPC 100% PSC 100% PPC 100% PSC 100% PPC Clinker Chhattisgarh Rail / Slag Road Flyash Gypsum Coromandal Fertilisers, Visakhapatnam Coal Indonesia/Australia/ South Africa/Domestic 3 B.S. Envi-Tech (P) Ltd., Secbad.
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9 Feature Altitude Longitude & Latitude Village, Tehsil, District, State IMD Station Max. Temp 0 C 47.7 Min. Temp 0 C 4.4 Relative Humidity % Annual rainfall Topography Soil Type Nearest Water Bodies Nearest Highway Nearest Railway station Nearest Industries Nearest Village Nearest Town Inter State Boundary Nearest Air port Bird Sanctuary/National Parks Nearest Forest Historical places TABLE - 1 SALIENT FEATURES OF THE MINE Details 245 m above MSL B15) 21 58'24.90"N B11) 21 58'9.90"E, B12) 83 16'10.10"N B2) 83 16'19.70"E, Sy. No. 26/1, Bhupdeopur Village, Kharsia Tehsil, Raigarh District, Chhattishgarh State. Sambalpur km SE mm Plain Murram soil Bilaspur Reservoir 0.3 km - N Ramtharan Nala 3.7 km - SSW Mand River 5.6 km - W National Highway (NH-49) - Raigarh Sarangarh km SE. State Highway (SH-1) - Ambikapur Raigarh km E. Nearest Major Road - Kharsia Raigarh - Proposed Cement Grinding unit N. Bhupdeopur RS km W Railway Siding Passing through the Proposed Cement grinding unit. Monnet Ispat and Energy Limited 3.8 km WNW Navdurga Fuel (Shrishtii TMT) 6.5 km NE Power Plant Unit-3 (25 x 3 MW) 9.0 km SE 400/219 KV Power Grid Raigarh SS 12.5 km SSE DB Thermal Power Plant Badadraha 11.0 km SW Sky Alloys & Power Private Limited 7.1 km - W Bilaspur 0.6 km - NNW Belari 0.5 km W Raigarh km - SE Chhattisgarh Odisha 28.0 km - E Jindal Airstrip 8.0 km WNW Raipur Airport km - SW None within 10 km radius Rabo RF 0.2 km N Urdana RF 4.4 km E None within 10 km radius * All distances mentioned in the above table are aerial distances. 6 B.S. Envi-Tech (P) Ltd., Secbad.
10 STORAGE CAPACITIES OF RAW MATERIAL The following raw material storage capacities will be provided in the plant complex. STORAGE CAPACITIES S. No. Material Capacity (Tonnes) 1 Clinker (8 days) Gypsum (30 days) 3390 GGBS (Ground 3 Granulated Blast Furnace Slag) ( days) 4 Fly ash (5 days) LAND The project will be located in an area of 3.5 Ha on the land which was earlier put to industrial use the activities of which are now abandoned. The existing infrastructure will be removed and this new cement grinding would be setup in the same location. LAND BREAKUP S.No Land use breakup Area (Ha.) 1 Built up area Parking area Green belt area Roads & Others Railway siding Vacant area 0.45 Total 3.50 Fig 4 shows the Layout of the Grinding Unit. 5.3 WATER Water requirement is about 20 m 3 /day and the same will be is sourced from existing bore wells and rainwater harvesting pond. 5.4 POWER The total power requirement for the proposed project is estimated to be about 5.0 MW which will be met from Grid. 7 B.S. Envi-Tech (P) Ltd., Secbad.
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12 5.5 MANPOWER CPPL will provide employment opportunity for about 24 persons directly and 72 persons indirectly for this project. 5.6 INFRASTRUCTURE Infrastructure required for setting up a Cement Grinding unit of 0.66 MTPA with allied facilities. The plant buildings/structure will include clinker silo, gypsum storage, cement mill feed hoppers, fly ash storage silo, cement mill building, weigh bridge, cement silo, packing plant building & empty bag store, truck loading bay, wagon loading platform, wagon tippler, compressor room, laboratory, technical office, general store, workshop & security office. 6.0 PRODUCTION DETAILS Clinker, Gypsum, fly ash and slag in a definite proportion are ground for the production of Portland Pozzolana Cement (PPC) and Portland slag cement (PSC). Clinker & Gypsum received through the railway wagons are unloaded directly in Hoppers and transported through belt conveyor system for storage in Clinker silo, Gypsum covered, Slag and Fly-Ash shed respectively. Clinker and Gypsum are subsequently extracted and transported in definite quantity as per the quality requirements to mill feed hoppers which are then be fed vertical to cement mill through weigh feeder in definite proportion. The mill contains grinding roller press resulting into crushing and attrition of the clinker and gypsum, into fine powder and is discharged through the mill called mill outlet. At the mill outlet proportionate classified fly ash/ Slag is added. The fly-ash/ Slag as extracted from hoppers is classified & the fine fly ash/ Slag will be transported to Grinding Unit through pneumatic transport. Storage silo for the fly ash/ Slag is provided. From the mill outlet the mix of fine clinker, gypsum and fly ash / slag is taken by means of bucket elevator & air slides to separator where a particular fineness of mix of clinker, gypsum and fly ash/ slag called Portland Pozzolana Cement is separated and Portland slag cement is then fed to Cement Silo by 9 B.S. Envi-Tech (P) Ltd., Secbad.
13 means of air-slides, belt conveyors and bucket elevator. In the Cement Silo the cement is homogenised by fluidisation method (for blending) and then extracted through specific equipments installed and fed to Electronic Roto-Packing Machine for packing in bags. After packing in bags in the packer machines the cement bags are transported by means of belt conveyor and loaded in Railway Wagons/Trucks by automatic Wagon/Truck Loading machines for onward dispatch to the customer. 6.1 PLANT AND MACHINERY CPPL Cement Grinding Unit comprises the following preparation, processing and handling units: 1. Clinker unloading, handling, storing and retrieval system. 2. Gypsum unloading, handling, storing and retrieval system. 3. Clinker proportioning and feeding 4. Gypsum storage, proportioning and feeding. 5. Clinker and Gypsum Grinding. 6. Fly ash extraction, classification, pneumatic transportation and Storing 7. Fly-ash proportioning and feeding 8. Ground Cement Handling and storage 9. Ground Cement Extraction 10. Cement Packing 11. Packed Cement Loading in trucks for dispatch. 12. Complete ancillary system of water, power & pneumatic system. 13. Slag extraction, classification, pneumatic transportation and storing. 14. Slag proportioning and feeding. Different sections/components of the above processing units are tabulated as below: S.No. Processing Unit Processing Unit comprises Of 1 Clinker unloading, handling, Storing and retrieval system 2 Gypsum unloading, handling, storing & retrieval system Tipplers, Belt Conveyor, Clinker Silo, Belt Conveyor, drives, instrumentation. Belt Conveyors, stockpile, drives and instrumentation. 10 B.S. Envi-Tech (P) Ltd., Secbad.
14 S.No. Processing Unit Processing Unit comprises Of 3 Clinker Proportioning and Feeding 4 Gypsum storage, Proportioning and Feeding 5 Clinker and Gypsum Grinding 6 Fly-Ash extraction, classification, pneumatic transportation and Storing. 7 Fly-Ash Proportioning and feeding Belt Conveyors, clinker hopper, clinker weigh feeder, bag filters, drives and instrumentation. Gypsum Reclaimer, belt conveyors, gypsum hopper, gypsum weigh feeder, drives, instrumentation. Vertical Mill (2X50 TPH), bucket elevator, air slides, separator, bag filters, Ball Mill auxiliaries (lubrication & cooling system), drives and instrumentation. Fly ash pneumatic pumps, classifier, pneumatic conveying equipment s, pipeline, Valves, bag filters, drives instrumentation. Fly ash Hopper, solid flow meter, flow control gates, air slides, drives, instrumentation etc., 8 Ground Cement Handling Bucket elevators, Cement Silo, air & storing slides, drives, instrumentation. 9 Ground Cement Extraction Blowers, air slides, flow control gates, bucket elevators, instrumentation. 10 Cement Packing Airslides, bucket elevators, Packing machines, belt conveyors, bag filters. 11 Packed Cement loading in Belt Conveyors, Truck loading trucks for dispatch. machines, chutes & ducts. 12 Complete ancillary system of water, power & pneumatic system, fire hydrant system. 13 Slag extraction, classification, pneumatic transportation and storing 14. Slag proportioning and feeding Overhead & underground water tanks, water Pipe lines, Drainage, Water Pumps, Main sub-station, Transformer & Central Control system. Compressor house, compressor, Air pipe lines & control system Slag pneumatic pump, classifier, pneumatic conveying equipment, pipeline, valves, bag filters, drives, instrumentation. Slag hopper, solid flow meter, flow control gates, air slides, drives, instrumentations. 7.0 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN FOR CONTROLLING THE IMPACT Any developing project exerts certain adverse and beneficial impacts on immediate surroundings. 11 B.S. Envi-Tech (P) Ltd., Secbad.
15 CPPL firmly believes in the concept of sustainable industrial operations at all their facilities. The proposed project will result in consumption of about 0.20 MTPA of Flyash and MTPA of slag which is otherwise treated as solid waste. CPPL has incorporated all necessary steps to mitigate the environmental pollution in the design stage itself. Environmental Management Plan of the plant details the environmental quality control measures proposed by CPPL during construction and operations phase of the project. 7.1 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN - CONSTRUCTION PHASE (i) AIR ENVIRONMENT Setting-up of grinding unit will result in the increase of dust concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be undertaken and will be continued after the completion of plant construction, as there is scope for heavy truck mobility. It will be ensured that both gasoline and diesel powered vehicles are properly maintained to comply with exhaust emission requirements. The outlet emission is restricted to less than 30 mg/nm 3 for the mill. (ii) NOISE ENVIRONMENT There will be marginal increase in noise levels during construction phase, which is temporary. Noise levels during night time are mainly from welding during the construction phase for short duration. (iii) WATER ENVIRONMENT During construction, the infra-structural services including water supply, sewage, drainage facilities and electrification will be provided to the construction labour. (iv) LAND ENVIRONMENT The project will be located in an area of 3.5 Ha on the land which was earlier put to industrial use the activities of which are now 12 B.S. Envi-Tech (P) Ltd., Secbad.
16 abandoned. The existing infrastructure will be removed and this new Cement Grinding would be setup in the same location. Greenbelt in an area of 1.2 Ha will be developed inside the plant boundary as per statutory norms. (v) SOCIO-ECONOMIC ENVIRONMENT Local people will be given preference through both direct and indirect employment. (vi) SAFETY AND HEALTH DURING CONSTRUCTION PHASE Adequate space will be provided for construction of temporary sheds for construction workers mobilized by the contractors. CPPL will supply potable water for the construction workers. The safety department will supervise the safe working of the contractor and their employees. Work spots will be maintained clean, provided with optimum lighting and enough ventilation to eliminate dust/fumes. 7.2 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN DURING OPERATIONAL PHASE AIR ENVIRONMENT The major sources of emissions from the grinding unit are: Clinker grinding process i.e. VRM Packing plant CONTROL MEASURES PROPOSED ARE: Installation of bag filter systems along ventilation systems to control the fugitive dust generated from the material handling areas. All the flue gas outlets will be provided with state of art air pollution control equipment to maintain the particulate emission level below 30 mg/nm 3 The grinding mill and packer house will be provided with Bag Filters designed for an outlet emission of less than 30 mg/nm 3 13 B.S. Envi-Tech (P) Ltd., Secbad.
17 The dust collected in the pollution control devices is recycled back to the process. The roads in the plant will be paved to prevent dust emissions. To control the dust emissions from dropping/transfer points of the belt and bucket conveyors, unit bag filters will be provided at various locations of the transfer points. All the raw material i.e. flyash, gypsum, slag and clinker will be stored in the silos provided with bag filters for control of fugitive dust emissions. Cement storage silos will be provided Bag filters. Apart from above, CPPL proposes to implement the following additional measures for control of fugitive dust: Development of greenbelt all around the plant boundary. FUGITIVE DUST CONTROL For control of fugitive dust, water spray arrangement will be provided to spray water all-round the fuel stock piles to suppress the dust and to wet the coal while compacting to minimize the dust nuisance. Adequate ventilation and dust suppression systems will be implemented in the coal conveyer system. Installation and operation of water spray nozzles at wagon tippler hopper to reduce the dust emission during unloading of wagons. Unloading of material will be carried out with great care by avoiding dropping of material from height, wetting the material by sprinkling water while unloading NOISE ENVIRONMENT Cement mills are the major sources of noise pollution. The following are proposed noise control measures Provision of acoustic dampeners in foundations and insulators in the interiors A scientifically designed greenbelt will be developed all around the plant boundary to act as noise attenuator. In addition personnel working near high noise level generating sources will be provided with earmuffs and ear plugs. Acoustically insulated cubicles will be provided to operators working near high noise generation sources. 14 B.S. Envi-Tech (P) Ltd., Secbad.
18 Effective preventive maintenance and vibration measurement of all rotating equipment will help in the improvement of plant life and also reduce noise. Noise level at the plant boundary is expected to be less than 55 db(a) without considering any attenuation factors WATER ENVIRONMENT No wastewater generation is envisaged from the grinding unit. Wastewater generation is only from domestic use i.e. about 1.8 m 3 /day and the same is treated in septic tanks followed by soak pits LAND ENVIRONMENT The site is free from habitation and hence no displacement of people is envisaged. Therefore the overall impact on land environment will be minimum SOLID WASTE GENERATION Dust collected from air pollution control equipment is 100% recycled in process and no solid waste is generated from cement grinding unit. The waste oil generated from the machines will be stored in barrels. About one barrel per year of waste oil will be generated from the plant. This oil will be disposed to authorised vendors HAZARDOUS WASTE MANAGEMENT RULES CPPL will store the hazardous waste in a designated area. This area will be isolated from the other utility areas. Spent Oil from the gear boxes and automobile batteries will be disposed to the authorized vendors as per the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, TRANSPORTATION The total raw material (except flyash) and finished product will be transported by rail. 15 B.S. Envi-Tech (P) Ltd., Secbad.
19 7.2.8 GREEN BELT DEVELOPMENT The plan for attenuation of the noise and air pollutant levels include design of plantations around the plant boundary, roadside, office buildings and stretches of open land. The vegetation for the attenuation of air pollution would be most needed in the areas where ground level concentrations of the pollutant are high. Of the total plant area of 3.50 Ha, 1.20 Ha. of the plant area will be covered under green belt. A curtain of trees all around the plant will be developed. The species that have history of good survival and growth under similar site conditions will be planted SOCIO ECONOMIC ENVIRONMENT Socio Economic Status in the study area is found to be moderate with respect to livelihood, amenities etc. Transport and other infrastructural facilities such as market centers, business establishment, recreation etc. in the area will be improved. A total of about 24 persons directly and 72 persons indirectly will be employed for this project. The management of CPPL has proposed to give preference to local people for recruitment in semiskilled and unskilled categories. All infrastructure facilities such as education, health facilities and other social facilities are adequate at nearby commercial area i.e., Gairah and Kharsia. CPPL will prepare a well-defined Corporate Social Responsibility (CSR) policy to Carryout social development and welfare measures in the surrounding villages. Under CSR activity CPPL will initiate community development projects, in the fields of health, education and environmental preservation, in and around the plant. 16 B.S. Envi-Tech (P) Ltd., Secbad.
20 OCCUPATIONAL SAFETY & HEALTH MANAGEMENT CPPL will provide all necessary provisions under Factory Act. In addition a Safety committee will be formed and manned by equal participants from Management and Workers. Safety shoes, helmet & uniform will be issued to each worker. Other safety equipment s will be used according to the nature of job involved. CPPL will establish a first aid center with necessary medicines. 8.0 BUDGET FOR EMP CPPL proposes to incur about Rs Crores for implementing the Environmental Management Plan. Table - 2 BUDGET FOR ENVIRONMENT MANAGEMENT PLAN Amount in Rs Crores Capital Cost Recurring Cost Phase - I Phase - II Phase - I Phase - II Pollution Control Equipment Online Monitoring Equipment Greenbelt development TOTAL B.S. Envi-Tech (P) Ltd., Secbad.