ACC Limited CHAIBASA CEMENT WORKS ENVIRONMENTAL STATEMENT (FINANCIAL YEAR ENDING MARCH 31st, 2016) PREPARED BY ACC Limited CHAIBASA CEMENT WORKS P.O. JHINKAPNI -833 215 DIST. WEST SINGHBHUM, JHARKHAND SEPTEMBER, 2016 1 of 18
INDEX PART PARTICULARS PAGE INTRODUCTION 03 A GENERAL STATEMENT 07 B CONSUMPTION STATEMENT 08 C POLLUTION GENERATED 11 D HAZARDOUS WASTE STATEMENT 13 E SOLID WASTE STATEMENT 14 F CHARACTERISATION STATEMENT 15 G IMPACT STATEMENT 16 H ADDITIONAL INVESTMENT STATEMENT 17 I MISCELLANEOUS 18 2 of 18
INTRODUCTION ACC (ACC Limited) is India's foremost manufacturer of cement and concrete. ACC's operations are spread throughout the country with 16 modern cement factories, 19 Ready mix concrete plants, 19 sales offices, and several zonal offices. ACC is among the first companies in India to include commitment towards environmental protection as one of its corporate objectives, long before pollution control norms and regulatory act came into existence. ACC is committed to provide a safe and healthy working atmosphere and maintaining harmony with its surrounding environment. Apart from corporate division of Environment, each manufacturing unit has a fully functional Environmental Management Cell having experienced environmental engineer and horticulturist etc. This Environmental Statement has been prepared by the ACC Ltd. Chaibasa Cement Works. All data necessary for the preparation of environmental statement have been collected from the existing records available in the works. REGULATORY FRAMEWORK For maintaining better environment in and around industry Government of India has made it statutory to submit an Environmental Statement every year for the financial year ending 31 st March to the concerned State Pollution Control Board, with reference to the notification issued by the Ministry of Environment and Forest on March 13, 1992 (amended vide notification N0. G. S. R. 386 (E) dated 22.04.1993) under environmental (Protection) Rules 1986 that all those persons carrying an industry, operation or process requiring Consent to operate under section 25 of the Water ( Prevention and Control of Pollution ) Act, 1974, ( 6 of 1974) or under section 21 of the Air (Prevention and Control of Pollution) Act, 1981(14 of 1981), or authorization under the Hazardous Waste ( Management & Handling ) Rules, 1989, and amended rules 2000 issued under the Environment ( Protection ) Act, 1986 ( 29 of 1986). Environmental statement is a tool approved by the government to the industries for making environmental self-introspection and setting environmental goals. It provided an opportunity to select options for waste minimizations which in turn could even benefits the industry in economic terms. It is for the industry to use the tool effectively. 3 of 18
LOCATION The is located near Jhinkpani in Chaibasa Tehsil of West Singhbhum district in Jharkhand. The plant is about 180 km from Ranchi airport and 2.2 km from Jhinkpani railway station. The plant is about 20 km by road from Chaibasa. The plant falls in the survey of India toposheet No. 73F/15 and can be located Latitude (N 22 25 30 ) and Longitude (E 85 45 30 ). TOPOGRAPHY Area around CCW is fairly plain topography with no hill or valleys in the immediate vicinity. Area around CCW is drained by the Gumua Nala. CLIMATIC CONDITION The Climate at Jhinkpani () is Semi Arid. Winds are light to moderate in summer and winter season, whereas its speed increases towards the end of the summer and beginning of the monsoon. Meteorological parameter recorded at CCW is given in table no. 1. Table no. 1 Meteorological parameter during financial year 2015-2016 Month Temperature ( C) Relative humidity (%) Rainfall Min. Max. Min. Max. (mm) Apr. 15 18.9 43.9 66 92 235 May 15 22.2 46.7 56 89 78 Jun. 15 23.9 44.4 70 92 244 Jul. 15 21.1 37.8 70 92 480 Aug. 15 22.8 36.7 68 88 218 Sep. 15 21.7 38.3 70 88 99 Oct. 15 17.2 36.7 70 87 42 Nov. 15 13.9 32.8 66 90 0 Dec. 15 8.3 32.2 68 90 27 Jan. 16 7.8 32.2 66 88 12 Feb. 16 13.3 37.8 61 96 10 Mar. - 16 17.8 40.6 66 92 12 4 of 18
MANUFACTURING PROCESS Low and high-grade limestone raised in the mine is crushed in a crusher located at the mine. Primary crushing of calcareous shale is also done at the mine and secondary crushing is done in the hammer crusher in the plant. Limestone is transported from mine to plant by tube conveyer. Stacker reclaimer is used for stockpiling of limestone in the plant. High grade limestone, low-grade limestone, bauxite and iron ore is dry ground in Vertical Roller Mill (VRM). The calcareous shale is wet ground in ball mills and subject to floatation. Dry limestone along with corrective materials and slurry is ground in VRM and stored in a blending cum storage silo. Raw mill gases along with pre-heater gas are dedusted in Bag house, where dust concentration reduces to less than 50 mg/nm 3 in discharge gas. The homogenized raw meal is passed through 5 stage pre-heater and pre-calciner and has 90% calcination before entering the kiln. Coal is fired in pre-calciner and kiln. The material is move from one end of kiln to the other end coming in contact with hot gases of combustion completing the Clinkerisation process with clinker coming out from other end of kiln. The clinker is cooled in reciprocating grate cooler and transported by deep pan conveyor to clinker storage silo. The clinker from the silo is transported by belt conveyor to the clinker storage bins. Clinker is taken to cement mill, where it is ground along with slag and gypsum to produce Portland Slag Cement, while ground with fly ash and gypsum to produce Portland Pozzolana Cement. The Cement is then transported to cement storage silos. Dust Collectors have been installed to control particulate emission from the cement mill. There are 12 cement silos of 14000 tons total capacity. Cement is extracted from the silos by pneumatic gravity conveyors and packed in bags by four Roto Packer machines of 100 TPH capacity each. Cement is packed in 50-kg bags and is loaded in trucks/ wagons for dispatch. Each packing unit is provided with individual dust collectors. Coal/Pet coke required for plant is crushed in crusher. The crushed coal/petcoke is ground in VRM. Bag filter is used for de-dusting gases from the VRM. Captive power plant power generation is based on thermal power generation process. 21 MW captive power plant is consisting of two nos. of TG sets comprises of 15MW, 6MW with four nos. of coal based boilers having three nos. of AFBC type water tube boilers and one nos. of stoker fired water tube boilers. Crushed coal/petcoke is fed into boiler furnace for the steaming process and the rated steam quality is given to turbine for mechanical rotation of the generator. Burnt coal ash is collected in a silo and further it is utilized as a filling material in our mines pit. All boilers are equipped with Electrostatic Precipitators to control dust emission. Accumulated fly ash through ESP is utilized in manufacturing of PPC cement. Desired quality of water is a prime factor for the economical use of fuels and life of the thermal power plant equipments. Deminerlized water is generated by ion exchange process to give as a make up water to boiler for steam generation. 5 of 18
Hardness free water is also generated by sodium ion exchange process in order to maintain heat exchanger equipments performance optimum level. Effluent water generated during water treatment process is neutralized before disposal. Water conservation is done by reutilization of power house drain water in dust suppression, gardening and as process waster in the thickener of our cement plant. Heat exchangers are utilized for the condensation of turbine exhaust steam to make it recycled in boiler as a boiler feed water. 6 of 18
[FORM-V] Environmental Audit Report for the financial year ending the 31 st March 2016 General Statement PART-A 1. (a) Name of the industry : ACC Limited, (b) Address of the industry : ACC Limited, P.O.- Jhinkpani - 833 215, Dist.- Singhbhum West Jharkhand (c) Registered Office : Cement House, 121, Maharshi Karve Road, Mumbai 400 020 Name of the Managing Director : Mr. Harish Badami Name of the Chief Executive at : Dr. Arun Kumar Saxena Director Plant 2. Industry Category : Cement Manufacture N.I.C. CODE (1987) 324.1(Clinker Manufacture) 324.2 (Cement Manufacture all Grade) 3. Production Capacity : Clinker 1.20 MTPA Cement 1.20 MTPA Power - 21 MW 4. Year of Establishment : 1947 & Expansion and modernization in the year 2005 5. Date of Last Environmental Statement : 28.09.2015 7 of 18
Consumption Statement PART -B Water Consumption Water requirement of the factory and colony of CCW is met from the abandoned mines pits and natural drains. Water drawn from quarry pits and natural drains is treated at CCW water treatment plant employing sand filtration and chlorination before being sent to the plant and colony. At Chaibasa cement works, Water is used in Cement Manufacturing process for preparation of lime stone slurry, power generation, and for cooling of shells of grinding mills and compressor etc. Cooling water is recycled and pumped back to the system after making up for evaporation losses. Quantity of Water consumed in process, power house, cooling purpose and for domestic use during the financial year 2015-2016 is presented in Table no. - 2 Table no. 2 Water Consumption Water Used Water Consumption in KL KL Per ton of Cement 2015-2016 Process 556940 0.60 Domestic 735030 0.79 Cooling 609900 0.66 Total 1901870 2.06 Note: 1. per unit consumption has been calculated considering Cement as Product. 2. On line Flow meter has been provided in water supply line. 3. Source of water supply: Water requirement of CCW & colony are met from the water reservoir in abandoned quarry, Gumua nala and from working mines pits. Raw Material Consumption The major raw materials and fuels used for manufacturing of cement at CCW are Limestone, Iron ore, Coal, Gypsum, Slag, Fly ash, Bauxite & Petcoke. The amount of Clinker and Cement produced in the current and previous financial year is given in Table no.4. The quantity of Raw material used in the current and previous financial year with corresponding amounts used per unit production are given in Table no. 5. 8 of 18
Table no. 4 Production in Tonnes Name of the product Quantity produced for the financial year 2014-2015 2015-2016 Clinker 634561 727123 Cement 1. PSC 741969 735818 2. PPC 149188 187909 Total 891157 923727 Table no. 5 Raw material consumption Sr. No. Name of Raw materials Consumption of raw material During financial year Per Tonnes of Product* 2014-2015 2015-2016 2014-2015 2015-2016 1. Limestone 777212 1058593 1.22 1.45 2. Iron ore 634 0 0.001 0 3. Bauxite 0 17328 0.00 0.02 4. Laterite 43457 25129 0.07 0.03 5. Fuel Consumption (Pet Coke + Coal)** 143863 161858 0.23 0.18 6. Gypsum 20878 30347 0.02 0.03 7. Slag 264139 348334 0.29 0.38 8. Fly Ash 34724 43160 0.04 0.05 *Per unit consumption for raw materials No. 1 to 4 has been calculated considering clinker as product and for raw materials 5 to 8 cement produced is considered as product. ** - Fuel consumption in Kiln, Slag Dryer & Captive Power Plant 9 of 18
Pollution generated PART - C Water pollution statement Industrial Effluent : Avg. water consumption is around 158490 KL/Month. As stated earlier in this statement, CCW uses water for preparation of limestone slurry, power generation, cooling of various equipments such as grinding mill shells, bearings, compressor etc. and for domestic use. Cooling water is recycled back into the system after making up for evaporation losses. Water used for making limestone slurry gets evaporated in the kiln. Effluent generated from Power house is used as process water in thickener. Treatment : Neutralization pit and settling chambers have been provided for the recycling of water. Domestic Effluent : On an average of 1685 KL/day water is consumed for residential colony and office building for domestic activity during day period & then discharged for treatment. Treatment : Effluent generated from the domestic is treated in STP with a capacity of 600 meter cube per day within the colony premises. Effluent is sampled and analyzed regularly and utmost care is taken to ensure that its quality remains below the norms, prescribed by the PCB. Results are shown in Table no. 6. 10 of 18
Table no. 6 Effluent Quality during the financial year 2015-2016 Parameter Cement Plant Power Plant Domestic Min. Max. Avg. Min. Max. Avg. Min. Max. Avg. ph 7.0 7.2 7.1 6.5 8.2 7.3 6.8 7.9 7.2 Temp 0 C 24 30 27 25 32 29 20 27 24 T.D.S. (mg/l) 89 98 93 92 125 111 101 130 123 T.S.S. (mg/l) 68 95 78 70 95 82 18 25 21 Chloride as Cl (mg/l) 31 36 34 18 22 20 19 24 22 B.O.D. (mg/l) 6 12 8 4 9 6 5 10 7 C.O.D. (mg/l) 24 33 28 18 25 20 18 25 20 Air pollution statement Source of particulate matter : Source of particulate emission at the plants while manufacturing cement are (a) Crushing, (b) Raw materials storage, (c) Raw meal preparation, (d) Kiln (e) Cement mills (f) Packing Plant (g) Slag dryer & (h) Boilers. Fugitive emissions include dust generation at transfer points, wind blown dust from the storage piles, dust generated due to movement of vehicles on plant roads. Treatment : CCW has provided Reverse Air Bag House, ESPs, Bag filters and dust suppression systems as air pollution controlling device to control the particulate emissions from the process and for controlling fugitive emission from handling of materials. Fugitive emissions of finish product are control by adopting pneumatically conveying system instead of traditional conveying system. The fugitive emissions of particulate matter from road transporting activity in the plants are also controlled by water sprinkling system and by using vacuum road sweeping machines. CCW Regularly monitors and analyzes the point sources and ambient air quality in and around process activity. Result of which are shown in table no.7 & 8. 11 of 18
Table no. 7 Average SPM emission from point sources during the financial year 2015-2016 Sr. Source APCD SPM (mg/nm 3 ) No. 1. Kiln- VRM RABH 15 2. Cooler ESP 18 3. Coal VRM Bag filter 32 4. Cement Mill No. 1 Bag filter 43 5. Cement Mill No. 2 Bag filter 31 6. Cement Mill No. 5 Bag filter 26 7. Cement Mill No. 6 Bag filter 31 8. Cement Mill No. 7 Bag filter 41 9. Slag Dryer Bag filter 47 10. Boiler # 1 (6 MW) 11. Boiler # 2 (6 MW) Hybrid-ESP 38 12. 15 MW ESP 30 Table no. 8 Ambient Air Quality (SPM) during the financial year 2015-2016 Sr. Location No. Min. Max. Average 1. Guest House no. 2 35 56 45 2. Water treatment Plant 24 53 39 3. Guest House no. 1 40 55 32 4. Eastern Gate 24 41 36 12 of 18
PART - D Hazardous Waste as specified under Hazardous Waste (Management and Handling and Transboundary Movement) Rules, 2008 Hazardous waste generated at CCW includes small quantity of used oil from gear boxes, compressor and transformers etc. Used oil is generated during oil changes in such equipment. It is collected in drums and reused for lubrication of bearings and other mechanical parts. This reused oil is once again recollected in drums and sold to the venders who are authorized by the Central Pollution Control Boards. Hazardous waste generated in the current and previous financial year is given in Table no. 9. Table no. 9 Hazardous waste generation Sr. No. Hazardous waste category During financial year Total Quantity (liters) Per Ton of Product (Clinker) 2014 2015 2015-2016 2014 2015 2015-2016 1. Used Oil (5.1) 6720 4620 0.010 0.006 13 of 18
Solid wastes statement PART - E Table no. 10 Solid waste generation & disposal facility Type of Waste Source Disposal Facility Dust Dust Collectors, ESPs 100% Recycled back into the system. Garbage Colony, Canteen, Factory, office building Co-processed in kiln and landfilled. Flotation Rejects From Lime stone flotation tank Used for reclamation of worked out mines/ cement manufacturing. Cinder From Captive Power Plant Used for reclamation of worked out mines/ Bricks manufacturing. Fly Ash From Captive Power Plant Manufacturing of Portland Pozzolana Cement/ Bricks manufacturing/ Used for reclamation of worked out mines. Lead Batteries Vehicle, Plant Return to dealer/ Sold to the private parties duly authorized by Pollution Control Board. Quantity of solid waste generated during the financial year 2014 2015 and 2015 2016 is given in Table No. 11. Table no. 11 Solid waste generation at CCW Sr. No. Type of Solid waste Quantity produced in Tonnes for the financial year 2014-2015 2015-2016 Status of waste 1. Cinder/ bottom ash 1830 6430 Used for Mine reclamation 2. Fly ash 36865 43533 Used for PPC manufacturing/ Mine reclamation 3. Float Rejects 70642 84256 Used for Mine reclamation 14 of 18
PART - F Characterization statement of hazardous / solid waste Used Oil: Sr. No. Parameter Results 1 Polychlorinated biphenyls (PCBs) Below Detection Limit 2 Lead <0.5 PPM 3 Arsenic <0.10 PPM 4 Cadmium + Chromium + Nickel <1.0 ppm 5 Polyaromatic hydrocarbons (PAH) 0.17 % Solid Waste from Process Solid Waste from Pollution Control Facility : Dust Collected in Bag filters equivalent to the product quality. : Septic tank sludge collected during cleaning of septic tank is completely biodegradable in nature and it is being used as manure or disposed off as a land filling material. Solid Garbage : Dry garbage collected from canteen, colony is totally biodegradable in nature. Flotation Rejects and Cinder : Garbage collected from Offices and factory is totally combustible in nature, which mainly contains waste paper etc. Sr. No. Parameter Composition in % in sample of L/S Flotation Rejects Power House Cinder 1. SiO 2 48-52 55 60 2. Al 2 O 3 4.4-4.8 18 25 3. Fe 2 O 3 2.0-2.2 6 8 4. CaO 19.5-20.5 1 2 5. MgO 0.8 1.0 0.4-1.0 6. Alkali Traces Nil 7. Combustible matter Nil 10 13 15 of 18
PART - G Impact of pollution control measure on the conservation of natural resources and consequently on the cost of production. IMPACT STATEMENT: Water : In CCW water is required mostly in process of preparation of limestone slurry, power generation and for the cooling purpose. Occurrence of contamination in industrial process water is negligible; hence quality of water is not drastically changed with respect to inlet characterization. It has only thermal effect in terms of the rising water temperature, which subsequently reduced in cooling devices. Fresh water is only added in cooling tanks as a make up quantity against evaporated water quantity as per requirement. Used water is recycled back to the system continuously, which in terms reduces the fresh water consumption. Air : Cement manufacturing activity is basically air pollution prone activity but by providing better quality of pollution control equipment like Reverse Air Bag House, ESPs, Pulse jet dust collector etc., CCW has sustained the impact of cement manufacturing activity nicely. From the results of ambient air quality which is being monitored regularly in and around of the plants, clearly shows that the pollutant concentration is well within the limits prescribed by the Pollution control board. Noise : CCW has well controlled its industrial operation by lubrication,regular maintenance of machinery and by providing shielding between machinery in such way that there is very negligible generation of noise. Apart from this plantation shielding is helping in controlling the work environment noise, if any generated. Hazardous Waste Social Economic : Used oil is sold to the private venders, authorized by the Central Pollution Control Board. : The Awareness level towards environmental aspects has increased amongst the employees as well as local people through various social activities and program conducted by the CCW on regular basis. : Standard of living of the people has been increased due to the various activities of CCW. 16 of 18
PART - H Additional measure / investment proposal for environmental protection. Additional Investment Statement The management of M/s ACC is fully conscious about their responsibilities for environmental protection and pollution control abatement. These activities are always given top priority in the annual budget of. The following Budget was allocated for the financial year 2015-2016. Sl. No. Revenue ITEM 1 Environmental monitoring Expenditure in Lac INR Payment of fees for renewal of Consents to operate to State Pollution Control Board. 2.00 Payment of water cess to State Pollution Control Board. 1.20 Environmental monitoring 12.00 Sub-total 15.20 2 Environment Management System Renewal of Certification of IS 14001:2004 EMS by the BSI, Government of India 0.75 3 Awareness development Celebration of World Environment Day, Environment Week & awareness generation 0.40 4 Development of Green belt and Green cover New plantation, maintenance of old plantation and maintenance of gardens 57.85 5 Pollution Control O&M of bag filters & ESP 20.50 Water tanker for water sprinkling 24.00 Sub-total 44.50 6 CSR & Rural development Education,Health,Infrastructure and livelihood programmes 155.63 Grand Total 274.33 17 of 18
PART - I Any other particulars for improving quality of environment. Green Belt Development 5250 Sapling of various species like Teak, Kathsagwan, Casia, and Sheesham etc. has been planted inside and around the cement plant, mines & colony. 18 of 18