JAYPEE REWA PLANT (A Unit of Jaiprakash Associates Limited) JAYPEE NAGAR REWA (M.P.) 2014 2015 SUBMITTED TO M.P. POLLUTION CONTROL BOARD BHOPAL (M.P.)
Jaypee Rewa Plant (A unit of Jaiprakash Associates Limited) Introduction: Jaypee Rewa Plant is a cement plant of capacity 3.5MTPA under the division of Jaiprakash Associates Limited (JAL) groups of Company with Head and Registered Office at Noida (U.P.), a leading Business House with its presence in Core Industries like Cement industry, Construction division, Hydropower & Thermal Power, Education, I.T., Agro based products & a chain of five star hotels in major cities of India,and constructed the world class racing track to organized FORMULA ONE racing competition first time in India, which has been at the vanguard in generating wealth for the Nation. Transforming challenges into opportunities has been the hallmark of the Jaypee Group, ever since its inception five decades ago. The Group is a diversified infrastructure conglomerate with business interests in Engineering & Construction, Cement, Power, Real Estate, Expressways, Fertilizer, Hospitality, Healthcare, Sports, Information Technology and Education (not-for-profit). The group produces special blend of Portland Pozzolana Cement under the brand name Jaypee Cement (PPC). Its cement division currently operates modern, computerized process control cement plants.the Group is committed towards the safety and health of employees and the public. The motto of the Group is Work for Safe, Healthy, Clean & Green Environment. Both Jaypee Rewa & Jaypee Bela Plants of Jaiprakash Associates Limited at Jaypee Nagar and Jaypeepuram respectively were awarded Five Star Rating & subsequently prestigious Sword of Honour by the British Safety Council, U.K. for Safety and Health Management System. The group produces Ordinary Portland Cement and Portland Pozzolona Cement under brand name Jaypee Cement. Rewa cement complex has three modern, computerized process control cement plants namely Jaypee Rewa Cement Plant (02 Nos. Kiln) & Jaypee Bela Cement Plant (01 No. Kiln) with an aggregate production capacity of 6.0 MTPA cement. JRP Unit-I and Unit-II is located in Huzur Tehsil, Rewa district of Madhya Pradesh state at an aerial distance of about 15 km North-West of Rewa Town. Geographically, it is located at latitude 24 0 33 47 North and longitude 81 0 11 41 East. JRP Unit-I and Unit-II have come into operation in the year 1986 and year 1992 respectively. The production capacity of both the units was enhanced in the
year 2005. The cement production process is based on dry process. Present production capacity of Jaypee Rewa plant is 3.50 million tonne Cement per Annum.
FORM V (See rule 14) ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE 31 st MARCH 2015 PART A (I) Name & Address of the Owner / Occupier of the Industry Operation or Process Jaypee Rewa Plant (Unit of Jaiprakash Associates Limited) Jaypee Nagar - 486 450 REWA (M.P.) (II) Industry Category Primary ( STC CODE ) Secondary ( SIC CODE ) Red Category and Large industry (Primary STC Category) (III) Production Capacity Unit-I Unit-II 1.5 Million TPA Cement 2.0 Million TPA Cement (IV) Year of Establishment Unit-I Unit-II Year 1986 Year 1992 (V) Date of last Environmental Statement Submitted 15 th September, 2014
PART B Water & Raw Material Consumption A. Water Consumption - m3/d (i) Process - 2433 Cooling - 683 Domestic - 1768 Name of the Product Process (Spraying) Water Consumption per unit of Product Output (m 3 /MT) During the Previous During the Current Financial Year (2013-14) Financial Year (2014-2015) Cement 0.344 (Only Process) 0.354 (Only Process) 0.453 (Total Water Cooling & Spraying) (ii). Raw Material Consumption Name of the Raw Material Name of Product Consumption of Raw Material per Unit Product Output (MT/MT of Cement) During the Previous During the Current Financial Year (2013-14) Financial Year (2014-2015) Limestone 1.505 1.548 Laterite 0.022 0.031 Iron-ore Cement 0.013 0.011 Coal 0.121 0.124 Gypsum 0.025 0.024 Pozzolona 0.172 0.169 Pet coke 0.006 0.010
Total Cement Production (MT) During Previous During Current Name of Product Financial Year (13-14) MT Financial Year (14-15) MT Cement 2309320 2259886
PART - C Pollutant Discharged To Environment / Unit of Output (Parameters as specified in the consent issued) S. No. Pollutants Quantity of Pollutants Discharged (Mass / day) (tonne/day) Concentrations of Pollutants in discharged (Mass / Volume) (mg/nm3) Percentage of variation from prescribed standard with reasons (a) Water (i) Domestic Zero discharge is maintained. Treated domestic water is being used in Horticulture and Plant process (ii) Industrial Zero discharge (b) Air Monitoring of Ambient Air Quality parameter within limit and report attached as Annexure- I Stack emission (a) Bag Filters Crusher Bag Filter 0.0120 33.8 (b) ESPs Raw mill / Kiln U-I ESP 0.7246 73.8 Raw mill / Kiln U-II ESP 0.7340 73.5 Cooler U-I ESP 0.2515 63.9 Cooler U-II ESP 0.4078 66.3 Coal Mill U-II ESP 0.1183 58.8 Cement Mill-I Bag House Cement Mill-II Bag House Cement Mill-IV Bag House 0.0249 30.7 0.0265 31.2 0.0247 31.7 Within the standard permissible limit PART D (As specified under [Hazardous Waste (Management, Handling & Transboundary Movement) Rules 2008)] Total Quantity (Kg) Hazardous Waste During the Previous Financial Year (2013-2014) During the Current Financial Year (2014-2015) Used oil Waste oil Used oil Waste oil (a) From Process 24948 10500 45432 Nil (b) From Pollution Control Facilities. Nil Nil
PART E Solid Waste Solid Wastes Total Quantity During the Previous During the Current Financial Year (2013-2014) Financial Year (2014-2015) (a) From Process No solid waste is generated from the cement manufacturing process. No solid waste is generated from the cement manufacturing process. (b) From Pollution All the collected material is All the collected material is Control facilities recycled in the process. recycled in the process. (c) (i) Qty. recycled or reutilised within the unit. All the collected swept Solid waste is reused in the process. All the collected swept Solid waste is reused in the process. (ii) Sold (iii) Disposed Nil Nil Nil Nil PART F PLEASE SPECIFY THE CHARACTERISATIONS (IN TERMS OF COMPOSITION AND QUANTUM) OF HAZARDOUS AS WELL AS SOLID WASTES AND INDICATE DISPOSAL PRACTICE ADOPTED FOR BOTH THESE CATEGORIES OF WASTES. Hazardous waste : All the used oil, waste oil, burnt grease generated from the different sections of plant is being collected in empty drums and barrels and then sent to store deptt for proper handling and storage. Collected hazardous waste at specified location as per Hazardous Waste (Management, Handling & Transboundary Movement) Rule, 2008 from where the stored hazardous waste is being sold out to authorized recyclers.
Characteristic: 1. Used oil SN Parameter Result Unit Maximum Permissble Limit as per HWMH&TM Rules 2008 schedules- V Part A 1 Arsenic < 1 PPM 5 2 Cadmium+Chromium+Nickel < 1 PPM 500 3 Lead < 1 PPM 100 4 Poly Chlorinated Biphenyls(PCBs) BDL PPM <2 5 Polyaromatic Hydrocarbons ( PAH) N.D. % 6 Solid waste: The solid waste is generated in the form of MS scrap which is sent to Hi-Tech casting centre for recycling. Used refractory bricks are collected by Refractory bricks manufacturer for reuse, used tyres, rejected rubber belts, filter bags, are generated during cement manufacturing process & these solid wastes are being sold to authorized parties. PART G IMPACT OF THE POLLUTION ABATEMENT MEASURES TAKEN ON CONSERVATION OF NATURAL RESOURCES AND ON THE COST OF PRODUCTION. Following measures have been adopted for abatement of pollution, conservation of natural resources:- 1. Conservation of Limestone a) Utilization of Shale Limestone is being used for manufacturing of cement by proper blending of different grade of limestone for preparation of proper raw mix to produce a good quality of clinker & cement. The raw mix design is being prepared in such a way that it reduces the limestone stone saturation factor by which substantial quality of limestone has been conserved. Almost 7.2 % Shale has been used in place of Lime Stone for the clinker manufacturing. b) Utilization of Fly Ash for the manufacturing of cement We have used fly ash up to 28.18% (382142 MT) of total Portland Pozzolonic Cement manufactured, which directly reduced the extraction of limestone from L/S mines. Reduction in consumption of limestone in cement manufacturing process leads in reduction of fossil fuel consumption and ultimately reducing the generation of different pollutant like Suspended Particulate Matter, emission of SO 2 and NOx, fugitive emission from various stages of handling
of limestone (From drilling to grinding stages) & during loading & unloading of coal, laterite & gypsum. Substantial quantity of electrical and thermal energy has also been saved. We have 2 nos. of Captive Power Plant (CPP) having capacity of 25 MW and 38.5 MW which generate approx 485 MT of flyash per day. The flyash generated is being stored in closed steel silos from where it is pneumatically conveyed to the cement mills for manufacturing of PPC cement. Additionally, we are also consuming approx 1000 MT flyash for PPC cement manufacturing which is being sourced from the different thermal power plants and being transported in closed tankers and directly fed into the cement grinding through pneumatic feeding system. The percentage of fly ash consumption during last five years is depicted as under. 2. Conservation of Mineral Gypsum a) Utilization of Chemical Gypsum We have used fertilizer industry byproduct which is waste in nature and its chemical properties are as good as gypsum. This Chemical gypsum is used for cement manufacturing process; almost 25092 MT of chemical gypsum (45.71 % of total gypsum i.e 54899 MT) has been consumed in place of mineral gypsum for cement manufacturing process during the 2014 2015. 3. Conservation of Fossil Fuel a) Utilization of Pet Coke The Pet Coke which is petroleum refinery industry by- product is a waste in nature and having very high calorific value. This refinery by- product is used as alternate fuel in cement kiln, almost 8.38 % (23519 MT) of total fuel consumption during the 2014-2015 was in the form of pet coke.
Thermal energy Consumption The raw mix quality and process parameters have been maintained. 4. Water Conservation We have 6.0 km garland canal for rain water harvesting from colony and plant premises. This harvested rain water is stored in our own abandoned mines reservoirs. We have four mines reservoirs.the total rain water is collected and stored in these reservoirs and from these reservoirs, the stored water is used for cement manufacturing process and cooling purpose. The capacity and quantity of water collected in reservoirs as on March 2015 is as under, Reservoir Total Area (ha) Total capacity (Lac m 3 ) Present Status (Lac m 3 ) I 18.5 12.78 9.96 II 3.0 1.8 1.08 III 12.187 11.7 9.88 IV 8.0 6.0 3.60 A Glimpse of Reservoir I, Favorable destination for migratory birds. 5. Water spraying system at Limestone Crusher A dedicated, water pipe line, desired head pump and required nozzles have been placed for water spraying during unloading of limestone in dump hopper. The water spraying at limestone dump hopper has substantially reduced the fugitive emission during unloading of limestone at hopper.
6. Good House keeping practices Following measures have been taken for good housekeeping at Jaypee Rewa Plant:- a. Laterite is stored in covered sheds. b. Raw Coal is stored in covered shed c. Clinker and cement is being stored in the covered shed and silos. d. Regular road sweeping is being carried out. e. Incorporation of DCL system for extraction of Clinker and Cement bulk loading f. Unloading of Fly ash at covered mechanized unloading tippler and storage in MS bin g. Auto workshop and CPPs treated water is being utilized for the regular road water spraying & wetting of raw material. h. Internal road concreting 7. Scheduled maintenance and monitoring of Pollution Control Devices. Maintenance of all Pollution Control Devices are being done as per prescribed schedule by dedicated environmental management team which comprises of mechanical, electrical and environment engineers and monitoring of all these are done regularly as per PCB Norms. We are also certified with ISO-14001 and maintaining all the clauses mentioned therein. PART H ADDITONAL MEASURES / INVESTMENT PROPOSALS FOR ENVIRONMENTAL PROTECTION INCLUDING ABATEMENT POLLUTION, PREVENTION OF POLLUTION. Additional measures taken for Environmental Protection are as under 1. Polythene waste incineration in Kiln Polythene waste becomes a big problem before the humanity as well as for our environment. Jaypee Group is committed for initiating the green activities. For this a system has been developed for collection and segregation of polythene waste of Jaypee Rewa Plant, colony & surrounding area. All the polythene waste in segregated form is being transported to our site for incineration in cement kiln. The required infrastructure / modification have been installed to carry out the incineration of waste. We have incinerated around 297.18 Tonnes polythene waste in our kiln till March, 2015. 2. Extensive plantation in and around the Plant. We have a dedicated team of skilled horticulturists for the afforestation and greenery development program at our plant and mines under the supervision of senior experienced person. Addition to the horticulture deptt. Environment Cell also does the plantation activity. The plantation details are given below Steps taken to protect plantation: 1. Barricading provided for protection of plants. 2. Two numbers of dedicated water tankers having capacity of 1800 liter are provided for regular watering of plant. 3. Dedicated manpower is provided for regular watering the plants. 4. Tree Guard is provided for protection of the plants.
PLANTATION DETAILS S. No. Name of Plant Total Area (Ha.) Plantation (Nos.) 1 Jaypee Rewa Plant 89.752 63530 2 Naubasta Lime Stone Mine 470.941 246307 3 North North Naubasta Lime Stone Mine 183.937 61595 4 Bankuiyan Lime Stone Mine 541.005 19722 5 Jaypee Rewa Plant (Township) 95.82 159140 PART I ANY OTHER PARTICULARS FOR IMPROVING THE QUALITY OF THE ENVIRONMENT. Details of Improvement Management Program for Environment Protection are as under S.No. Department/ Plant 1 Environment 2 Environment 3 Environment 4 Environment 5 Environment 6 Environment Details of IMP Environmental Benefits Conversion of Coal Mill U-II Stack Emission reduction ESP to Hybrid Bag House Conversion of Raw Mill U-I Stack Emission reduction ESP to Hybrid System Conversion of Cooler ESP U-I Stack Emission reduction to Hybrid System Reduction of fugitive emission Reduction of Fugitive Emission from Clinker Stock Pile Conversion of Raw Mill U-II Stack Emission reduction ESP to Hybrid System Conversion of Cooler ESP U-II Stack Emission reduction to Hybrid System
CSR Works- JAYPEE GROUP has set up JAIPRAKASH SEWA SANSTHAN with the noble cause of service to the poor and downtrodden people of the society wherever the Company has its establishments. Jaiprakash Sewa Sansthan has launched Comprehensive Rural Development Programme (C.R.D.P.) for overall socio-economic development of the lots of inhabitants in 13 adopted villages initially in year 1996 around Cement Complex at Jaypeenagar, Rewa. These adopted villages have since been increased to 28. The main activities carried out in these villages are below: JACHCHA-BACHCHA MEDICALCAMPS- The main activities carried out in these villages are below: JACHCHA-BACHCHA MEDICAL CAMPS To provide basic health and medical care Services closer to home. Camps have been running for 17 years Free consultation & medication Complicated cases referred to hospital for follow up. YEAR NO. OF PATIENTS Up to March 2012 26095 April 2012- March13 2134 April 2013- March14 2055 April 2014-March 15 1775 PULSE POLIO CAMPS To eradicate the disease. Camps have been running for 19 years
200 camps 46,110 children immunized. In collaboration with national programs Camps run twice a year YEAR NO. OF PATIENTS Up to March 2012 44058 April 2012- March13 990 April 2013- March14 612 April 2014- March15 860 SCHOOL HEALTH CHEACK-UP CAMPS YEAR NO. OF PATIENTS Up to March 2012 7218 April 2012- March13 499 April 2013 -March14 2425 April 2014- March15 2467 To overcome malnutrition, contagious diseases and to identify congenital diseases. The health checks have been running for 13 years. A total of 102 Health Checks have been conducted We ve checked 12,609 children. The checks and any follow ups or medicines are free. All children are given deworming medicine. In Feb 2014 dental checkup was done for 2793 students. COMMUNITY HEALTH AWARENESS CAMPS
YEAR NO. OF PATIENTS Up to March 2012 8737 April 2012- March13 5175 April 2013 - March14 8905 April 2014- March15 5407 Educate on common diseases, their prevention and immediate first-aid measure. These camps have been running for 14 years A total 292 camps held 28,224 people have attended these camps We couple these camps with Parent-Teacher meetings at Balwadi centers held monthly. LAPROSCOPIC CAMP YEAR NO. OF CAMP Up to March 2012 16 April 2012- March13 1 April 2013 -March14 3 April 2014 -March15 19 Population control. Camps have been running for 11 years 21 camps 65 men sterilized 729 women ligated Team of doctors and paramedical staff come from government hospital Surgeries conducted at the JSS hospital Patients paid by the government to undergo treatment
VITAMIN A IMMUNISATION YEAR NO. OF PATIENTS Up to March 2012 250 April 2012- March13 2158 April 2013- March14 2589 April 2014- March15 `464 This programme started in the year 2011-2012. Vitamin A angels, a California based NGO is regularly supplying us with Vitamin A capsules & Deworming medicines free of cost From 2011-2015 total number of children immunized are 6461. This programme runs every Friday in the Jaypee Hospital & twice a year in Balwadi playschools. VETERINARY CAMPS YEAR NO. OF ANIMALTREATMENT Up to March 2012 31021 April 2012- March13 4424 April 2013- March14 6013 April 2014- March15 1423 To educate on breeding methods, feeding and management of the animals. Increase milk production. The camps have been running for 15 years A total of 196 camps held A total of 41,458 animals treated 15 camps per year Free consultation
Free medication. VACCINATION OF ANIMALS YEAR NO. OF ANIMAL VACCINATED Up to March 2012 11892 April 2012- March13 8057 April 2013- March14 8460 April 2014- March15 3454 To prevent diseases in animals This programs has been running for 10 years A total of 30,596 animals have been vaccinated The program runs from April to March. Free medicines Free consultation HS, BQ, Anthrax, Intro-toxin. TEACHER S TRAINING PROGRAMME Teach effective teaching and communication methods. Educate them on personal hygiene and mannerism. The importance of maintaining a clean environment. This program is held twice a year once by an outside consultant and the second at the Jaypee College of Education.
ADULT EDUCATION To eradicate adult illiteracy. Current results of %age qualified. Stage I: 100 % qualified Stage II: 63 % qualified Stage III: 74 % qualified Currently 5 classes are running TAILORING CLASSES Women empowerment through self employment. This program has been running for 13 years 1037 women have qualified this program. 54.24 % qualification rate in 2011-2012. These classes run in the afternoons at the Balwadi centres. All tailoring teachers are graduates from M. Gopala Rao Industrial Training Centre, Jaypee nagar. This program is affiliated with USHA International, a renowned company in the sewing industry. 207 Sewing machines distributed. Agriculture awareness camp To educate the local farmers on effective agricultural methods to improve quality of produce. This program was introduced in the year 2011.
One camp 200 farmers attended 3 guest speakers Guest speakers are invited from Agriculture Colleges around the region DRINKING WATER HAND PUMP To provide safe drinking water to the residents. 283 hand pumps, 6 tube wells and 34 bore wells have been installed in total. Maintenance and repair has been stopped since July 2011 by the company. VILLAGE ROAD CONSTRUCTION To connect all adopted villages to the main arteries. Plain Cement Concrete (PCC) Water Bound Macadam (WBM) A total of 42.3 km completed at a cost of 18 lacs (21176.47 pounds). Concreting of road and beautification of the area in Rewa city at a cost of 62 lacs (72941.17 pounds)
SULABH COMPLEX CONSTRUCTION SULABH COMPLEX AT MADHEYPUR Build clean public restrooms and bathrooms. Sulabh complex built: Chijjwar Village (Police Chowki) 18 Toilets + 8 Bathrooms Chijjwar Village (Tri-junction) 18T+12B Sonra Village 15T+8B Total cost of Rs. 17.3 lacs (20353 pounds). Madheypur has 5 complexes consisting of 8 Toilets each. Kachoor Village has 1 complex of 8 Toilets. Total expenditure is Rs. 13 lacs (15294.11) BALWADI CONSTRUCTION RENOVATION OF VETERINARY HOSPITAL AT KACHOOR
TREE PLANTATION TEMPLE CONSTRUCTION AT KACHOOR Shiva Temple in Kachoor village is more than 300 years old(1600-1700 AD). It was constructed by the King of Rewa. It was a dilapidated & neglected structure as shown in the picture. In 1998 Jaypee Group spent Rs 15 Lakhs to reconstruct the old monument to its original architecture. Every year during Shivratri the local people assemble in great number to solemnize the festival of Lord Shiva with Parvati. RANI TALAB TEMPLE, REWA(M.P) DURING CONSTRUCTION
ON COMPLETION RANI TALAB TEMPLE, REWA(M.P) In the year 1691 King Bhav Singh made the temple of Goddess Kali(Destroyer of Demons) so that his offspring survives. His wife was Ajab Kunwar Rani Sahiba, daughter of Maharaja Raj Singh of Chittorgarh.She was a grand daughter of a famous king Maharana Pratap Singh of Chittorgarh who fought & won many battles in the History of India. Devotees come to pray for the welfare & well being of their children. This is a popular tourist spot. Jaypee Group has spent 169.91 lakhs for the beautification & development of the surrounding area of this temple. BABA BHAIRON NATH TEMPLE GURH DISTT. REWA (M.P) Baba Bhairon Nath Temple was constructed in 1000-1100 AD by Kalchuri Kaleen Dynasty. It is situated near Gurh,about 42 km from Rewa. The statue is horizontal where Baba Bhairon Nath is lying down. It is 8.50 meters long & 3.70 meters wide. There is a big festival celebrations here on Shivratri and Basant Panchami. For Jaypee Rewa Plant, (A Unit of Jaiprakash Associates Limited) Jaypee Nagar, REWA (M.P.)