ENVIRONMENT MANAGEMENT PLAN 9.1 …environmentclearance.nic.in/writereaddata/FormB/EC/EIA...Proposed...

Proposed Grinding Unit of M/s Marce Cement Works Ltd.

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Fulgro Environmental & Engineering Services (I) Pvt. Ltd., Jaipur

ENVIRONMENT MANAGEMENT PLAN

9.1 INTRODUCTION

M/s Marce Cement Works Ltd. is committed to comprehensive Environment Management Plan for environmental protection and conservation in proposed cement grinding unit at Village: Patnawan, Tehsil: Ramnagar, District: Chandauli.

Based on the evaluation of impacts and baseline conditions, an Environmental Management Plan (EMP) has been delineated to mitigate the adverse impacts of proposed expansion project on environment of the area.

The environmental management plan consists of the set of waste minimization, impact mitigation, management, monitoring and institutional measures to be taken during implementation and operation to eliminate the adverse environmental impacts or reduce them to acceptable levels. The present environmental management plan addresses the components of environment affected during construction of the plant and by different operations in a Cement Grinding Unit.

No major construction work will be carried out for the proposed expansion activity; as the proposed expansion will take place within the existing premises by process optimization; hence, no major impact is envisaged during the construction phase on any of the environmental parameter due to the expansion project.

The EMP is herein outlined after taking into account the various Acts, Rules and Regulations/Standards concerned with the environmental management. Aims of EMP:

§ Overall conservation of the environment.

§ Minimization of waste generation and pollution.

§ Judicious use of natural resources and water.

§ Safety, welfare and good health of the work force.

§ Ensure effective operation of all control measures.

§ Vigilance against probable disasters and accidents.

§ Monitoring of cumulative and longtime impacts.

Environmental Management Plan is detailed under the following heads:

§ Air Quality Management

§ Noise Management

§ Waste Water Management


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§ Solid & Hazardous Waste Management

§ Energy Conservation

§ Greenbelt Development & Plantation Programme

§ Occupational Health & Safety Measures.

9.2 AIR QUALITY MANAGEMENT

The major pollutants of air in a cement grinding unit are the particulate matters from the various stacks and fugitive emissions due to material handling.

9.2.1 Stack Emissions & Control Technologies

A stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called flue gases are emitted to the outside air.

To keep the PM emissions from stack below permissible limits (i.e. <50 mg/Nm3), all major sources of air pollution are being / will be provided with Bag/Filters.

9.2.2 Air Pollution Control devices (APCD) :

Bag Filter:-

For the removal of fine dust and fumes, a bag house has been installed and one more is

proposed for expansion plan. The fabric is usually made into bags of tubular or envelope

shape. The entire structure housing the bags is called a bag house (fabric filter). The bag


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house consists of a woven or felted fabric through which dust laden gas will be forced. A

combination of the factors results in the collection of particles on the fabric fibers. When

woven fabrics are used, a dust cake eventually form which, in turn, acts predominantly as

a sieving mechanisms are a combination of inertial forces, electrostatic, impingement etc.,

as related to individual particle collection on single fibers. The cloths than serves mainly as

a supporting structure for the dust mat responsible for the high collection efficiency. These

are essential the same mechanisms experienced in “Air Cleaning Type” filters. The dust

free air is sucked by induced draft fan and is exhausted to atmosphere. Periodically the

accumulated dust is removed for disposal. Some residual dust remains serve as an aid to

further filtering.

Emission Details

Case 1: Ball Mill of 400 TPD

Pulse Jet Bag Filter Specifications

Gas volume 15,000 Nm3/hr

Temperature 45-50 0C

Pressure 215 mmWc

Air to cloth ratio 1.96 m3/min/m2

Total filtration area 127.25 m2

No. Of filter bags 90 Nos.

No. Of module 1 No.

Compressed air quantity 80 m3/hr. at 6-8 Kg/cm2

Pressure drop across bag filter 215 - 230 mmWC

Size and quantity solenoid valves 1½ “ BSP/ 10 Nos.

Pulse duration 40-60 millisecond

Pulse interval 10-30 sec

Expected outlet particulate matter after APC system Below 50 mg/m3

Inlet dust concentration 20-25 mg/m3


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Sequential control timer 10 channel

Filter Bag and Cage Specifications

Quantity 90 nos.

Fabric 100% Polyester needle felt, Non Woven,

Bag Dimensions 150mm dia. X 3000 mm long

Type Collar

weight 550 gsm

Thickness of Fabric 1.9 mm

Tensile Strength (Wrap Direction)

>1200 N/5 X 20 cm

Tensile Strength (Weft Direction)

>1400 N/5 X 20cm

Air permeability, at 20 mm WG

16-20 m3/min/m2

Max. Surge Temperature

150 °C

ID FAN Specifications

Application Area After Bag Filter

Quantity 1 set

Gas Volume 18,000 Nm3/h

Operating Temperature 45-50 °C

Static Pressure at Operating Temp.

275 mm WC

Recommended Motor Rating HP/ 1440 RPM,30 HP

Drive Arrangement Direct Coupled

MOC of Fan Casing MS IS 2062


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MOC of Impeller MS IS 2062

Shaft EN9

Inlet Damper To be provided

Accessories Base Frame, Inlet Damper, Inlet – Outlet Canvas

Case 2: Ball Mill of 400 TPD

Pulse Jet Bag Filter Specifications

GAS VOLUME 15,000 Nm3/hr

TEMPERATURE 45-50°C

PRESSURE 215 mmWc

AIR TO CLOTH RATIO 1.96 m3/min/m2

TOTAL FILTRATION AREA 127.25m2

NO: OF FILTER BAGS 90 Nos:

NO: OF MODULE 1 Nos:

COMPRESSED AIR QUANTITY 80 m3/hr. at 6-8 Kg/cm2

SIZE AND QUANTITYSOLENOID VALVES

1½ “ BSP/ 9 Nos.

PULSE DURATION 40-60 millisecond

PULSE INTERVAL 10-30 sec

EXPECTED OUTLET PARTICULATE MATTER AFTER

APC SYSTEM

Below 50 mg/m3

INLET DUST CONCENTRATION 20-25 mg/m3

SEQUENTIAL CONTROL TIMER 10 channel


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Filter Bag and Cage Specifications

Bag Filter Specifications

Quantity 1 Set

Make DDOC

Air to Cloth Ratio 1.96m 3/min/m2

Total Filtration Area 84.83 m2

Number of Bags 60 nos.

Number of Hopper 1 no.

Series 10 X 6

MOC of Hopper & Casing MS IS 2062

Quantity 90 nos.

Fabric 100% Polyester needle felt, Non Woven,

Bag Dimensions 150mm dia. X 3000 mm long

Type Collar

weight 550 gsm

Thickness of Fabric 1.9 mm

Tensile Strength (Wrap Direction)

>1200 N/5 X 20 cm

Tensile Strength (Weft Direction)

>1400 N/5 X 20cm

Air permeability, at 20 mm WG

16-20 m3/min/m2

Max. Surge Temperature 150 °C


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ID FAN Specifications

Application Area After Bag Filter

Quantity 1 set

Gas Volume 18,000 Nm3/h

Operating Temperature 45-50 °C

Static Pressure at Operating Temp.

275 mm WC

Recommended Motor Rating HP/ 1440 RPM,30 HP

Drive Arrangement Direct Coupled

MOC of Fan Casing MS IS 2062

MOC of Impeller MS IS 2062

Shaft EN9

Inlet Damper To be provided

Accessories Base Frame, Inlet Damper, Inlet – Outlet Canvas

9.2.2 Fugitive Emissions, Sources and Control Technologies

9.2.2.1 Fugitive Emissions

Fugitive emissions are the air pollutants released in the air other than those from stacks or vents. Fugitive dust may be defined as “any solid particulate matter that becomes airborne by natural or man-made activities, excluding particulate matter emitted from an exhaust stack”.

Factors that influence emissions

Factors affecting emissions that are common to most operations include the following:

§ Moisture content of the material § Type of material processed § Type of equipment § Operating practices employed.


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9.2.2.2 Sources of Fugitive Emissions in Cement Grinding Unit and Mitigation Measures

Storage of Raw Materials and Finished Product

Dust may be generated here due to carryover by wind. However, to avoid this, clinker is being stored in silo &covered shed; fly ash is being stored in silos & gypsum in covered shed.

Details reg. storage facilities for raw material & product are given in below table

Table – 5

S. No Material Type of storage

1 Clinker Silo & Covered Shed

2 Gypsum Covered Shed

3 Fly Ash Steel Silo & Concrete

Silo

4 Cement Silo

Transportation

Movement of heavy trucks/vehicles on the non-metallic roads generates substantial quantity of dust emission. This is due to the presence of dust over the road, which is carried away by wind.

To control the generation of dust, all the roads inside the plant premises are concreted.

Regular sweeping of all the roads water through tankers is being done on bare lands and roads.

Material Transfer

Dust is generated from all the transfer points of belt conveyors. This is being controlled by providing bag filters at all transfer points. M/s Marce Cement Works Ltd. have already installed sufficient number of Bag Filters at various material transfer points & silo tops.

As per CPCB Guidelines following measures are being / will be implemented in the Cement Grinding Unit to control the generation of fugitive emissions:

§ Enclosures are provided for unloading operations. § Water is being sprayed during unloading of materials.


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§ All transfer point locations are fully enclosed. § Bag filters are installed at all Transfer points to reduce fugitive dust

emissions.

§ Water Spray on roads & other areas by Mobile tanker/water sprinklers.

§ All the Roads inside the plant premises are concreted.

§ Regular sweeping of all the roads & floors is done.

§ Dust collected from air pollution control equipment is totally recycled in the

process.

§ The packing machine is equipped with dust extraction arrangement. Dust is

being / will be captured in bag filters.

Other Measures implemented in the Cement Grinding Unit to reduce the Dust

Emission

Ø Maintenance of Bag Filters

Maintenance of the Bag filters includes replacement of bags, checking the performance of the Bag filters, maintenance of ID fans etc.

The information on performance of Bag filters in relation to the process/ production conditions is being collected to optimize the efficiency of Bag filters.

Ø Sources of Emissions in the Cement Grinding Unit

For achieving effective prevention and control of potential fugitive emission sources in cement manufacturing units, specific requirements along with guidelines have been given by CPCB, which are being followed specifically in the project operation. Regular inspection is being carried out for all fugitive control system and records are being maintained as per CPCB guidelines. Same will be followed for proposed expansion project. For the purpose of effective prevention and control of fugitive emissions, following measures have been/ will be taken as per the guidelines:

§ Enclosures are provided for all unloading operations, except wet materials like gypsum.

§ Water is sprayed on the material prior and during unloading. § Transfer point locations are fully enclosed. § Air borne dust at all transfer operations / points is controlled either by

spraying water or by extracting to bag filter. § Clinker is stored in covered shed / silo which have a venting arrangement

along with a bag filter.


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§ The dust extracted and captured in bag filter is being avoided to feed back/recycled to the clinker stockpile, if possible.

§ Dry Fly ash is stored in silos only provided with a bag filter system to the vent out air borne fines.

§ Loading of clinker by pay loaders into trucks/trailers will be carried out in an enclosure fitted with a bag filter.

§ Fly ash is being/will be sent to closed silos by pneumatically enclosed loop.

9.3 NOISE MANAGEMENT

Exposure of high noise level to workers for long duration may lead to certain occupational diseases. To mitigate the high noise level, following measures are being adopted. The same will be practiced for proposed expansion also.

§ Walls and ceilings of the concerned buildings are lined with sound absorbing materials.

§ Properly insulated enclosures are provided to equipment making excessive noise.

§ Improved silencers are provided in the equipment generating high noise. § Proper maintenance, oiling and greasing of machines at regular intervals is

being done to reduce generation of noise. § Personal Protective Equipment (PPEs) like earplugs and earmuffs is being

provided to the workers exposed to high noise level. § Area having high noise level being displayed at site with Noise level and

signage for usages of Personal Protective Equipments (PPE’s). § Green Belt of appropriate width inside the pant premises and at the plant

boundary has been developed and same will be maintained in future. § Regular monitoring of noise level is being carried out and corrective

measures in concerned machinery are being adapted accordingly to the possible extent.

9.4 WATER MANAGEMENT

9.4.1 Water Requirement

Overall water requirement in the process shall be 5 KL/day. Gram Panchayat NOC is being attached as Annexure No.2.

9.4.2 Waste Water Management

No industrial wastewater is being generated from the Cement manufacturing process.


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§ Domestic wastewater generated being treated in Septic tank followed by Soak pit and treated water is being / will be utilized for greenbelt development / plantation.

§ Same practices will be followed in future for proposed expansion project. § No process effluent will be generated. § Domestic sewage will be disposed off through septic tank to soak pit. No

effluent will be discharged outside the premises and Zero’ discharge will be adopted

9.5 Energy Conservation

Cement manufacturing is an energy-intensive process.

The following measures will be adopted by Marce Cement Works Ltd. for reduction in specific energy consumption:

§ Installation of energy efficient lightings. Use of energy saving light fittings § Installing low watt tube lights § Procurement of energy efficient machineries § Minimizing idle running of vehicle, machines and electrical appliances § Optimizing loads and periodic preventive maintenance & lubrication § Prevention of leakages of compressed air § Periodic energy audits § Training, awareness and motivational programmes.

9.6 Natural Resource Conservation

§ Rain water harvesting system has been installed to conserve water & to replenish ground water resources of the area for long term sustenance of the industry. Rain Water Harvesting is carried out by the following methods:

• Roof top rainwater harvesting • Surface rainwater runoff available from paved area, green area and

open land will be used for recharging through injection wells. • Natural rainfall recharge to open land.

9.7 SOLID AND HAZARDOUS WASTE MANAGEMENT

§ No solid waste is being generated from the cement manufacturing process.

§ Dust collected from air pollution control equipment is being totally recycled

back in the process.

§ Used oil and grease generated from plant machinery / gear as hazardous

waste is being used for lubrication in conveyor belts and rest is being sold to


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CPCB authorized recycler. Same practices will be followed in future for

proposed expansion project.

9.8 GREEN BELT DEVELOPMENT

Greenbelt development program will be designed within 10 km in particular

species selection reflects flora known to be resistant to the local conditions.

A Greenbelt development is necessary for:

1. Landscaping and providing shelter

2. Help in reducing Pollution level

3. Surface air purification by providing oxygen and letting SPM to settle on the leaves.

4. To attenuate noise generation by movement of vehicles and other machinery.

5. Prevent soil erosion to great extent

6. Improve ecological conditions.

7. Improves the aesthetics & beneficially influence the microclimate of the

surrounding.

The following characteristics will be taken into consideration while selecting plant

species for green belt development and tree plantation.

(a) They should be local indigenous and drought resistant species.

(b) They should be fast growing and tall trees.

(c) They should be perennial and evergreen.

(d) They should have thick canopy cover.

(e) The planting should be in appropriate alternate rows around the site to prevent

lateral pollution dispersion.

(f) The trees should maintain regional ecological balance and confirm to soil and

hydrological conditions. Indigenous species should be preferred.

(g) Species will be planted as per CPCB guidelines and native species.

General Guidelines for plantation

i. Plantation of trees will be done along road side and nearby areas such as in

school, in social forestry in villages or on the baron space to arrest auto-exhaust


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and noise pollution, and in such a way that there is no direct line of sight to the

mine when viewed from a point outside the foliage perimeter.

ii. Since tree trunks are normally devoid of foliage (up to 3 m), it will be appropriate

to have shrubbery in form of such trees to give coverage to trunk portion of these

trees.

iii. Fast growing trees with thick perennial foliage will be grown, as it will take

many years for trees to grow to their full height.

iv. Vegetation covers in and around the cement plant workings generally helps in:

§ Stabilizing erodible slopes to minimize pollution.

§ Control of dust.

§ Enhancement of aesthetic value.

§ Maximize evapo-transpiration, which helps minimizing run off.

§ Reducing noise.

Green belts are created not only for the purpose of protecting sensitive areas or to

maintain ecological balance but because they also act as efficient biological filters.

Green belt development provides an important tool to address the issue of

mitigating the adverse effect of fugitive emission on surrounding

environment.There is the proposal of development of green belt over an area of

3750 sq mtr. (0.375 ha) with 375 numbers of plants. Comprehensive

greenbelt/plantation program will be undertaken in and around the project. The

species selection will depend upon crown shape, surface of bark and leaves, flower,

color, capacity of growth in the wide variations of ecological conditions etc. A

mixture of soil should be prepared by mixing commercial fertilizer, cow dung, and

BHC powder in the topsoil. All the Plantation will be carried within the first three

years. Thereafter maintenance of the plants will be taken care of.


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Table No. 6 Greenbelt Development Programme

Common Name Scientific Name No. of Trees proposed to be planted

Mango Mangifera indica 75 Shisham Dalbergia shishoo 75 Neem Azadirachta indica 75 Jamun Syzygium cumini 75

Ashoka Saraca asoca 75

Total 375

Conservation Methods for Threatened Plant Species:

Direct and indirect approach is required to provide effective conservation, which is

suggested as under;

· Some provision of rewards for growing maximum threatened plant species.

· To create awareness among the villagers and encourage them to grow threatened

plant species in numbers in their farms by mentioning their medicinal and

economic value.

· Another way to help preserve the endangered species is to create society

dedicated to ecological ethics. All the conservation measures will be implemented

with the help of and in the consultation of the state forest department.

· A series of conservation awareness workshops for village and school children

should be conducted in the different villages. Interactive discussion will be carried

out participants.

· Encourage afforestation activities around and maintain them.

· Suggest strategies to minimize negative impacts of changing environment in

nearby area of promote conservation.

9.9 OCCUPATIONAL HEALTH AND SAFETY MEASURES

To control and minimize the risks at workplace, M/s Marce Cement Works Ltd. has

implemented Health, Safety and Environment Policy with the following objectives:

§ To prevent hazards


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§ To provide safe and healthy environment to all the employees.

§ The company, therefore, has adopted the policy set below for the purpose of

creating and maintaining safe and healthy environment.

9.8.2 OCCUPATIONAL HEALTH SURVEILLANCE

In cement grinding unit, the occupational health surveillance of the employee is

being done on a regular basis and records of the same are being maintained as per

the Factory Act. The occupational health surveillance programme includes lung

function; sputum analysis and audiometric analysis on regular basis to observe any

contraction due to exposure to dust and noise and corrective measures will be taken

accordingly. Vocational training programmes have also been/ will be conducted.

Under vocational training, the workers are being / will be given training related to

all safety and health aspects pertaining to their vocation and thereafter, every

quarter special training courses/ awareness programme for Malaria eradication,

HIV and health effects on exposure to dust, heat, noise, chemicals are organized for

employed person.

9.3 ENVIRONMENT POLICY

The industry’s management should actively initiate, develop and support the

environmental policy, which is relevant to its activities, products and services and

their environmental effect. Broadly this should be:

§ Consistent with the occupational health and safety policy and other industrial

policies (such as quality policy).

§ Indicate which of the industrial activities are covered by the environmental

management system.

§ Be communicated and implementation at all levels of the industry.

§ Be available publicly.

Environment Policy:

“To be a role model in protection of environment for sustainable development,

lessees is committed to implement the best global practices in all its operations

through prevention/ mitigation of pollution and bringing awareness among all the

stakeholders for continual improvement in environmental performance”


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Objectives:

• To take account of environment concerns in planning and decision-making.

• Committed to comply with applicable statutory requirements, proper

implementation, and management for prevention of pollution as per

Environment Clearance/Clearance from pollution control board/Environmental

Laws / CPCB norms / guidelines issued from time to time by related

department.

· Continue to improve the effectiveness of our environment and management

system by regular training with optimum use of natural resources, better

productivity by regular internal audit and up gradation of technology.

· Energy efficient technology will adopted with proper care of environment.

· To monitor and measure environment parameters in order to assess and

analyze the level and to control them to conform or improve in accordance with

environment policy and objectives.

• Identification of significant impacts and preparation of environment

management systems for implementation at project site and surrounding areas.

• Optimum utilization of resources.

• To take up developmental works in surrounding villages as a part of Corporate

Social Responsibility (CSR).

· Monitoring & Maintenance of plantation development.

· To provide appropriate training and disseminate information to enable all the

employees to accept individual responsibility for environment protection,

implement best practices and work in partnership to create a culture of

continual improvement.

The Environmental Policy, objectives and guidelines will be display of the same at

the conspicuous places for bringing awareness among the employees of M/s Marce

Cement Works Ltd.

Non-Compliance Reporting System

1. In case of any violation of any environmental norms, case will be put to the

higher authority of the company.


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2. Environmental Monitoring .i.e Air, Water, soil, Noise & Stack monitoring will be

conveyed to respective person/Laboratory for taking up necessary corrective

action.

9.4 ENVIRONMENTAL MANGAMENT PLAN BUDGET

The management of “M/s Marce Cement Works Ltd. is quite conscious of its roles &

responsibilities for maintaining clean environment. The management is also keen

to make more efficient measures towards suppression of pollution sources. The unit

is proposed to invest Rs. 11,55,000 lac as the capital cost on the environmental

action programme and the annual recurring cost will be Rs. 1,67,000 /- on pollution

control measures, green belt development and other environment management.

Table 7.0 EXISTING & PROPOSED EXPENDITURE FOR ENVIRONMENT PROTECTION PROGRAM

S.No.

Particulars Proposed Capital Cost in Rs.

Proposed Recurring Cost in Rs.

1 Air Pollution Control 10,00,000 60,000

2 Water Pollution Control

20,000 2,000

3 Noise Pollution Control

30,000 10,000

4 Environment Monitoring and Management

-- 65,000

5 Occupational Health 35,000 10,000

6 Green Belt 70,000 20,000

TOTAL 11,55,000 1,67,000

9.5 Labour Welfare Details

Following facilities are proposed to be created at factory premises for the casual worker including truck driver during operation phase. 1. Safe drinking water and water coolers will be provided.

2. Urinal and lavatories, wash basins, bathrooms will be provided.


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3. One toilet facility per 10 workers shall be provided.

4. Separate toilets for males and females with proper signage in local language.

5. Equipped first aid boxes or cupboards will be at the disposal and accessibility of

the workers. Conveyance arrangements to hospitals or dispensaries from the

project site will be provided.

6. Helmets, face masks, gloves, earmuffs and goggles will be provided to the

workers as per safety norms.

7. Canteen facility will be provided to workers.

8. Rest house/shelters will ne provided for truck drivers.

(i) General Working Conditions The House keeping practices employed would be:

· All the passages, floors and stairways will be maintained in good conditions.

· Walkways will be always kept free from obstructions. · Safety precautions and instructions will be displayed at strategic locations

in Hindi Language. · Distribution of working hours, rest hours, meal times and breaks will be

identified for all workmen.

Worker’s Health services:

· Factory will have first aid, emergency aid, and medical examinations

for the workers.

Workers’ Education:

1. Labour & their children will be encouraged to attend regularly

primary education (literacy) facilities.

2. Health education viz. Awareness programme on HIV–AIDS

through poster/visual aids will be displayed.

9. Analysis of proposal (Final Recommendations) The Project proposal of M/s MARCE CEMENT WORKS LIMITED is justified

taking into account the potential Economic & Social Development including

Environmental impacts. All around Development activities have necessitated for

undertaking proper Environmental Monitoring and Environmental Management

plans in order to ensure sustainable growth and Development of the Country.


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The entire project as described in the above pages will be carried out under specific

environmental norms and regulations so as to avoid interference with the

environment and causing no harm to the surrounding locality and vegetation.

ENVIRONMENT MANAGEMENT PLAN 9.1 …environmentclearance.nic.in/writereaddata/FormB/EC/EIA...Proposed...

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