JAYPEE REWA PLANT (A Unit of Jaiprakash Associates Limited) JAYPEE NAGAR REWA (M.P.) 2012 2013 SUBMITTED TO M.P. POLLUTION CONTROL BOARD BHOPAL (M.P.)
Jaypee Rewa Plant (A unit of Jaiprakash Associates Limited) Introduction: Jaypee Group is the 3 rd largest cement producer in the country. The Groups cement facilities are located in various states viz. M.P., U.P., H.P., A.P., Gujarat etc. Oldest plants of the Group are in Satna Cluster (M.P.), which is the highest cement production capacity at a single location. 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. 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. Jaypee Rewa Cement Plant (JRP) is a division of Jaiprakash Associates Limited (JAL) groups of Companies with Head Office and Registered Office both 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. & a chain of five star hotels in major cities of India, which has been at the vanguard in generating wealth for the Nation. 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 3.5 million tonne Cement per Annum.
FORM V ( See rule 14 ) ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE 31 st MARCH 2013 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 24 th September, 2012
PART B Water & Raw Material Consumption A. Water Consumption m3/d (i) Process - 2316 Cooling - 619 Domestic - 1455 Process Water Consumption per unit of Name of the Product Output (m 3 /MT) Product During the Previous Financial Year (2011-12) During the Current Financial Year (2012-2013) Cement 0.288 0.323 (ii). Raw Material Consumption Consumption of Raw Material per Unit Name of the Raw Material Name of Product Product Output (MT/MT of Cement) During the Previous During the Current Financial Year (2011-12) Financial Year (2012-2013) Limestone Laterite Iron-ore Coal Gypsum Pozzolona Pet coke Cement 1.44 0.03 0.01 0.14 0.03 0.16 0.003 1.680 0.025 0.019 0.143 0.026 0.163 0.01 Total Cement Production (MT) Name of Product During Previous Financial Year (11-12) MT During Current Financial Year (12-13) MT Cement 2557000 2364379
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 SPM parameter within limit and report attached as Annexure- I Stack emission (a) Bag Filters Crusher Bag Filter 0.016 35.5 (b) ESPs Raw mill / Kiln U-I ESP 0.890 73.6 Raw mill / Kiln U-II ESP 0.992 76.6 Cooler U-I ESP 0.365 70.6 Cooler U-II ESP 0.482 69.8 Coal Mill U-II ESP 0.267 68.8 Cement Mill-I Bag House Cement Mill-II Bag House Cement Mill-III Bag House Cement Mill-IV Bag House 0.041 34.6 0.034 33.2 0.042 35.2 0.034 33.5 Within the standard permissible level PART D (As specified under [Hazardous Waste (Management, Handling & Transboundary Movement) Rules 2008)] Total Quantity (Kg) Hazardous Waste During the Previous Financial Year (2011-2012) During the Current Financial Year (2012-2013) Used oil Waste oil Used oil Waste oil (a) From Process 57078 6061 47628 16595
(b) From Pollution Control Facilities. Nil Nil PART E Solid Waste Solid Wastes Total Quantity During the Previous During the Current Financial Year (2011-2012) Financial Year (2012-2013) (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 Requirements as per CPCB schedules-5 1 Arsenic < 1 ppm 5 Max 2 Cadmium+Chromium+Nickel < 1 ppm 500 Max 3 Lead < 1 ppm 100 Max Poly Chlorinated Below Detection 4 BDL ---- Biphenyls(PCB) Limit 5 Polyaromatic Hydrocarbons ( PAH) N.D. % 6 Max Quantity in kg 47628 2. Waste Oil Requirements SN Parameter Result Unit as per CPCB schedules-5 1 Water Content 65.02 % v/w --- 2 Sediments 3.68 % by 5 max 3 Sulphur Content 3.41 4 Arsenic + Cadmium + Chromium+ Lead+ Nickel mass % by mass 5 PCB BDL --- --- 102 ppm 605 Max Below Detection Limit 6 PAH N.D % 6 Max 7 Total Halogens 780 ppm 4000 Max Quantity in kg 16595 Solid waste: The solid waste is generated in the form of MS scrap sent to Hi-Tech casting centre for recycling. Used refractory bricks were 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 7.31 % Shale (291680MT) waste quarried material 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 30.25% (387226 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 544 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 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 19413 MT of chemical gypsum (31.5 % of total gypsum i.e 61521 MT) has been consumed in place of mineral gypsum for cement manufacturing process during the 2012 2013. 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 7.78% (25698 MT) of total fuel consumption during the 2012-2013 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 reservoir, the stored water is used for cement manufacturing process and cooling purpose. The capacity and quantity of water collected in our fours reservoirs as on March 2013 is as under, Reservoir Total Area (ha) Total capacity (Lac m 3 ) Present Status (Lac m 3 ) I 18.5 12.78 11.05 II 3.0 1.8 1.23 III 12.187 11.7 10.61 IV 8.0 6.0 5.0 A Glimpse of Reservoir I, Favorable destination for migratory birds. 5. Water spraying system at Lime Stone 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 Toady 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 has been installed to carry out the incineration of waste. We have incinerated around 211.78 Tonnes polythene waste in our kiln till March, 2013. 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.
Particulars Last Financial Year (11-12) Current Financial Year(12-13) Township area 5550 6524 Plant area 13845 8362 Total 19395 14886 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 Details of IMP Establish a system for reduction of fugitive emission from clinker stock Pile Conversion of coal mill ESP U-II to hybrid system Conversion of Raw mill ESP U-II to hybrid system Conversion of cooler ESP U-II to hybrid system Installation of Online Ambient Air Quality Stations & Continuous Emission Monitoring System Environmental Benefits Reduction of Fugitive Emission Stack Emission reduction Stack Emission reduction Stack Emission reduction Continuous Air Quality Data Monitoring For Jaypee Rewa Plant, (A Unit of Jaiprakash Associates Limited) Jaypee Nagar, REWA (M.P.) (Alok Joshi) Jt. President (P & QC)
Annexure-I