DRAFT ENVIRONMENTAL IMPACT ASSESSMENT

REPORT

FOR ADDITION OF VSK OF CAPACITY 80TPD IN EXISTING CEMENT PLANT

At

Industrial Extension Area, Halti More, District - Kathua, Jammu & Kashmir.

APPLICANT M/s. R. Kay Grinding (Jammu)Pvt. Limited

Industrial Extension Area, Halti More, District - Kathua, Jammu & Kashmir.

Study Period: Winter Season (1st Nov 2015 to 31st January 2016)

ENVIRONMENT CONSULTANT Chandigarh Pollution Testing Laboratory-EIA Division

(NABET/EIA/1619/IA0012) E-126, Industrial Area, Phase-VII, SAS Nagar,

Mohali, Punjab-160073 Mail ID: cptleia@gmail.com, eia@cptl.co.in Contact No. 0172-4669295, 9988127295

EXECUTIVE SUMMARY

1.0 INTRODUCTION

India, the fourth largest economy in the world, has been maintaining a GDP

growth rate of around 8 % for more than a decade. Analysts have projected that

India has the potential to almost double her present rate of growth with labor and

capital productivity improvements. Industrial development plays an essential

supportive role in improving labor and capital productivity. Investment in

industrial sector is also an indicator of economic growth in all market economies.

Reform process in industrial sector has garnered unprecedented momentum. With

vast untapped opportunities, India could well be the desired location for the

industrial sector in the non-too-distant future. A parallel can be drawn from China,

which receives almost three times of the FDI inflows in India.

Cement is an essential component of infrastructure development and most

important input of construction industry, particularly in the government’s

infrastructure and housing programs, which are necessary for the country’s

socioeconomic growth and development. It is also the second most consumed

material on the planet. The Indian cement industry is the second largest producer

of cement in the world just behind China, but ahead of the United States and Japan.

It is consented to be a core sector accounting for approximately 1.3% of GDP and

employing over 0.14 million people. Also the industry is a significant contributor

to the revenue collected by both the central and state governments through excise

and sales taxes.

R. Kay Grinding (Jammu) Pvt. Ltd., a Private Limited Company incorporated as

per Companies Act, 1956 in the year 1993. Now they are proposing to install a

vertical shaft Kiln (VSK) of 80 TPD along with other auxiliary equipment as

additional machinery to manufacture good quality clinker. After the installation of

VSK along with other equipment, the installed capacity of the unit would be to

manufacture 26400 MT of clinker and 33000 MT of cement per annum based on

three shifts and 330 working days. As per EIA notification No S.O. 1533 dated

14.09.2006, it is a Cement manufacturing plants having capacity < 1.0 million

tons/ annum under activity 3(b) & falls in CATEGORY-B project and required

Environmental Clearance, from SEIAA, MOEF&CC, Jammu & Kashmir. One of

the conditions in the standard TORs is to conduct public hearing & result should be

incorporated in the EIA Report. Accordingly, this Draft EIA Report of the project

has been prepared for submission to J&K State Pollution Control Board for the

public hearing.

1.1 Methodology

The methodology adopted for carrying out the EIA study is based on the guidelines

and Standard TOR issued by the MoEF&CC. The EIA report is based on data

collected from primary and secondary sources that included;

• Collection of information on existing baseline conditions.

• Ambient air, water and soil quality and noise level monitoring

• Identification of environmentally sensitive locations (if any) in the impacted

area

• Assess the adverse impacts on the environment and to avoid the impacts,

suggest cost effective mitigation and management measures to mitigate the

negative impacts

• Preparation of Environmental Management Plan, which will include associated

costs for execution of mitigation and enhancement, works; development of an

environmental monitoring program

• Addressing the derived issues involving occupational health and safety, and

emergency/disaster management to limit/contain the adverse effects.

2.0 THE PROJECT

R. Kay Grinding (Jammu) Pvt. Ltd., Kathua, is proposing to install a vertical shaft

Kiln (VSK) of 80 TPD along with other auxiliary equipment as additional

machinery to manufacture good quality clinker. After the installation of VSK along

with other equipment, the installed capacity of the unit would be to manufacture

26400 MT of clinker and 33000 MT of cement per annum based on three shifts and

330 working days.

The plant is being set up on piece of land measuring about 7 Kanals, in a notified

and approved Industrial Extension Area, Hatli Morh, Kathua of Jammu and

Kashmir. The total capital investment to be incurred on the project would be

approximately Rs. 5.25 Crores. The industry would require around 600 KW of

power load for its clinker process operations from State electricity supply. During

the operation of the industrial unit, there would be employment generation for

around 50 persons within the industrial complex. The industry would employ local

manpower for the production process and no residential colony would be

developed within the industry.

2.1 Raw Material

Lime Stone – Limestone is the main raw material for the production of clinker. It

should have the following chemical composition/specifications (as per NCBM) for

its use in the cement industry.

Other raw materials - The other raw materials required by the unit are pet coke,

clay, iron dust and gypsum. The requirement of various components of raw

material per ton of clinker is computed after selecting modules for lime, silica

and aluminum. However the general composition factor would be more or less as

follows:

S.

No.

Raw Material Consumption per ton of cement

Requirements by the proposed unit (MT/day)

1. Limestone 1.224 98

2. Clay 0.255 20

3. Coal/pet coke 0.204 16.5

4. Iron ore/dust 0.017 1.5

TOTAL 1.700 136

2.2 Production

The production details of products with quantity are given below;

S. No. ITEM UNIT TOTAL

1. Cement Clinker MT/day 80

2. Cement (PPC/OPC), Existing MT/day 100

2.3 Manufacturing Process

R Kay Grinding Pvt. Ltd. would use the ‘dry method’ for the production of clinker and cement. The different process steps involved in the production of cement are discussed as under;

Limestone - The industrial unit would procure limestone from the adjoining limestone mines.

Crushing of Limestone - The crushing would be carried out in double stages by

using primary crusher and secondary crusher.

Prehomogenisation - The crushed limestone would be pre-blended with the help

of stacker and reclaimer systems.

Grinding of Raw Materials - Vertical Roller Mill and Tube Mill Grinding

machines would be used for production of pulverized raw meal.

Homogenisaton - The raw meal ground in the raw mill would be thoroughly

blended in vertically tall blending silos.

Pyroprocessing - The modern pyroprocessing system comprises of three important

sections namely preheating and precalcining, clinkerisation and cooling. Pre

calcining of raw meal would be carried out in separate vessel vertically held and

placed in between preheating and clinkerisation section. The clinkerisation reaction

would be carried out in a vertical shaft kiln and rotary kiln.

Clinker Formation - Conversion of raw meal into cement clinker would be

accomplished in steps in various zones of kiln circuit. The pulverized fuel would

be pushed into the burning zone of vertical shaft kiln. In the burning zone of the

kiln, part of raw mill would be transformed into liquid after achieving appropriate

melting temperature and powdery form of raw meal would be converted into

nodulized clinker form.The final clinkerisation of raw meal would be achieved

between the temperature range of 1250-1450oC.

Cement Grinding - The clinker along with appropriate quantity of gypsum and

other additive materials for production of finely pulverized cement with desired

fineness would be grinded in the ball mills and roller press.

Cement Storage, Packing & Dispatch - The pulverized different types of

cements would be stored in different silos installed with different capacities.

Depending upon the market requirements the cement would be loaded in bulk or

packed in 50 KG bags with the help of conventional rotary packages or electronic

packages, loaded onto trucks and finally dispatched to the required destinations.

3.0 BASELINE ENVIRONMENTAL SETTING

This section describes existing environmental status in an area encompassed within

10 km radius around site of the proposed plant.

The environmental monitoring for the EIA study was conducted for the winter

season. Initially, a reconnaissance survey of the study area was carried out and then

field monitoring for measuring meteorological parameters, ambient air quality,

water quality, soil quality and noise levels was carried out from 1st November,

2015 to 31st January 2016 and one month study in the month of November 1016. In

addition, certain aspects like land area, socio-economic status, past meteorological

conditions, etc., have been analyzed based on secondary information available

from sources like district census reports, district gazetteers, Indian meteorological

department, etc.

3.1 Meteorology

The project zone lies in the sub tropical region with four distinct seasons – Winter

(December to February), Summer (March to June), Monsoon (July to September),

Post Monsoon (October to November).

In the study area, annual minimum and maximum temperature range (of extreme

variation) is 0–48ºC. During the study period, the daily range of temperature

variation was 0-27ºC. The average annual rainfall in Kathua is about 1650 mm.

On annual basis, it can be noted that high humidity occurs in the month of

December, January, July, August and September and low humidity occurs in the

month of April and May.

Annual trend indicates mean wind speeds are highest in the months of March,

April, May, June and July (7.8-15.5 km/hour). During the study period, the

predominant wind direction from North East and South East directions.

3.2 Air environment

To establish the existing baseline status of ambient air quality, 8 AAQM stations

were selected. Various pollutants monitored were (PM10 and 2.5), sulphur dioxide

(SO2) and oxides of nitrogen (NOx). The ambient air quality monitoring was

carried out twice a week for the winter season.

During the study period, PM10 concentrations have ranged from 32 to 78µg/m3.

Minimum PM10 concentration has been observed at Village Mehtabpur and highest

PM10 concentration has been observed at Kathua City. The higher value of PM10

at Kathua City is due to the proximity of National highway 1 and Industrial areas

nearby in that area. PM2.5 concentrations have ranged from 15 to 38µg/m3. The

highest value of PM2.5 has been observed at Kathua City and the minimum values

for PM2.5 has been found in Village Mehtabpur. SO2 concentrations at various

ambient air quality monitoring stations have ranged from 5.1 to 13.8µg/m3. NOx

levels in the ambient air at different ambient air quality monitoring locations

ranged from 10.2 to 28.0µg/m3.

3.3 Noise

The study area of 10 km radius, with reference to the site, has been covered for

noise environment. The three zones, viz., residential, highways and silent zones

have been considered for noise monitoring. NH 1A has been covered to assess the

noise due to traffic. Noise monitoring has been undertaken for 24 hours at each

location. The noise survey involved the determination of noise levels at 8

locations. Noise level was recorded at every hour for 10 minutes continuously for

24 hours at ‘A’ response. The maximum day and night time values recorded were

59 dB(A) and 49 dB(A).

3.4 Water quality

River Ravi flows within 6 km radius of the project site. Other than this, there is no

other natural surface water body flowing within the study area. The project

authorities are neither discharging nor withdrawing water into/from it, so there

would not be any impact of the project on it.

For assessing the baseline quality status of the Ravi river, two samples were

collected from river Ravi, one upstream and one downstream of the project site

area. Upstream sample has been collected from point near Lakhanpur and

downstream sample has been collected from a point near Village Bhadrali.

To assess the ground water quality of the study area, 8 no. of ground water samples

were collected. The physical, chemical and biological characteristics of the ground

water samples were found within the limits as specified in IS-10500:1991.

3.5 Land environment

3.5.1 Land use pattern

Kathua district has a total land area of 2650 sq.km as per revenue records. Out of

this 450 sq.km is for agricultural use, 350 sq.km constitutes barren land and

uncultivable land excluding fallow land, 120 sq.km accounts for cultivable waste,

130 sq.km is under misc. trees, 100 sq.km forms permanent pastures, 10 sq.km is

fallow land other than current fallows, 140 sq.km is the area under current fallows

and 610 sq.km Ha is net area sown. 630 sq. km represents the area sown more than

once.

3.5.2 Soil characteristics

The study area is predominantly an agricultural area with around 25 % of the land

use is for agricultural purposes. The texture of the soil in the study area is sandy

loam. Bulk density of soil samples varies between 1.31 to 1.77gm/cm3. The soils

of all the sites are moderately porous (porosities ranging between 51.4 to 59.9%).

pH of soil samples ranged between 7.8 to 8.2. The availability of nitrogen is of

prime importance to grow plants since they are dependent on adequate supply of

nitrates and ammonia. Total kjeldahl nitrogen available for different soil sample

ranged between 0.01 to 0.09%.

3.6 Biological environment

The forests of Kathua District are bound in valuable and useful trees, bushes,

herbs, medicinal plants which are valued at very high prices in national and

international markets. The forests are rich with 178 plant, 10 wild life and 71 bird

species. The main tree species which grow in Billawer Division in general and

Bani area in particular are Deodar, Chir, Oak, Kail, Khair, Ban Khode, Khadak,

Shehtoot, Akhrot, popular, Prunusbaddus, Kenth, Cheo, Rasount bush and

Dhaman. Apart from the valuable trees the forests of Bani are rich in the yield of

valuable herbs and medicinal plants used in the preparation of the lifesaving drugs

such as Kood, Pateesh, Dhoop, Beladona, Mushak Bala, Kinse, Kuth, Banafsha,

Jangliajwain, Mentha vulgaris, Bhang, Brahmi, vitis, Straw berry, mushrooms and

last but not the least Orchis Latifolia. Black bear, samber, antelope, leopard, musk

deer, pigged, wild cats, rabits, wild boar, porcupine and many aquatic birds are

found in abundance in the forests of Bani, Basohli and Billawer.

3.7 Socio-economic environment

The socio-economic profile of the study area is given below;

• Settlement pattern: Kathua district is one of 22 administrative districts that

comprise the state of Jammu and Kashmir under Indian rule. It is divided into 8

blocks: Bani, Barnoti, Basholi, Billawar, Duggan, Ghagwal, Hiranagar, Kathua

and Lohai Malhar. It has approximately 512 villages.

• Communications: The state is having strong communication networks. The

Jammu & Kashmir State Road Transport Corporation operates on 153 routes

conveying around 50 lacks commuters per annum state wide.

• Industry: Kathua is coming as an advent infrastructure provider for the existing

as well as prospective industries. In the last few years, there has been a

significant increase in the industrial establishments in the district. SICOP (State

Industrial Co-operation), on the outskirts of Kathua, is a well-developed

industrial estate, includes the Nirmal Industries, Chenab Textile Mill (CTM).

• Mineral and mining: The area is having limestone as natural minerals. Many

limestone queries exists in the area. In fact, the govt. of Jammu and Kashmir

has declared it as limestone industrial area.

• Medical and public health: The area is connected with the medical and public

health facilities. In Kathua, there is 1 Government Allopathic Hospital having

25 beds capacity. There are 25 Primary health centers in the district.

• Education: Literacy rate in Kathua district is 73.09 %. The literacy percentage

in case of males is 81.53 % and in case of females is 63.72 % (Census 2011).

• Demography: Kathua District is spread over an area of 2651 Sq. Kms

constituting 1.9 percent of the total area of the State. The District has a

population of over 6, 16,435 comprising 3, 26,109 males and 2, 90,326 females

as per 2011 census. The density of population of the district has gone upto 246

persons per square km. Sex ratio in the district is 890 females per 1000 male.

4.0 ENVIRONMENTAL IMPACT IDENTIFICATION AND ASSESSMENT

In the present study, the most probable impacts on various components of the

surrounding environment due to the proposed development have been predicted.

4.1 Impact identification

4.1.1 Land alteration/regime modification

• Atmosphere No significant impact.

• Water resources Limiting uncontrolled surface run-off and storm water management will have positive contribution to water scenario

4.1.2 Resource extraction and consumption/renewal

• Atmosphere Processing for production of building materials will put

some stress on air quality at the respective activity sites.

These effects are marginal and not specific to the study

area/site.

• Water resources The ground water will be marginally decreased due to the

proposed activity, but will be compensated due to improved

storm water management.

¤ Economic

conditions

The activity will generate extra job and business

opportunities.

4.1.3 Processing/industrial activity

• Atmosphere Gaseous emissions will have local effect. There will be

indirect improvement (due to responsible handling and

recycling of the scrap metal and resource conservation).

¤ Economic

conditions

The activity will generate extra employment and business

opportunities.

4.2 Quantification of significant impacts

Flue gas emissions would be the only significant object that could have adverse

impact on the environment. SPM and SO2 are the main constituents of flue gas

emissions that need to be modeled and quantified. Computer modeling has been

carried out using Gaussian Plume Dispersion Model (PTMTP) to verify the

impact of flue gas emissions into the atmosphere and their effect on ground level.

Accordingly to the modeling, increase in SPM and SO2 level due to the project

would be ~ 5µg/m3 for SPM and ~ 6µg/m3 for SO2. The overall SPM and SO2

concentration in the atmosphere would be within the permissible limits.

5.0 ENVIRONMENTAL MANAGEMENT PLAN

5.1 Mitigation Measures

5.1.1 Wastewater generation and treatment

The industry would generate only domestic effluent from its industrial premises.

The quantity of domestic effluent generation would be around 4 m3/day. The

average wastewater characteristics will be : BOD – 200-250 mg/l, COD – 450-500

mg/l, TSS – 300-400 mg/l, TKN (as N) – 30-35 mg/l, and total phosphorus (as P) –

10-12 mg/l. The wastewater would be treated in a septic tank before its utilisation

on land for irrigation purposes.

5.1.2 Air pollution

5.1.2.1 Fugitive emission control

Limestone unloading operation - For the control of fugitive emissions from

limestone unloading section the “dust containment cum suppression systems”

would be installed.

Lime Stone Crushing Operation - Dust generated during crushing operation

would be captured with dust extraction cum pulse jet bag filter type control system.

Lime Stone Transfer Point - Dust extraction cum pulsejet bag filter type control

system would be adopted at limestone transfer points.

Lime stone Stacker and Reclaimer - To control emissions, a set of water spray

nozzles would be provided over the conveyor belt in the stacker feed point.

Coal Unloading Operation - The dump hopper would be enclosed in a shed. The

industrial unit will have dust suppression arrangement for suppressing the fugitive

emissions alongwith dry extraction cum bag filter.

Coal Crushing Operation - Bag filter type control system would be adopted for

capturing the dust emissions. The collected dust would be recycled on conveyor

belt.

Coal Transfer Points (Primary Crusher to Stacker/stockpiles) - Bag filter type

control system would be adopted for capturing the dust emissions.

Coal Stacker & Reclaimer - To control emissions, generally a set of water spray

nozzles are provided over the conveyor belt in the stacker feed point.

Clinker Transfer Point (Clinker Cooler to Clinker Stock Piles) - The industrial

unit will have dry type dust extraction cum bag filter systems installed for transfer

points.

Packing Section - Natural ventilation would be provided for dust dispersion in

shop-floor.

Silo Vents - All the silo vents would be provided with bag filters.

Emissions from Road - The industrial unit would provide concrete paved road

upto its plant premises and within the industry.

5.1.3 Solid waste

The industry would not generate any solid wastes as whole of the process rejects

solid wastes would be reused for the production of cement.

5.1.4 Hazardous waste management

Hazardous waste will include used/spent oils and lubricants [classifiable under

Category 5.1 of Schedule – I of Hazardous Wastes (Management, Handling and

Transboundary Movement) Rules, 2008] – ~500 litre/year. The used oils will be in

metallic drums inside a lined and covered room and will be, ultimately, sold to the

authorized recyclers.

5.2 Environmental monitoring

The industry would get the monitoring done for various parameters from approved

labs of NABL/J & K State Pollution Control Board.

5.3 Disaster and emergency response management

Disaster, in this situation, may include incidences of flood, earthquake, fire, or

disruptive incidents of human extremism. While the incidences of natural disaster

are remote, these may result in significant loss of life and property. There is no fire

sensitive establishment within or vicinity of the industrial complex. Adequate, fire

fighting arrangement at micro level will be provided by the promoter.

5.4 Management, staffing and capacity development

The industry shall have an environmental, health and safety committee (from

amongst the regular staff of the industry), headed by a co-ordinator, who will be

adequately trained.

Suitable training programs will be arranged for the manpower, which are directly

responsible for the pollution control systems and emergency response planning, in

their respective field/area of responsibility.

An estimated 10% of the project cost has been earmarked for implementation of

environmental management plan.

6.0 EXPENDITURE ON ENVIRONMENTAL MEASURES

COST OF ENVIRONMENT PROTECTION MEASURES

S. No. DESCRIPTION COST(Rs. in Lakhs)

1 Bag House Filters for VSK 15.00

2 Bag House Filters for other processes 25.00

3 Sprinkling System for control of dust 5.00

4 Plantation and Green Belt Development 2.00

5 Laboratory for analysis of environmental parameters 5.00

TOTAL 52.00

Note:- Rs. 3.0 lac shall be spent on CSR annually for the benefit of the society

specially the weaker section.