HALF YEARLY COMPLIANCE REPORT (Oct 14 Mar 15) ENVIRONMENTAL CLEARANCE (CLINKER 2.48 MTPA TO 2.78 MTPA AND CEMENT 3.30 MTPA TO 3.90 MTPA) Letter No. F. No. J-11011/1180/2007- IA II (I) dated 11 th June, 2008 S. No CONDITION COMPLIANCE STATUS A. SPECIFIC CONDITIONS: i. The company shall obtain necessary clearances / approval from the concerned Departments i.e. Indian Bureau of Mines, State Government, Ministry of Environment and Forests etc. for the linked mining component before undertaking any construction activity at the project site and a copy submitted to the Ministry and its Regional Office at Bhubaneswar Complied - Necessary clearances / approval are obtained from the concerned Departments i.e. Indian Bureau of Mines, State Government, Ministry of Environment and Forests etc. for the linked mining components. Linked up Limestone Mines vide Mellacheruvu Mine MoEF - EC No. J-11015/35/2001.IA.II (M) Dt. 12.03.2004 and J-11015/8/2000.IA.II (M) Dt. 15.04.2002. IBM - Mining Plan approval AP/NLG/MP/Lst-29/HYD, Dt. 22.09.2014 (amalgamation of ML-1& ML-2) Industries & Commerce Dept. - Mining Lease grant G.O.No.298 Dt. 07.11.2006 (amalgamation of ML-1 & ML-2). Yepalamadhavaram Mine MoEF - EC No. J-11015/37/2002.IA.II (M) Dt. 12.04.2004. IBM - Mining Plan approval MS/AP/NLG/LST-230-SZ Dt. 08.09.2011 Industries & Commerce Dept. - Mining Lease grant G.O.No.53 Dt. 02.02.2002. Choutapalli Mine MoEF - EC No. J-11015/25/2006.IA.II (M) Dt. 26.05.2006 and J-11015/576/2007.IA.II (M) dt 31.07.2008. IBM - Mining Plan approval No. AP/NLG/MP/LST-55/HYD, Dt. 22.09.2014 (amalgamation of ML-1 & ML- 2) Industries & Commerce Dept. - Mining Lease grant G.O.No.328 Dt.12.12.2008 (amalgamation of ML-1& ML-2). Shale Mine MoEF-EC No. SEIAA/AP/NLG-76/2013 2745 (M) Dt:30.07.2013. IBM-Mining Plan approval Letter No. 8112/MS-NLG/11, Dt.14-07-2011. Industries & Commerce Dept. Mining Lease grant G.O.Ms.No.276 Dt. 11.11.2004 Page 1 of 35
S. No CONDITION COMPLIANCE STATUS ii. Continuous monitoring system to monitor gaseous emissions shall be provided and limit of SPM shall be controlled within 50 mg/nm 3 by installing adequate air pollution control system viz. Electrostatic precipitator (ESP), bag house, bag filters etc. and data submitted to the Ministry s Regional Office at Bangalore, A. P. Pollution Control Board (APPCB) and CPCB regularly. Photos showing online monitoring systems are presented in Annexure-1 Installed online Continuous Emission Monitoring System (CEMS) for 14 stacks viz., 3 Nos. Kiln stacks, 3 Nos. Clinker Cooler ESP stacks, 3 Nos. Coal mill baghouse stacks, 5 Nos. Cement Mill baghouse stack) and are connected to TSPCB and CPCB server as well. 3 No. Continuous Ambient Air Quality Monitoring Systems (CAAQMS) are installed one each in downwind, upwind and Turbulent direction and the same are connected to TSPCB/CPCB servers. Adequate air pollution control systems are provided as detailed below to maintain SPM well within the prescribed limits. Raw mill & Kilns Clinker Coolers Limestone crusher, Coal mill & cement mills All transfer points Limestone dump hopper Limestone stacker : Reverse Air Bag House (RABH) : Electro Static Precipitator (ESP) : Bag Filters : Dust Collectors : Water spray system : water spray system Data being submitted to the MoEF RO at Bangalore, APPCB on regular basis. Stacks emission monitoring data from October 14 to March 15 is enclosed as Annexure-2 Page 2 of 35
S. No CONDITION COMPLIANCE STATUS iii. The company shall install adequate dust collection and extraction system to control fugitive dust emissions at various transfer points, raw mill handling (unloading, Raw mill & Kilns conveying, transporting, stacking), vehicular movement, bagging and packing areas etc. All the raw material stock piles shall be covered. A Clinker Coolers Limestone crusher, Coal mill & cement mills All transfer points : Bag Filters closed clinker stockpile system shall be Limestone dump hopper provided. All conveyers shall be covered with Limestone stackers GI sheets. Covered sheds for storage of raw materials and fully covered conveyers for transportation of materials shall be provided besides coal, cement, fly ash and clinker shall be equipment are designed for < 50 mg/nm 3. stored in silos. Pneumatic system shall be used for fly ash handling. Adequate air pollution control systems are installed. Dust collectors and extraction systems at various sections for controlling fugitive dust emissions are detailed below : Reverse Air Bag House (RABH) : Electro Static Precipitator (ESP) : Dust Collectors : Water spray system : Water spray system All transfer points and storage silos are provided with dust collection and extraction systems for effective control of fugitive emissions. All the installed pollution control The dust collected from the pollution control equipment is being recycled back into the process. Clinker is being stored in clinker storage tanks of capacity 1,10,000 tonnes & 30,000 tonnes to control fugitive emissions that might be caused due to clinker stock piles. Gypsum and additives are being stored in covered storage sheds with storage capacity of 5800 tonnes and 7400 tonnes respectively. Flyash is being stored in 5 silos with total capacity of about 3100 tonnes and pneumatic system is installed for flyash handling. Cement is being stored in 6 silos with total capacity of about 37,100 tonnes. All raw material transfer conveyor are covered with non-asbestos sheets. All roads and open area in the plant are cement concreted. Page 3 of 35
S. No CONDITION COMPLIANCE STATUS iv. Secondary fugitive emissions from all the sources shall be controlled within the latest permissible limits issued by the Ministry and regularly monitored. Guidelines / Code of Practice issued by the CPCB shall be followed and data submitted to the Ministry s Regional Office at Bangalore, CPCB and APPCB. All transfer points and storage silos are provided with dust collection and extraction systems for effective control of fugitive emissions. Clinker is being stored in clinker storage tanks, Gypsum and additives are being stored in covered storage sheds, Flyash & cement is being stored in silos and raw material transfer conveyors are covered with GI sheets to avoid any secondary fugitive emissions. All roads and open areas in the plant area are cement concreted and vehicle movement is allowed only through specific routes for control of secondary fugitive dust emissions. Truck mounted vacuum cleaner and road sweepers are deployed and good housekeeping is being maintained for controlling secondary fugitive dust emissions. v. Asphalting/concreting of roads and water spray all around the stockyard and loading/ unloading areas in the cement plant shall be carried out to control fugitive emissions. Regular water sprinkling shall be carried out in critical areas prone to air pollution and having high levels of SPM and RPM such as haul road, loading and unloading points, transfer points and other vulnerable areas. It shall be ensured that the ambient air quality parameters conform to the norms prescribed by the Central Pollution Control Board in this regard. Requisite data / information / monitoring data are being submitted to Regional Office, MoEF regularly. All roads and most of the open areas in the plant area are cement concreted and vehicle movement is allowed only through specific routes for controlling fugitive dust emissions. Bag filters are provided at all transfer points; storage silos and water spray system is provided for limestone dump hopper and stacker for dust suppression. Fixed water sprinklers for suppression of fugitive dust generated due to vehicular movement are installed at various critical roads in cement plant and mines. Fixed water sprinklers installed in cement plant is depicted in Annexure 8. Ambient air quality parameters are maintained well within the prescribed limits. Monitoring data from October 14 to March 15 is enclosed as Annexure-3. Page 4 of 35
S. No CONDITION COMPLIANCE STATUS vi. Efforts shall be made to reduce impact of the transport of the raw materials and end products on the surrounding environment including agricultural land. All the raw Flyash is transported in bulk tankers only. materials including fly ash shall be transported in the closed containers only and shall not be overloaded. Vehicular emissions shall be regularly monitored. Measures shall be taken for maintenance of vehicles used in mining operations and in transportation of mineral. vii. viii. Total water requirement for cement plant shall not exceed 1,260 m 3 /day. 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. Permission for the drawl of 1,260 m 3 /day water shall be obtained from the concerned Department. To ensure and reduce impact of transport on the surrounding environment; raw materials and cement is transported mostly by rail and in trucks covered with tarpaulin. Transport vehicles are periodically checked for Pollution Under Control certificate from approved RTA agencies. Separate railway siding is commissioned in March 2012 from Mellacheruvu RS to our factory site to transport raw materials and cement. Over 99% of clinker is transported through rail; 40 45% of cement dispatch and coal receipts is also carried out by rail thereby reducing the impact on the surrounding environment caused by transportation activity. Dry process is used for manufacturing cement; hence there is no generation of process wastewater. Return water from cooling system is routed back to collection tank and recycled back into system. Domestic wastewater is treated in Sewage Treatment Plant (STP) and it is being used for greenbelt maintenance completely. The existing STP has been upgraded to Moving Bed Bio-Film reactor for better treatment of water. The same is depicted in Annexure - 4 Clearance obtained from the Central Ground Water Authority to draw ground water. Vide Lr.No.1465/Hg/S.T/96 dt 03.12.1998 to tap 1500 m 3 /day of ground water. Page 5 of 35
S. No CONDITION COMPLIANCE STATUS ix. Existing Sewage treatment plant (STP) shall be used for the treatment of sewage from the colony and treated domestic effluent shall be used for green belt development within the plant premises. Domestic waste from colony and STP shall be segregated into biodegradable water. Commissioning of plant is completed in March 2014. and non-biodegradable. Bio- The same is depicted in Annexure - 4 degradable waste shall be composted and nonbiodegradable waste shall be land filled at identified sites. Effluent treatment plant (ETP) shall also be provided for workshop. x. All the bag filter dust, raw meal dust, coal dust, clinker dust and cement dust 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. Spent oil and batteries shall be sold to authorized recyclers / reprocessors only. xi. Efforts shall be made to use low grade lime, more fly ash and solid waste in the cement manufacturing. Sewage treatment plant (STP) treated wastewater is 100% used for greenbelt development within the plant premises. The existing STP has been upgraded to Moving Bed Bio-Film reactor for better treatment of Dust collected from pollution control equipments is 100% recycled and reused in the process for cement manufacturing. Sludge will be used for greenbelt development as and when generated. Spent oil is completely reused in cement plant equipment as lubricant and batteries are being sold to authorised recyclers/re-processors only. Low grade limestone is being used along-with high grade to ensure optimum utilization of the resources. All possible efforts are being made to use more fly ash in cement manufacturing. PPC production is about 45-50 % of total cement production. Fly ash generated from the captive power plant is being 100% utilized in the cement plant. Page 6 of 35
S. No CONDITION COMPLIANCE STATUS xii. An effort shall be made to use of high calorific hazardous waste in the cement kiln and necessary provision shall be made accordingly. As per the CPCB Guidelines on Co-processing in Cement/Power/Steel Feb 2010, We have installed & commissioned system for co-processing of liquid hazardous waste in cement kiln main burner in March 2012. The project cost was about 10 crores. Liquid hazardous waste (spent solvents) from pharmaceutical industries is being utilized as secondary fuel alongwith coal in our Cement Kilns system of Unit-II&III. Liquid HW handling system is presented in Annexure-5 and Liquid hazardous waste (spent solvents) utilized during October 14 March 15 is tabulated in xiii. xiv. All the fly ash shall be utilized as per Fly ash Notification, 1999 subsequently amended in 2003. As proposed, green belt shall be developed in at least 33 % area in and around the cement plant as per the CPCB guidelines to mitigate the effects of air emissions in consultation with local DFO. Annexure 6. Fly ash generated from the captive power plant is being 100% utilized in the cement plant. Greenbelt along the boundary of the cement plant and at open areas is being strengthened. We have started developing additional greenbelt area in phased manner and total greenbelt area developed at cement plant, colony and mines is about 69 ha. The species, which give better yield in this rocky area, are planted for better survival rate. In addition to existing greenbelt, an area of about 5.3 ha. has been developed under greenbelt with 5200 number of plantations during year 2014-2015. Photos showing greenbelt developed in year 2014-15 is enclosed as Annexure-7. xv. All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for the Cement plants shall be implemented. Recommendations made in the CREP for cement plants are being followed. Compliance report is enclosed as Annexure-11. Page 7 of 35
S. No CONDITION COMPLIANCE STATUS xvi. Permission and Recommendations of the concerned Department regarding impact of cement plant on the Yepalamadhavaram ecosensitive area located at 1.60 km shall be obtained. Measures shall also be taken to prevent impact of particulate emissions / fugitive emissions, if any from the proposed plant on the Yepalamadhavaram eco-sensitive area. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department shall be prepared and implemented. B. GENERAL CONDITIONS: i. The project authority shall adhere to the stipulations made by Andhra Pradesh Pollution Control Board (APPCB) and State Government. ii. No further expansion or modification of the plant shall be carried out without prior approval of this Ministry. Government of Andhra Pradesh, Forest Department has issued Flora & Fauna Certificate (Rc. No. 565/2008/S5, dated 9.06.2008) stating that there are no endangered flora and fauna species found in the vicinity of Yepalamadhavaram Forest Block and My Home Industries Ltd. Standards stipulated by Telangana State Pollution Control Board (APPCB) are being followed Will be followed. Page 8 of 35
S. No CONDITION COMPLIANCE STATUS iii. The gaseous and particulate matter emissions from various units shall conform to the standards prescribed by the T.N. 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. Particulate matter emissions from various units are conforming to the prescribed standard of 50 mg/nm 3 by the Andhra Pradesh Control Board. The particulate emissions from the cement plant are confirming to 50 mg/nm 3. Continuous online stack monitoring equipment is installed for all 14 major stacks viz. Kilns RABH stacks, Clinker Cooler ESP, Coal mill Bagfilter, Cement Mill Bagfilters and Captive Thermal Power Plant ESP stacks. Particulate emissions from the stacks are maintained well within the prescribed limits. Interlocking facilities are provided for all major pollution control equipment such that in the event of the pollution control equipment not working, the respective unit(s) is shut down automatically. iv. One ambient air quality monitoring station shall be installed in downwind direction. Ambient air quality including ambient noise levels shall not exceed the standards stipulated under EPA or by the State authorities. Monitoring of ambient air quality and stack emissions shall be carried out regularly in consultation with APPCB and report submitted to the APPCB quarterly and to the Ministry s Regional Office at Bangalore half-yearly. Stacks emission monitoring data from October 14 to March 15 is enclosed as Annexure-2 3 Nos. Continuous Ambient Air Quality Monitoring System (CAAQMS) are installed in predominant upwind, downwind direction and turbulent direction. Ambient air quality and ambient noise levels are being maintained well within the prescribed standards. 4 Ambient air quality monitored stations are recognized at the periphery of the plant and monitoring is done on regular basis. Ambient air quality, ambient noise levels and stack monitoring are being done on monthly basis. Ambient air quality at core zone and buffer zone is being monitored on monthly ba sis. Monitoring data for the period October 14 to March 15 is enclosed as Annexure 3. Page 9 of 35
S. No CONDITION COMPLIANCE STATUS v. 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. Sumps are constructed in the Mine area and in the cement plant for harvesting rainwater. Rainwater collected in the sumps are utilized for power plant, cement plant, greenbelt and for water spraying. vi. vii. viii. ix. The company shall undertake eco-development measures including community welfare measures in the project area. 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) and 70 dba (night time). All recommendations made in the Corporate Responsibility for Environment Protection (CREP) for cement plants shall be implemented. Proper house keeping shall be taken up. Regular annual medical examination of all the employees shall be carried out from the occupational health point of view and records maintained. MHIL has spent about 84.49 lakhs on welfare activities in the near villages till March 2015 during year 2014-15. The noise levels are being monitored and efforts are being made to maintain the noise levels within the prescribed limits. Silencers are provided to all the Clinker Cooler fans of Unit-I, Unit-II & Unit-III to maintain the noise level well within the prescribed limits. Ambient noise level monitoring data for the period Oct 14 to March 15 is enclosed as Annexure 3(e). Efforts are being made to follow the CREP guidelines pertaining to cement plants. Compliance report enclosed as Annexure-11. Truck mounted vacuum cleaner and road sweepers are deployed and good housekeeping is being maintained. Photos of truck mounted vacuum cleaning machine, road sweeping machines are enclosed as Annexure-8 for your reference. Page 10 of 35
S. No CONDITION COMPLIANCE STATUS x. 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 already in place. Environmental Policy of the company was published on 10 th Dec 2010. MHIL implemented Environmental Management System (EMS) and certified as per ISO 14001:2004 in June 2011. MHIL Environmental Policy and ISO certificate is presented in Annexure-9. World Environment Day 2014 was celebrated at MHIL to create environmental awareness. Photos showing WED 2014 celebration is presented in Annexure-10. The award ceremonies of the above mentioned awards are depicted in Annexure 12. xi. As proposed, Rs. 38.66 Crores and Rs. 3.10 Crores shall be earmarked towards capital cost and environment pollution control measures respectively and 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. xii. The Regional Office of this Ministry at Bangalore / CPCB / APPCB shall monitor the stipulated conditions. A six monthly compliance report and the monitored data alongwith statistical interpretation shall be submitted to them regularly. The proposed capital expenditure was totally utilized for environmental equipment and pollution control measures. During the year 2014 MHIL has spent Rs.468 lakhs toward recurring expenditure and Rs. 52.17 Lakhs towards non-recurring expenditure of pollution control system and maintenance. Requisite data / information / monitoring data are being submitted to Regional Office, MOEF regularly on basis. Page 11 of 35
S. No CONDITION COMPLIANCE STATUS xiii. The Project Authorities shall inform the Required information was communicated. Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of commencing the land development work. xiv. The Project Proponent shall inform the public Communicated to the Ministry of Environment and Forests vide our Lr. No. MHIL/S&E/2007- that the project has been accorded 08/34, dated 07 th July 2008. environmental clearance by the Ministry and copies of the clearance letter are available with the A.P. Pollution Control Board / Committee and may also be seen at Website of the Ministry of Environment and Forests at http:/envfor.nic.in. This should be advertised within seven days from the date of issue of the clearance letter at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the Regional office at Bangalore. Page 12 of 35
Annexure 1(a) Continuous Ambient Air Quality Monitoring Station and CEMS [CEMS1, CEMS2, Upwind direction and Turbulent direction(colony) connected to CPCB server] Page 13 of 35
Annexure 1(b) Continuous Emission Monitoring System Page 14 of 35
Annexure 1 (c) Overview of locations of CAAQM stations with respect to Cement Plant Page 15 of 35
Annexure 2 Stack emission monitoring data (SPM in mg/nm 3 ) Oct 14 Mar 15 LOCATION Oct -14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Min Max Avg KILN - I RABH 48 44 41 45 47 49 41 49 45.67 COAL MILL - I BF 26 29 26 29 27 36 26 36 28.83 COOLER - I ESP 34 31 29 26 27 30 26 34 29.50 CEMENT MILL - IA BF 20 18 15 21 20 24 15 24 19.67 CEMENT MILL - I BF 31 24 22 27 25 29 22 31 26.33 KILN - II RABH 43 40 38 35 32 36 32 43 37.33 COAL MILL - II BF 23 32 30 33 31 26 23 33 29.17 COOLER - II ESP 30 28 25 23 22 24 22 30 25.33 CEMENT MILL - II BF 23 21 16 19 17 18 16 23 19.00 LS CRUSHER - II BF 47 43 40 42 40 43 40 47 42.50 KILN - III RABH 35 32 30 27 29 33 27 35 31.00 COAL MILL - III BF 28 35 41 36 40 28 28 41 34.67 COOLER - III ESP 24 22 20 18 18 21 18 24 20.50 CEMENT MILL - IV BF 28 26 17 23 19 26 17 28 23.17 CEMENT MILL - V BF 25 22 30 25 24 26 22 30 25.33 LS CRUSHER - III BF 39 46 44 38 34 39 34 46 40.00 Page 16 of 35
Annexure 2 Graphical Representation of emissions from various stacks in Cement Plant Oct 14 Mar 15 Page 17 of 35
Annexure 3 (a) Ambient Air Quality in [PM10] µg/m 3 Oct 14 Mar 15 PM10 Oct -14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Min Max Avg Cement Plant Main Gate 88 76 73 68 71 80 68 88 76.00 Colony Premises 75 68 65 57 63 67 57 75 68.83 Shale Mine 70 59 54 52 57 59 52 70 58.50 Near Choutapalli Mine Office 72 64 60 74 72 82 60 82 70.67 Mellacheruvu Mines 65 72 69 66 68 76 66 76 69.33 CPP-II 59 63 64 61 70 74 61 74 65.17 Mellacheruvu Village 58 64 61 59 57 63 57 64 60.33 Choutapalli Village 45 49 51 47 44 56 44 56 48.67 Mattampalli Village 53 42 48 49 42 51 42 53 47.50 Venkataramapuram Village 49 47 44 56 59 60 44 60 52.50 Raghunathapalem Village 50 59 53 50 52 48 48 59 52.00 Jaggutanda Village 55 56 58 54 57 59 54 59 56.50 Yepalamadhavaram Village 62 49 46 43 49 54 43 62 50.50 Bakkamanthulagudem Village 42 38 40 38 36 43 36 43 39.50 Mallareddygudem Village 40 45 57 51 50 52 40 57 49.17 Page 18 of 35
Annexure 3 (b) Ambient Air Quality [PM2.5] in µg/m 3 Oct 14 Mar 15 PM2.5 Oct -14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Min Max Avg Cement Plant Main Gate 35 28 35 24 26 29 24 35 27.83 Colony Premises 25 21 18 17 19 20 17 25 20.00 Shale Mine 26 17 15 14 21 16 14 26 18.17 Near Choutapalli Mine Office 23 24 22 27 25 31 22 31 25.33 Mellacheruvu Mines 30 37 24 21 23 26 21 37 26.83 CPP-II 21 32 27 19 18 22 18 32 23.17 Mellacheruvu Village 25 28 26 24 23 28 23 28 25.67 Choutapalli Village 19 17 21 19 21 22 17 22 19.83 Mattampalli Village 20 21 18 16 19 17 16 21 18.50 Venkataramapuram Village 15 16 17 23 29 26 15 29 21.00 Raghunathapalem Village 18 19 16 15 27 15 15 27 18.33 Jaggutanda Village 21 23 24 22 23 24 21 24 22.83 Yepalamadhavaram Village 29 25 19 14 15 20 14 29 20.33 Bakkamanthulagudem Village 16 17 15 12 11 14 11 17 14.17 Mallareddygudem Village 14 12 20 21 26 19 12 26 18.67 Page 19 of 35
Annexure 3 (c) Ambient Air Quality [SO2] in µg/m 3 Oct 14 Mar 15 PM SO2 Oct -14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Min Max Avg Cement Plant Main Gate 10 7 6 9 8 7 6 10 07.83 Colony Premises 13 14 12 11 13 10 10 14 12.17 Shale Mine 9 8 10 8 11 12 8 12 09.67 Near Choutapalli Mine Office 8 9 7 6 9 8 6 9 07.83 Mellacheruvu Mines 8 10 8 10 7 9 7 10 08.50 CPP-II 7 13 9 7 8 13 7 13 09.25 Mellacheruvu Village 13 8 7 8 9 6 6 13 08.50 Choutapalli Village 10 12 13 11 12 10 10 13 11.33 Mattampalli Village 9 7 6 9 7 13 6 13 08.50 Venkataramapuram Village 11 10 9 10 11 8 8 11 09.83 Raghunathapalem Village 6 9 11 13 14 12 6 14 10.83 Jaggutanda Village 9 12 7 6 8 7 6 12 08.17 Yepalamadhavaram Village 8 6 8 12 10 11 6 12 09.17 Bakkamanthulagudem Village 7 13 10 14 11 9 7 14 10.67 Mallareddygudem Village 12 11 12 7 13 8 7 13 10.50 Page 20 of 35
Annexure 3 (d) Ambient Air Quality [NOx] in µg/m 3 Oct 14 Mar 15 PM NOx Oct -14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Min Max Avg Cement Plant Main Gate 23 18 21 26 24 16 16 26 21.33 Colony Premises 25 20 27 24 22 19 19 27 22.83 Shale Mine 20 16 19 17 18 20 16 20 18.33 Near Choutapalli Mine Office 22 25 23 19 11 13 11 25 18.33 Mellacheruvu Mines 24 18 16 20 21 25 16 25 20.50 CPP-II 17 21 18 22 23 21 18 23 21.00 Mellacheruvu Village 21 17 22 24 23 15 15 24 20.33 Choutapalli Village 19 20 18 20 21 19 18 21 19.50 Mattampalli Village 23 16 17 16 18 20 16 23 18.33 Venkataramapuram Village 20 18 23 21 20 24 18 24 21.00 Raghunathapalem Village 16 17 19 18 17 23 16 23 18.33 Jaggutanda Village 28 19 21 23 24 18 18 28 22.17 Yepalamadhavaram Village 23 15 16 15 16 15 15 23 15.67 Bakkamanthulagudem Village 17 21 17 19 18 20 17 21 18.67 Mallareddygudem Village 19 23 20 22 21 17 17 23 20.33 Page 21 of 35
Annexure 3 (e) Ambient Noise Levels Oct 14 Mar 15 Location February (Winter) Ld Ln Ldn Mellacheruvu Village 45.5 41.9 43.70 Choutapalli Village 51.9 44.9 48.40 Mattampalli Village 49.2 46.4 47.80 Yepalamadhavaram Village 51.9 46.8 49.35 Venkataramapuram Village 50.9 47.6 49.25 Mallareddygudem Village 46.2 41.8 44.00 Bakkamanthulagudem Village 47.4 42.3 44.85 Page 22 of 35
Annexure 4(a) Sewage Treatment Plant Page 23 of 35
Annexure 4(b) Sewage Treatment Plant Treated Water Analysis Oct 14 Mar 15 Parameters Min Max Avg ph 7.10 7.84 --- Oil & Grease 0.007 0.009 0.0078 TS 21 25 22.80 TDS 747 786 766.4 BOD for 3 days 6 9 7.4 COD 35 43 39 Chloride 188 210 197.60 Sulphates 65 83 72.6 Page 24 of 35
Annexure 5 Co-Processing of Liquid Hazardous Waste Storage system Page 25 of 35
Annexure 6 Utilization of Liquid Hazardous Waste for Co-Processing in Cement Kiln Oct 14 Mar 15 Month Qty Utilized (tonnes) Oct 14 985.77 Nov 14 771.07 Dec 14 456.57 Jan 15 853.59 Feb 15 689.79 Mar 15 1019.01 Total 4775.8 Page 26 of 35
Annexure 7 Greenbelt Development Year 2014-2015 [Upto March 2015] (Peripheral plantation -North side of plant boundary) Page 27 of 35
Annexure -8 Photos Of Truck Mounted Vacuum Cleaning Machine, Road Sweeping Machines Page 28 of 35
Fixed Water Sprinklers Installed at Cement Plant Main Gate to suppress fugitive dust emissions due to vehicular movement Page 29 of 35
Annexure-9 MHIL Environmental Policy & ISO 14001 Certification Page 30 of 35
Annexure-10 World Environment Day 2014 Celebration at MHIL Site Page 31 of 35
Annexure-11 Compliance Report on Charter on Corporate Responsibility for Environmental Protection S. No CONDITION COMPLIANCE STATUS 1 Cement Plants, which are not complying with notified standards, Complying with notified standards of SPM 50 mg/nm 3 shall do the following to meet the standards; Augmentation of existing Air Pollution Control Devices - by July 2003 Replacement of existing Air Pollution Control Devices - by July 2004 2 Cement Plants located in critically polluted or urban areas Not applicable located in rural area (including 5 km distance outside urban boundary) will meet 100 mg/ Nm3 limit or particulate matter by December 2004 and continue working to reduce the emission of particulate matter to 50 mg/nm3. 3 The new cement kilns to be accorded NOC/Environmental Clearance w.e.f 01.04.2003 will meet the limit of 50 mg/nm3 for particulate matter emissions. Complied Kiln emission are controlled through RABH system to meet the standard of SPM 50 mg/nm 3 4 CPCB will evolve load based standards by December 2003. -- 5 CPCB and NCBM will evolve SO2 and NOx emission standards by June 2004. Standards will be followed they are stipulated by CPCB / MoEF Page 32 of 35
S. No CONDITION COMPLIANCE STATUS 6 The Cement industries will control fugitive emissions from all the CPCB Environmental Guidelines for Prevention and Control raw material and products storage and transfer points by December of Fugitive Emissions from Cement Plants are being 2003. However, the feasibility for the control of fugitive emissions followed from limestone and coal storage areas will be decided by the All transfer points and storage silos are provided with National Task Force (NTF). The NTF shall submit its dust collection and extraction systems for effective recommendations within three months. control of fugitive emissions. All the installed pollution control equipment are designed for < 50 mg/nm 3. The dust collected from the pollution control equipment is being recycled back into the process. Clinker is being stored in clinker storage tanks of capacity 1,10,000 tonnes & 30,000 tonnes to control fugitive emissions. Gypsum and additives are being stored in covered storage sheds with storage capacity of 5800 tonnes and 7400 tonnes respectively. Flyash is being stored in 5 silos with total capacity of about 3100 tonnes and pneumatic system for flyash handling. Cement is being stored in 6 silos with total capacity of about 37,100 tonnes All raw material transfer conveyor are covered with GI sheet. Truck mounted vacuum cleaner and road sweeper are deployed and good housekeeping is being maintained for 7 CPCB, NCBM, BIS and Oil refineries will jointly prepare the policy on use of petroleum cokes as fuel in cement kiln by July 2003. controlling secondary fugitive dust emissions. ------ Page 33 of 35
S. No CONDITION COMPLIANCE STATUS 8 After performance evaluation of various types of continuous monitoring equipment and feedback from the industries and equipment manufactures, NTF will decide feasible unit operations/ sections for installation of continuous monitoring equipment. The industry will install the continuous monitoring systems (CMS) by December 2003 Installed online Continuous emission monitoring system (CEMS) for 14 stacks 3 Nos. Kiln RABH stacks, 3 Nos. Clinker Cooler ESP stacks, 3 Nos. Coal mill stacks, 5 Nos. Cement Mill stacks and are connected to APPCB server. 3 No. Continuous Ambient Air Quality Monitoring System (CAAQMS) installed in downwind, upwind direction and Turbulent direction are connected to TSPCB/CPCB servers. 9 Tripping in kiln ESP to be minimized by July 2003 as per the ESPs are replaced with RABH for all Kilns. No tripping is recommendations of NTF. 10 Industries will submit the target date to enhance the utilization of waste material by April, 2003. 11 NCBM will carry out a study on hazardous waste utilization in cement kiln by December 2003. envisaged Flyash generated from thermal power plant and gypsum from fertilizer units are being utilised in cement manufacturing process. Flyash is being utilized since year 2002 in manufacturing PPC. Year Fly Ash consumption Gypsum Consumption (MT) (%) (MT) (%) 2014-15 183542 32.85 70954.51 4.56 2013-14 278512 32.23 80333.49 3.92 2012-13 350506 32.31 101740.28 4.00 2011-12 277844 31.95 36412.84 4.19 2010-11 312862 31.91 41722.15 4.26 ------- Page 34 of 35
S. No CONDITION COMPLIANCE STATUS 12 Cement industries will carry out feasibility study and submit target dates to CPCB for co-generation of power by July 2003. MHIL installed & commissioned system for co-processing of liquid hazardous waste in cement kiln main burner during March 2012. The project cost was about 10 crores. Liquid hazardous waste (spent solvents) from pharmaceutical industries is being utilized as secondary fuel alongwith coal in our Cement Kilns system of Unit-II&III. The consumption of alternate fuel for the period October 14 March 15 is presented in Annexure 6. Page 35 of 35