Mangalam Cement Ltd. Name of the Project :- New Cement Plant Unit - III and 17.5 mw CPP-II Project Code :- Raj- 80-600 - 2008 Clearance Letter No. :-F NO. J - 11011 / 30/2006 - IA II (I), dtd 17/07/2007 Period of Compliance Report : -April-17 to Sept-17 SPECIFIC CONDITIONS Sr. No. Conditions Compliance Status i. The gaseous emissions from various units shall conform to the standards prescribed by the State Pollution Control Board. Bag filters and Electrostatic Precipitator of highest efficiency shall be installed and particulate emissions from the cement plant shall be less than 50 mg/nm 3 and for CPP the same will be less than 100 mg/nm 3. Particulate emissions from DG house will be rejected to 40 mg/nm 3 The gaseous emission form all units are within the norms as per prescribed by state pollution control board. Every six monthly data are being send to Regional office at Lucknow, Rajasthan pollution control board at Jaipur and Central Pollution control board, Delhi. 17.5 MW Captive Power Plants - II (M/s Mangalam Cement Ltd.) Particulates Stack Matter Details of Stack No. Concentration 1 Main Stack Captive Power Plant - II 36.45 2 Coal Transfer 13.80 3 Coal Bunker-II 18.32 4 Coal Crusher 19.89 5 Coal Vibrating 15.37 ii For the control of air emission from the captive power plant, a four chambered electro static precipitator with a stack height of 75 m shall be installed. The Raw mill and kiln and coal mill will have stacks of 112 m and 110 m respectively. The clinker cooler and cement mill will have stacks of 55 m each. Stack No. Mangalam Cement Grinding Unit (UNIT-III) Particulates Matter Concentration Details of Stack 1 Cement Mill Stack 15.65 The stack height are as under: Cement Mill stack 45.00 Mtrs. Power Plant stack 77.00 Mtrs Stack No. 17.5 MW Captive Power Plants - II (M/s Mangalam Cement Ltd.) Details of Stack Particulates Matter Concentration 1 Main Stack Captive Power Plant - II 36.45 2 Coal Transfer 13.80 3 Coal Bunker-II 18.32 4 Coal Crusher 19.89 5 Coal Vibrating 15.37
iii Continuous on-line monitors for particulate emissions, So2 and NOx in Raw/kiln mill, clinker cooler, coal mill, cement mill etc. shall be provided and shall make necessary arrangement for submission of online real time emission data CPCB website. Interlocking facility shall be provided between pollution control equipment and the process operation so that in the event of the pollution control equipment not working the respective unit (s) is shutdown automatically. iv Low Nox burners shall be installed to control Nox emissions. v Regular Ambient air quality monitoring shall be carried out. The monitoring stations will be set up in consultation with the state pollution control board. It will be ensured that at least one monitoring station is set up in up wind & sown wind direction along with those inother directions. Online data for air emissions shall be transferred to the CPCB and RPCB regularly. The instruments used for ambient air quality monitoringshall be calibrated regularly. Stack No. Mangalam Cement Grinding Unit (UNIT-III) Particulates Matter Concentration Details of Stack 1 Cement Mill Stack 15.65 We have provided all monitoring system to monitor dust and gaseous emissions. We will install low Nox burners to control emissions. Ambient air quality-monitoring stations are provided at the periphery of our existing premises for the monitoring of ambient air quality. The locations of these stations were decided in consultation with R.O.Kota. Sr No 17.5MW Power Plant-II M/S Mangalam Cement Ltd. Ambient Air Quality Monitoring Results Location Parameter s Norms (µg/m3) Near Railway Gate Near Securit y Gate Near Rack Loading Area Near Work Shop 1 PM10 100 65.93 73.60 64.51 69.56 2 PM2.5 60 33.91 37.02 33.97 34.46 3 So 2 80 08.01 09.06 08.37 08.57 4 NOx 80 17.94 18.90 21.94 19.93 5 CO 4000 490 480 550 530 Stack No. Mangalam Cement Grinding Unit (UNIT-III) Particulates Matter Concentration Details of Stack 1 Cement Mill Stack 15.65
vi vii viii ix Raw material will be stored in covered yards and clinker shall be stored in silos or in adame with all round high sidewalls to control fugitive emissions fugitive emissions from cement mill packing area and coal yard shall also be controlled. Dust collectors and extraction system (suction apparatus) shall be installed to control fugitive dust emissions at coal and lime stone unloading points, at all the transfer point s stockpiles to arrest free release of dust. Materials will be transported in tippers, covered trucks, covered containers, covered rail wagons etc. Windbreakers will be installed to restrict fugitive dust x Water sprinkling arrangement should be made in the raw material stack yard and dust collectors in cement bag loading areas. xi Total water requirement shall be met form mine sump and shall not exceed 1310m3/d. 40 KLD will be sourcedfrom the groundwater and 36kld from other sources, permission from the ground water board will be submitted as soon as received. xii Minimum cycle of concentration (COC) for the CPP will be 5.0 xiii The wastewater form CPP and domestic activities shall be treated in effluent treatment plant (ETP) and sewage water reclamation plant (SWRP) respectively and recycled /reused in cement plant for make up in CPP for cooling dust suppression other plant related activities and green belt development no wastewater will be released outside the premises. Zero discharge shall be strictly adopted. During monsoon the wastewater will be stored in the mine pit. All raw materials are stored in covered yard. Fly ash is coming from Kota and other place in the closed containers. Water spray system is available to control vehicular emissions. Cement Grinding Unit III & 17.5MW Power Plant-II Results of Fugitive Emission S.No. Location SPM (500 µg/m³) 1 Near Coal Storage (CPP-I & II) 466.39 2 Near Packing Plant 394.54 3 Near Cement Mill-III 388.87 Dust collectors and extraction system (suction apparatus) have been installed. All incoming raw materials coming from deferent places in the closed containers. We shall complied with the conditions. We have installed water spray system in all raw material hoppers & dust collectors in cement bag loading areas. Total water requirement being met form mine sump only. We are maintaining COC less than 5.0. Industrial waste water is being recycled and zero discharge is being maintained. STP treated water is being used for plantation.
xiv The entire domestic effluent generated from the colony will be reused after treatment in the cement plant for cooling / plantation/ gardening purpose. The treated water and sludge will also be used for green belt development. xv Solid waste generated shall be 100 % recycled and reutilized in the process itself and no solid waste shall be disposed off outside the plant premises. 150 TPD fly ash from captive power plant will be used in the cement manufacturing process along with bottom ash the sludge generated from the sewage treatment plant will be 10 TPM. Which will be used as manure waste oil sludge shall be reused in the plant and finally burnt in the kiln or sold to authorizedrecyclers / re processors. xvi The company shall strictly follow all the recommendations mentioned in the charter on corporate responsibility for environmental protection (CREP). xvii As agreed green belt shall be developed in 12 ha area in consultation with DFO and it will be as per CPCB guidelines. xviii The company shall harvest surface as well as rainwater from the rooftops of the buildings proposed in the expansion project 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. Industrial waste water is being recycled and zero discharge is being maintained. STP treated water and sludge is being used for plantation. All solid waste quantity is being used in the plant 1. Fly ash / bottom ash from CPP for PPC cement. 2. STP sludge as manure 3. Burnt oil sludge being sold to authorized recycler / re processors. These will be complied as per recommendations mentioned in the charter on corporate responsibility for environmental protection (CREP). We are developing 33 % green belt area in & around of our cement plant, as per the CPCB guidelines. Sr. No. Cement Grinding Unit-III M/S Mangalam Cement Ltd. Year Wise Tree Plantation Year Plant Names Numbers 1 13-14 Neem, Karanj, 14545 2 14-15 Sheesam, Sirus, 1050 3 15-16 Bad, Peepal, 998 4 16-17 Palash, Khejri, 1378 5 Upto Sept-17 Chareel, Mango, Jamphaletc 566 To recharge ground water, rain harvesting system is being implemented.
xix The company will have a occupational health and safety programme and regular medical checkups shall be undertaken for the employees and workers. Company is taking utmost care for community development& welfare progress. GENERAL CONDITIONS i The project authority shall adhere to the stipulations made by State Pollution Control Board (SPCB) and State Government. ii No further expansion or modification of the plant shall be carried out without prior approval of this Ministry. Weshall adhere to the stipulations made by State Pollution Control Board (SPCB) and State Government. Expansion or modification of the plant we shall take prior approval of the Ministry. iii iv v vi Adequate number of influent and effluent quality monitoring stations shall be set up in consultation with CPCB regular monitoring shall be carried out for relevant parameters. The project proponent shall also comply with all the environmental protection measures and safeguards recommended in the EIA/ EMP report. Industrial wastewater shall be properly collected and treated so as to conform to the standards prescribed under GSR 422 (E) dated 19 th May 1993 31 st December 1993 and as mended from time to time. The treated wastewater shall be utilized for plantation purpose. The overall noise levels in and around the plant area shall be limited within the prescribed standards (85 dba) by providing noise control measures including acoustic hoods silencers enclosures etc. on all sources of noise generation. Adequate numbers of quality monitoring stations shall be set up in consultation with CPCB for regular monitoring shall be carried out of relevant parameters. We are comply with all the environmental protection measures and safeguards recommended in the EIA/ EMP report. Industrial waste water are being collected and treat as per GSR 422 (E) dtd. 19th May 1993 guidelines and used for plantation purpose after treatment. Noise is being checked on regularly basis as per standard& limited within the prescribed standards. Annexure-V Cement Grinding Unit-III (M/S Mangalam Cement Ltd.) Results of Noise Sr. Ambient Air Noise Results (db) No Location Day. Night 1 Near Security Gate 65.30 59.10 2 Near Railway Gate 3 Near Rack Loading Area 4 Near Work Shop 68.00 61.85 70.00 62.45 70.65 61.75
vii Proper housekeeping and adequate occupational health programmes shall be taken up. Regular occupational health surveillance programme shall be carried and records shall be maintained properly for at least 30-40 years. The programme shall include lung function and sputum tests once in six months. Sufficient preventive measures shall be adopted to avoid direct exposure to dust etc. viii A separate environment management cell with full fledge laboratory facilities to carry out various management and monitoring functions shall be set up under the control of senior executive. ix Adequate funds shall be earmarked to meet the capital cost and recurring cost / annum for the environmental protection measures shall be used judiciously to implement the conditions stipulated by the ministry of environment and forests as well as the state government. The funds as provided shall not be diverted for any other purpose. Good house keepings maintained & Regular occupational health surveillance programme shall be carried and records shall be maintained as per guidelines. We have well equipped Environmental lab. Withwell-educated staff. This Environmental Lab. headed by VP (P&QA) Earmark capital for environmental projects will be used exclusively for its implementations as maintained in EIA / EMP Reports. Mangalam Cement Ltd Environmental expenditure incurred during the period from April-17 to Sept-17for environment protection measures. S. No. Department Total Cost (In Rs.) 1. Total Expenditures (Rs.) 48,42,608.685 x The concerned Regional office of this ministry / state pollution control board / central pollution control board shall monitor the implementation of the stipulated conditions. Six monthly compliance status report and monitoring data along with statistical interpretation shall be submitted to them regularly and will be placed on the web site of the company. Compliance report being sent to the all authorities regularly.
xi xii The Project Proponent should advertise in at least two local newspapers widely circulated in the region around the project one of which shall be in the vernacular language of the locality concerned informing that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the Rajasthan State Pollution Control Board / Committee and may also be seen at Website of the Ministry of Environment and Forests at http:/envfor.nic.in. The advertisement should be made within seven days from the date of issue of the clearance letter and a copy of the same should be forwarded to the Regional office at Bhopal. The project authorities shall inform the 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 start of land development work. We had advertised information of Environmental clearance letter in two local newspapers in local language of the locality concerned and same copy sent to the Rajasthan Pollution Control Board, Jaipur and the Regional office at Lucknow. We will inform the regional office as well as to the ministry the date of financial closure and final approval of the project.
EXISTING PLANT CAPTIVE POWER PLANT CCR BUILDING PACKING PLANT AREA
RAIN WATER STORAGE AT MINES GARDEN CPP PLANT VIEW NEAR PLANT VIEW COLONY VIEW CENTRAL GARDEN VIEW
PLANTATION IN MANDIR AREA RAIN WATER HARVESTING PLANTATION IN MINES AREA PLANTATION NEAR CRUSHER PLANTATION NEAR CRUSHER WATER SPRINKLING ON ROAD
Crusher MATERIAL TRANSFER BELT COAL TRANSFER BELT COVER RACK LOADING AREA CLINKER TRANSFER BELT GYPSUM YARD RAW MATERIAL TRANSFER BELT
Annexure-I 17.5 MW Captive Power Plants - II (M/s Mangalam Cement Ltd.-Unit-III) Stack No. Details of Stack Stack Attached with Height (Mtrs.) Dia (Mtrs.) Particulates Matter Concentration (mg/nm 3 ) April-17 to June-17 July-17 to Sept-17 1 Main Stack Power plant - II ESP 77.0 2.5 32.91 40.00 36.45 2 Coal Transfer Bag House 30.0 0.5 12.80 14.80 13.80 3 Coal Bunker - II Bag House 30.0 0.6 20.95 15.70 18.32 4 Coal Crusher Bag House 30.0 0.85 24.78 15.00 19.89 5 Coal Vibrating Bag House 30.0 1.00 16.95 13.80 15.37
Mangalam Cement Ltd. (UNIT-III) Annexure-II Ambient Air Quality Monitoring Results Sr No Location Parameters Near Railway Gate Near Security Gate Near Rack Loading Area Near Work Shop April-17 to June-17 July-17 to Sept-17 April-17 to June-17 July-17 to Sept-17 April-17 to June-17 July-17 to Sept-17 April-17 to June-17 July-17 to Sept-17 1 PM10 (µg/m3) 76.66 55.20 65.93 86.00 61.20 73.60 75.92 53.10 64.51 77.83 59.30 69.56 2 PM2.5 (µg/m3) 33.93 33.90 33.91 37.65 36.40 37.02 35.85 32.10 33.97 33.82 35.10 34.46 3 So 2 (µg/m3) 06.63 09.40 08.01 08.33 09.80 09.06 07.68 11.20 08.37 06.94 10.20 08.57 4 NOx (µg/m3) 13.78 22.10 17.94 16.51 21.30 18.90 17.68 26.20 21.94 15.67 24.20 19.93 5 CO (µg/m3) 300 680 490 290 670 480 340 760 550 340 720 530
Mangalam Cement Ltd. Annexure-III Cement Grinding unit III &17.5 MW Power Plant II Results of Fugitive Emission Sr. No. Location April-17 to June-17 SPM (µg/m 3 ) July-17 to Sept-17 1 Near Coal Storage (CPP-I & II) 469.78 463.00 466.39 2 Near Packing Plant 433.09 356.00 394.54 3 Near Cement Mill-III 459.75 318.00 388.87
Annexure-IV Mangalam Cement Grinding (Unit III) Stack No. Details of Stack Stack Attached with Height (Mtrs) Dia (Meter) Particulates Matter Concentration mg/nm 3 April-17 to June-17 July-17 to Sept-17 1 Cement Mill Stack Bag House 45.00 0.66 13.91 17.40 15.65
Annexure-V Cement Grinding unit III (M/S Mangalam Cement Ltd.) Results of Noise Ambient Air Noise Results (Db)A Sr. No. Location April-17 to June-17 July-17 to Sept-17 Day Night Day Night Day Night 1 Near Security Gate 65.20 57.40 65.40 60.80 65.30 59.10 2 Near Railway gate 68.80 60.30 67.20 63.40 68.00 61.85 3 Near Rack loading area 71.30 64.30 68.70 60.60 70.00 62.45 4 Near Work Shop 70.50 62.60 70.80 60.90 70.65 61.75
Eakxye~ lhesavfyfevsmesafujarjmrltzudhfuxjkuhgsrq 11 midj.kksadksrspcbvksjcpcblstksmj[kk A Annexure-VI
Cement Grinding unit III M/s Mangalam Cement Ltd. Annexure-VII Year Wise Tree Plantation Sr. No. Year Plant Names Numbers Survival Rate Location Total Plant Area Area (hector) Total 33 % Plantation area to be developed 1 2 3 13-14 14-15 15-16 Neem, Sheesham, Kuchanar, Kurunu, Kaner, Bounganvilla, Gulmohar, Siras, Churrel, Casswiasumea, Komta, Rose, Amrood, Papya, Amla,Belpetra, Shegtoot. 14545 1050 998 70% 70% 70% Plant & Colony Plant & Colony Plant & Colony 37 12.2 37 12.2 37 12.2 4 16-17 1378 70% Plant & Colony 37 12.2 5 Upto 2017 566 70% Plant & Colony 37 12.2
Annexure-VIII MANGALAM CEMENT LIMITED (Unit-III) CSR Expenditure for the period from April-17 to Sept-17 S.No. Particulars of CSR Activities AMOUNT 1. Morak Gram Panchayat 295600 2. HiriayaKhedi Gram Panchayat 80000 3. Budhkan Gram Panchayat 200000 4. Chechat Gram Panchayat 100000 5. Vocational Skill Development program (Tailoring Classes) 139000 6. Vocational Skill Development Program (Driving ) 238500 Total Amount Rs. 1053100/-
Annexure-IX
Annexure-X Cement Grinding Unit-III (M/s Mangalam Cement Ltd.) Details of Water Harvesting:- Sr. No. Location Roof Area 1. Engineering Building 725 m 2 2. Load Center Building 1458 m 2 3. Store Building 1620 m 2 4. Captive Power Plant I 1200 m 2
Annexure-XI Mangalam Cement Ltd Environmental expenditure incurred during the period from April-17 to Sept-17 for environment protection measures. (Unit III & CPP II) S. No. Department Total Cost (In Rs.) 1. Total Expenditures 48,42,608.685