chapter - 1 introduction - Meghalaya State Pollution Control Board
chapter - 1 introduction - Meghalaya State Pollution Control Board
chapter - 1 introduction - Meghalaya State Pollution Control Board
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Hills Cement Co. Limited.<br />
CHAPTER - 1<br />
INTRODUCTION<br />
1.1 GENERAL<br />
For more than hundred and fifty years cement has been used extensively in<br />
construction of a small building to a multi purpose project. Cement is the<br />
critical ingredient in concrete, locking together the sand and gravel<br />
constituents in an inert matrix. Concrete is required for development of basic<br />
infrastructure such as houses, roads, bridges, water treatment facilities,<br />
schools and hospitals etc. Concrete is global material that underwrites<br />
commercial well being and social development. The cement industry<br />
absorbs a large volume of different agro-industrial wastes such as fly ash<br />
from thermal power stations, blast furnace slag from iron and steel industry,<br />
chemical gypsum (phosphorus and fluoro-gypsum) from fertilizer and<br />
chemical industries. Besides rice husk, bagasse, and to some extent diesel<br />
sludge are used by some plants. More than 90 percent of the plants are<br />
based on the dry process technology with suspension preheater and precalcinator.<br />
With globalization, Indian cement industry has realized that to be<br />
competitive in the international scene, the production technology must be at<br />
par with the state of art technology as in advanced countries and<br />
consistency of quality of the product has to be ensured at any cost. At<br />
present, our country accounts for less than 7% of the global cement trade<br />
and exported less than 8% of the cement production, despite being the<br />
second largest producers. From a level of 0.22 million ton in 2005-2006,<br />
cement demand in <strong>Meghalaya</strong> is likely to reach around 0.26 million ton in<br />
2007-2008 and 0.43 million ton in 2014-2015.<br />
M/s Hill Cements Company Limited (HCCL) intends to set up a 3,000-tpd<br />
cement project (In two phases of 1,500 tpd each), a captive power plant of<br />
10 MW and operate mining lease for lime stone in district Jaintia Hills<br />
<strong>Meghalaya</strong> state. The lime stone shall be obtained from nearby lime stone<br />
lease areas. The proposed project site is located near village Mynkre,<br />
Taluka Khelirihat, District Jaintia Hills, which is about 115 km from Shillong<br />
on NH-44 (Shillong-Silchar Road).<br />
The Company was incorporated on 23 December 2003. It was promoted by<br />
leading industrialists and businessmen with the objective of manufacturing<br />
cement. The Jhunjhunwala group of Shillong and the Mittal group of<br />
Guwahati have promoted the company jointly.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd.
Hills Cement Co. Limited.<br />
The promoters of the company are existing industrialists/businessmen from<br />
the northeast region and have good experience in the marketing and<br />
production of cement, iron and steel, coal and coal products.<br />
The registered office is at Mynkre, Taluka Khelirihat, District Jaintia Hills,<br />
(<strong>Meghalaya</strong>).<br />
The present directors of the company are:<br />
1. Shri Basant Kumar Mittal<br />
2. Shri Narayan Prasad Jhunjhunwala<br />
3. Shri Pankaj Jhunjhunwala<br />
4. Shri Ashok Anand Singhal<br />
5. Shri Madan Lal Mittal<br />
6. Shri Rajesh Kumar Mittal<br />
7. Shri Thomas Nongtdu<br />
8. Shri Anand Kumar Goyal<br />
9. Shri Connie F Sawknie<br />
M/s Hills Cement Co. Limited awarded the job of environmental assessment<br />
to M/s. <strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd., Jaipur, who has<br />
conducted similar studies for Hindustan Copper Ltd and others for their<br />
industrial and mining projects. Based on the studies & reports environmental<br />
clearance had been granted by the MOEF.<br />
1.2 OBJECTIVES OF THE STUDY<br />
• Studies for assessment of impacts on environmental parameters, if<br />
any, due to the proposed project<br />
• To minimize, if not possible to avoid the environmental impacts, and<br />
• To formulate plan to mitigate all the adverse impacts, that may arise<br />
in future due to the project establishment.<br />
• To obtain environmental clearance from Ministry of Environment and<br />
Forest Govt. of India, before establishing the project,<br />
Project proponent shall take adequate and efficient measures to keep the<br />
dust emissions at lowest level, which will keep the ecology of the area<br />
undisturbed.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 2
Hills Cement Co. Limited.<br />
1.3 SCOPE OF ASSIGNMENT<br />
The scope includes field study and data collection in respect of -<br />
a. Air Environment - For one season relating to the existing status of<br />
Ambient Air Quality, Collection of Meteorological data and establishing<br />
the range of all existing emission sources in the study area, if any.<br />
b. Water Environment - By collecting samples of surface and ground<br />
water in different seasons and analyzing the same as per IS -<br />
Standards and also conduct ecological examination of site.<br />
c. Flora & Fauna - The existing status of the Flora and Fauna in 10 Km<br />
radius of study area shall be studied.<br />
d. Noise Environment - shall be studied considering existing incremental<br />
noise level of the study area.<br />
e. Dust Fall Studies - shall be made as per the guidelines of the<br />
CPCB/MOEF.<br />
A reconnaissance survey of the area was undertaken for -<br />
(i) Collection of prospecting data to propose a suitable actionplan.<br />
(ii) Collection of base-line information on air, water, soil,<br />
vegetation, flora, meteorology, noise and vibration.<br />
(iii) Collection of data on land use pattern, demography and<br />
Socio-economic conditions from various reports of<br />
Central/<strong>State</strong> Government agencies and through field surveys.<br />
1.4 COST OF THE PROJECT<br />
The cost of the project has been estimated at Rs. 360 Crores under the<br />
following heads: <br />
<br />
S.No. Particulars Cost Rs. Lacs<br />
1. Land and site Development 750<br />
2. Building and other Civil Structures 6,107<br />
3. Plant & Machinery 18,180<br />
4. Technical Know-how Fees 200<br />
5. Expenses on Training 15<br />
6. Miscellaneous Fixed Assests 5881<br />
7. Pre-Operative Expenses 2135<br />
8. Provision for Contingencies 2,143<br />
9. Margin for Working Capital 564<br />
TOTAL Rs. 360 Crores (Say) 35,975<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 3
Hills Cement Co. Limited.<br />
1.5 SCHEDULE OF IMPLEMENTATION<br />
The implementation of a project depends to large extent upon availability of<br />
funds, procurement of plant and equipment, methods and materials<br />
employed for construction and erection at site, etc. Therefore a well-defined<br />
and elaborated system of project implementation is being followed. The<br />
implementations plan will involve right from inception to commissioning.<br />
1.6 SCOPING OF ENVIRONMENTAL STUDIES<br />
The investigations were carried out to establish scope of environmental<br />
studies by identifying more prominent parameters and critical issues that<br />
may have significant impact on environment in present project activities.<br />
The main concerns include the following:<br />
• The emissions from the cement plant that releases in the<br />
environment raise harmful air-borne dust and capable of polluting<br />
ambient air quality.<br />
• The existing area configuration gets disturbed due to construction<br />
and mining activities. The magnitude of disturbance varies depending<br />
on surface topography, geology, size of operation, manufacturing<br />
technique, chemical properties of the ingredients used and<br />
beneficiation process.<br />
• Generation of huge volumes of overburden due to mining, If not<br />
planned properly. Top soil gets completely lost during removal of<br />
overburden.<br />
• Uncontrolled sediments deposition in surface water bodies causes<br />
the spoiling of water quality.<br />
• All the pollutants released from the power plant contribute to<br />
particulates and gaseous emissions.<br />
<br />
• Sometimes increased human activities in and around eco-sensitive<br />
regions may disrupt migratory route(s) of animals, fragment<br />
<br />
connectivity between important eco-systems, affect vegetation and<br />
wildlife habitat.<br />
The base line data has been collected to examine these issues in<br />
detail and to correctly assess the impact of proposed activities on<br />
environmental concerns.<br />
Preparation of environmental management plan [EMP] based on actual field<br />
surveys of the study area; dump yards and the proximity area. Efforts have<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 4
Hills Cement Co. Limited.<br />
been made to collect all possible information on land use pattern, socioeconomic<br />
status and other data from various agents and trough public<br />
interviews.<br />
The project plan and the studies already conducted have been considered<br />
and relied upon. The data available have also been utilized to supplement the<br />
data collected by the field study team of the consultants. The anticipated<br />
impacts of the various project activities on the different environmental<br />
parameters have been worked out, by using a checklist method classified as<br />
beneficial or degradational. The ranking of the impact intensity is rather<br />
subjective; the identification of the impact area is sufficiently objective in<br />
nature. The anticipated intensity of impact has been graded as low,<br />
moderate and high.<br />
In the present context, M/S Hills Cement Co. Ltd (HCCL) its is an area of<br />
concern, whose impact is to be evaluated on the existing environmental<br />
domains. The study area has been selected 10 Kms surrounding village<br />
Mynkre (Near 116 km stone on NH-44 Shillong-Silchar Road).<br />
The area has been studied with respect to physiography, topography,<br />
climate, geology and minerals, hydrology and water quality, forest, flora and<br />
fauna, land use and crop pattern, socio-economic aspects and places of<br />
interest etc.<br />
1.7 PRESENT STATUS<br />
The above studies are conducted and assessments made to meet the<br />
requirements specified in the guidelines of the MOEF and or <strong>State</strong> <strong>Pollution</strong><br />
<strong>Control</strong> <strong>Board</strong> as applicable.<br />
The project profile and Terms of Reference for proposed Environmental<br />
Studies were presented before the Hon’ble Expert Committee for appraisal.<br />
The Committee issued following Terms of Reference:<br />
TORs for Cement Plant:<br />
1 Present land use based on satellite imagery. Study area should be<br />
10 km radius.<br />
2 Details of location of wildlife sanctuary and national parks within 10<br />
km radius of the plant should be included.<br />
3 Year-wise availability of resources and future plan for acquiring raw<br />
material from other mines should be incorporated.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 5
Hills Cement Co. Limited.<br />
4 Site-specific micro-meteorological data including inversion height and<br />
mixing height should be included.<br />
5 Data on existing air, water, soil & noise etc. should be included.<br />
6 Ambient air quality monitoring modeling for cement plant and CPP (If<br />
any) should be incorporated.<br />
7 An action plan to mitigate SO 2 since <strong>Meghalaya</strong> coal contains higher<br />
sulphur content should be included.<br />
8 Sources of secondary emissions, its control and monitoring as per<br />
the CPCB guidelines should be included.<br />
9 Chemical characterization of RSPM and incorporation of RSPM data.<br />
Location of at least one AAQMS in downwind direction.<br />
10 One-month data for gaseous emissions for winter season should be<br />
included.<br />
11 Water balance cycle data including quantity of effluent to be<br />
generated, recycled and reused and discharged should be included.<br />
12 A <strong>chapter</strong> on hydrology study by the <strong>State</strong> Govt. may be included.<br />
Ground water monitoring minimum at 8 locations should also be<br />
included.<br />
13 Impact of the transport of the raw materials and end products on the<br />
surrounding environment including agricultural land.<br />
14 Surface as well as roof top rain water harvesting and ground water<br />
recharge should be included.<br />
15 Scheme of proper storage of fly ash, gypsum, clinker should be<br />
included.<br />
16 A write up on possibility of using of high calorific hazardous wastes in<br />
kiln and commitment regarding use of hazardous waste should be<br />
included.<br />
17 Risk assessment and damage control should be incorporated.<br />
18 Occupational health of the workers should be incorporated.<br />
19 Green belt development plan for 33% as per CPCB guidelines should<br />
be incorporated.<br />
20 Socio-economic development activities should be included.<br />
21 Compliance to the recommendations mentioned in the CREP<br />
guidelines should be included.<br />
22 Detailed Environment management Plan (EMP) with specific<br />
reference to air pollution control system, water management,<br />
monitoring frequency, responsibility and time bound implementation<br />
plan should be included.<br />
23 EMP should include the concept of waste minimization,<br />
recycle/reuse/recover techniques, energy conservation, and natural<br />
resource conservation should be included.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 6
Hills Cement Co. Limited.<br />
“These TORs should be considered for the preparation of draft EIA / EMP<br />
report for the Integrated cement plant (3,000 TPD), Mining Lease (lime<br />
stone 3000 TPD capacity) and coal based Captive Thermal Power Plant (10<br />
MW) near Village Mynkree P.O. Khliehriat, District Jaintia Hills, <strong>Meghalaya</strong><br />
in addition to all the relevant information as per the general structure of EIA<br />
given in Appendix III and IIIA in the EIA Notification, 2006. The draft<br />
EIA/EMP as per TORs should be submitted to the Chairman, <strong>Meghalaya</strong><br />
<strong>State</strong> <strong>Pollution</strong> <strong>Control</strong> <strong>Board</strong> for public consultation. The <strong>Meghalaya</strong> SPCB<br />
shall conduct the public hearing/public consultation as per the provisions of<br />
EIA notification, 2006.”<br />
Compliance of Terms of Reference (Cement Plant and Power Plant)<br />
S. No. TOR Points Compliance<br />
1 Present land use based on<br />
satellite imagery. Study area<br />
should be 10 km radius.<br />
2 Details of location of wildlife<br />
sanctuary and national parks<br />
within 10 km radius of the plant<br />
should be included.<br />
3 Year-wise availability of resources<br />
and future plan for acquiring raw<br />
material from other mines should<br />
be incorporated.<br />
4 Site-specific micro-meteorological<br />
data including inversion height<br />
and mixing height should be<br />
included.<br />
5 Data on existing air, water, soil &<br />
noise etc. should be included.<br />
6 Ambient air quality monitoring<br />
modeling for cement plant and<br />
CPP (if any) should be<br />
incorporated.<br />
Study area of 10 Kms surrounding<br />
project site is considered. Present<br />
land use based on satellite<br />
imagery is provided.<br />
Please refer page no. 40<br />
There is no wildlife sanctuary and<br />
national parks within 10 Kms<br />
radius of the plant.<br />
Availability of resources and future<br />
plan for acquiring raw material<br />
from other mines is incorporated.<br />
Please refer page no.34-35<br />
Site-specific micro-meteorological<br />
data including inversion height and<br />
mixing height is provided.<br />
Please refer Annexure - I<br />
Data on existing air, water, soil &<br />
noise etc. is included.<br />
Please refer page no.51-69<br />
Ambient air quality monitoring and<br />
modeling for cement plant and<br />
CPP is incorporated.<br />
Please refer page nos. 51-63 &<br />
82-87<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 7
Hills Cement Co. Limited.<br />
7 An Action Plan to mitigate SO 2<br />
since <strong>Meghalaya</strong> coal contains<br />
higher Sulphur content should be<br />
included.<br />
8 Sources of secondary emissions,<br />
its control and monitoring as per<br />
the CPCB guidelines should be<br />
included.<br />
9 Chemical characterization of<br />
RSPM and incorporation of RSPM<br />
data. Location of at least one<br />
AAQMS in downwind direction.<br />
10 One-month data for gaseous<br />
emissions for winter season<br />
should be included.<br />
11 Water balance cycle data<br />
including quantity of effluent to be<br />
generated, recycled and reused<br />
and discharged should be<br />
included.<br />
12 A <strong>chapter</strong> on hydrology study by<br />
the <strong>State</strong> Govt. may be included.<br />
Ground water monitoring minimum<br />
at 8 locations should also be<br />
included.<br />
13 Impact of the transport of the raw<br />
materials and end products on the<br />
surrounding environment including<br />
agricultural land.<br />
14 Surface as well as roof top rain<br />
water harvesting and ground<br />
water recharge should be<br />
included.<br />
15 Scheme of proper storage of fly<br />
ash, gypsum, clinker should be<br />
included.<br />
Since <strong>Meghalaya</strong> coal contains<br />
higher sulphur, action plan to<br />
mitigate SO 2 is included. Please<br />
refer page no.84<br />
<strong>Control</strong> and monitoring of<br />
secondary emissions is included<br />
as per CPCB guidelines. Please<br />
refer page no.92-93<br />
AAQMS shall be established in<br />
downwind direction and regular<br />
chemical characterization of<br />
RSPM shall be carried out after<br />
commissioning of plant. Record of<br />
RSPM data shall be maintained.<br />
Data for gaseous emissions for<br />
winter season is included.<br />
Please refer page no. 52-63<br />
Water balance cycle data including<br />
quantity of effluent to be<br />
generated, recycled and reused<br />
and<br />
discharged.<br />
Please refer page no. 31-32<br />
Please refer page no. 36-39<br />
Impact of the transport of the raw<br />
materials and end products.<br />
Please refer page no.70-72<br />
Rains are to the tune of 4,000 mm.<br />
Water is available in plenty.<br />
Ground water springs out from<br />
surface, which will be used in plant<br />
and process. Ground water<br />
recharge is not feasible.<br />
Scheme of proper storage of fly<br />
ash, gypsum, clinker is included.<br />
Please refer page no.29<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 8
Hills Cement Co. Limited.<br />
16 A write up on possibility of using<br />
of high calorific hazardous wastes<br />
in kiln and commitment regarding<br />
use of hazardous waste should<br />
be included.<br />
Possibility of using of high calorific<br />
hazardous wastes in kiln and<br />
commitment regarding use of<br />
hazardous waste is included.<br />
Please refer page no.101-102<br />
17 Risk assessment and damage<br />
control should be incorporated<br />
18 Occupational health of the<br />
workers should be<br />
incorporated.<br />
19 Green belt development plan for<br />
33% as per CPCB guidelines<br />
20 Socio-economic development<br />
activities should be included<br />
21 Compliance to the<br />
recommendations mentioned<br />
in the CREP guidelines should<br />
be included.<br />
22 Detailed Environment<br />
management Plan (EMP) with<br />
specific reference to air pollution<br />
control system, water<br />
management, monitoring<br />
frequency, responsibility and time<br />
bound implementation plan should<br />
be included.<br />
23 EMP should include the concept<br />
of waste minimization,<br />
recycle/reuse/ recover techniques,<br />
energy conservation, and natural<br />
resource conservation should be<br />
included.<br />
Risk assessment and damage<br />
control is incorporated.<br />
Please refer page no. 130-135<br />
Adequate medical facilities are<br />
being provided to maintain &<br />
periodically check occupational<br />
health of workers.<br />
Please refer page no. 110<br />
Nearly 40% area has been<br />
reserved for green belt<br />
development.<br />
Socio-economic development<br />
activities are included.<br />
Please refer page no.107<br />
The recommendations mentioned<br />
in the CREP guidelines shall be<br />
complied with.<br />
Environment management plan<br />
(EMP) with air pollution control<br />
system, water management,<br />
monitoring<br />
frequency,<br />
responsibility and time bound<br />
implementation plan is included.<br />
Please refer page no, 92-99<br />
EMP includes the concept of<br />
waste<br />
minimization,<br />
recycle/reuse/recover techniques,<br />
energy conservation, and natural<br />
resource<br />
conservation.<br />
Please refer page no. 109-113<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 9
Hills Cement Co. Limited.<br />
Compliance of Terms of Reference (Limestone Mines)<br />
S.No. TOR points<br />
1. The study area should comprise of<br />
10 km zone around the mine lease<br />
from lease periphery.<br />
2. Geological map indicating approved,<br />
estimated, inferred deposits and life<br />
of the mine should be included.<br />
3. Land use of the study area<br />
delineating forest area, agricultural<br />
land, grazing land, wildlife sanctuary<br />
and national park, migratory routes<br />
of fauna, water bodies, human<br />
settlements and other ecological<br />
features should be included.<br />
4. Land use plan of the mine lease<br />
area should be prepared to<br />
encompass pre-operational,<br />
operational and post operational<br />
phases. Impact of change of land<br />
use particularly agriculture land and<br />
gaucher / grazing land, if any.<br />
5. Stabilization plan to avoid soil<br />
erosion should be included.<br />
6. Location of National Parks,<br />
Sanctuaries, Biosphere Reserves,<br />
Wildlife corridors within 10 km of the<br />
mine lease should be clearly<br />
indicated. A location map duly<br />
authenticated by Chief Wildlife<br />
Warden should also be provided in<br />
this regard. Necessary clearance, if<br />
any, as may be applicable to such<br />
projects due to proximity of the<br />
ecologically sensitive areas as<br />
mentioned above should be<br />
obtained from the <strong>State</strong> Wildlife<br />
Department / Chief Wildlife Warden<br />
under the Wildlife (Protection) Act,<br />
1972 and copy furnished<br />
Compliance<br />
Study area of 10 Kms surrounding<br />
project site is considered as study<br />
area. Present land use based on<br />
satellite imagery is provided.<br />
Geological map indicating<br />
approved, estimated, inferred<br />
deposits and life of the mine is<br />
included.<br />
There is no wildlife sanctuary and<br />
national parks within 10 Kms<br />
radius of the plant.<br />
Impact on land use pattern of the<br />
study area and land use plan is<br />
provided<br />
Please refer page No. 40.<br />
Stabilization plan to avoid soil<br />
erosion is included.<br />
There is no National Parks,<br />
Sanctuaries, Biosphere Reserves,<br />
Wildlife corridors within 10 km of<br />
the mine lease.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 10
Hills Cement Co. Limited.<br />
7. Mine technology selected and type<br />
of the equipments to be used.<br />
Techno-economical<br />
and<br />
environmental compatibility should<br />
be included.<br />
8. Details of drilling and blasting<br />
method to be adopted.<br />
9. <strong>Control</strong> of noise and vibration should<br />
be included.<br />
10. A detailed biological study for the<br />
study area [core zone and buffer<br />
zone (10 km radius of the periphery<br />
of the mine lease)] shall be carried<br />
out. Details of flora and fauna, duly<br />
authenticated, separately for core<br />
and buffer zone should be furnished<br />
based on field survey clearly<br />
indicating the Schedule of the fauna<br />
present. In case of any scheduled-I<br />
fauna found in the study area, the<br />
necessary plan for their<br />
conservation should be prepared in<br />
consultation with <strong>State</strong> Forest and<br />
Wildlife Department and details<br />
furnished. Necessary allocation of<br />
funds for implementing the same<br />
should be made as part of the<br />
project cost.<br />
11. Collection of one season (nonmonsoon)<br />
primary baseline data on<br />
ambient air quality, water quality,<br />
noise level, soil and flora and fauna.<br />
Site-specific meteorological data<br />
should also be collected. The<br />
location of the monitoring stations<br />
should be justified.<br />
Mechanized and manual both<br />
methods of opencast mining shall<br />
be adopted. Techno-economical<br />
and environmental compatibility is<br />
considered. Please refer page No.<br />
35.<br />
Details of drilling and blasting<br />
method are provided. Please refer<br />
page no. 76-78<br />
<strong>Control</strong> of noise and vibration<br />
should be included.<br />
Please refer page no. 96-98<br />
A detailed biological study for the<br />
study area [core zone and buffer<br />
zone (10 km radius of the<br />
periphery of the mine lease)] has<br />
been carried out. Details of flora<br />
and fauna, duly authenticated,<br />
separately for core and buffer zone<br />
is furnished based on field survey<br />
clearly indicating the Schedule of<br />
the fauna present. No scheduled-I<br />
fauna is found in the study area.<br />
Please refer page No. 42-47.<br />
Data on existing air, water, soil &<br />
noise etc. is included.<br />
Please refer page no. 52-63<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 11
Hills Cement Co. Limited.<br />
12. Air quality modeling should be<br />
carried out for prediction of impact of<br />
the project on the air quality of the<br />
area. It should also take into account<br />
the impact of movement of vehicles<br />
for transportation of mineral. The<br />
details of the model used and input<br />
parameters used for modeling<br />
should be provided. The air quality<br />
contours may be shown on a<br />
location map clearly indicating the<br />
location of the site, location of<br />
sensitive receptors, if any and the<br />
habitation. The wind roses showing<br />
pre-dominant wind direction may<br />
also be indicated on the map.<br />
13. The water requirement for the<br />
project, its availability and source<br />
along with the permission from the<br />
Competent Authority should be<br />
included. A detailed water balance<br />
should also be provided. Fresh<br />
water requirement for the project<br />
should also be indicated.<br />
14. Details of water protection and<br />
conservation measures proposed to<br />
be adopted in the project should be<br />
included.<br />
15. Impact of the project on the water<br />
quality both surface and<br />
groundwater should be assessed<br />
and necessary safeguard measures,<br />
if any required should be provided.<br />
16. Details of rainwater harvesting<br />
proposed, if any, in the project to be<br />
provided.<br />
Ambient air quality monitoring and<br />
modeling for cement plant and<br />
CPP is incorporated.<br />
Please refer page nos. 51-63 & 82-<br />
87<br />
No water is required for mining<br />
activities except some water for<br />
wet drilling and for dust<br />
suppression. Treated waste water<br />
from plant area shall be used for<br />
this purpose. No fresh water is<br />
required for the mining activities.<br />
Details of water protection and<br />
conservation measures adopted in<br />
the project are included.<br />
Impact of the project on the water<br />
quality both surface and<br />
groundwater is assessed. No<br />
specific safeguard measures are<br />
required.<br />
Rains are to the tune of 4,000 mm.<br />
Water is available in plenty.<br />
Ground water springs out from<br />
surface, which will be used in plant<br />
and process. Ground water<br />
recharge is not feasible.<br />
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Hills Cement Co. Limited.<br />
17. Protection plan for river and<br />
drainage passing through mine<br />
should be included.<br />
18. Hydro-geological studies for the area<br />
should be carried out and included<br />
in the report.<br />
19. Precautions to be taken for ground<br />
water interference should be<br />
included.<br />
20. Information on site elevation,<br />
working depth, groundwater table<br />
should be provided both in AMSL<br />
and BGL. A schematic diagram may<br />
also be provided for the same. In<br />
case the working will intersect<br />
groundwater table, a detailed hydrogeological<br />
study should be<br />
undertaken and report furnished.<br />
21. Quantity of solid waste generation to<br />
be estimated and details for its<br />
disposal and management should<br />
be included.<br />
22. The reclamation plan, post mine<br />
land use and progressive greenbelt<br />
development plan should be<br />
prepared in tabular form (prescribed<br />
format) and submitted.<br />
23. Impact on local transport<br />
infrastructure due to the project.<br />
Projected increase in truck traffic as<br />
a result of the project in the present<br />
road network (including those<br />
outside the project area) and<br />
whether it is capable of handling the<br />
increased load. Arrangement for<br />
improving the infrastructure, if<br />
No river is passing through the<br />
mine area. The water collected in<br />
mine will be pumped to the sump<br />
in plant for in-house use. Any<br />
surplus water is drained into the<br />
river flowing nearby.<br />
Hydrology study report by the<br />
<strong>State</strong> Govt. is included. Ground<br />
water naturally springs out near<br />
site.<br />
Please refer<br />
page no. 36-39.<br />
Limestone is inert and non-toxic<br />
parent rock of the area. It does not<br />
have any impact on water regime.<br />
Information on site elevation,<br />
working depth, groundwater table<br />
is provided both in AMSL and<br />
BGL.<br />
Estimation of Quantity of solid<br />
waste generation and details for its<br />
disposal and management are<br />
included.<br />
The reclamation plan, post mine<br />
land use and progressive<br />
greenbelt development plan is<br />
prepared.<br />
The location of mines is in<br />
between the hills and the plant<br />
away from road and habitat. The<br />
impact will be confined within the<br />
project boundary and is expected<br />
to be negligible outside the project<br />
area. Proper upkeep and<br />
maintenance of vehicles, sprinkling<br />
of water on roads and construction<br />
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Hills Cement Co. Limited.<br />
contemplated including action to be<br />
taken by other agencies such as<br />
<strong>State</strong> Govt., if any, should be<br />
covered.<br />
24. Details of the infrastructure facilities<br />
to be provided for the mine workers<br />
should be included.<br />
25. Conceptual post mine land use and<br />
reclamation and rehabilitation of<br />
mined out area (with plans and with<br />
adequate number of sections)<br />
should be included.<br />
26. Slope stability, details of bench<br />
formation and height should be<br />
included.<br />
27. OB contents, Management and<br />
utilization plan, Concurrent<br />
restoration plan.<br />
28. Phase-wise plan of green belt<br />
development as per CPCB<br />
guidelines in 33 % area, plantation<br />
and compensatory afforestation<br />
clearly indicating the area to be<br />
covered under plantation and the<br />
species to be planted. The details of<br />
plantation already done should be<br />
given.<br />
29. Occupational health impact of the<br />
project should be provided.<br />
30. Measures of socio-economic<br />
influence to the local community<br />
proposed to be provided by project<br />
proponent. As far as possible,<br />
quantitative dimension to be given.<br />
31. Detailed environmental management<br />
plan to mitigate the environmental<br />
impacts, which should inter-alia also<br />
include the impact due to change of<br />
site, providing sufficient vegetation<br />
etc. are some of the measures that<br />
would greatly reduce the impacts.<br />
Details of the infrastructure<br />
facilities being provided for the<br />
mine workers. Please refer page<br />
No. 41-42.<br />
Conceptual post mine land use<br />
and reclamation and rehabilitation<br />
of mined out area (with plans and<br />
with adequate number of sections)<br />
shall be submitted later.<br />
Details of bench formation, height<br />
and slope stability included.<br />
OB contents, Management and<br />
utilization plan, Concurrent<br />
restoration plan is given.<br />
Nearly 40% area has been<br />
reserved for green belt<br />
development.<br />
Adequate medical facilities are<br />
being provided to maintain &<br />
periodically check occupational<br />
health of workers.<br />
Please refer page no. 110<br />
Socio-economic development<br />
activities are included.<br />
Please refer page no.101.<br />
EMP includes the concept of waste<br />
minimization,<br />
recycle/reuse/recover techniques,<br />
energy conservation, and natural<br />
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Hills Cement Co. Limited.<br />
land use, due to loss of agricultural<br />
land and grazing land, if any,<br />
besides other impacts of the projects<br />
should be provided.<br />
32. Rehabilitation and resettlement plan<br />
/ compensation details for the<br />
project affected people, if any should<br />
be included.<br />
33. Public hearing / public consultation<br />
points raised and commitment of the<br />
project proponent on the same along<br />
with time bound action plan to<br />
implement the same should be<br />
provided.<br />
34. Any litigation pending against the<br />
project and / or any direction / order<br />
passed by any Court of Law against<br />
the project, if so, details thereof<br />
should be provided.<br />
resource<br />
conservation.<br />
Please refer page no. 109-113<br />
Details of Rehabilitation and<br />
resettlement plan is given.<br />
Public hearing / public consultation<br />
points raised and commitment of<br />
the project proponent on the same<br />
along with time bound action plan<br />
to implement the same shall be<br />
provided after Public Hearing.<br />
No litigation and / or any direction /<br />
order passed by any Court of Law<br />
are pending against the project.<br />
All the above issues have been complied with and included in the EIA/EMP for<br />
proposed Cement Plant with captive 10 MW Power Plant and Lime Stone Mines.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 15
Hills Cement Co. Limited.<br />
2.1 SITE SELECTION CRITERIA<br />
CHAPTER- 2<br />
PROJECT DESCRIPTION<br />
The proposed project site is located near village Mynkre, Taluka Khelirihat,<br />
District Jaintia Hills of <strong>Meghalaya</strong> state, which is about 115 km from Shillong<br />
on NH-44 (Shillong-Silchar Road).<br />
The major criteria for locating a cement plant may be following:-<br />
• Availability of limestone deposit close to the cement plant site location,<br />
• The perennial source of water exists in the vicinity of the plant site,<br />
• Availability of reliable power and fuel supply.<br />
• The site is flat / slightly undulating area for plant.<br />
• Proximity to an established township, which would offer reasonable<br />
amenities to the plant employees.<br />
• The site is well connected with National /<strong>State</strong> Highway and nearest to<br />
the Khelirihat and have basic infrastructure for establishment of a<br />
cement plant with captive power plant.<br />
2.2 ANALYSIS OF ALTERNATIVES<br />
(i)<br />
SITE ALTERNATIVES<br />
M/s HILLS CEMENT CO. LIMITED has proposed for setting up a<br />
cement plant of 3,000TPD based on limestone deposits in the area<br />
along with 10MW CPP. Required infrastructure, off-site facilities<br />
including residential colony for the employees are also planned.<br />
Alternative site near village Suruphi was considered.<br />
The present site was selected having advantages and being more<br />
eco-friendly.<br />
The present site has the following advantages:<br />
• Proximity to captive limestone mines<br />
• Proximity to river for water intake<br />
• Availability of fuel (Coal)<br />
• Availability of adequate land for cement plant<br />
• Proximity to National Highway (NH-44)<br />
• Absence of any irrigation canal or drainage channel within the<br />
selected area<br />
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Hills Cement Co. Limited.<br />
• Thinly populated area with fairly leveled terrain<br />
• Availability of infrastructural facilities in the nearby area<br />
• No sensitive places nearby<br />
• Availability of manpower from surrounding villages<br />
• Captive power plant of 10MW capacity proposed<br />
(ii)<br />
TECHNOLOGY ALTERNATIVES<br />
The selection of kiln process is mainly governed by thermal and<br />
electrical energy economy. Dry process is most widely used for<br />
cement production in India. The dry process will be used for the<br />
manufacture of cement in proposed plant. To avail the overall energy<br />
efficiency, dry process of manufacture with pre-heater and precalcinator<br />
has been selected for the proposed plant along with 100%<br />
coal as fuel for kiln and pre-calcinator. A closed circuit ball mill of 120<br />
TPH has been considered to meet the raw material drying and<br />
grinding requirements.<br />
2.3 CEMENT PLANT<br />
The cement production capacity of the proposed plant is 3,000 tpd. It shall<br />
be achieved in two phases of 1,500 tpd each. The annual production<br />
capacity will be one million tons. Captive power plant of capacity 10 MW is<br />
also proposed for continuous supply to cement plant.<br />
LAND REQUIREMENT<br />
HCCL posses land measuring 55.5403 Hectares for proposed cement plant<br />
and captive power plant. The area is generally plain. M/s HCCL had initially<br />
planned installation of 600 TPD cement plant for which consent to establish<br />
was obtained from <strong>Meghalaya</strong> <strong>State</strong> <strong>Pollution</strong> <strong>Control</strong> <strong>Board</strong>. Land<br />
development activities have already been completed by HCCL. The<br />
company has prospecting licenses of 4 ha, 16 ha and 40.2 ha for exploration<br />
and mining of lime stone in nearby adjoining area. The exploration work is in<br />
progress. Reserves have been proved. Mining lease is being obtained.<br />
MANUFACTURING PROCESS:-<br />
1. Kiln Feed Preparation: - Raw material preparation is an electricityintensive<br />
production step requiring generally about 25-35 kWh/tonne raw<br />
material (23-32 kWh/short ton), although it could require as little as 11<br />
kWh/tonne. Basic ingredients used for manufacture of cement are<br />
limestone, coal, fly ash, additives and gypsum.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 17
Hills Cement Co. Limited.<br />
Raw mix is prepared in following approximate proportions:-<br />
Raw mix (%)<br />
(i) Limestone - 83.00%<br />
(ii) Clay - 10.48%<br />
(iii) Sand stone - 6.52%<br />
i. Clinkerisation Factor - 1.56<br />
ii. Fuel consumption - 850<br />
(Kcal/kg Clinker)<br />
iii. Calorific value of coal - 6,500<br />
(Kcal/kg)<br />
iv. Fuel consumption - 13%<br />
v. Gypsum - 5%<br />
(Addition in OPC)<br />
vi Calcinite clay /Limestone - 5%<br />
(Addition in OPC)<br />
After primary and secondary size reduction, the raw materials are further<br />
reduced in size by grinding.<br />
The storage capacities for various raw materials and products are as under:<br />
S.No. Section Storage capacity in kiln<br />
days<br />
01 Limestone Stockpile 8<br />
02 Clay 14<br />
03 Iron Ore 14<br />
04 Raw Meal Storage (Active) 3<br />
05 Clinker 10<br />
06 Coal 30<br />
07 Calcined Clay 15<br />
08 Cement 6<br />
09 Gypsum 15<br />
Broad Sizing of Main Storages<br />
The type and capacities of the storages for various materials, as derived in<br />
the technical concept for the proposed project based on the norms for<br />
storage capacities are given below:<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 18
Hills Cement Co. Limited.<br />
Capacity and Type of Main Storages<br />
SL NO Material<br />
Capacity Tons Type<br />
01 Crushed<br />
Limestone<br />
3x12,000 Rectangular in-line<br />
pre-blending stockpile<br />
02 Clay 7,600 Storage Yard<br />
03 Sand stone 4,700 Storage Yard<br />
04 Gypsum 3,000 Covered Storage<br />
05 Calcined Clay 1,500 Covered Storage<br />
06 Clinker 23,500 RCC Silo<br />
07 Cement 18,000 Stock Pile<br />
08 Coal 7,000 Covered Storage<br />
2. Dry grinding processing<br />
The materials are ground into a flow able powder in horizontal ball mills or<br />
in vertical roller mills. Utilizing waste heat from the kiln exhaust, clinker<br />
cooler hood, or auxiliary heat from a standalone air heater before<br />
pyroprocessing may further dry the raw materials. The moisture content in<br />
the kiln feed of the dry kiln is typically around 0.5% (0 - 0.7%). In a dry<br />
rotary kiln, feed material with much lower moisture content (0.5%) is<br />
used, thereby reducing the need for evaporation and reducing kiln length.<br />
3. Clinker Production<br />
Clinker production is the most energy-intensive stage in cement<br />
production, accounting for over 90% of total industry energy use, and<br />
virtually all of the fuel use. Clinker is produced by pyroprocessing in large<br />
kilns. While many different fuels can be used in the kiln, coal has been<br />
used as the primary fuel.<br />
Alkali or kiln dust (KD) bypass systems may be required in kilns to<br />
remove alkalis, sulfates, and/or chlorides. Such systems lead to additional<br />
energy losses since sensible heat is removed with the bypass gas and<br />
dust. Once the clinker is formed in the rotary kiln, it is cooled rapidly to<br />
minimize the formation of a glass phase and ensure the maximum yield.<br />
The main cooling technologies are either the grate cooler or the tube or<br />
planetary cooler. In the grate cooler, the clinker is transported over a<br />
reciprocating grate. Air flows perpendicular to the flow of clinker.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 19
Hills Cement Co. Limited.<br />
4. Grinding<br />
After cooling, the clinker can be stored in the clinker dome, silos, and bins<br />
or outside. To produce powdered cement, the nodules of clinker are<br />
ground. Grinding of clinker, together with additions (3-5% gypsum to<br />
control the setting properties of the cement) can be done in ball mills, ball<br />
mills in combination with roller presses, roller mills, or roller presses.<br />
Power consumption for grinding depends on the surface area required for<br />
the final product and the additives used. Electricity use for raw meal and<br />
finish grinding depends strongly on the hardness of the material<br />
(limestone, clinker, pozzolana extenders) and the desired fineness of the<br />
cement as well as the amount of additives. Blast furnace slag is harder to<br />
grind and hence use more grinding power, between 50 and 70<br />
kWh/tonne. Modern ball mills may use between 32 and 37 kWh/tonne.<br />
Modern state-of-the-art concepts utilize a high-pressure roller mill and the<br />
horizontal roller mill that are claimed to use 20-50% less energy than a<br />
ball mill.<br />
Finished cement is stored in silos, tested and filled into bags, or shipped<br />
in bulk on bulk cement trucks, railcars, barges or ships. Facilities for<br />
testing the physical properties like sieve analysis, setting time,<br />
soundness, fineness, CCS, grind ability, moisture content, lime reactivity<br />
& drying shrinkage, etc. For determining the particle size distribution of<br />
the raw mix, clinker, cements, etc. a laser diffraction type PSD analyzer<br />
may be installed having typical particle size range of 0.3 mm – 400<br />
micron. To ensure consistent product quality and to permit the trouble<br />
free and cost effective operation, the quality control plan for sampling &<br />
testing of various raw materials, in-process materials and the final product<br />
is suggested.<br />
Additional power for conveyor belts and packing of cement is generally<br />
low and not more than 5% of total power use that is estimated at 1-2<br />
kWh/tonne cement. The power consumption for packing depends on the<br />
share of cement packed in bags.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 20
Hills Cement Co. Limited.<br />
Flow Chart of Cement Manufacturing Process Æ<br />
Mining<br />
Additives<br />
Limestone<br />
Clay<br />
Crusher<br />
Homogenous raw material<br />
(Through Preheater System)<br />
Crushing<br />
& Drying<br />
Coal Crushing<br />
Kiln Clinker Grate<br />
& Drying<br />
Cooler<br />
Storage<br />
Ordinary Portland<br />
Cement<br />
Grinder<br />
Gypsum<br />
Packing<br />
Dispatch<br />
QUALITY CONTROL PLAN<br />
While proposing the methods and procedures for quality control, the following<br />
aspects have been taken into account:<br />
• Requirements and norms, particularly in cement testing.<br />
• Corrective measures to be undertaken as quickly as possible in the<br />
process operation.<br />
• Desired degree of automation.<br />
• Available raw materials and process equipment.<br />
The three main areas of quality control have been envisaged:<br />
Facilities and equipment envisaged for quality control of the raw materials<br />
and final products for the proposed plant are as follows:<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 21
Hills Cement Co. Limited.<br />
Raw mix preparation<br />
Pyro-processing<br />
Cement<br />
- Raw material control in quarry<br />
- Raw material control before pre-blending<br />
- Raw material control after raw mill<br />
- Kiln feed<br />
- Fuel<br />
- Clinker<br />
- Before cement mill<br />
- After cement mill<br />
UTILITY SYSTEMS<br />
Compressed Air Supply<br />
The compressed air is required mainly for dust collection equipment and<br />
operation of pneumatic valves. Blowers will be used for aeration of silos. Two<br />
centralized compressor room are proposed, one for the Clinkerisation section<br />
and the other for cement grinding, storage and packing section. Blowers may<br />
be suitably accommodated under buildings / silos near points of utility.<br />
Power<br />
The power requirement for the plant has been estimated as 10 MVA. The<br />
project proponent has a sanction of 10 MW from MeSEB. The power<br />
requirement will also be met by captive power plant.<br />
Water Requirement<br />
Total water requirement for project is expected to be 400 m 3 / day. Some<br />
quantity of water will be required drinking and sanitation for plant personnel.<br />
Total requirement of fresh water make-up including drinking, auxiliary cooling<br />
etc. will be 6-8 M 3 /Hr. Water is available in plenty from nearby underground<br />
natural spring.<br />
Water balance including requirement of water for power plant is given<br />
separately. (Page ref. 32)<br />
Manpower Requirement<br />
Several cement plants are operating in region’s vicinity. Therefore the trained<br />
manpower in marginal, supervisory and skilled categories is expected to be<br />
easily available.<br />
For operation of the power plant and outside service facilities, like coal<br />
handling plant (for AFBC boiler only), ash evacuation system from the ash<br />
silo etc. as well as for day-to-day preventive maintenance of the plant,<br />
necessary manpower has been considered. The estimated number of<br />
technical personnel required is around 450 comprising executives, skilled, a<br />
semi- skilled and unskilled worker. About 150 workers and staff shall be<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 22
Hills Cement Co. Limited.<br />
required for operations of mines. Personnel in the semi-skilled and unskilled<br />
categories are proposed to be employed from nearby villages/ towns.<br />
2.4 POWER PLANT<br />
Basic Requirements<br />
1. Main fuels : 100% coal<br />
70% coal / 30%<br />
Washery reject<br />
or char<br />
2. Boiler capacity at 100% MCR : 45 TPH<br />
3. Steam pressure at super heater outlet : 67 kg / cm 2<br />
4. Steam temperature at super heater outlet : 495° +/- 5 o C<br />
5. Field water temperature at economizer : 130 o C Inlet<br />
6. Rating of Turbo Generator : 10 MW<br />
7. Auxiliary Consumption : 1.20 MW<br />
8. Net Power output from power plant : 8.8 MW<br />
Fuel Requirement<br />
The fuels required for operation of the AFBC Boiler of the proposed CPP are<br />
as under:<br />
i) Coal as main fuel from <strong>Meghalaya</strong> coal mines.<br />
ii) Coal Fines.<br />
iii) HSD / LDO as secondary fuel from nearby oil repository for start up of<br />
Boiler.<br />
The annual coal (including coal fines) requirement will be about 48,000 MT<br />
per year with coal of about 18% ash content and of 5,500 Kcal /Kg calorific<br />
value. HSD / LDO will be used only during start up of AFBC as secondary<br />
fuel and no regular oil firing is required.<br />
Main fuels: Coal / Char<br />
Char<br />
Coal<br />
Carbon % : --- 37.10<br />
Hydrogen % : --- 2.30<br />
Nitrogen % : --- 0.70<br />
Oxygen % : --- 6.60<br />
Sulphur % : --- 0.30<br />
Moisture % : --- 45.00<br />
GCV kcals / kg: --- 3500<br />
Cooling water inlet temperature : 32Û&<br />
Cooling water outlet temperature : 40Û&<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 23
Hills Cement Co. Limited.<br />
Atmospheric Fluidized Bed Boiler<br />
The power plant is envisaged with installation of atmospheric fluidized bed<br />
boiler of 45 TPH steam capacity at a steam pressure of 67 ata and<br />
temperature of 495 o C. The atmospheric fluidized bed boiler will meet the<br />
steam requirement of the turbine of the power plant. The boiler will be of<br />
single drum construction and will include the complete furnace, the super<br />
heater, economizer, steam drum, air heater etc. The ash handling system<br />
comprises of conveying the bed ash generated from the bottom of the<br />
atmospheric Fluidized Bed boiler and the fly ash generated that economizer,<br />
air heater and ESP. Bottom ash shall be manually disposed off and fly ash<br />
shall be pneumatically. The boiler will also be provided with an electrostatic<br />
precipitator to restrict the outlet dust concentration to 50 mg / Nm 3 . The<br />
power will be provided with chimney of suitable height to take into<br />
consideration the <strong>Pollution</strong> <strong>Control</strong> <strong>Board</strong> requirements.<br />
The Atmospheric Fluidized Bed Boiler will be provided with necessary field<br />
mounted gauges, switches, transmitters, I/P converters, pneumatically<br />
operated control valves.<br />
The transmitters and converters for the open loops and closed loops to<br />
monitor and control the various process parameters of the boiler will be of<br />
electronic type.<br />
¾<br />
¾<br />
¾<br />
¾<br />
¾<br />
¾<br />
Combustion control along with master pressure control<br />
Drum level control (3 Element)<br />
Super heater temperature control<br />
Furnace draft control<br />
Deaerator pressure control<br />
Deaerator level control<br />
The transmitters for the open loops to monitor the pressure, temperature,<br />
flow and level at various points of the boiler will be directly connected to the<br />
Analog Input Modules of the main DCS system and the signal will be<br />
processed and displayed on the monitor.<br />
Turbo – Generator<br />
The steam generated from the boiler will be fed into 10 MW Turbo-<br />
Generators. 10 MW Turbo-Generators will generate power at 11 KV, which<br />
shall be stepped up to 33 KV through 16 MVA step up cum step down<br />
transformer. Output of this 33 KV Switchgear will be connected by 33 / 19 KV<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 24
Hills Cement Co. Limited.<br />
XLPE insulated aluminum conductor screened & armored cable directly to 33<br />
KV bus of the Substation.<br />
The concept of the instrumentation system for the TG will also be similar to<br />
that of traveling grate boiler. DCS will be provided for the following closed<br />
loop controls:<br />
¾ Hot well level control<br />
¾ Gland steam pressure control<br />
¾ Pressure and temperature control<br />
The transmitters for the open loops of TG will also be wired to the main DCS<br />
system. The protection and interlocking system of the turbine will also be<br />
performed by the main DCS by connecting the field-mounted switches to the<br />
DCS system.<br />
The turbine will also be provided with the surface condenser, condensate<br />
extraction pumps, and gland vent condenser. Governing system of the<br />
turbine will be by electro hydraulic type to govern the turbine speed during<br />
varying load demands the fluctuations. The speed governing system will limit<br />
the over speed of the TG set on loss of full load to avoid tripping by the over<br />
speed device.<br />
The instrumentation and control system for the Atmospheric Fluidized Bed<br />
Boiler and the turbo generator unit, etc., will be of electronic instruments with<br />
pneumatic final control elements using the latest state of art of technology<br />
viz., DCS system along with PC based automation system for monitoring and<br />
control of the power plants from the control room. All the necessary<br />
instruments required for proper operation of the plants will be provided.<br />
The CPP is proposed to be operated in synchronous mode with <strong>Meghalaya</strong><br />
<strong>State</strong> Grid. The generated electrical power will be consumed in-house for the<br />
existing cement plant and CPP auxiliaries’ power. The plant utility<br />
requirements like compressed air, instrument air, water, etc., are all suitably<br />
designed to meet the power plant requirement. The capacities of the<br />
equipments used in this system have been considered with sufficient margins<br />
to take care of these requirements.<br />
WATER REQUIREMENT<br />
Apart from steam generation, water is used as a cooling medium in the heat<br />
exchanger equipments in power plant such as condensers, oil coolers,<br />
generator air coolers etc. of turbo generator. Nearly 1,100 M 3 / day water<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 25
Hills Cement Co. Limited.<br />
shall be required for steam generation and cooling circuits. 80-85% water is<br />
recirculated. About 150 M 3 /day shall be the net consumption. Evaporation<br />
losses from cooling tower and other places account for nearly 100 M 3 / day.<br />
Waste water from various streams shall be 50 M 3 / day. This waste water<br />
along with waste water from cement plant (nearly 30 M 3 / day) and 80 M 3 /<br />
day domestic effluent shall be separately or jointly treated in effluent<br />
treatment plant. It shall be used for ash quenching, ash handling system,<br />
dust suppression system in coal storage area, and greenery development.<br />
The intake water system will consist of an intake pump house near raw water<br />
reservoir. The intake pump and associated pipe work have been planned<br />
such that it is sufficient to run the pump for about 48 hours to meet the plant<br />
requirement.<br />
Make-up water system:<br />
Make-up water system will consist of the following major items of equipment:<br />
1) Raw water treatment plant (RWTP) with raw water pump sets will be<br />
installed to meet the entire make-up water requirements of power<br />
plant.<br />
2) Raw water pipe work from storage sump to RWTP.<br />
3) Make-up water pipe work from RWTP to filter and softener and to<br />
cooling water basin cum storage sump.<br />
The break-up of make-up water for various consumers are given below.<br />
S.No. System Normal (Approx.)<br />
Make-up water (m 3 / hr)<br />
1. Air Cooling water system 5.0<br />
With Aux cooling Tower<br />
2. Demineralised make-up water for boiler 3.0<br />
3. Requirements of demineralization plant, 2.0<br />
Sludge, back wash, and regeneration<br />
The total blow down from the cooling tower is expected to be about 6 m 3 / hr<br />
during normal condition.<br />
The entire blow down water will be used in dust suppression system and<br />
green belt development.<br />
Demineralization & Softening Plant:<br />
The condenser extraction pumps at the condensate storage tank pump the<br />
condensate form the surface condenser. The make-up from DM water<br />
storage tank will be added to the condensate storage tank. Boiler feed water<br />
from this condensate storage tank will be pumped to the deaerator through<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 26
Hills Cement Co. Limited.<br />
transfer pumps with standby facility. The level inside the deaerated feed<br />
water storage tank shall be maintained at constant set valves by controlling<br />
the quantum of feed pumped by the transfer pumps.<br />
The deaerated feed water from the feed water storage tank will be supplied<br />
to the steam generator by means of boiler feed water pumps of adequate<br />
capacity to cater the requirements of 45 TPH Boiler. To cater the make-up<br />
water requirement of the steam generation/turbine cycle, a demineralization<br />
water plant having capacity of 4 cum / hr is proposed.<br />
COMPRESSED AIR SYSTEM<br />
To cater the requirement of the compressed air for instruments and the<br />
control systems two compressors rated for 100 N.Cu.M/hr at 8.0 Kg/Cm 2<br />
shall be installed. The air compressor shall be provided with accessories like<br />
inter cooler, moisture separators, air dryers, air receivers, and control panel.<br />
Two stage reciprocating air compressors shall be belt driven, oil free, nonlubricating<br />
type. The design of the reciprocating compressor shall be in<br />
accordance with API 618. The rotating parts shall be dynamically balanced<br />
according to the standard to minimize noise and vibrations.<br />
VENTILATION AND AIR CONDITIONING SYSTEM<br />
Air-conditioning systems, where required with suitable natural as well as<br />
mechanical ventilation be proved for various plant areas. Filtered air supply<br />
and exhaust arrangements shall be provided for MCC rooms and switchgear<br />
rooms. The rooms shall be kept under positive pressure of +5 mm by means<br />
of gravity louvers. Necessary roof extractors will be provided in the machine<br />
bay to ensure at least ten (10) number of air change.<br />
DC Power supply System<br />
The essential loads within the power plant which are too maintained during<br />
an emergency situation are listed below:<br />
Emergency lube oil pump<br />
¾<br />
¾<br />
Emergency lighting<br />
<strong>Control</strong> power supply to various switchboards, electrical control panels<br />
of 11 kV.<br />
Annunciation system<br />
In order to meet the above requirement at 110 V DC, Maintenance free lead<br />
acid battery bank of adequate capacity along with charger unit will be<br />
provided. The battery capacity will be designed based on 30 min supply to<br />
the essential auxiliaries and one-hour duration for emergency lighting<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 27
Hills Cement Co. Limited.<br />
system. The 110 VDC distribution board will cater to the needs of the above<br />
essential auxiliaries loads.<br />
LT & HT Switchgear room<br />
The 11 kV generators switch board (GSB) will also be located within the<br />
power house. The 415 V switchboards and motor control centers (MCC) for<br />
turbo generator, boiler, ESP, Fuel Handling system will be located in ground<br />
floor level. These LT boards will have provision for cable entry from bottom.<br />
All cables within this room will be routed through civil cable trenches.<br />
Adequate exhaust ventilation system will be provided for the switchgear<br />
rooms.<br />
Lightening Protection System<br />
The plant earth grid as well as the turbo generator building-earthing grid will<br />
be interconnected in order to limit the overall resistance of the earthing<br />
system. The design of earthing station will be as per IS: 3043. Galvanized<br />
steel flats will be used for earth mats. All electrical equipment and steel<br />
structure will be earthed properly and distinctly at two points. Separate and<br />
independent earthing connection will be made for electronic equipment in<br />
order to make its functioning free from system disturbances. The entire<br />
power plant buildings/structures at isolated locations will be protected against<br />
lighting. The design of the lightning protection system will be as stipulated in<br />
IS: 2309. The substation earthing system will be provided to keep touch and<br />
step potential within limits. Earthing system consists of earthling station,<br />
earthling conductors and accessories for providing complete earthling to<br />
equipment and system earthing. The Shielding considered for protection of<br />
all outdoor equipment from lighting strokes will be with GS spikes supported<br />
on top of substation structures. Spikes will be connected to the substation<br />
earthing. The lightening arrestors will be outdoor, heavy duty, gapless, ZnO,<br />
non linear resistor, station type with the terminal suitable for outdoor bus<br />
system and earth side terminal suitable for connection with galvanized MS<br />
flats. The nominal discharge current ratings will be 10 kA.<br />
Power monitoring system<br />
Necessary electrical transducers to monitor the parameters such as bus<br />
voltage, current, frequency, power, energy will be provided as part of the<br />
electrical distribution system and these transducers will be wired to the main<br />
DCS unit through remote I/O units for monitoring the power distribution<br />
arrangement. Also contact inputs for various circuit breakers status positions<br />
will be wired to the main DCS unit to monitor the status of the different<br />
distribution breakers and fault condition.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 28
Hills Cement Co. Limited.<br />
The PC based automation system provided in the control room will be<br />
complete with the following:<br />
Pc Server hardware of latest configuration with CD-ROM drive, printers along<br />
with 2 nos. of PC based operator stations. Job specific application software<br />
packages developed for this power plant that includes mimic displays, alarm<br />
displays, trending, logs and reports will be provided as part of the automation<br />
system.<br />
Storage and Handling System:<br />
Online magnetic separator (permanent magnet) and metal detector on the<br />
conveyor will be provided. Required monorail beams along with mechanical<br />
maintenance hoists at strategic points will be provided for maintenance<br />
purpose. A suitable conveyor will be provided for the fly ash, gypsum and<br />
clinker separately.<br />
Mobile loading conveyor (mini-stacker) machines are considered in the fuel<br />
receipt area near the feeding Zone to utilize the same to stock pile the fuels<br />
to a heap height of 8 to 10 meters. These mini stackers will also be utilized to<br />
feed the fuel to de-stoner for processing. Fuel handling system will be<br />
provided with one belt conveying system.<br />
Ash Handling System:<br />
The estimated fly ash from economizer APH & ESPs will be collected in ash<br />
hopper and will be carried through ms pipes by lean cum dense phase<br />
system all operation will be through D.C.S. only. Ash silo capacity 300 cu<br />
meter R.C.C. / Steel and silo discharge ash will be conveyed mechanically.<br />
Total ash per day 70 / Husk & 30% coal will be approx 120MT/day detail<br />
calculation will be done during finalization.<br />
The bottom ash from bed material of will be collected manually by trolley at<br />
regular intervals and disposed off trolleys at regular intervals and disposed<br />
off. The temperature of is ash coming out from the bed ash cooler is<br />
expected to be about 250°C.<br />
ELECTRICAL EQUIPMENT/SYSTEM<br />
The following power Supply standard voltage levels will be adopted for the<br />
various Systems.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 29
Hills Cement Co. Limited.<br />
i) Evacuation and Transmission 33 KV, 3 Phase, 3 Wire 50 Hz<br />
Solidly earthed<br />
ii) Generator Output 11 KV, 3 Phase, 3 Wire 50 Hz,<br />
Resistance Earthed<br />
iii) Station Supply 415 V, 3 phase, 4 Wire Solidly<br />
Earthed<br />
iv) A.C. Drive Motors 415 V, 3 phase, 4 Wire Solidly<br />
Earthed<br />
v) Instrumentation and <strong>Control</strong><br />
Including Protection inter<br />
110 V, 1 Phase 2 Wire 50 Hz A.C.,<br />
(Battery Backed up UPS System)<br />
vi)<br />
Locking System<br />
<strong>Control</strong> & Protection of HT and<br />
LT Switchgear and D.C. Drives<br />
110V, 2 Wire Unearthed D.C.<br />
vii) Panel Lighting and Space<br />
Heaters<br />
viii) DCS/PLC Power supply 50 Hz,<br />
A.C. Stabilized<br />
240 V, 1 Phase, 2 Wire 50 Hz,<br />
A.C with one Point Earthed<br />
110 V, 1 Phase, 2 Wire through<br />
Battery Backed up UPS System<br />
ix) Welding Socket Outlets 415 V, 3 Phase, 50 Hz. A.C.<br />
POWER PLANT CONTROL ROOM<br />
Generator <strong>Control</strong>, relay and synchronizing panel will be located in the<br />
control room located at + 6.0 levels in annex bay. VFD panels, ESP<br />
controllers, battery and battery chargers will also be installed in this floor.<br />
False flooring will be provided in the control room for cabling. The control<br />
room will be air-conditioned.<br />
OTHER FACILITIES<br />
All equipment / devices essential for safe and reliable operation of the CPP<br />
shall be controlled from the control room with DCS based interfaced PC and<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 30
Hills Cement Co. Limited.<br />
key board. Facility shall be provided also for selective manual control from<br />
local control station / respective switchgears / MCCs.<br />
The layout of electrical equipment will be provided with consideration of<br />
safety, ease of movement and with standard clearances stipulated. 16MVA<br />
Step up with cum step down transformer and CPP auxiliary transformer will<br />
be located and MCC s shall be suitably located in different locations / floor<br />
levels of TG Building. Cables will be routed through RCC trenches in<br />
Transformer yard and 33KV Substation areas. As deemed necessary some<br />
places Cables will be laid on over head pipe racks or otherwise supported on<br />
Structures. Once CPP is started synchronization will be done at 11KV bus.<br />
The functions such as sequencing, protection and interlocking system<br />
required for other facilities namely fuel handling system, Pump house and<br />
water treatment plant will also be performed by main DCS system. With this<br />
arrangement, monitoring and controlling of the auxiliary units also doe from<br />
the control room. DM plant operation will be controlled through dedicated sub<br />
controller in the respective plant units and these PLC units will also be<br />
interfaced to the main DCS system. With this arrangement, monitoring of the<br />
auxiliary units also can be done from the control room.<br />
WATER BALANCE FOR CEMENT PLANT ALONGWITH CPP<br />
Total water requirement for project shall be 1,500 M 3 / day. Nearly 1,100 M 3 /<br />
day condensate and water from other closed circuits shall be either<br />
recirculated or reused. Net fresh water requirement shall be only 400 M 3 / day<br />
out of which 260 M 3 / day shall be evaporation losses. 140 M 3 / day treated<br />
waste water shall be used in ash quenching, ash handling, dust suppression<br />
and greenery development.<br />
The water balance chart follows:<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 31
Hills Cement Co. Limited.<br />
WATER BALANCE<br />
Fresh make up water 400 m<br />
3 /day<br />
Reuse/Recycle<br />
(150 M 3 /day)<br />
Total water requirement for the<br />
project (1,500 M 3 /day)<br />
Reuse/Recycle<br />
(950 M 3 /day)<br />
Requirement for 3,000 tpd<br />
Cement Plant (300 M 3 /day)<br />
Domestic Water Requirement<br />
(100 M 3 /day)<br />
Requirement for 10 MW Power<br />
Plant (1,100 M 3 /day)<br />
Evaporation Losses<br />
(120 M 3 /day)<br />
3 3<br />
Evaporation Losses<br />
(20 M 3 /day)<br />
Waste Water<br />
(80 M 3 /day)<br />
Evaporation Losses<br />
(100 M 3 /day)<br />
Waste Water<br />
(30 M 3 /day)<br />
Net fresh water requirement<br />
(400 M 3 /day)<br />
Losses<br />
(20 M 3 /day)<br />
Effluent Treatment Plant<br />
160 M 3 /day<br />
Waste Water<br />
(50M 3 /day)<br />
Treated water use in ash quenching/ash handling/ dust<br />
suppression & Green belt development 140 M 3 /day<br />
3<br />
Losses (260 M 3 /day)<br />
140 M 3 /day treated water used<br />
or dust suppression/greenery<br />
development<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd.
Hills Cement Co. Limited.<br />
2.5 LIMESTONE MINING<br />
Mining normally means an operation that involves the physical removal of<br />
rock and earth. The process includes excavations in underground mines and<br />
surface excavations in open-pit, or opencast (strip) mines.<br />
The deposit occurs in and around the project site near the Shillong –Badarpur<br />
road (NH-44). The deposit falls in Survey of India topo sheet No.83C/SW<br />
(Restricted) and is bounded by the following co ordinates:<br />
Longitude: 92 0 05’00” to 92 0 22’52”<br />
Latitude: 25 0 10’16” to 26 0 00’00”<br />
The deposit represents the Sylhet stage of the Jaintia series of Eocene age<br />
and comprises of three limestone beds interbedded with thin to thick<br />
sandstone bands. According to the Geological Survey of India (GSI) report,<br />
the limestone extends over an area of around 76.8 Sq. Kms between the<br />
rivers, Um Lunar and Um Seshympa.<br />
HCCL has two prospecting licenses for lime stone mining, one for 16 Ha and<br />
other for 40.2 Ha (both contiguous and nearby).<br />
The description reports of the prospecting licenses are as under-<br />
DESCRIPTION REPORT OF 16 Ha PL<br />
FIXED REFERENCE POINT-116 KM STONE, NH-44<br />
FROM TO BEARING DISTANCE<br />
116 KM STONE<br />
NH-44 1 358°45’ 91.00<br />
1 2 19°15’ 111.50<br />
2 3 95°45’ 185.00<br />
3 4 91°30’ 263.00<br />
4 5 88°00’ 138.00<br />
5 6 88°15’ 265.00<br />
6 7 106°00’ 187.00<br />
7 8 96°30’ 237.00<br />
8 A 52°00’ 20.00<br />
A B 142°00’ 400.00<br />
B C 232°00’ 400.00<br />
C D 322°00’ 400.00<br />
D 8 52°00’ 200.00<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd.
Hills Cement Co. Limited.<br />
DESCRIPTION REPORT OF 40.2 Ha PL<br />
FIXED REFERENCE POINT-116 KM STONE, NH-44<br />
FROM TO BEARING DISTANCE<br />
116 KM STONE<br />
NH-44 1 358°45’ 91.00<br />
1 2 19°15’ 111.50<br />
2 3 95°45’ 185.00<br />
3 4 91°30’ 263.00<br />
4 5 88°00’ 138.00<br />
5 6 88°15’ 265.00<br />
6 7 106°00’ 187.00<br />
7 L 96°30’ 513.70<br />
L M 360°00’ 73.59<br />
M N 90°00’ 791.67<br />
N O 180°00’ 700.00<br />
O P 270°00’ 308.33<br />
P L 322°00’ 791.20<br />
The exploration work is in progress. Mineable reserves have been calculated based<br />
on the exposed and presently explored/proven category of reserves. The mineable<br />
reserves are 11.25 million tons. Considering annual depletion of limestone reserves<br />
at 0.80 million tons, the total available mineable reserves of inferred category are<br />
sufficient for about 15 years of deposit life. The anticipated life of the deposit life<br />
shall be augmented, when additional mineral bearing area, adjoining the present<br />
area, is acquired and an ML is obtained for it.<br />
There are many mines in private lands. Limestone is available in plenty. The<br />
limestone will also be procured from nearby mining leases held by local occupants of<br />
the area.<br />
Following activities will be involved in the mining of lime stone<br />
1. Land acquisition<br />
2. Topsoil removal and storage<br />
3. Overburden removal and storage<br />
4. Limestone & calcite extraction<br />
5. Heavy Earth Moving machinery {HEMM} and maintenance<br />
6. Site development – creation of infrastructure including roads<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 34
Hills Cement Co. Limited.<br />
7. Drilling and blasting<br />
8. Toxic waste treatment disposal<br />
9. Mine water pumping<br />
10. Material (limestone & calcite) transport<br />
11. Site restoration/reclamation- back filling, treatment, spreading of<br />
topsoil, re vegetation.<br />
12. Material processing<br />
Open cast both manual and mechanized methods of mining will be<br />
continued to win the mineral. Mechanical loader and trippers shall be<br />
used for fast removal of overburden, loading of mineral and waste and<br />
for construction of haul roads. The mining is proposed as per present<br />
situation of the deposit, about 1,000 meters away from habitation.<br />
Blasting will be taken up with consent from DGMS/ Concerning<br />
Authorities. No mineral beneficiation shall be carried out at site.<br />
The haul road is proposed up to benches, workings, infrastructure and<br />
site of dumps from nearest tar road. Tractor trolleys and trippers are<br />
proposed to transport mineral and waste.<br />
The tentative year wise mineral production and waste generation for first<br />
5 years is given below:<br />
Year Waste in tonnes Rom mineral in tonnes<br />
I 40,200 5,01,000<br />
II 62,300 7,07,000<br />
III 63,200 7,51,000<br />
IV 72,650 8,11,000<br />
V 73,800 8,15,000<br />
Total 3,12,150 35,94,000<br />
The environmental impacts of above various mining activities are assessed and<br />
EIA prepared as per TORs issued by the Hon’ble Expert Committee of MoEF.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 35
Hills Cement Co. Limited.<br />
<br />
<br />
CHAPTER-3<br />
BASELINE DATA GENERATION<br />
3.1 GEOGRAPHY OF THE AREA<br />
<br />
The area is generally plain but will require some cutting and fitting. The<br />
proposed Plant will be located in the premises of the existing Cement Plant<br />
Complex at village Mynkree, 116 KM Stone, NH 44, Sub Div. Kheliehriat,<br />
District Jaintia Hills (<strong>Meghalaya</strong>). The longitude and latitude (Approx.) of the<br />
project site are E 92ÛDQG1Û7KHJHRORJLFDOIRUPDWLRQVLts<br />
resultant topography and tendency of headward erosion by rainwater have<br />
led to the creation of drainage network in the area. The prevailing weather<br />
and climate in the study area is characterized by heavy rainfall, which favors<br />
the action of streams to a considerable extent.<br />
Predominantly two different kinds of drainage patterns can be seen in the<br />
study area. They are mainly dendrite and trellis pattern. Dendrite kind of<br />
drainage pattern has generally developed in the most dissected parts of the<br />
plateau. In this case the consequent river receives number of tributaries,<br />
which are fed by innumerable smaller streams. In the case of trellis pattern of<br />
drainage the consequent stream cuts across the crest and subsequent<br />
streams follow the strike valleys. Innumerable first order and second order<br />
streams signify the high density of drainage system of the project area.<br />
HYDROGEOLOGICAL CONDITIONS<br />
Total area of <strong>Meghalaya</strong> state is 22,429 Sq. Kms. There are total 7 districts, 32<br />
blocks and mainly four physiographic units, namely -<br />
ƒ<br />
ƒ<br />
ƒ<br />
ƒ<br />
Uplifted Plateau,<br />
Denudational high hills,<br />
Denudational low hills and<br />
Intermontane valleys<br />
<strong>State</strong> is drained by Brahmaputra, Meghna and its tributaries. Rainfall is 2,050 mm<br />
with 200 rainy days.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 36
Hills Cement Co. Limited.<br />
GROUND WATER MEDIUM<br />
The northern part of the <strong>State</strong> is covered by consolidated formations comprising<br />
granites, gneisses, schists, quartzite, phyllites and conglomerates with basic and<br />
acid intrusive. The zone of weathering is the main repository of ground water;<br />
however, the weak planes, fissure, joints and fractures also hold substantial<br />
quantity of ground water. Semi-consolidated sandstones with other sedimentary<br />
formations cover the entire south western and south eastern part of the <strong>State</strong> in<br />
Khasi and Jaintia hills district. The tube wells in the sedimentary formations in<br />
valleys yield 25-50 m 3 /hr. Unconsolidated formations are restricted to a narrow<br />
belt in the extreme north western fringe where hills rolls down to Assam and<br />
Bangladesh plains. The deep tube wells in these alluvial formations can yield 54<br />
to 110 m 3 /hr. Shallow tube wells in river fills in Garo hills district yield 25 to 40<br />
m 3 /hr. Ground water in the <strong>State</strong> is characterized by low salinity.<br />
GROUND WATER EXPLORATION/SOURCES FINDINGS<br />
Dynamic Resources<br />
Annual Replenish able Ground water<br />
Resource<br />
1.15 BCM<br />
Net Annual Ground Water Availability<br />
Annual Ground Water Draft<br />
1.04 BCM<br />
0.002 BCM<br />
Stage of Ground Water Development 0.18 %<br />
Developmental Monitoring<br />
Over Exploited<br />
Critical<br />
Semi- critical<br />
Exploratory Tube wells Constructed (as on<br />
31.03.2007)<br />
No. of ground water observation wells 38<br />
Ground water user maps<br />
NIL<br />
NIL<br />
NIL<br />
78<br />
7 districts<br />
Source: Central Ground Water <strong>Board</strong>.<br />
<br />
There are no critical areas in <strong>Meghalaya</strong> from water availability point of<br />
view.<br />
<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 37
Hills Cement Co. Limited.<br />
TABLE 3.1<br />
LIST OF INDUSTRIES IN STUDY AREA<br />
Sl. No. Particulars Distance, (Approx.) Kms Direction<br />
1. CMCL 10.0 SE<br />
2. JUD Cement 5.0 SE<br />
3. Adhunik cement 4.0 SW<br />
4. MCL 3.0 SE<br />
5. Green valley cement 3.0 NE<br />
3.2 SOCIO-ECONOMIC ENVIRONMENT<br />
Socio-economic environment includes description of demography, and<br />
available basic data. The study area lies in Kheliehriat community<br />
development block of district Jaintia Hills. The district of Jaintia Hills lies in the<br />
eastern part of the <strong>Meghalaya</strong> and bounded on the north and east by the<br />
state of Assam, on the west by East Khasi Hills and shares a common<br />
international boundary with Bangladesh in south. The District has four<br />
community development blocks viz. Thadlaskein, Laskein, Amlarem and<br />
Kheliehriat. For administrative purposes, district is divided into two subdivisions<br />
viz. Amlarem and Kheliehriat.<br />
The satellite image of the proposed site in placed below:<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 38
Hills Cement Co. Limited.<br />
The 10 km radius study area around the plant comprises of 14 villages as per<br />
Census 2001.The socio-economic profile of the study area is presented<br />
based on site visits, discussions with the villagers and the secondary data<br />
available form various agencies.<br />
POPULATION<br />
The study area includes 14 villages with an estimated population figure of<br />
9,197 (census 2001), covering an area of 10 Kms around the site.<br />
Table 3.2<br />
Demographic Details of the Study Area<br />
S.No. Particulars Census 2001<br />
1 Total Population 9,197<br />
2 No. of Males 4,607<br />
3 No. of Female 4,590<br />
4 Household 1,630<br />
5 Schedule Tribes 9,030<br />
Table 3.3 Classification of the Villages Based on Population Size<br />
S.No. Village Group Population<br />
Range<br />
Number Of Villages<br />
Census 2001<br />
1 Diminutive villages Below 1<br />
2 Diminutive villages 50 – 99 1<br />
3 Diminutive villages 100 –199 1<br />
4 Small villages 200 – 499 9<br />
5 Medium villages 500 –1999 1<br />
6 Large villages 2000 – 4999 1<br />
7 Very large villages 5000 – 9000 NIL<br />
8 Special villages 10,000 + NIL<br />
Total<br />
14<br />
Most of the villages in the study area have the population less than 500 and<br />
only two villages in the study area have population more than 1000. No<br />
village has been found having population more than 5000.<br />
From table given below, it can be concluded that, study area is mainly<br />
dominated by schedule tribes and very minor ratio of schedule castes.<br />
Decadal growth in the population of the study area is 52.7%; and Decadal<br />
growth in the sex ratio of the study area is 6.1%.<br />
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Hills Cement Co. Limited.<br />
Demographic details of the study area are summarized in Table 3.4<br />
<br />
Table 3.4<br />
Demographic details<br />
VILLAGE NAME T_HH T_P T_M T_F ST_P ST_M ST_F<br />
Thangskai 57 342 178 164 338 174 164<br />
Umshangiar 59 334 160 174 334 160 174<br />
Khaddum 37 188 103 85 188 103 85<br />
Larseng 14 83 56 27 53 32 21<br />
Lumshnong 231 1250 643 607 1230 632 598<br />
Mynkre 64 293 148 145 219 96 123<br />
Nongsning 65 365 185 180 344 172 172<br />
Nongthymme 50 282 135 147 282 135 147<br />
Shiehruphi 73 416 211 205 416 211 205<br />
Umbadoh - - - - - - -<br />
Umlong 52 260 138 122 260 138 122<br />
Umtyra 59 330 171 159 330 171 159<br />
Wahiajer 741 4295 2088 2207 4278 2080 2198<br />
Wahsarang 81 498 252 246 497 251 246<br />
<br />
Total 1630 9197 4607 4590 9030 4494 4536<br />
Land Use Pattern of the Study Area<br />
The main crop of the area is Paddy. The minor crops of the area are Maize,<br />
Rabi &other pulses, Other cereals & small millet, Sesamum, Rape & Mustard,<br />
Soya bean etc. Land use of the study area i.e. 10 km radius around the<br />
project site covering five major categories:<br />
(i) Settlement, (ii) Agriculture, (iii) Forests, (iv) Grassland Scrub and (v)<br />
Barren land. The land use pattern has been worked out with Satellite<br />
Imageries of RF 1:50,000 scales. The imageries were overlaid on the<br />
topographical sheets of Survey of India of the same scale.<br />
The forest cover accounts for 69% of the geographical area. Agriculture is the<br />
next important land use in the area. Most of the agricultural lands account for<br />
orchard, paddy fields etc. The tone and texture of imageries clearly identified<br />
the grass and scrubs, which account for about 6% of the total geographical<br />
area. Barren land which occupies about 5% of the area includes broken land,<br />
rocky knobs, boulders and sandy river bed.<br />
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3.3 INFRASTRUCTURAL FACILITIES<br />
Nearest habitation is in the village Mynkre at about 3 Km from the plant. All<br />
basic amenities such as school, hospital, market, etc. are available in the<br />
Kheliehriat town, which is about 35 Km from the plant site. The study area is<br />
well equipped with educational and medical facilities, drinking water supply,<br />
post offices, approach roads etc. Drinking water was available in all the<br />
villages. The main source of drinking water was through tube wells, springs,<br />
perennial streams and hand pumps. Some villages also have tap water<br />
facilities, which have been further improved now. The study area had good<br />
postal network. All villages were having post offices.<br />
Transport and communication facilities are considered as administrative<br />
necessity as well as a public convenience. However, a well-knit transportation<br />
system is a pre-requisite for the social and economic development of any<br />
district. The linking of one place with the other byroad is very essential to<br />
provide good transport system. The study area had good road network. About<br />
55% of the villages had pucca approach road. Based on the survey made in<br />
the study area, facilities have further improved now. Almost all the villages<br />
had access to power supply. Based on the survey made in the study area,<br />
facilities have further improved now. There are no historical / archeologically<br />
important sites present within 10 km radius around the project site.<br />
<br />
Details of the available infrastructural facilities, are listed in table 3.5<br />
Table 3.5<br />
Infrastructural facilities,<br />
VILL_ EDU_ MEDI_ DRINKING<br />
POST_ COMM_ BANK_ POWER_<br />
NAME FAC FAC WATER TUBEWELL OFF FAC FAC FAC<br />
Nongthymme 1 2 1 2 0 1 2 2<br />
Thangskai 1 2 1 2 0 1 2 2<br />
Umshangiar 1 2 1 2 1 1 2 0<br />
Khaddum 1 2 1 2 1 2 2 0<br />
Larseng 1 2 1 2 0 1 2 0<br />
Lumshnong 1 1 1 1 1 1 1 2<br />
Mynkre 1 2 1 2 0 1 2 2<br />
Nongsning 1 2 1 2 0 1 2 2<br />
Nongthymme 1 2 1 2 0 2 2 2<br />
Shiehruphi 1 2 1 2 1 1 2 2<br />
Umbadoh 0 0 0 0 0 0 0 0<br />
Umlong 1 1 1 2 0 2 2 0<br />
Umtyra 1 2 1 2 0 1 2 2<br />
Wahiajer 1 1 1 2 1 1 2 2<br />
Wahsarang 2 2 1 2 0 2 2 0<br />
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Hills Cement Co. Limited.<br />
Education<br />
Almost all the villages had education facilities up to primary level. Based on<br />
the survey made in the study area, it was found that the educational facilities<br />
have been further strengthened in the study area.<br />
Medical and Public Health<br />
Almost all the villages were having medical facilities. Medical facilities have<br />
been further strengthened and numbers of private doctors are also practicing<br />
in the study area.<br />
3.4 BIOLOGICAL ENVIRONMENT<br />
Biological Environment is one of the most important aspects in view of the<br />
need for conservation of environmental quality and biodiversity. Ecological<br />
systems show complex inter-relationships between biotic and abiotic<br />
components including dependence, competition and mutualism. Biotic<br />
components comprise both plant and animal communities, which interact not<br />
only within and between them but also with the abiotic components viz.<br />
physical & chemical components of the environment. Flora & Fauna has been<br />
carried out in study area:<br />
Flora and Fauna<br />
Flora<br />
The details of flora found in the study area are given in Tables 3.6 (a, b, c, d)<br />
Table 3.6 (a) Tree Species Available in the Study Area<br />
S.No. Species Family<br />
1 Actinodaphne obovata Lauraceae<br />
2 Ailanthes grandis Simarubaceae<br />
3 Albizzia lucida Mimosaceae<br />
4 Alstonia scholaris Apocynaceae<br />
5 Anthocephalus chinense Rubiaceae<br />
6 Aralia armata Araliaceae<br />
7 Ardisia nerifolia Myrsinaceae<br />
8 Artocarpus heterophyllus Moraeceae<br />
9 Bambusa tulda Gramineae<br />
10 Bauhinia purpurea Caesalpinaceae<br />
11 Bischofia javanica Bischofiaceae<br />
12 Bombax ceiba Bombacaceae<br />
13 Bridelia sp. Euphorbiaceae<br />
14 Callicarpa arborea Verbenaceae<br />
15 Caryota urens Palmae<br />
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16 Castanopsis indica Fagaceae<br />
17 Cinnamomum obtusifolium Lauraceae<br />
18 Citrus sp. Rutaceae<br />
19 Cyathea sp. Leguminosae<br />
20 Dendrocalamus hamiltonii Gramineae<br />
21 Duabanga grandiflora Sonneratiaceae<br />
22 Elaeocarpus aristatus Eleocarpaceae<br />
23 Englegardtia spicata Juglanaceae<br />
24 Exbucklandia populnea Hammamelidaceae<br />
25 Ficus sp. Moraceae<br />
26 Garcinia acuminate Clusiaceae<br />
27 Gmelina arborea Verbenaceae<br />
28 Grewia disperma Tiliaceae<br />
29 Hevea brasiliensis Hernandiaceae<br />
30 Hibiscus macrophyllus Malvaceae<br />
31 Hydnocarpus kurzii Flacourtiaceae<br />
32 Litsaea sebifera Lauraceae<br />
33 Macropanax disperma Analiaceae<br />
34 Magnolia hodgsonii Magnoliaceae<br />
35 Mallotus tetracoccus Euphorbiaceae<br />
36 Meliosma sp. Meliaceae<br />
37 Oroxylum indicum Bigoniaceae<br />
38 Pandanus sp. Pandanaceae<br />
39 Persea sp. Lauraceae<br />
40 Pithecellobium sp. Leguminosae<br />
41 Premna milleflora Verbenaceae<br />
42 Prunus acuminate Rosaceae<br />
43 Pterospermum lancifolium Sterculiaceae<br />
44 Quercus lancifolia Fagaceae<br />
45 Sapium baccatum Euphorbiaceae<br />
46 Sarcosperma griffithii Sapotaceae<br />
47 Saurauia sp. Ternstroemiaceae<br />
48 Shima sp. Theaceae<br />
49 Spondias pinnata Anacardiaceae<br />
50 Streospermum chelenoides Bigoniaceae<br />
51 Syzygium sp. Myrtaceae<br />
52 Terminalia chebula Combretaceae<br />
53 Trema orientalis Ulmaceae<br />
54 Villebrunea frutescens Urticaceae<br />
55 Vitex sp. Verbenaceae<br />
56 Wendlandia paniculata Rubiaceae<br />
57 Xerospermum sp. Sapindaceae<br />
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Hills Cement Co. Limited.<br />
Table 3.6 (b)<br />
Shrub/Herbs Species Available in the Study Area.<br />
S.No Species S.No Species<br />
1 Ageratum conyzoides 33 Forrestia sp.<br />
2 Alpinia sp. 34 Globba sp.<br />
3 Amaranthus sp. 35 Hedychium sp.<br />
4 Ardisia nerifolia 36 Jasminum sp.<br />
5 Aroides sp. 37 Laportea crenulata<br />
6 Arundina graminifolia 38 Leea indica<br />
7 Baliospermum montana 39 Licuala peltata<br />
8 Begonia sp. 40 Luduwigia octovalis<br />
9 Bidens pilosa 41 Lycopodium sp.<br />
10 Blachnum sp. 42 Maesa indica<br />
11 Boehmeria glomerulifera 43 Melastoma malabathricum<br />
12 Calamus flagellum 44 Mannihot esculenta<br />
13 Carax cruciata 45 Mimosa himalayana<br />
14 Chenopodium sp. 46 Morinda angustifolia<br />
15 Clerodendrum sp. 47 Musa sp.<br />
16 Coffea sp. 48 Osbekia crenata<br />
17 Coleus sp. 49 Oxalis corniculata<br />
18 Commelina sp. 50 Oxyspora sp.<br />
19 Crassocephalum crepidioides 51 Phrynium capitata<br />
20 Cyathula prostrate 52 Phrynium pubenervae<br />
21 Dracena sp. 53 Pinanga gracilis<br />
22 Elatostema sp. 54 Polygonum chinense<br />
23 Erigeron Canadensis 55 Pteris sp.<br />
24 Eupatorium odoratum 56 Randia sp.<br />
25 Fagopteris auriculata 57 Rhynchotecum ellipticum<br />
26 Saccharum spontaneum 58 Rungia sp.<br />
27 Salamona sp. 59 Spilanthus paniculata<br />
28 Saurauia sp. 60 Tabernaemontana divericata<br />
29 Scoperia dulcis 61 Thysanolaena maxima<br />
30 Selaginella sp. 62 Trevesia palmata<br />
31 Solanum torvum 63 Triumfetta pilosa<br />
32 Ferns sp. 64 Urena lobata<br />
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Table 3.6 (c)<br />
Climbers/Epiphytes Species Available in the Study Area.<br />
S.No. Species S.No. Species<br />
1 Acacia pinnata 14 Lygodium flexuosum<br />
2 Acampe sp. 15 Melocalamus compectiflorus<br />
3 Aeschynanthus sp.<br />
4 Agapetes sp. 18 Microsorum sp.<br />
5 Asplenium nidus 19 Mikenia macrantha<br />
6 Byttneria aspera 20 Neohouzia helferii<br />
7 Dendrobium sp. 22 Paederia scandens<br />
8 Derris sp. 23 Porana paniculata<br />
9 Dioscorea sp. 24 Pothos sp.<br />
10 Ficus sp. 25 Raphidophora lancifolia<br />
11 Hedyotis scandens 26 Scefflera venulosa<br />
12 Hoya sp. 27 Smilex sp.<br />
13 Luisea sp. 28 Thunbergia grandiflora<br />
Based on the above tables, flora of the study area may be summarized as<br />
given in Table 3.6 (d)<br />
S.No. Particulars Species<br />
1 Agricultural Crops<br />
2 Commercial Crops<br />
Table 3.6 (d)<br />
Dominant Species Available in the Study Area<br />
Brassica nigra, Capsicum frutescens, Cucumis<br />
sativus,Oryza sativa, Phaseolus vulgaris, Raphanus<br />
sativus,Zea mays<br />
Citrus aurantium, Haevea brasilensis,Thysanolaena<br />
maxima<br />
3 Plantation Litsea citrata, Populus glambelei, Terminalia myriocarpa<br />
4 Grasslands<br />
5 Endangered Species<br />
6 Endemic Species Nil<br />
Mimosa himalayana, Osbekia sp., Oxyspora<br />
sp.,Saccharum spontaneum,Salamona sp., Sellaginella<br />
sp.,Solanum torvum<br />
Arundina graminifolia, Cyathea spinulosa, Dendrobium<br />
sp.,<br />
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Fauna<br />
The details of fauna found in the study area are given in Tables 3.7 (a, b)<br />
Table 3.7 (a)<br />
Vertebrates Available in the Study Area<br />
S.No. Zoological Name Common Name Schedule status<br />
Birds<br />
1 Acridotheres tristis tristis Indian Myna US<br />
2 Bubo flavipes Tawny Fish Owl US<br />
3 Milvus migrans lineatus Large Indian Kite US<br />
4 Scolopax rusticola rusticola Wood Cock US<br />
Reptiles<br />
5<br />
Calotes versicolor Garden Lizard US<br />
6 Collophis macclellandi Coral Snake US<br />
7 Natrix pscicolor Water Snake US<br />
8 Chameleon sp. Cameleon Schedule II Part I<br />
Amphibians<br />
9 Amolops afghanus US<br />
10 Rana danieli Frog US<br />
11 Rana livida Frog US<br />
12 Rhacophorus maximus US<br />
Fishes<br />
13 Danio dangila Shalynnai US<br />
14 Labeo rohita Kha bah US<br />
15 Puntius shalynius Shalynnai US<br />
Mammals<br />
16 Arctonyx collaris Hog Badger Schedule I Part I<br />
17 Cannomys badius badius Bamboo Rat Schedule V<br />
18<br />
Collosciurus erythraeus<br />
erythraeus Squirrel US<br />
19<br />
Crocidura attenuata<br />
rubricosa Grey Shrew Schedule V<br />
20<br />
Felis bengalensis<br />
bengalensis Leopard Cat Schedule I Part I<br />
21 Mus booduga Field Rat Schedule V<br />
22 Mus musculus House Mouse Schedule V<br />
23 Presbytis pileatus Monkey Schedule V<br />
24 Rattus rattus House Rat Schedule V<br />
25 Rhinolopus pearsoni<br />
Pearson’s Horse Shoe<br />
Bat<br />
US<br />
26 Scotomanes ornatus ornatus<br />
Harlequin Horse Shoe<br />
Bat<br />
US<br />
27 Suncus murinus griffithi House Shrew US<br />
US- Un-scheduled animals<br />
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Table 3.7 (b) Invertebrates Available in the Study Area<br />
S.No. Zoological Name Common Name<br />
Acari<br />
1 Malaconothrus sp. US<br />
2 Scheloribates parvus US<br />
Annelida:<br />
Oligochaeta<br />
3 Drawidia sp. Earthworm US<br />
Arthopoda: Crustacea<br />
4 Macrobrachium assamensis Shrimp US<br />
Arthopoda: Lepidoptera<br />
5 Arneta atkinsoni US<br />
6 Halpe kumara US<br />
7 Matapa druna US<br />
Arthopoda: Insecta<br />
8 Trichptera- Immature US<br />
9 Odonata- Immature US<br />
10 Chironomidae larvae US<br />
Mollosca: Gastropoda<br />
11 Bellamya bendalensis Snail US<br />
12 Brachonus calciflorus US<br />
13 Filinia longiseita US<br />
Zooplankton: Cladocera<br />
14 Sida crystalline US<br />
15 Daphnia carinata US<br />
Zooplankton: Copepoda<br />
16 Heliodiaptomus sp. US<br />
17 Mescocyclops leuckrti US<br />
US- Un-scheduled animals<br />
3.5 METEOROLOGY AT SITE<br />
Schedule<br />
status<br />
District has tropical climate characterized by high rainfall and humidity<br />
generally warm summer and moderately cold winter. A meteorological station<br />
was installed during the months from December 2007 to march 2008 to<br />
record various meteorological parameters to understand the Wind pattern,<br />
Temperature variation, Relative humidity and Rainfall. On-site monitoring was<br />
undertaken for recording of various meteorological variables, viz., wind<br />
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speed, wind direction, relative humidity, rainfall and temperature in order to<br />
generate site-specific data. The data generated is computed to obtain windroses<br />
of the area. The wind direction describes three quadrants of 24-hour<br />
time period. The wind roses plotted for the wind directions recorded during<br />
the study period from December 2007 to March 2008 are presented. The<br />
study period from December 2007 to March 2008 recorded ambient air<br />
temperatures minimum and maximum as 11Û&DQGÛ&UHVSHFWLYHO\<br />
Relative Humidity (RH)<br />
The region generally experiences tropical climatic condition throughout the<br />
year except during winters. The lowest relative humidity recorded of the study<br />
area was 60% and highest as 90% and average humidity, yearly was found<br />
70%. Day times experience higher humidity levels as compared to nights.<br />
Average rainfall is 3042 mm. The duration of rainfall is about 6 months in a<br />
year. It is observed that rainfall is occurred towards the end of March, 2008.<br />
Wind<br />
The wind direction is WE. The basic wind velocity as per IS: 875-1987, Part<br />
III, 4 Km/hr can be considered for designing the civil structures. The average<br />
wind speed ranged from 0.6 m/s during the study period.<br />
Wind pressure:<br />
0-8m 900 kN/m 2<br />
8-20m 1,400 kN/m 2<br />
Above 20m 1,950 kN/m 2<br />
Table-3.8 Environmental Attributes & Frequency of Monitoring<br />
Attribute Parameters Frequency of Monitoring<br />
Ambient Air<br />
Quality<br />
Meteorology<br />
Water Quality<br />
SPM, RSPM<br />
SO 2 , NOx, CO, HC<br />
Surface: Wind speed, Wind<br />
direction, Temperature,<br />
Relative humidity and Rainfall<br />
Physical, Chemical and<br />
Bacteriological Parameters<br />
24 hourly samples twice a<br />
week during study period.<br />
8 hourly samples twice a<br />
week during study period.<br />
Surface: Continuous<br />
monitoring station for entire<br />
study period on hourly<br />
basis and also data<br />
collection from secondary<br />
sources.<br />
Once during the study<br />
season<br />
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Ecology Existing Flora and Fauna Through field visit during<br />
the study period and<br />
substantiated through<br />
secondary sources.<br />
Noise Levels Noise levels in dB Observations for 24 hours<br />
per location.<br />
Soil<br />
Characteristics<br />
Land Use<br />
Socioeconomic<br />
aspects<br />
Parameters related to<br />
agricultural and afforestation<br />
potential<br />
Trend of land use change for<br />
different categories<br />
Socio-economic<br />
characteristics,<br />
labour force characteristics,<br />
population statistics and<br />
existing amenities in the study<br />
area.<br />
Ambient air quality standards*<br />
Once during the season.<br />
Data from various<br />
Government agencies<br />
(Census Handbooks,<br />
2001).<br />
Parameters<br />
(24 hrs sampling) Industrial<br />
areas<br />
Concentration in µg/m 3<br />
Residential &<br />
rural areas<br />
Sensitive areas<br />
Suspended<br />
Particulate Matter<br />
(SPM)<br />
Respirable<br />
Particulate Matter<br />
(RPM)<br />
Sulphur Dioxide<br />
(SO2)<br />
Oxides of Nitrogen<br />
(NOx)<br />
Carbon Monoxide<br />
(CO )<br />
Lead<br />
(Pb)<br />
500 200 100<br />
150 100 75<br />
120 80 30<br />
120 80 30<br />
4ppm 2ppm 1ppm<br />
1.5 1.0 0.75<br />
*Source: CPCB Publications ambient air quality monitoring<br />
The data generation for ambient air quality status within 10 km radius of the<br />
proposed site has been compiled.<br />
To establish the ambient air quality, air sampling and measurements were<br />
conducted. Air sampling stations were established at – locations around the<br />
proposed site to assess the background air pollution levels. The ambient air<br />
sampling was carried out at following locations:<br />
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Hills Cement Co. Limited.<br />
<br />
- Mynkre<br />
- Umlong<br />
- Umtyra<br />
- Lumshnong<br />
- Umshangiar<br />
- Khaddum<br />
<br />
S.No. Location<br />
Code<br />
Table-3.9 AAQ Sampling Location Details<br />
Location<br />
Name<br />
Distance<br />
(kms)<br />
form Plant<br />
Direction<br />
w.r.t. Plant<br />
Environmental<br />
Setting<br />
<br />
1 A1 Mynkre 0 - Village<br />
2 A2 Umlong 6.5 W Village<br />
3 A3 Umtyra 5.2 N Village<br />
4 A4 Lumshnong 6 S Village<br />
5 A5 Umshangiar 7.5 E Village<br />
6 A6 Umrasong 5.9 W Village<br />
Table-3.10 Methodology of AAQ Sampling and analysis<br />
<br />
S.<br />
No<br />
Sampling Details SPM RSPM SO2 NOX CO<br />
1. Monitoring equipment Respirable dust<br />
sampler<br />
2. Sampling media GF/A TCM Abs.<br />
Soln.<br />
HVS with Impinger<br />
assembly<br />
NaOH<br />
Abs.<br />
Soln.<br />
GC analysis<br />
Tedler Bags<br />
3. Flow rate 1.0-1.3 m 3 /min 0.5-1 l/min 1.5 l/min<br />
4. Sampling frequency 24 Hourly 8 hourly<br />
5. Sampling period Continuous 24 hours for 24 sampling days<br />
6. Analysis methodology Gravimetric Method Spectrophotometer Chromatogra<br />
<br />
phy<br />
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Hills Cement Co. Limited.<br />
Table-3.11 AAQ Summary during Pre-monsoon Season (Dec’07–Mar’08)<br />
Air Quality<br />
Station<br />
Mynkre<br />
Code Particulars SPM RPM SO 2 NOx<br />
A1<br />
Minimum 87 16 3.9 7.4<br />
Umlong<br />
Umtyra<br />
Lumshnong<br />
Umshangiar<br />
Umrasong<br />
A2<br />
A3<br />
A4<br />
A5<br />
A6<br />
Maximum 112 41 11.2 14.4<br />
Minimum 62 17 3.2 4.5<br />
Maximum 115 34 13 10<br />
Minimum 87 18 3.1 4.8<br />
Maximum 115 43 8.1 13.7<br />
Minimum 89 22 4.0 13.3<br />
Maximum 118 46 9.2 5.1<br />
Minimum 87 46 3.5 4.5<br />
Maximum 119 19 9.5 13.7<br />
Minimum 89 16 4.5 5.1<br />
<br />
Observations of Ambient Air Quality:<br />
Maximum 115 43 11.3 13.7<br />
The results of AAQ monitoring parameters are summarized in the preceding<br />
table. The total 8 sampling locations within the study area are well within the<br />
stipulated limits of NAAQ Standards. Locations in downwind direction were found<br />
to have more concentrations of SPM and RPM as compared to crosswind<br />
directions. The overall maximum concentration of SPM, RPM, SO 2 and NOx were<br />
REVHUYHG DW /XPVKQRQJ YLOODJH ZLWK FRQFHQWUDWLRQ YDOXHV JFXP <br />
JFXPJFXPDQGJFXP7KH&RQFHQWUDWLRQYDOXHVRI&2DQG+&<br />
are far below the detection limits.<br />
Ambient air quality of the study area has been assessed during study period<br />
through a network of 6 ambient air quality stations, which are shown in Table<br />
3.12-3.17.<br />
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<br />
Table-3.12: Ambient Air Quality Report for AQ1<br />
S.<br />
No.<br />
Station : Mynkre<br />
Month Week Day SPM RSPM 62JP<br />
JP JP 3 ) 12[JP 3 )<br />
3) 3)<br />
06 –<br />
14 hrs<br />
15 - 22<br />
hrs<br />
23 - 06<br />
hrs<br />
24 hrs<br />
Average<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 -06<br />
hrs<br />
24 hrs<br />
Average<br />
1. December’ I st 1 st 87 23 5.5 7.8 6.9 7.6 12.9 8.2 10.0 11.5<br />
2007<br />
2.<br />
2 nd 88 29 4.2 7.2 5.5 6.0 10.6 10.1 10.2 8.9<br />
3. IInd 1 st 90 26 6.7 7.8 6.2 7.2 11.3 5.3 9.5 9.9<br />
4.<br />
2 nd 90 21 8.5 6.3 5.1 5.6 10.6 6.0 9.2 8.7<br />
5. IIIrd 1 st 92 32 7.2 6.5 6.5 6.2 11.9 5.8 8.5 9.3<br />
6.<br />
2 nd 98 41 6.3 7.8 7.9 4.5 14.4 6.7 8.8 8.5<br />
7. IVth 1 st 100 18 7.1 3.9 5.6 5.3 10.8 7.8 7.8 9.6<br />
8.<br />
2 nd 107 24 4.7 5.1 8.9 6.9 15.3 5.7 9.1 7.4<br />
1. January’ Ist 1 st 102 24 5.9 4.0 7.9 8.9 11.7 6.9 7.5 9.5<br />
2008<br />
2.<br />
2 nd 100 16 5.0 5.6 6.7 7.0 11.8 7.4 6.4 10.2<br />
3. IInd 1 st 105 32 7.0 5.6 5.5 7.1 10.6 5.4 7.6 9.1<br />
4.<br />
2 nd 98 41 8.2 6.5 5.5 7.7 10.5 8.2 7.6 8.9<br />
5. IIIrd 1 st 102 24 7.0 7.8 7.3 5.7 12.2 10.1 9.4 10.9<br />
6.<br />
2 nd 100 18 7.0 3.9 8.2 4.8 14.7 5.3 12.0 13.3<br />
7. IVth 1 st 96 24 7.4 5.1 10.2 4.6 10.5 9.3 7.6 9.2<br />
8.<br />
2 nd 105 34 4.9 4.0 8.7 9.3 15.1 13.6 11.9 13.5<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 52
Hills Cement Co. Limited.<br />
1. February’ Ist 1 st 108 19 5.5 5.6 8.6 9.3 12.4 11.2 9.5 11.0<br />
2008<br />
2.<br />
2 nd 102 18 4.2 5.6 7.0 7.5 12.1 10.5 8.8 10.4<br />
3. IInd 1 st 90 18 6.7 4.0 5.7 6.7 10.8 9.5 7.8 9.4<br />
4.<br />
2 nd 94 25 8.5 5.8 4.6 5.5 14.7 13.5 15.0 14.4<br />
5. IIIrd 1 st 96 24 7.2 7.8 7.1 7.8 11.6 10.5 8.8 10.3<br />
6.<br />
2 nd 92 18 6.3 8.8 7.1 8.3 13.6 12.2 7.3 12.1<br />
7. IVth 1 st 97 25 7.1 12.0 10.1 11.2 10.4 9.2 8.3 9.1<br />
8.<br />
2 nd 100 33 4.7 8.9 8.3 8.9 14.7 13.2 7.2 13.1<br />
1. March’ Ist 1 st 102 20 5.9 11.4 4.4 6.1 8.6 7.4 9.1 10.6<br />
2008<br />
2.<br />
2 nd 102 19 5.0 9.5 3.8 7.1 6.5 7.5 11.3 12.9<br />
3. IInd 1 st 106 24 7.0 8.2 3.8 3.9 9.6 7.8 7.9 9.5<br />
4.<br />
2 nd 98 34 8.2 7.6 4.5 5.1 11.3 8.9 12.1 13.7<br />
5. IIIrd 1 st 100 19 7.0 7.1 3.3 4.4 6.7 8.6 8.8 10.3<br />
6.<br />
2 nd 105 18 7.0 6.7 7.9 4.8 7.2 7.4 8.5 10.1<br />
7. IVth 1 st 110 18 7.4 6.2 5.6 5.4 7.4 6.0 7.8 9.2<br />
8.<br />
2 nd 112 25 4.9 5.8 8.9 3.9 8.0 5.8 7.4 9.1<br />
Min 87.0 16.0 3.9 7.4<br />
Max 112.0 41.0 11.2 14.4<br />
Mean 99.2 24.5 6.5 10.4<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 53
Hills Cement Co. Limited.<br />
5<br />
0Q<br />
/QPVJ 9GGM &C[ 52/<br />
IO <br />
452/<br />
IO <br />
L<br />
JTU<br />
Table-3.13: Ambient Air Quality Report for AQ2<br />
5VCVKQP7ONQPI<br />
<br />
JTU<br />
51 IO 01Z IO <br />
<br />
JTU<br />
JTU<br />
#XGTCIG<br />
L<br />
JTU<br />
<br />
JTU<br />
&GEGODGTO + UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
,CPWCT[O +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
<br />
JTU<br />
JTU<br />
#XGTCIG<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 54
Hills Cement Co. Limited.<br />
<br />
PF <br />
(GDTWCT[O +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
/CTEJO +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
/KP <br />
<br />
/CZ <br />
/GCP<br />
<br />
<br />
<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 55
Hills Cement Co. Limited.<br />
Table-3.14: Ambient Air Quality Report for AQ3<br />
S.<br />
No.<br />
Station : Umtyra<br />
Month Week Day SPM RSPM<br />
SO JP<br />
JP JP 2 3 ) 12[JP 3 )<br />
3) 3)<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 - 06<br />
hrs<br />
24 hrs<br />
Average<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 -06<br />
hrs<br />
24 hrs<br />
Average<br />
1. December’ I st 1 st 87 25 7.0 5.5 3.8 4.5 3.2 6.8 5.1 6.7<br />
2007<br />
2.<br />
2 nd 92 19 7.0 4.2 4.5 5.0 5.5 7.4 5.7 7.4<br />
3. IInd 1 st 92 26 7.4 6.7 4.2 5.2 5.0 6.9 5.2 6.8<br />
4.<br />
2 nd 97 26 4.9 8.5 4.0 4.9 8.4 7.2 6.5 7.1<br />
5. IIIrd 1 st 100 20 5.5 7.2 2.9 3.5 6.4 5.3 8.4 5.1<br />
6.<br />
2 nd 102 32 4.2 6.3 3.6 6.3 10.2 8.8 3.5 8.7<br />
7. IVth 1 st 100 41 6.7 5.8 3.8 8.1 13.0 11.8 4.3 11.6<br />
8.<br />
2 nd 114 23 6.9 6.3 4.2 6.7 7.0 9.5 41 9.4<br />
1. January’ Ist 1 st 100 30 6.1 5.2 4.6 5.6 6.8 5.6 5.0 5.5<br />
2008<br />
2.<br />
2 nd 109 31 8.4 4.9 2.9 6.2 10.2 8.6 6.8 8.6<br />
3. IInd 1 st 112 29 8.6 6/7 3.8 4.5 10.5 6.3 4.5 6.1<br />
4.<br />
2 nd 115 27 6.3 6.5 4.4 5.3 8.8 7.6 5.9 7.5<br />
5. IIIrd 1 st 107 19 6.6 7.8 3.7 4.3 7.0 5.6 3.9 5.4<br />
6.<br />
2 nd 89 32 7.2 3.9 5.5 6.6 6.9 9.1 7.4 9.0<br />
7. IVth 1 st 92 43 6.9 5.1 6.7 7.8 7.3 11.5 9.8 11.3<br />
8.<br />
2 nd 97 23 7.0 4.0 5.9 6.5 7.8 9.3 7.6 9.2<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 56
Hills Cement Co. Limited.<br />
1. February’ Ist 1 st 95 31 7.0 5.6 5.5 6.3 8.1 6.3 4.6 6.2<br />
2008<br />
2.<br />
2 nd 107 21 7.4 6.6 6.0 6.5 6.4 8.9 7.2 8.9<br />
3. IInd 1 st 105 28 4.9 5.5 3.7 4.7 7.7 6.4 4.7 6.3<br />
4.<br />
2 nd 98 28 5.0 4.6 3.5 4.4 7.9 6.7 5/0 6.6<br />
5. IIIrd 1 st 105 20 4.8 4.2 3.5 4.1 6.1 5.0 3.3 4.8<br />
6.<br />
2 nd 108 29 5.9 6.1 4.4 5.5 9.4 8.0 7.9 7.9<br />
7. IVth 1 st 110 42 8.1 8.5 6.6 7.7 12.6 6.0 12.1 10.6<br />
8.<br />
2 nd 97 23 6.6 6.1 5.5 6.1 10.4 5.8 8.8 12.9<br />
1. March’ Ist 1 st 92 24 7.2 5.9 3.6 4.4 8.0 6.7 8.5 9.5<br />
2008<br />
2.<br />
2 nd 97 34 6.3 5.0 4.2 3.8 9.0 7.8 7.6 13.7<br />
3. IInd 1 st 100 19 7.1 7.0 5.8 3.8 8.2 5.7 7.6 10.3<br />
4.<br />
2 nd 102 18 4.7 8.2 5.2 4.5 11.3 8.5 9.4 10.1<br />
5. IIIrd 1 st 100 18 5.9 4.4 7.0 3.3 6.7 9.8 12.0 9.2<br />
6.<br />
2 nd 114 25 5.0 7.2 6.1 5.1 10-.8 5.0 7.6 9.1<br />
7. IVth 1 st 100 24 7.0 8.6 4.8 5.6 7.5 6.7 11.9 11.4<br />
8.<br />
2 nd 109 18 8.2 6.5 5.7 3.1 10.5 6.4 10.5 9.9<br />
Min 87.0 18.0 3.1 4.8<br />
Max 115.0 43.0 8.1 13.7<br />
<br />
Mean 101.4 26.5 5.3 8.5<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 57
Hills Cement Co. Limited.<br />
S.<br />
No.<br />
Table-3.15: Ambient Air Quality Report for AQ4<br />
5VCVKQP.WOUJPQPI<br />
Month Week Day SPM RSPM<br />
SO2JP<br />
JP JP 3 ) 12[JP 3 )<br />
3) 3)<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 - 06<br />
hrs<br />
24 hrs<br />
Average<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 -06<br />
hrs<br />
24 hrs<br />
Average<br />
1. December I st 1 st 106 29 6.2 8.0 3.0 5.7 7.3 7.3 7.6 8.7<br />
’ 2007<br />
2.<br />
2 nd 110 22 6.8 6.2 4.8 6.7 11.0 7.8 11.8 10.6<br />
3. IInd 1 st 102 31 5.6 7.2 8.9 5.3 14.4 8.5 8.7 7.4<br />
4.<br />
2 nd 109 29 5.9 9.6 3.3 7.0 11.7 7.8 5.1 6.8<br />
5. IIIrd 1 st 112 35 4.6 7.5 4.4 7.1 8.7 8.0 8.6 7.1<br />
6.<br />
2 nd 118 43 7.2 9.5 3.8 7.7 10.7 6.9 6.1 5.1<br />
7. IVth 1 st 101 24 7.4 8.6 3.8 5.7 9.8 8.4 6.5 8.7<br />
8.<br />
2 nd 108 32 7.6 4.7 4.5 4.8 6.4 9.1 4.5 11.6<br />
1. January’ Ist 1 st 110 24 7.9 6.4 3.3 5.4 10.2 8.8 11.8 9.1<br />
2008<br />
2.<br />
2 nd 100 32 8.5 7.0 5.1 7.4 13.0 8.5 8.7 7.9<br />
3. IInd 1 st 108 25 5.9 6.4 5.6 5.5 7.0 9.1 5.1 8.4<br />
4.<br />
2 nd 102 35 5.4 5.2 3.1 5.7 6.8 8.3 8.6 8.1<br />
5. IIIrd 1 st 106 24 5.2 5.8 5.1 4.8 10.2 6.2 7.6 6.0<br />
6.<br />
2 nd 98 28 7.3 7.0 4.5 6.9 10.5 9.6 6.9 9.5<br />
7. IVth 1 st 100 29 9.3 7.6 5.6 8.9 8.8 13.2 5.8 13.0<br />
8.<br />
2 nd 105 22 6.8 7.3 5.5 7.8 7.0 10.2 8.5 10.1<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 58
Hills Cement Co. Limited.<br />
1. February’ Ist 1 st 110 35 6.0 5.5 5.2 7.9 11.3 7.5 5.8 7.4<br />
2008<br />
2.<br />
2 nd 112 43 7.0 4.0 4.4 6.6 6.7 10.6 8.9 10.6<br />
3. IInd 1 st 115 24 6.4 7.2 3.3 6.3 7.2 8.0 6.3 7.9<br />
4.<br />
2 nd 110 32 5.9 10.0 4.7 6.2 7.4 7.2 5.6 7.2<br />
5. IIIrd 1 st 89 24 6.3 8.6 3.9 4.6 8.0 5.6 3.9 5.4<br />
6.<br />
2 nd 92 32 6.2 6.4 4.7 5.8 9.0 8.5 6.8 8.4<br />
7. IVth 1 st 97 30 9.2 9.6 7.7 8.8 8.6 13.1 11.4 12.9<br />
8.<br />
2 nd 95 24 7.2 6.7 6.1 6.6 11.3 9.8 8.1 9.7<br />
1. March’ Ist 1 st 107 27 7.0 7.5 8.1 6.2 7.0 7.8 11.8 7.7<br />
2008<br />
2.<br />
2 nd 105 22 9.6 9.7 6.7 6.2 10.7 5.9 8.7 5.7<br />
3. IInd 1 st 109 34 7.8 7.1 5.7 5.3 14.7 9.3 5.1 9.2<br />
4.<br />
2 nd 112 46 7.2 7.1 6.8 4.0 11.9 13.5 8.6 13.3<br />
5. IIIrd 1 st 115 25 8.2 7.3 4.5 6.6 8.0 10.4 6.1 10.3<br />
6.<br />
2 nd 108 35 5.7 6.5 4.8 9.2 11.9 6.8 6.5 6.7<br />
7. IVth 1 st 112 24 6.3 5.0 4.1 7.2 9.1 10.3 4.5 10.3<br />
8.<br />
2 nd 115 28 5.4 4.6 5.8 6.4 9.4 7.8 7.9 7.7<br />
Min 89.0 22.0 4.0 5.1<br />
Max 118.0 46.0 9.2 13.3<br />
Mean 106.1 29.6 6.4 8.7<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 59
Hills Cement Co. Limited.<br />
<br />
5<br />
0Q<br />
/QPVJ 9GGM &C[ 52/<br />
IO <br />
452/<br />
IO <br />
L<br />
JTU<br />
6CDNG#ODKGPV#KT3WCNKV[4GRQTVHQT#3<br />
5VCVKQP7OUJCPIKCT<br />
<br />
JTU<br />
51 IO 01Z IO <br />
<br />
JTU<br />
JTU<br />
#XGTCIG<br />
L<br />
JTU<br />
&GEGODGTO + UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
,CPWCT[O +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
JTU<br />
<br />
<br />
JTU<br />
JTU<br />
#XGTCIG<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 60
Hills Cement Co. Limited.<br />
PF <br />
(GDTWCT[O +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
/CTEJO +UV UV <br />
PF <br />
++PF UV <br />
<br />
PF <br />
+++TF UV <br />
<br />
PF <br />
+8VJ UV <br />
<br />
PF <br />
/KP <br />
<br />
/CZ <br />
/GCP<br />
<br />
<br />
<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 61
Hills Cement Co. Limited.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 62
Hills Cement Co. Limited.<br />
S.<br />
No.<br />
<br />
Table-3.17: Ambient Air Quality Report for AQ6<br />
5VCVKQP7OTCUQPI<br />
Month Week Day 630JP 3) RSPM<br />
SO JP<br />
JP 2 3 ) 12[JP 3 )<br />
3)<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 - 06<br />
hrs<br />
24 hrs<br />
Average<br />
06 – 14<br />
hrs<br />
15 - 22<br />
hrs<br />
23 -06<br />
hrs<br />
24 hrs<br />
Average<br />
1. December’ I st 1 st 102 26 4.2 6.7 4.5 6.5 6.5 7.4 7.2 10.6<br />
2007<br />
2.<br />
2 nd 100 20 6.7 5.7 4.1 6.4 9.6 7.4 9.1 12.9<br />
3. IInd 1 st 114 32 8.5 8.0 3.0 8.0 8.2 5.4 11.3 9.5<br />
4.<br />
2 nd 100 41 7.2 6.2 4.8 9.3 8.4 8.2 7.9 13.7<br />
5. IIIrd 1 st 108 23 6.3 7.2 8.9 11.3 6.4 10.1 12.1 10.3<br />
6.<br />
2 nd 102 30 7.1 9.6 3.3 9.3 10.2 5.3 8.8 10.1<br />
7. IVth 1 st 106 31 4.7 7.5 4.4 9.3 13.0 6.0 8.5 9.2<br />
8.<br />
2 nd 98 29 5.9 9.5 3.8 7.5 7.0 5.8 7.6 5.2<br />
1. January’ Ist 1 st 100 27 5.0 8.6 3.8 6.7 6.8 6.7 7.6 8.1<br />
2008<br />
2.<br />
2 nd 105 19 7.0 4.7 4.5 5.5 10.2 7.8 9.4 10.0<br />
3. IInd 1 st 110 32 8.2 2.8 3.3 8.1 10.5 5.7 12.0 5.2<br />
4.<br />
2 nd 112 43 7.0 6.3 5.1 6.7 8.8 8.5 7.6 9.9<br />
5. IIIrd 1 st 115 23 7.0 5.2 5.6 5.6 7.0 9.8 11.9 8.7<br />
6.<br />
2 nd 110 35 7.4 3.7 3.1 6.2 11.3 5.0 9.5 10.6<br />
7. IVth 1 st 89 24 4.9 6.5 5.1 5.6 6.7 5.6 8.8 7.4<br />
8.<br />
2 nd 92 28 5.0 7.8 3.8 6.2 7.2 8.6 7.8 6.8<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 63
Hills Cement Co. Limited.<br />
1. February’ Ist 1 st 97 29 4.8 3.9 5.7 4.5 7.4 6.3 15.0 7.1<br />
2008<br />
2.<br />
2 nd 95 22 5.9 5.1 3.5 5.3 8.0 7.6 8.8 5.1<br />
3. IInd 1 st 107 35 6.6 4.0 4.1 6.9 9.0 5.6 4.2 8.7<br />
4.<br />
2 nd 105 43 7.8 5.6 3.3 8.9 8.6 9.1 7.6 11.6<br />
5. IIIrd 1 st 98 24 9.4 5.6 5.5 7.0 6.5 6.0 11.8 9.4<br />
6.<br />
2 nd 105 32 7.1 4.0 8.1 7.1 9.6 5.8 8.7 5.5<br />
7. IVth 1 st 108 24 10.0 6.8 6.7 7.7 7.0 6.7 5.1 8.6<br />
8.<br />
2 nd 110 32 9.4 7.5 5.7 6.3 6.8 7.8 8.6 6.1<br />
1. March’ Ist 1 st 97 21 8.1 3.7 4.5 8.1 10.2 5.7 6.1 7.5<br />
2008<br />
2.<br />
2 nd 110 18 6.7 5.8 4.1 6.7 10.5 8.5 6.5 9.9<br />
3. IInd 1 st 103 24 7.0 4.4 3.0 5.6 8.8 9.8 4.5 8.7<br />
4.<br />
2 nd 100 24 8.6 5.8 4.8 6.2 6.7 5.0 11.8 10.6<br />
5. IIIrd 1 st 109 16 9.7 4.7 8.9 4.5 10.5 6.7 8.7 12.9<br />
6.<br />
2 nd 112 24 11.7 3.4 3.3 6.7 12.7 6.1 5.5 9.5<br />
7. IVth 1 st 115 34 9.8 4.6 4.4 5.9 10-.8 6.9 3.6 13.7<br />
8.<br />
2 nd 108 19 10.1 5.2 3.8 5.5 6.8 6.9 7.1 10.3<br />
Min 89.0 16.0 4.5 5.1<br />
Max 115.0 43.0 11.3 13.7<br />
Mean 104.4 27.6 6.9 9.1<br />
Hydro Carbon (HC) and Carbon Monoxide (CO) in the ambient air is found below 1 PPM. Overall ambient air quality in and around the<br />
proposed project area is found to be well within the AAQ standards.<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 64
Hills Cement Co. Limited.<br />
MONITORING OF NOISE LEVELS<br />
Noise levels were measured near highways, residential areas and other<br />
settlements located within 10 km radius around the project site. The noise<br />
recording stations are shown in Fig-3.6 and the summary of noise levels in<br />
the study area is given in Table-3.17. The day equivalent noise levels and<br />
night equivalent noise levels were found to be less. Noise levels were<br />
recorded at each station with a time interval of one minute for about 30<br />
minutes in each hour and were computed for equivalent noise levels for<br />
day-equivalent, night-equivalent & day-night equivalent. Noise monitoring<br />
stations were established at six locations around the proposed site to<br />
assess existing noise levels. Noise level monitoring locations are given<br />
below:<br />
The noise level standard is given below:<br />
Ambient Noise Level Standards for Different Category of Area<br />
Category<br />
Day time<br />
Limit in dB<br />
Night time<br />
Industrial Area 75 70<br />
Commercial Area 65 55<br />
Residential Area 55 45<br />
Silence Zone 50 40<br />
Table-3.18 Noise Monitoring Locations<br />
S.<br />
No.<br />
Location<br />
Code<br />
Location<br />
Name<br />
Distance<br />
(kms)<br />
w.r.t. plant<br />
Direction<br />
w.r.t.<br />
Plant<br />
Environm<br />
-ental<br />
Setting<br />
1 NQ1 Mynkre 0 - Village<br />
2 NQ2 Umlong 6.5 W Village<br />
3 NQ3 Umtyra 5.2 N Village<br />
4 NQ4 Lumshnong 6 S Village<br />
5 NQ5 Umshangiar 7.5 E Village<br />
6 NQ6 Umrasong 5.9 W Village<br />
<strong>Pollution</strong> <strong>Control</strong> Consultants (India) Pvt. Ltd. 65
Hills Cement Co. Limited.<br />
Table-3.19 Equivalent Noise Levels in the Study Area (10 km radius)<br />
Time<br />
Noise Level Monitoring Station<br />
in Hrs Mynkre Umlong Umtyra Lumshnong Umshangiar Umrasong<br />
<br />
6:00 40.6 40.9 43.2 43.1 43.3 43.6<br />
8:00 46.2 44.5 46.5 45.1 44.2 45.4<br />
10:00 54.7 53.2 55.1 54.8 52.6 53.5<br />
12:00 50.3 50.5 51.3 51.1 49.6 50.2<br />
14:00 48.7 49.2 48.4 47.2 46.7 47.3<br />
16:00 44.8 47.4 45.3 45.1 44.8 46.2<br />
18:00 56.3 54.7 52.8 53.6 54.2 53.8<br />
20:00 45.1 48.3 46.6 47.1 45.9 47.5<br />
22:00 44.2 45.8 44.6 45.8 44.6 45.6<br />
00:00 43.6 44.7 43.8 45.1 44.1 45.2<br />
2:00 43.3 44.2 43.5 44.3 43.4 44.1<br />
4:00 43.2 43.5 43.2 44.3 43.1 43.9<br />
The noise levels values are well below the acceptable standard noise<br />
levels.<br />
H. Water Environment<br />
Assessment of baseline data on water environment includes<br />
• Identification of surface water sources<br />
• Identification of ground water sources<br />
• Collection of water samples<br />
• Analyzing water samples for physio-chemical and biological<br />
parameters<br />
Assessment of water quality in the study area includes the water quality<br />
testing and assessment per the Indian standard IS 10500 (drinking water<br />
standard). The locations of water sampling are shown in Fig 3.7 water<br />
samples from various locations in and around the lant site within 10 km<br />
radius were collected for assessment of the physico-chemical and<br />
bacteriological quality. Methodologies adopted for sampling and analysis<br />
were according to the IS methods.<br />
Field parameters such as pH, Temperature and Dissolved Oxygen were<br />
tested at site. The parameters thus analyzed were compared with IS<br />
10500. Details of water sampling locations are given in table below.<br />
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Hills Cement Co. Limited.<br />
<br />
S.No.<br />
Location<br />
Code<br />
Table-3.20 Water sampling locations<br />
Location Name<br />
Distance<br />
(kms)<br />
w.r.t. Plant<br />
Direction<br />
w.r.t. Plant<br />
Sample<br />
Source<br />
Sample Source<br />
1. GWQ1 Mynkre 0 - Ground<br />
Water/Bore Well<br />
2. GWQ2 Umlong 6.5 W Ground<br />
Water/Bore Well<br />
3. GWQ3 Umtyra 5.2 N Ground<br />
Water/Bore Well<br />
4. GWQ4 Lumshnong 6 S Ground<br />
Water/Bore Well<br />
5. GWQ5 Umshangiar 7.5 E Ground<br />
Water/Bore Well<br />
6. GWQ6 Umrasong 5.9 W Ground<br />
Water/Bore Well<br />
Table-3.21 Summary of Water Quality Analysis Results<br />
<br />
GWQ1<br />
GWQ2<br />
GWQ3<br />
Mynkre<br />
Umlong<br />
Umtyra<br />
S. Parameter Unit GWQ1 GWQ2 GWQ3<br />
No.<br />
1 Colour Hazen uts
Hills Cement Co. Limited.<br />
Compounds<br />
19 Mercury as mg/l BDL BDL BDL<br />
(Hg)<br />
20 Cadmium (Cd) mg/l BDL BDL BDL<br />
21 Selenium as mg/l BDL BDL BDL<br />
Se<br />
22 Arsenic as As mg/l BDL BDL BDL<br />
23 Cyanide as CN mg/l BDL BDL BDL<br />
24 Lead (Pb mg/l BDL BDL BDL<br />
25 Zinc (Zn) mg/l BDL BDL BDL<br />
26 Chromium (Cr) mg/l BDL BDL BDL<br />
27 Mineral Oil mg/l Nil Nil Nil<br />
28 Alkalinity as mg/l 58 27 45<br />
CaCO3<br />
29 Aluminium as mg/l BDL BDL BDL<br />
Al<br />
30 Boron as B mg/l 0.04 0.02 0.05<br />
31 Total Coliform MPN/100ml Nil Nil Nil<br />
<br />
GWQ4<br />
GWQ5<br />
GWQ6<br />
Table-3.22 Summary of Water Quality Analysis Results<br />
Lumshnong<br />
Umshangiar<br />
Umrasong<br />
S. Parameter Unit GWQ4 GWQ5 GWQ6<br />
No.<br />
1 Colour Hazen uts
Hills Cement Co. Limited.<br />
22 Arsenic as As mg/l BDL BDL BDL<br />
23 Cyanide as CN mg/l BDL BDL BDL<br />
24 Lead (Pb mg/l BDL BDL BDL<br />
25 Zinc (Zn) mg/l BDL BDL BDL<br />
26 Chromium (Cr) mg/l BDL BDL BDL<br />
27 Mineral Oil mg/l Nil Nil Nil<br />
28 Alkalinity as CaCO3 mg/l 67 38 71<br />
29 Aluminium as Al mg/l BDL BDL BDL<br />
30 Boron as B mg/l 0.04 0.03 0.05<br />
31 Total Coliform MPN/100ml Nil Nil Nil<br />
<br />
Soil Quality<br />
Soil sampling was carried out at six locations. The samples were tested<br />
for physico-chemical properties. The soil samples were collected from the<br />
agricultural lands from the buffer zone areas. The particulars of soil<br />
sampling locations are presented in the table below.<br />
Table-3.23 Location of Soil Sampling Stations<br />
S.No.<br />
Location<br />
Code<br />
Location Name<br />
Distance (kms)<br />
w.r.t. Plant<br />
Direction<br />
w.r.t. Plant<br />
1 S1 Mynkre 0 -<br />
2 S2 Umlong 6.5 W<br />
3 S3 Umtyra 5.2 N<br />
4 S4 Lumshnong 6 S<br />
5 S5 Umshangiar 7.5 E<br />
6 S6 Umrasong 5.9 W<br />
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Hills Cement Co. Limited.<br />
Table-3.24 Soil Quality Analysis Results<br />
S.<br />
No.<br />
Parameter<br />
Unit<br />
Soil Sampling Station<br />
S1 S2 S3 S4 S5 S6<br />
1 pH (1:2 Soil<br />
Water Extract)<br />
2 Electrical<br />
Conductivity<br />
- 5.5 6.2 6.4 5.8 6.6 5.9<br />
6FP 120 56 46 52 140 80<br />
3 Nitrate as N mg/kg 80 180 240 60 280 320<br />
4 Phosphorous<br />
as P2O5<br />
mg/kg 22 51 Traces 18 Traces 42<br />
5 Potash as K2O mg/kg 210 140 360 530 320 270<br />
6 Sodium as<br />
Na2O<br />
mg/kg 150 95 180 260 310 240<br />
7 Calcium as Ca mg/kg 1140 1460 980 2130 2670 1860<br />
8 Magnesium as<br />
Mg<br />
mg/kg 340 280 460 1030 140 870<br />
9 Chloride as Cl mg/kg 32 16 43 16 22 38<br />
10 Organic Carbon % 0.28 0.18 0.62 0.58 0.78 0.42<br />
11 Texture - Sandy<br />
<br />
Loam<br />
Sandy<br />
Loam<br />
Sandy clay<br />
loam<br />
Sandy<br />
Loam<br />
Sandy clay<br />
Loam<br />
Sand % 75 87 49 74 51 67<br />
Silt % 11 6 24 12 23 15<br />
Clay % 14 7 24 14 26 18<br />
Sandy Loam<br />
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Hills Cement Co. Limited.<br />
CHAPTER-4<br />
ENVIRONMENTAL IMPACT ASSESSMENT<br />
Various activities and parameters, which may have impact on environmental<br />
domain due to the proposed cement plant with captive power project are<br />
identified and enumerated in the EIA report. Production of cement and<br />
generation of power always played a vital role in developmental activities. EIA<br />
presents appraisal of various impacts from the proposed plant in the study area.<br />
The environmental parameters, which are expected to be affected, by<br />
developmental activities are:<br />
1. Topography (Physiography & Drainage)<br />
2. Water Environment<br />
3. Ambient Air Quality<br />
4. Soil Quality<br />
5. Noise Level & Ground Vibrations<br />
6. Flora and Fauna due to Deforestation<br />
7. Natural Resources<br />
.CPFFGITCFCVKQPFWGVQIGPGTCVKQPQHYCUVGTQEM<br />
<br />
The project is likely to create impact on the environment in two distinct phases:<br />
ENVIRONMENTAL IMPACTS<br />
(A) CEMENT PLANT<br />
4.1 IMPACT ON LAND USE<br />
-During construction phase (temporary and short term).<br />
-During operation phase (long term)<br />
The land available for the proposed plant is 55.5403 ha. Nearly 14 ha<br />
land will be utilized for cement plant & captive power plant of 10 MW.<br />
Balance will be used for future expansion and greenery development.<br />
The construction activities would attract a worker population of about 400.<br />
Work force will be arranged from local villages except for those, who have<br />
specialized experience will stay at the site. No significant impact on land<br />
environment is expected.<br />
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Hills Cement Co. Limited.<br />
4.2 IMPACT ON SOIL<br />
The proposed land was unutilized in past. The land had some undulating<br />
ground profile. The area has been leveled by utilizing the earth from the<br />
excavation. No significant adverse impact on the soil in the surrounding<br />
area is anticipated except localized constructional impact.<br />
4.3 IMPACT ON AIR QUALITY<br />
During construction phase, suspended particulate matter will be the main<br />
pollutant, which would be generated from the site development activities<br />
and vehicular movement on the road. NOx & CO may increase slightly<br />
due to increased vehicular traffic movement.<br />
Source of dust emission in the plant are given below:<br />
1. Coal grinding section<br />
2. Packing plant.<br />
3. Cement grinding<br />
4. Clinker Silo<br />
5. Preheater, kiln & cooler<br />
6. Blending Silo<br />
7. Raw material storage<br />
Cement manufacture involves 3 main areas of environmental concern,<br />
namely;<br />
1. Dust <strong>Pollution</strong> of the atmosphere and,<br />
2. Emission of Green House Gases (GHGs),<br />
3. Noise <strong>Pollution</strong><br />
Cement industry does not generate any hazardous or toxic emissions or<br />
effluents, which are injurious to health.<br />
1. DUST POLLUTION<br />
Dust is generated through emissions, handling, spillage, leakages,<br />
jamming, etc at every stage of cement manufacture, starting with<br />
the quarrying of the major raw material limestone and ending with<br />
the packing and dispatch of cement from the plant.<br />
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Hills Cement Co. Limited.<br />
The dust sources can be broadly divided into process related and<br />
fugitive sources:<br />
I) Process related dust sources<br />
* Drilling;<br />
* Crushing and grinding - Limestone, coal and clinker;<br />
* Kiln and<br />
* Clinker cooler<br />
II)<br />
Fugitive dust sources<br />
* Conveyor transfer points<br />
* Open material stockpiles<br />
* Discharge from hoppers<br />
* Leaking joints<br />
* Raw material transport and handling through dumpers and pay<br />
loaders<br />
Road traffic:<br />
The present traffic density nearest to site on NH 44 is 280 per hour<br />
including all type of vehicles. The contribution due to the proposed<br />
plant will be 80 on daily basis. The transportation vehicles will be<br />
regularized and allowed in such a manner so that there existence does<br />
not disturb the routine traffic. Blow of horns would be prohibited in and<br />
around parking area. The locations of mines are in between hills and<br />
the plant and away from habitat. The mineral transport will not have<br />
any impact on habitat or highway.<br />
2. EMISSION OF GREEN HOUSE GASES (GHGs)<br />
Cement industry's emission of CO 2 is next only to thermal power plants<br />
(coal based). Cement kilns burn coal and limestone both of which<br />
generate CO 2 . The approximate contributions of each of the CO 2<br />
sources are:<br />
Calcinations 50 - 55%<br />
Fuel combustion 40 - 50%<br />
Electricity 0 - 10%<br />
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Hills Cement Co. Limited.<br />
Total CO 2 emissions per tonne of cement (assuming a 0.95: 1<br />
clinker to cement ratio) ranges about from 0.85 to 1.15 tonne, say<br />
one tonne.<br />
*Prescribed limit for GHGs emissions: 150 mg/nm 3<br />
3 NOISE POLLUTION<br />
In cement plants noise is generated by machinery, such as<br />
crushers, grinding mills, fans, blowers, compressors, and<br />
conveyors. The noise levels emitted in cement plants is known to<br />
vary in general from 65 to 90 dB (decibels). The standards for noise<br />
levels prescribed for Indian industry are 70 to 75 dB.<br />
The present noise levels at site in day and night times respectively<br />
were found to be 65 and 52 dB.<br />
Major noise generating sources are given below:<br />
1. Kilns<br />
2. Raw mill<br />
3. Cement mill<br />
4. Crusher<br />
5. Power plant<br />
The above plants and equipments will be inside the plant and will<br />
not contribute much to the ambient noise outside the factory<br />
premises. All precautionary measures shall be taken to minimize<br />
the noise level inside plant area. The rotating equipments would be<br />
mounted on anti vibration pads and regularly maintained so that the<br />
resultant noise level is not more than 85 dB (A). The damage risk<br />
criteria as enforced by OSHA (Occupational Safety and Health<br />
Administration) to reduce hearing loss would be strictly adhered.<br />
(B)<br />
THERMAL POWER PLANT<br />
1. Flue gases from boiler section<br />
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2. Fly ash from the hoppers<br />
3. Furnace bottom ash<br />
A Thermal Power Plant is a potential source of environmental pollution<br />
both atmospheric and surface. Pollutants normally arising the plant are<br />
coal ash, coal dust, SOx, NOx, effluents from water treatment and blow<br />
down, sewage etc. besides noise emitted from high speed drives and<br />
steam exhausts to atmosphere and also at times the leaks of obnoxious<br />
gases from the system. Nevertheless, adequate provisions, such as<br />
installation of ESP, treatment of effluents, neutralization, etc. have been<br />
envisaged for the proposed Power plant to keep the pollution level well<br />
within limits prescribed by the Statutory bodies and as specifically<br />
recommended for a Power Plant to come in a location like that of the<br />
proposed Plant.<br />
4.4 EFFLUENT WATER<br />
No process water will be generated, as the cement plant is based d on the<br />
dry process. Water is mainly used in closed circuits at certain stages in the<br />
process like in cement and raw mills. All the process water will be<br />
recycled.<br />
All blows down water from boiler, auxiliary cooling tower basin, system<br />
leakage water through equipment overflow drain (EOD) etc. will be<br />
channelised to a common sump. Water from the CEP will then be pumped<br />
out for following purposes within the plant area.<br />
• Horticulture<br />
• Dust Suppression<br />
• Ash Conditioning<br />
The water quality analysis results of all locations show that all the<br />
parameters are within the prescribed limits as per the surface water quality<br />
standard of IS: 2296. There will be no industrial effluent generated from<br />
cement plant. Domestic wastewater will also be generated which have to<br />
be treated. Rainwater run off may cause turbidity for which control<br />
measures have to be taken.<br />
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Principle of zero discharge will be adopted and no impermissible<br />
discharge will be allowed out side factory. All water from DM plant will be<br />
used. Blow down water from boiler, auxiliary cooling tower basin, system<br />
leakage water through equipment overflow drain will be managed inside<br />
the cement plant and factory.<br />
4.5 SOLID WASTE<br />
There will be no solid waste generation in the proposed plant. Rejected<br />
materials like packaging material, steel scrap, used tires etc. will be<br />
disposed off. Fly ash generation from CPP shall be handled properly. All<br />
the fly ash will be utilized in cement manufacture.<br />
(C)<br />
ENVIRONMENTAL IMPACTS DUE TO MINING:<br />
Various project activities which may have direct impact on above<br />
environmental parameters are as follows-<br />
A) Land acquisition & site preparation<br />
B) Creation of infrastructure<br />
C) Mining activities<br />
D) Blasting<br />
E) Transportation of mineral and waste rock<br />
F) Stocking of material<br />
G) Waste rock disposal<br />
H) Mine waste disposal<br />
I) Surface transportation and dispatch of mineral<br />
Land degradation, waste rock generation and management<br />
The existing land will be disturbed by the mining operations by three<br />
typesa)<br />
Land degradation caused due to excavation of pits.<br />
b) Land degradation caused due to dumping of waste generated<br />
during mining.<br />
c) Land degradation due to erection of infrastructure facility such<br />
as mines road, site office, rest shelter etc.<br />
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Hills Cement Co. Limited.<br />
The lease area is having exposed rocks. The area is hilly and devoid<br />
of any vegetation except wild bushes and shrubs. Major direct<br />
impact on land use during the pre mining phase is the removal of<br />
vegetation. No displacement of any habitat is involved. By opening<br />
the mine no loss of rare plants and endemic species is involved.<br />
Rehabilitation measures can take care of regeneration of species<br />
suitable for species without disturbing the surrounding area due to<br />
installation of crusher and movement of limestone by road. There will<br />
be no crushing and screening at the mine. The planning of<br />
development work have thus, addressed fully to the importance of least<br />
disturbance to the existing flora. It shall be normal duty of the lessee to<br />
utilize the barren land for the plantation growth. Trees most commonly<br />
available and easily grown in area shall be further planted.<br />
4.6 IMPACT OF BLASTING<br />
Limited blasting will be carried out at mining site. The degree of<br />
damage that may results from blast vibration to a structure will<br />
depend on the inherent strength, height and foundation design of the<br />
structure concerned. Another important point of consideration is the<br />
frequency of blast waves. If, the frequency of blast waves matches<br />
the natural frequency of the structure, the resonance will occur.<br />
Since the natural frequencies of the structure and their components<br />
lie in the range of 5 to 40 Hz the blast waves having low frequency<br />
(
Hills Cement Co. Limited.<br />
The pattern of drilling and blasting has been designed as follows:<br />
Proposed bench height : 6.0m<br />
Proposed diameter of hole : 100 mm,<br />
Effective depth of hole : 7.0m<br />
To maintain good fragmentation<br />
for quick removal of blasted<br />
muck, suggested burden : 3-3.5m<br />
Spacing : 4.0-4.5m<br />
Stemming column : 3.0-3.5m<br />
Tonnage of rock per hole : 236 tonnes.<br />
Impact on stability of slopes<br />
Rock slides in and around the vicinity-<br />
There are no visible signs of rock slides around the vicinity of the mine<br />
and no tension cracks or loosened boulders are present. The mining<br />
activity will have adverse impact on the slope stability, if appropriate<br />
control measures are not adopted. <strong>Control</strong>led blasting shall be adopted<br />
to avoid tension cracks and back breaks. Such crack filled with water<br />
reduces stability of excavated slopes and angle of slopes. Good<br />
drainage shall be provided in and around the quarry.<br />
Rolling boulders<br />
When mining of a bench reaches the edge of the hill, it may give rise to<br />
rolling of boulders downwards along the hill slopes. It may have<br />
adverse impacts on flora and structures on the way. It may also lead to<br />
serious injuries to human beings or animals. Adequate control<br />
measures as given below have been proposed to prevent this<br />
phenoena.<br />
On end bench 8m from the edge is to be considered as “Caution Zone”.<br />
Regular mining shall not be done in the zone. The orientation of the<br />
face will be kept parallel to the edge of the hill in the area and the<br />
bench height is restricted to 2m only. <strong>Control</strong>led blasting will be<br />
adopted for the last blast. Pre-splitting will be done, if required.<br />
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Hills Cement Co. Limited.<br />
WASTE ROCK MANAGEMENT<br />
It is expected that about 1, 40, 000 M 3 waste rock will be generated in<br />
first five years of working. Nearly 40,000 M 3 shall be either used in<br />
leveling of low lying areas. Part of it will be used in road construction<br />
and taken by local villagers for house construction free of charge.<br />
Remaining 1, 00,000 M 3 would be dumped on waste disposal site in<br />
maximum dump height of 15 M with two benches of 5 M each. Waste<br />
generation shall be significantly reduced thereafter, since there will be<br />
no overburden. Two external dump sites are earmarked with total<br />
dumps area of<br />
0.7 Ha and 0.9 Ha respectively. The dumps shall be<br />
later stabilized, planted and reclaimed.<br />
Year Waste in tonnes Rom mineral in tonnes<br />
I 40,200 5,01,000<br />
II 62,300 7,07,000<br />
III 63,200 7,51,000<br />
IV 72,650 8,11,000<br />
V 73,800 8,15,000<br />
Total 3,12,150 35,94,000<br />
Impact on soil quality-<br />
The site for mine pit does not have any topsoil. The site for rejects<br />
stack yard also does not bear topsoil. Therefore, there may not be an<br />
adverse effect on topsoil due to the mining. However some adverse<br />
effects on land use pattern will occur due to mining activities.<br />
Impact on ambient air quality-<br />
The major sources/activities of dust emissions are drilling and blasting,<br />
haul roads, transportation etc. Because of semi mechanized/ manual<br />
mining and nature of ore and waste, there shall be less air pollution due<br />
to the mining activities. Some quantity of dust will be generated due to<br />
drilling and blasting. Adequate precautions shall be taken to control the<br />
dust generation. There will be no work in the mine in the night. Dust will<br />
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naturally and automatically settle down. There will not be much effect of<br />
air quality.<br />
Impact of noise and ground vibrations-<br />
Noise is caused due to increased mechanization during transport<br />
activities and blasting operations carried out in mining. In the present<br />
case the location of mines is in between hills and plant. The hilly terrain<br />
is also helpful in damping the noise generated. The height of<br />
surrounding hills is not more. Mining is proposed by semi mechanized/<br />
manual open cast mining methods. Wet drilling and delayed detonator<br />
pattern shall be adopted to reduce noise generation. No heavy<br />
machinery will be deployed in mining operation except hammer for<br />
drilling and trucks for transportation. These will neither generate much<br />
noise to disturb the area nor produce the much vibration.<br />
4.7 IMPACT ON WATER ENVIRONMENT<br />
No surface water is found in the area. Thus there would not be any<br />
degradation or pollution of surface water due to the mining in this area.<br />
The lime stone is parent rock system of the area. It is inert and nontoxic.<br />
The major impacts are water pollution due to erosion, oil and<br />
grease, contamination of water bodies due to discharge of mine water,<br />
toxic wastes, salinity from mine fires, acid mine drainage, etc. Ground<br />
water pollution can only take place, if dumps and stockpiles contain<br />
harmful chemical substances. No chemicals are associated with the<br />
deposit. The mining activities will not have any impact on water quality.<br />
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Hills Cement Co. Limited.<br />
4.8 SAFETY AND SECURITY<br />
Barbed wire fencing is proposed around the proposed excavation to check<br />
the inadvertent entry of human and livestock in the mining area. Security<br />
personal shall be deployed for watch and ward duty. The watchman will not<br />
allow any unauthorized person and livestock near the deep cuttings of the<br />
proposed workings. The safe workings are proposed in the supervision of<br />
technical and qualified supervisory staff. Safety measures will be provided as<br />
per Mines Act.<br />
4.9 FLORA AND FAUNA<br />
There is no forest area, wildlife sanctuary in the study area. The site is<br />
covered with grass, bushes & few trees. No endangered or rare species are<br />
reported or observed in the study area. Also there is no significant aquatic<br />
body within the study area. The proposed land was unutilized.<br />
Construction of plants or operations of mines in nearby areas will not involve<br />
in clearance of major flora. The impact on fauna is also negligible.<br />
4.10 SEISMICITY<br />
The region is one of the well-known seismically active regions and falls under<br />
Zone V. The study area has experienced two largest earthquakes.<br />
• 12 June 1897 (mag 8.7)<br />
• 15 August 1950 (mag 8.5)<br />
Both these earthquakes are reported to occur causing widespread damage.<br />
The epicenter of the earthquake in 12 June 1897 occurred at Shillong massif<br />
while the 1950 earthquake has its epicenter further Northeast.<br />
The most commendable scientific evidence for the high seismicity is<br />
attributed to the tectonic features of the Northeast. The Northeast region is<br />
very close to the junction of Himalayan and the Burmese arcs which bear<br />
resemblance to that of Pamir Knot at the other extreme corner of the<br />
Himalayas.<br />
Shillong plateau of Archaean shied of an altitude about 2 km has been<br />
affected by several large earthquakes. The western and the northern<br />
boundaries of the plateau follow the Brahmputra river. On the southern<br />
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portion of the old rocks of the plateau is the thrust over the Haflong-Disang<br />
fault zone. The Shillong shield extends Northeast and the foreland under the<br />
Bramhaputra alluvium. The seismicity of the region is defined by the collision<br />
of the India and the Eurasian plates, as explained above the Indian plates are<br />
moving at the north easterly direction and is under thrusting the Eurasian<br />
plate, hence the strong seismic influence in the study area.<br />
4.11 SOCIO-ECONOMICS<br />
The major beneficial impacts of mining project are changes in<br />
employment and income opportunity, infrastructure, community<br />
development, communication transport, and educational, commercial<br />
etc. facilities.<br />
The adverse impacts are the displacement and<br />
rehabilitation/resettlement of affected people including change in<br />
culture, heritage & related features. The crime & illicit activities may<br />
also increase.<br />
The land is presently unutilized. There shall be no displacement of any<br />
habitat. There shall be no adverse effect of mining activities on the<br />
social and demographic profile. The mining activities in this region will<br />
improve the socio-economic conditions of the inhabitants because the<br />
mining activities in this area will provide better opportunities to earn<br />
additional and substantial amount of money to meet their livelihood.<br />
This will improve the standard of the inhabitants. Mining activities<br />
provide both direct / indirect employment opportunities to the local<br />
population.<br />
Job opportunities for the local people will be generated due to the coming of<br />
this project. Local people will be given preference, whenever found suitable<br />
for all jobs in the plant. People will be benefited both directly and indirectly.<br />
People will be engaged in the form of retailers through out the state. Due to<br />
the coming of proposed plant, the nearby villages would be developed with<br />
facilities like good road network and improve the economic structure of the<br />
area.<br />
The product is used for making houses and will be available at a cheaper<br />
cost to local people due to reduction in freight costs. The realization of the<br />
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project will result into direct revenue to both state and central exchequer in<br />
terms of power tariff, taxes, duties, royalties, etc.<br />
4.12 AIR DISPERSION MODELLING<br />
Air quality impact of cement plant (3,000 tons), and captive power thermal<br />
power (10 MW) project has been assessed with the help of mathematical<br />
modeling.<br />
The impacts have been predicted for the proposed Cement and Power plant<br />
assuming that the pollution due to the existing activities has already been<br />
covered under baseline environmental monitoring and continue to remain<br />
same till the operation of the project.<br />
Exhaust emissions from vehicles and equipment deployed during the<br />
construction phase is also likely to result in marginal increase in the levels of<br />
SO 2 , NOx, SPM, and CO. Construction activities may cause changes in the<br />
SPM levels locally. The impact will, however, be reversible, marginal, and<br />
temporary in nature.<br />
The impact of such activities would be temporary and restricted to the<br />
construction phase.<br />
The location of mines is in between the hills and the plant away from road<br />
and habitat. The impact will be confined within the project boundary and is<br />
expected to be negligible outside the project area. Proper upkeep and<br />
maintenance of vehicles, sprinkling of water on roads and construction site,<br />
providing sufficient vegetation etc. are some of the measures that would<br />
greatly reduce the impacts during the construction phase etc. are some of the<br />
measures that would greatly reduce the impacts during the construction<br />
phase.<br />
IMPACT DURING OPERATION PHASE<br />
The model simulations deal with the major pollutant viz., Suspended<br />
Particulate Matter (SPM) and Sulphur dioxide (SO 2 ) and Oxides of Nitrogen<br />
(NOx) for Cement and Captive coal based thermal power plant will be the<br />
important pollutants.<br />
The various measures proposed to minimize the pollution from the cement<br />
plant, power plant and mines are as follows:<br />
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-Electrostatic precipitators with appropriate efficiency will be installed to limit<br />
the particulate (SPM) emission within statutory limit of 70 mg/Nm 3 .<br />
-To facilitate wider dispersion of pollutants, 70-m high stack will be provided.<br />
-<strong>Control</strong>ling combustion measures, which will be approached by way of low<br />
NOx burners or by air staging in furnace, will control the NOx emissions from<br />
the boilers.<br />
-Wet drilling and delayed detonator techniques for blasting shall be adopted<br />
to control dust generation.<br />
-Fugitive dust will be controlled by adopting dust extraction and dust<br />
suppression measures and development of green belt along the periphery of<br />
the proposed power plant.<br />
Prediction of impacts on air environment has been carried out employing<br />
mathematical model based on a steady state Gaussian plume dispersion<br />
model designed for multiple point sources for short term. In the present case,<br />
Industrial Source Complex [ISC3] 1993 dispersion model based on steady<br />
state Gaussian plume dispersion, designed for multiple point sources for<br />
short term and developed by United <strong>State</strong>s Environmental Protection Agency<br />
[USEPA] has been used for simulations from point sources.<br />
Prediction of ground level concentrations (glc’s) due to proposed cement<br />
plant and captive thermal power plant has been made by Industrial Source<br />
Complex, Short Term (ISCST3) as per CPCB guidelines. ISCST3 is US-EPA<br />
approved model to predict the air quality.<br />
The model simulations deal with three major pollutants viz., Sulphur Dioxide<br />
(SO 2 ), Oxides of Nitrogen (NOx) and Suspended Particulate Matter (SPM)<br />
emitted from the proposed projects all together i.e., cement plant, captive<br />
thermal power project and captive mines. The model uses rural dispersion<br />
and regulatory defaults options as per guidelines on air quality models<br />
(PROBES/70/1997-1998). The model assumes receptors on flat terrain.<br />
OPTIONS USED FOR MODEL COMPUTATIONS<br />
The options used for short-term computations are:<br />
• The plume rise is estimated by Briggs formulae, but the final rise is<br />
always limited to that of the mixing layer<br />
• Stack tip down wash is not considered<br />
• Buoyancy induced dispersion is used to describe the increase in<br />
plume dispersion during the ascension phase<br />
• Calms processing routine is used by default;<br />
• Wind profile exponents are used by default, 'Irwin';<br />
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• Flat terrain is used for computations;<br />
• Assumed that the pollutants do not undergo physico-chemical<br />
transformation and that there is no removal by dry dust deposition;<br />
• Cartesian co-ordinate system has been used for computations; and<br />
• The model computations have been done for 20 km with 500-m<br />
interval.<br />
• Washout by rain is not considered.<br />
• Meteorological inputs required are wind speed and direction, ambient<br />
temperature, stability class, and mixing height.<br />
INPUT DATA<br />
For the modeling purpose, sulphur dioxide, Oxides of nitrogen and<br />
Suspended particulate matter from cement and captive thermal power project<br />
are considered. The emission details are given below:<br />
Cement and Captive Thermal Power Project Emissions<br />
Captive Power Plant And Cement Plant Emissions<br />
DESCRIPTION Raw Mill Cooler Klin Coal<br />
Mill<br />
Stack Height Ht.<br />
(m)<br />
Exit flue<br />
Diameter(m)<br />
Flue gas Exit<br />
Velocity (m/s)<br />
Flue gas Exit<br />
Temp ( 0 C)<br />
Cement<br />
Mill<br />
Packing<br />
Plant<br />
70 45 70 45 40 32 59<br />
3.5 2.5 3.5 1.5 1.2 1 1.3<br />
CPP<br />
6.4 18.50 14.28 11.91 38.85 8.39 16.55<br />
90 325 340 110 120 120 120<br />
Flow rate Nm 3 /hr 1,80,000 1,80000 230000 60000 120000 18000 60000<br />
Air Emissions<br />
SPM in gm/sec 4.5 5.0 9.0 2.0 1.8 0.5 2.5<br />
SO 2 in gm/sec 20.00 30<br />
NOx in gm/sec 25.00 12.5<br />
For the prediction purpose RSPM is taken to be 35 % of SPM emissions.<br />
Gaussian Plume Model (ISCST3 )<br />
The ISC short term area source model is based on a numerical integration<br />
over the area in the upwind and cross wind directions of Gaussian plume<br />
formula. This can be applied to the point, area, and line or volume sources<br />
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simultaneously and their resultant incremental concentration of the pollutant<br />
can be predicted.<br />
Extrapolation of Wind Speed<br />
Power law as given below calculates wind speed at stack level.<br />
U stack = U10 (Stack height/10) p<br />
Where U10 is the wind speed at 10-meter level and p is the power law<br />
coefficient (0.07, 0.07, 0.10, 0.15, 0.35 and 0.55 for stability classes A, B, C,<br />
D, E and F respectively) as per Irwin for rural areas (USEPA, 1987).<br />
Stability Classification<br />
Hourly stability is determined by wind direction fluctuation method as<br />
suggested by Slade (1965) and recommended by CPCB (PROBES/70/1997-<br />
1998).<br />
1a = Wdr/6<br />
1a is standard deviation of wind direction fluctuation; W dr is the overall wind<br />
direction fluctuation or width of the wind direction in degrees. The table for<br />
stability classes is given as under.<br />
Stability<br />
Class<br />
1a (degree)<br />
A > 22.5<br />
B 22.4 – 17.5<br />
C 17.4 – 12.5<br />
D 12.4 – 7.5<br />
E 7.4 – 3.5<br />
F < 3.5<br />
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Dispersion Parameters<br />
Dispersion parameters and for open country conditions (Briggs, 1974) are<br />
used as the project is located on a flat terrain in a rural area. Atmospheric<br />
dispersion coefficients vary with downwind distance (x) from emission<br />
sources for different atmospheric stability conditions. (CPCB –<br />
PROBES/70/1997-98)<br />
Mixing Height<br />
As site specific mixing heights were not available, mixing heights based on<br />
CPCB publication, “SPATIAL DISTRIBUTION OF HOURLY MIXING DEPTH<br />
OVER INDIAN REGION”, PROBES/88/2002-03 has been considered for<br />
Industrial Source Complex model to establish the worst case scenario.<br />
Meteorological Data<br />
Data recorded at the continuous weather monitoring station on wind speed,<br />
direction, and temperature for the monitoring period was used as<br />
meteorological input.<br />
In the present case model simulations have been carried using the triple joint<br />
frequency data. Short-term simulations were carried to estimate<br />
concentrations at the receptors to obtain an optimum description of variations<br />
in concentrations over the site in 20-km radius covering 16 directions.<br />
The incremental concentrations are estimated for the monitoring period. For<br />
each time scale, i.e. for 24 hr (short term) the model computes the highest<br />
concentrations observed during the period over all the measurement points.<br />
The maximum incremental GLCs due to the proposed cement plant, and<br />
captive thermal power projects together for SPM, SO 2 and NOx are<br />
superimposed on the maximum baseline SPM, SO 2 and NOx concentrations<br />
recorded at the monitoring locations during the field monitoring period winter<br />
2007-2008. The incremental concentration due to operation of thermal power<br />
plant, cement plant and their combined cumulative concentrations (baseline +<br />
incremental) after implementation are tabulated below in Table- 4.1, Table<br />
4.2 and Table 4.3 respectively. The maximum GLCs for SPM, SO 2 and NOx<br />
after implementation of the proposed project are likely to be within the<br />
prescribed NAAQ standards for Rural and Residential areas.<br />
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TABLE 4.1: IMPACT OF THERMAL POWER PLANT ALONE<br />
(Baseline + Incremental)<br />
Sampling<br />
Locations<br />
Direction<br />
from<br />
Cement<br />
Plant Site<br />
Aerial<br />
distance<br />
in km. from<br />
site<br />
Monitored data ( Maximum) THERMAL POWER<br />
PLANT<br />
ONLY<br />
Incremental Maximum<br />
Resultant Ground level<br />
Concentration<br />
RPM SPM SO2 NOx RPM SPM SO2 NOx RPM SPM SO2 NOx<br />
Mynkre - 0 41.0 112.0 11.2 14.4 1.06 2.1 0.5 0.2 43.2 115 12.2 14.6<br />
Umlong W 6.5 34.0 115.0 13.0 10.0 0.06 0.08 0.04 0.03 34.7 115.8 13.1 10.03<br />
Umtyra N 5.2 43.0 115.0 8.1 13.7 0.9 1.8 0.2 0.1 44.5 117.6 9 13.8<br />
Lumshnong S 6.0 46.0 118.0 9.2 13.3 0.1 0.3 0.08 0.06 46.8 119.2 10 13.36<br />
Umshangiar E 7.5 46.0 119.0 9.5 13.7 0.04 0.06 0.02 0.01 46.08 119.09 9.55 13.71<br />
Umrasong W 5.9 43.0 115.0 11.3 13.7 0.4 0.8 0.1 0.09 44.8 117.4 11.9 13.79<br />
Mines Site W 1.0 42.0 114 12 14 1.0 1.5 0,7 0.6 43.51 115.5 12.7 14.6<br />
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TABLE 4.2: IMPACT OF CEMENT PLANT ALONE<br />
(Baseline + Incremental)<br />
Sampling<br />
Locations<br />
Direction<br />
from<br />
Cement<br />
Plant<br />
Site<br />
Aerial<br />
distance<br />
in km.<br />
from<br />
site<br />
Monitored Data ( Max.) CEMENT PLANT Incremental<br />
Maximum<br />
Resultant Ground level<br />
Concentration<br />
RPM SPM SO2 NOx RPM SPM SO2 NOx RPM SPM SO2 NOx<br />
Mynkre - 0 41.0 112.0 11.2 14.4 1.8 2.6 0.8 0.3 42.8 114.6 12 14.7<br />
Umlong W 6.5 34.0 115.0 13.0 10.0 0.1 0.4 0.09 0.05 34.1 115.4 13.09 10.05<br />
Umtyra N 5.2 43.0 115.0 8.1 13.7 1.2 2.2 0.6 0.5 44.2 117.2 8.7 14.2<br />
Lumshnong S 6.0 46.0 118.0 9.2 13.3 0.6 0.9 0.4 0.2 46.6 118.9 9.6 13.5<br />
Umshangiar E 7.5 46.0 119.0 9.5 13.7 0.07 0.09 0.04 0.02 46.07 119.09 9.54 13.72<br />
Umrasong W 5.9 43.0 115.0 11.3 13.7 1.1 1.4 0.3 0.1 44.1 116.4 11.6 13.8<br />
Mines Site W 1.0 42.0 114 12 14 2.0 2.5 0,9 0.8 44 116.5 12.9 14.8<br />
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TABLE 4.3: CUMULATIVE IMPACT OF THERMAL POWER PLANT AND CEMENT PLANTS<br />
Sampling<br />
Locations<br />
Directio<br />
n from<br />
Cement<br />
Plant<br />
Site<br />
Aerial<br />
distance<br />
in km.<br />
from<br />
site<br />
Monitored data ( Maximum) CEMENT PLANT & POWER<br />
PLANT<br />
Incremental Maximum<br />
Resultant Ground level<br />
Concentration<br />
RPM SPM SO2 NOx RPM SPM SO2 NOx RPM SPM SO2 NOx<br />
Mynkre - 0 41.0 112.0 11.2 14.4 2.2 3.0 1.0 0.8 42.06 114.1 11.7 15.2<br />
Umlong W 6.5 34.0 115.0 13.0 10.0 0.7 0.8 0.1 0.09 34.06 115.08 13.04 10.09<br />
Umtyra N 5.2 43.0 115.0 8.1 13.7 1.5 2.6 0.9 0.6 43.9 116.8 8.3 14.3<br />
Lumshnong S 6.0 46.0 118.0 9.2 13.3 0.8 1.2 0.8 0.5 46.1 118.3 9.28 13.8<br />
Umshangiar E 7.5 46.0 119.0 9.5 13.7 0.08 0.09 0.05 0.02 46.04 119.06 9.52 13.72<br />
Umrasong W 5.9 43.0 115.0 11.3 13.7 1.8 2.4 0.6 0.2 43.4 115.8 11.4 13.9<br />
Mine Site W 1.0 42.0 114 12 14 3.0 3.8 1.8 2.0 45.0 117.8 13.8 16<br />
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CHAPTER-5<br />
ENVIRONMENTAL MANAGEMENT PLAN<br />
The Environmental Management Plan (EMP) is required to ensure sustainable<br />
development in the study area (10 Kms) of the project site. The impact assessment<br />
due to the proposed project has highlighted certain areas, which need special<br />
attention. The Environmental Management Plan consists of mitigation measures for<br />
activity during the construction, operation and the life cycle to minimize adverse<br />
environmental impacts of the project. It would also delineate the environmental<br />
monitoring plan for compliance of various environmental regulations.<br />
The project will carry out the control measures for air pollution by installing air<br />
pollution control system and installation of sewage treatment plant and plantation<br />
programme.<br />
5.1 POLLUTION CONTROL MEASURES<br />
CONSTRUCTION PHASE<br />
Air pollution <strong>Control</strong><br />
During construction phase, effective mitigating measures will be adopted to<br />
reduce the primary impact on air environment to the minimum. These include<br />
effective water sprinkling over the transport roads (especially unpaved) and<br />
over the areas where loose materials (including earth works) are handled<br />
(excavated, loaded and unloaded), which will reduce the pollution due to<br />
dust. The machinery used in construction will be well maintained, regularly<br />
overhauled and tuned which will prevent air pollution due to exhaust<br />
emissions. In this way, it is anticipated that the air pollution during<br />
construction will be negligible and will remain well below the prescribed limits<br />
CPCB/SPCB.<br />
5.2 OPERATION PHASE<br />
Fugitive emissions<br />
It is proposed to cover the trucks loaded with raw material by tarpaulins to<br />
prevent the material from becoming airborne during transportation. It is also<br />
proposed to sprinkle water over the roads (especially unpaved) to prevent<br />
dust from becoming airborne as a result of tire-road interaction in and around<br />
the plant area.<br />
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Bag filters will be installed at all material transfer points and material<br />
conveying systems - air slides, bucket elevators etc. Belt conveyor swill be<br />
used for stacking the -80 mm size limestone to reduce the falling height and<br />
hence to reduce dust generation. Gypsum and coal will be received in wet<br />
condition, hence; will not require any specific control measures. All raw<br />
material storages and conveyors will be covered. In order to control air<br />
pollution systems like fly ash system with ESPs, dust suppression systems<br />
with water spraying and ventilation systems have been envisaged.<br />
The main stacks emitting most of the SPM emission are given in Table 5.1<br />
along with the proposed air pollution control equipment.<br />
TABLE 5.1<br />
MAIN STACKS AND SPM CONTROL EQUIPMENT<br />
Sl.<br />
Stack name<br />
Height<br />
Dia<br />
SPM control<br />
Max. SPM<br />
No.<br />
(m)<br />
(m)<br />
equipment<br />
emission in<br />
mg/Nm 3<br />
1. Clinker cooler 30.0 1.80 ESP 55.0<br />
2. Primary crusher 21.0 1.19 Bag house 50.0<br />
3. Secondary crusher 13.0 1.00 Bag house 60.0<br />
4. RABH (kiln & raw mill) 47.5 3.00 Bag house 65.0<br />
5. Coal mill 37.0 1.18 Bag house 50.0<br />
6. Cement mill 20.5 1.20 Bag house 52.0<br />
7. Packing plant 10.0 0.60 Bag house 45.0<br />
8. Power plant 80.0 2.50 ESP 75.0<br />
<strong>Pollution</strong> control equipment for outlet of raw mill & kiln has got two options,<br />
namely: ESP and bag filter, both are extensively used by large cement plants.<br />
ESP has got the advantage of low-pressure loss, high temperature<br />
adaptability and low recurring cost. However, tripping due to system failures<br />
rather common & frequent, requiring high degree of maintenance. Bag filters<br />
are also available for high temperature (up to 260°C on continuous basis and<br />
280°C for a shorter period). Pressure loss is high and maintenance cost is<br />
high as it requires regular replacement of bags. If the system fails due to<br />
process disturbance and temperature increases, fresh air is automatically<br />
drawn in, to maintain the temperature of gases within permissible<br />
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temperature range. Many cement plants having excellent environmental<br />
cleanliness are successfully & satisfactorily using bag filters. For the main<br />
stack, bag filter offers to be a better choice from environmental point of view.<br />
Emission levels are generally low in case of bag filter compared to that of<br />
ESP. For clinker cooler, ESP will be the only choice. Multicyclone will not be<br />
able to maintain emission level below 50 mg/Nm 3 . Use of efficient multi<br />
channel burners is envisaged to keep NO 2 emission low. This plant has<br />
planned to adopt latest technology for low NOx generation in its precalcinator.<br />
ESP will also be provided for controlling the emissions from captive power<br />
plant. Thus, it is proposed to restrict the emission to within the stipulated<br />
norms.<br />
This in combination with adequate height of the stacks will help in keeping the<br />
incremental values of pollutants to the bare minimum levels as has been<br />
proved by dispersion modeling study. In this way, it is anticipated that the air<br />
pollution during operation will be meager and will remain well below the<br />
prescribed limits of CPCB/SPCB in respect of stack emissions standards as<br />
well as ambient air quality standards.<br />
Since <strong>Meghalaya</strong> coal contains higher sulphur content (Up to about 3)<br />
adequate care is taken in designing the height of the chimney of AFBC boiler.<br />
Stack of around 80 M height in line with the stipulations of the Central<br />
<strong>Pollution</strong> <strong>Control</strong> <strong>Board</strong> will be provided.<br />
The following measures will be adopted for the proposed power plant to<br />
minimize air pollution:<br />
• Particulate emission rate from flue gas at stack outlet will be restricted<br />
to a maximum of 150 mg / Nm 3 .<br />
• Dedusting System will be provided to arrest fugitive emissions in the<br />
work zone.<br />
• The dust control System will be installed and Commissioned along<br />
with the main Plant. These Systems will be checked and their emission<br />
rates will also be monitored.<br />
• The stack will be provided with necessary instruments for monitoring of<br />
SPM, SO 2 and NOx.<br />
Dust extraction system will be installed at the following sections. The<br />
location of air pollution control systems is also mention.<br />
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1. Raw material storage and transport- Bag filter<br />
2. Raw meal preparation- Bag filter & Bag house<br />
3. Blending Silo- Bag filter<br />
4. Preheater, Kiln & Cooler- Cooler ESP<br />
5. Clinker Silo- Bag filter<br />
6. Cement Grinding- Bag filter<br />
7. Packing Plant- Bag filter<br />
8. Coal Grinding- Bag filter<br />
Similarly ESP will be installed in the Captive power plant to arrest the<br />
particulate matter. The efficiency of ESP will be 98% to maintain the emission<br />
level.<br />
The dust concentration level in the chimney will be periodically monitored.<br />
Sulphur-dioxide and Nitrogen dioxide can be control by limestone charging,<br />
or by keeping AFBC boiler combustion temperature below 900°C.<br />
Fly Ash will be removed on the principle of Dry Dense Phase Pneumatic<br />
System and transported in dry condition to an Ash Silo. Ash from the Silo will<br />
be transported internally to the Fly ash inlet hopper of the Cement Plant. Fly<br />
ash shall be conditioned (moistened by water) at the Ash Silo Outlet<br />
satisfying the Environmental requirement.<br />
More granular bottom ash being only of very small quantity will be reused,<br />
after proper sieving, as bed materials in AFBC Boiler.<br />
Fugitive emissions are generated from material handling systems; raw<br />
material storage yards and material movement will be suppressed by water<br />
spraying.<br />
There will be no major leveling operation and hence so no major excavation<br />
will be necessary except for the purpose of foundations. Dust, the major<br />
source of air pollution is likely to be generated from construction activities and<br />
transportation. Hence water sprinkling will be done on regular basis in the<br />
months December to March. The construction vehicles will be properly<br />
maintained to minimize smoke in the exhaust emissions.<br />
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5.3 MITIGATION OF DUST POLLUTION<br />
The sources and levels of emission before treatment and methods of dust<br />
extraction/suppression in different section of a cement plant are stated<br />
below:<br />
• Crushing<br />
Cyclone or bag filter is the type of dust collector mainly employed here to<br />
draw off the air-borne dust through hoods and ducts into a dust collector by<br />
means of a fan operating downstream of the collector, which provides the<br />
necessary suction to draw off the air stream.<br />
• Raw Mill<br />
Bag type filter is used with ball mills, whereas electrostatic precipitator (ESP)<br />
functions as dust collector in the case of roller mill. In some cases,<br />
cyclones/multiclones are used as a pre-collector in order to reduce the load<br />
on the final dust collectors like bag filter or ESP.<br />
• Kiln<br />
Kiln exhaust gases constitute the major source of particulate matter in any<br />
cement plant.<br />
Cement plants (more then 600TPD) use ESP's with gas conditioning towers.<br />
The current trend in almost all new plants is to use reverse air bag houses<br />
with woven fiberglass fabric. However, since such fabric can not be used over<br />
high gas temperature of 260° C, the gas is cooled either by atmospheric air<br />
dilution or by radiant cooler.<br />
The kiln (as well as cooler) ESP's are provided with electronic instruments<br />
called ESPMS (ESP Management System) and opacity meter at the chimney<br />
for constant monitoring of emission. EPMS continuously regulates the current<br />
and voltage of the ESP to keep the emission below the specified limits, on the<br />
basis of feedback signal from opacity meter. The combination of opacity<br />
meter and EPMS keeps the emission always below the specified limits with<br />
optimum power consumption.<br />
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• Clinker Cooler<br />
The exit gases from grate coolers contain coarse particles and their<br />
temperature is about 200°C. The exhaust air from grate coolers is traditionally<br />
dedusted by means of cyclones or small diameter multiclones, which,<br />
however, do not dedust completely. For higher efficiency, three different<br />
types of dust collectors, viz., bag filters, gravel bed filters and ESP, are used.<br />
ESP has the advantages of a low-pressure drop and low maintenance cost.<br />
Bag filters are also used having high ratio pulse jet polyester as a fabric<br />
material, preceded by heat exchanger. Emission of cooler ESP shall be 40-65<br />
mg/Nm 3 .<br />
• Coal Mill<br />
Coal mill gases are generally dedusted by installing bag filters or ESPs. The<br />
dust contents of the exhaust gases from the coal mill are in the range 25-60<br />
g/Nm 3 and the dust is usually of a very fine nature.<br />
• Cement Mill<br />
Two types of dust collectors are generally employed for dedusting vent<br />
gas/air from the cement mill, viz., bag filters and ESPs. Use of ESPs is more<br />
common in cases where internal water spray system is used for cooling. For<br />
external water spray cooling system, both bag filter and ESPs can be used.<br />
• Packing<br />
In the packing area, dust from various dust generating points like hoppers,<br />
handling points, etc., is collected through proper hoods and ducted to a<br />
common dust collector. The dust concentration is usually 20 - 30 g/Nm 3 . As<br />
the volumetric flow rate is low, fabric filters are generally preferred.<br />
Training and Development<br />
Smooth operation of environmental management systems (EMS) has come<br />
into its own as a distinct discipline, as will testify the ISO 14000 standards. So<br />
much so, training of personnel in this area has become a priority activity for<br />
Indian cement industry.<br />
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5.4 LIMITING CO 2 EMISSIONS<br />
The measures in this regard fall broadly under process modification and<br />
Product modification.<br />
a) Process modification<br />
Process modification measures include substitution of coal by lower<br />
carbon fuels like lignite and natural gas, use of washed coal, improved<br />
kilns, multiple-stage preheater, precalciners, cogeneration, etc.<br />
Noteworthy of mention is afforestation and planting of trees in the<br />
plants' environs by many cement plants; these act like a "sink" for<br />
GHG's.<br />
b) Product modification.<br />
Product modification, on the other hand, includes blended cement<br />
manufacture and increased use of pozzolana in concrete. This is<br />
recognized as the most cost effective emission reduction method.<br />
Each tonne of pozzolana or cementation material used reduces CO 2<br />
emissions by one tonne.<br />
The exemplary measures of ecological conservation adopted by<br />
cement plants in their limestone mines have received repeated<br />
acclamation from institutions like Indian Bureau of Mines.<br />
5.5 NOISE POLLUTION<br />
Noise generation during construction phase will be due to the operation of<br />
heavy equipments and increased frequency of vehicular traffic in the area.<br />
The nearest habitation is at a distance of 1-km. Hence the noise generated<br />
will be diffused by the natural obstructions and with distance. On-site workers<br />
will be provided earmuffs. As far as possible noise prone activities will be<br />
restricted during night (10 pm to 6 am).<br />
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TABLE 5.2<br />
NOISE POLLUTION LEVEL OF THE EQUIPMENTS<br />
Equipments Noise Level in dB (A)<br />
Mills 86 - 100<br />
Forced draft fan 85 - 100<br />
Induced draft fan 76 - 97<br />
Compressors 82 - 105<br />
Turbo generator 90<br />
Mitigation measures<br />
In general, the following measures will be adopted for noise pollution<br />
control:<br />
• Technical Measures<br />
• Administrative measures<br />
• Personnel protection Measures<br />
In Thermal Power Plant, the noise sources are mostly high pressure Pumps,<br />
Turbines and leaking Steam pipelines.<br />
The following technical measures will be taken to reduce noise:<br />
• Checking leakages in High Pressure Pipelines and plugging them, as<br />
required.<br />
• Providing enclosures / barriers for turbines high-pressure pumps.<br />
• Proving silencers at inlet / outlet of the Fans.<br />
• Regular checking of vibration level due to high speed machines and<br />
taking necessary step to mitigate the same.<br />
In the Boiler Plant there are various noise producing areas such as High<br />
Pressure pipelines where technical measures will not be practically effective.<br />
In such cases, the following administrative measures are proposed:<br />
• Workers will be put on rotational duties.<br />
• Regular medical check up for all workers.<br />
Besides above, the workers exposed to high noise will be provided with<br />
personnel protective devices such as earplugs and earmuffs.<br />
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The noise generation will be reduced at source by erecting noise dampening<br />
enclosures, by maintaining the machines and greasing them regularly. The<br />
vehicles are and will be equipped with silencers. The equipments shall be<br />
provided with acoustic shields or enclosures to limit the sound level inside the<br />
plant, the existing equipment already have these provisions. The secondary<br />
protective measures will be adopted at receptor points to reduce negative<br />
impact due to high noise levels. All the workers engaged at and around high<br />
noise generating sources are and shall be provided with ear protection<br />
devices like ear mufflers/plugs. Their place of attending the work will be<br />
changed regularly so as to reduce their exposure duration to high levels.<br />
They will be regularly subjected to medical check-up for detecting any<br />
adverse impact on the ears. The existing and proposed green belt will also<br />
help to prevent noise generated within the plant from spreading beyond the<br />
plant boundary in its own limited way.<br />
The following measures will be taken up to keep the noise levels with in<br />
permissible limits. a) Provision and maintenance of thick green belt to screen<br />
noise) Proper maintenance of noise generating machinery including<br />
Transportation vehicles) Provision of air silencers to modulate the noise<br />
generated by the machines/equipments) Reducing the exposure time of<br />
workers to the higher noise levels by rotation) Proper encasement of noise<br />
generating sources will be done to control noise level. Besides, ear<br />
muffs/plugs will be provided to the workers in the close vicinity of noise<br />
source) Provision will be made for special vibration dampers and monitoring<br />
to prevent propagation of vibration to surrounding areas. All workers working<br />
in noise borne area will be regularly subjected to medical check-up for<br />
detecting any adverse impact on their TLV of hearing.<br />
The above control measures have already been adopted in existing<br />
machinery/plant, which are very successful as is clear from the monitoring<br />
results.<br />
5.6 WATER POLLUTION<br />
Mitigation measures<br />
The plant is designed for closed re-circulation cooling water system. The<br />
discharge of wastewater from other sources as DM water plant, boilers blow<br />
down will not be significant and can be re-used for dust suppression and in<br />
plant gardening etc.<br />
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The measures envisaged for controlling water pollution will be contain the<br />
water pollution within tolerance limit as specified in MOEF notifications and<br />
other related statutory norms. The Waste Water generated from the various<br />
Plants will be let out after proper treatment in order to reduce pollutants in the<br />
wastewater within the acceptable limits.<br />
There will be temporary houses along with canteen and toilet facilities. Water<br />
for washing & sanitary requirement will be meet out from the stored rainwater.<br />
There will be negligible impact on the surface water quality. The drinking<br />
water will be purchased from out side. It is proposed to utilize maximum<br />
rainwater from the stored reservoir.<br />
A) Domestic Effluent<br />
60 m 3 / day waste water will be treated in the effluent treatment plant<br />
based on activated sludge process. The treated waste water will be<br />
utilized quantitatively for green belt and plantation in the area. The<br />
plant will be based on zero discharge principle. Thus there is no<br />
discharge of effluents envisaged from the plant.<br />
B) Industrial Effluent<br />
- To prevent water pollution by oil/grease and sewage waste, following<br />
control measures are proposed to be implemented:<br />
- Leak proof containers will be used for storage and transportation of<br />
oil.- Water quality monitoring will be done regularly.<br />
- Workshop effluent will be passed through pit / grease trap and<br />
recirculated.<br />
- “Demineralization plant regeneration chemicals” will be first led to the<br />
neutralization pit and then to the common effluent pit<br />
- Waste water from potable water system, Boiler blow down, CT blow<br />
down and Waste water from clarifier will be directly led to the common<br />
effluent pit<br />
- Thus about 160 M 3 / day treated water will be available from the<br />
common effluent pit which will be used for dust suppression, gardening<br />
etc.<br />
Wastewater management:<br />
Principle of “Zero Discharge” will be adopted. There is no waste water<br />
generated from the cement plant except domestic effluent from the colony. All<br />
effluent from demineralization plant, where chemical will be used, shall be<br />
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properly treated in the neutralization pit and then transferred to the “Common<br />
Effluent Pit” (CEP).<br />
Further, all blow down water from Boiler, Auxiliary Cooling Tower basin,<br />
System leakage water through equipment overflow drain (EOD) etc. will be<br />
channelised to CEP.<br />
Water from the CEP will then be pumped out for various purposes like<br />
Horticulture, Dust Suppression, & Ash Conditioning within the plant area.<br />
Sewage treatment plant<br />
i) Sewage Collection System<br />
Sewage from all the areas will be collected into a collection tank. The<br />
location of Sewage treatment plant will be beneficial both in terms of<br />
easy maintenance and most economical system. The location<br />
advantage of the site is considered like (a) all the waste waters shall<br />
flow by gravity and (b) total equipment like aerators, pumps etc, will be<br />
located at one place only, hence operation is easy.<br />
ii)<br />
Design data<br />
Sewage Treatment plant has been designed based on the following<br />
characteristics of wastewater.<br />
pH : 6.0–8.5<br />
Total Suspended Solids : 500 mg/L<br />
Biochemical Oxygen Demand : 300 mg/L<br />
COD : 900 mg/L<br />
Oil & Grease : 20 mg/L<br />
iii)<br />
Process description<br />
All the sewage from colony and plant is collected into a collection tank<br />
after passing through bar screen and oil & grease trap. In oil & grease<br />
trap most of the oil & grease is separated. In aeration tank diffusers<br />
will be provided with powered twin lobe blowers to supply necessary<br />
oxygen for the survival of microorganisms.<br />
In the aerobic biological treatment, biological growths will be created<br />
which absorb organic matter from the wastes and convert it into simple<br />
end products like CO 2 , H 2 O, NO x etc. by means of oxidation enzyme<br />
systems in presence of oxygen. External aeration activates sludge<br />
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particles and encourages growth of an active culture of aerobic<br />
organisms. Main features of aerobic treatment are to clarify effluent by<br />
absorbing majority of colloidal and suspended solids on the surface of<br />
sludge particles and oxidize organic matter.<br />
Over flow from aeration tank shall flow by gravity to secondary clarifier<br />
(Tube settler). A part of the sludge from secondary clarifier is recirculated<br />
to aeration tank to maintain desired quantity of mixed liquor<br />
suspended solids (MLSS) and excess sludge is sent to sludge drying<br />
beds. The dried sludge is composted and used as manure for green<br />
belt. The clarified and treated wastewater from secondary clarifier is<br />
collected into a storage tank and passed through pressure sand filter<br />
and used for green belt. The treated sewage shall have the following<br />
characteristics.<br />
pH : 6.5 to 8.5<br />
Total Suspended Solids : < 50 mg/L<br />
Biochemical Oxygen Demand : < 30 mg/L<br />
COD : < 100 mg/l<br />
Oil & Grease : < 10 mg/L<br />
Solid Waste Disposal<br />
Solid wastes from Thermal Power Plants generally consist of fly ash<br />
and solid waste from faecal sewage. The following measures will be<br />
taken to reduce/re-use the solid wastes:<br />
• Bottom ash, almost in dry form will be sieved for re-cycling as bed<br />
material in the AFBC Boiler.<br />
• Fly ash, collected in various hoppers of he dust collection Systems<br />
provided in the path of the flue gas, will be pneumatically transported<br />
to the silos from where the same will be taken out to ash dump area by<br />
totally enclosed dumpers.<br />
• Normally, the dry ash will be utilized for secondary use, land filling,<br />
road construction, cement making, etc.<br />
• Green belt around ash disposal area will be developed.<br />
The municipal solid waste generated from the plant and the colony<br />
will be segregated and separated as combustible and noncombustibles<br />
wastes. The combustible wastes will be used as fuel<br />
in the kiln. This will solve the problem of solid waste disposal and<br />
will also reduce the fuel requirement for the kiln. The kiln will act as<br />
an incinerator in this case. The non-combustible wastes will be land<br />
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filled for composting and other (non-compost able) waste will be<br />
sold to the authorized recycling vendors. Therefore, no adverse<br />
impact on soil is anticipated from the solid waste.<br />
c. Hazardous waste<br />
The hazardous waste like transformer oil, spent oil etc will be<br />
utilized in kiln as a source of high calorific fuel, which will also<br />
reduce the fuel consumption and solve the problem of hazardous<br />
waste disposal. Therefore, no adverse impact is anticipated on soil<br />
due to hazardous waste.<br />
d. Soil<br />
The solid waste, which will be used for landfill, is basically ground<br />
dust, which has no toxic elements as constituents. Hence the<br />
question of soil contamination, by the way of disposal of soil waste,<br />
does not arise. No adverse impact on soil is anticipated due to<br />
sewage sludge, combustible, compost able and hazardous waste.<br />
RAINWATER HARVESTING<br />
It is hilly terrain. Rains are to the tune of 4,000 mm. The plant layout would<br />
be evolved in such a manner so that rain water of the plant area is<br />
collected and stored, which can be used for plant operations. Ground<br />
water recharge is not practically feasible. The consumption by plant<br />
operations shall have a positive effect on the overall hydrograph of the<br />
area.<br />
5.7 ECOLOGY<br />
Mitigation measures<br />
Following measures are proposed to mitigate ecological impacts:<br />
Plantation programme<br />
An extensive plantation programme will be carried out inside the plant<br />
area, which will help in controlling air pollution and also in providing green<br />
area for various faunal species for shelter. The plantation will cover more<br />
than 1/3rd of the plant area. Special care will be taken while planting trees,<br />
as regards the type and the number, within the plant premises in order to<br />
confine the pollutants to the area and prevent their dispersal.<br />
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To reduce the impact of air pollution, particularly the SPM content, it has<br />
been proposed to create and maintain a green belt around the plant.Total<br />
green belt envisaged is 20 ha out of which 4 ha have already been<br />
planted. Plantation will be carried out within the premises of the plant<br />
where fugitive dust emissions are anticipated. Lawns and gardens will also<br />
be created near the office areas and other service areas like canteens,<br />
parking lot, etc. The number of trees to be planted as a part of the<br />
plantation programme is taken as 1500 trees per hectare for green belt<br />
and along roads.<br />
In addition to the trees planted as mentioned in the above table, a variety<br />
of small flowering shrubs and plants will be planted in the gardens and<br />
lawns. These flowering plants will improve the aesthetics of the area.<br />
Wildlife conservation programme<br />
Visualizing and interviewing many local residents of nearby villages<br />
prepare the list of animal diversity. Due to ban in poaching many animals<br />
have shown increasing trend. There is no schedule I species observed in<br />
the study area.<br />
There are no threatened species of plants. Monkey of Schedule II is the<br />
only threatened species. No special measures are required except that the<br />
employees as well as the population of surrounding villages will be<br />
educated for conservation and protection of the Monkey through specially<br />
arranged camps and continuous campaign through posters at prominent<br />
places.<br />
5.8 LAND ENVIRONMENT AND SOLID WASTE MANAGEMENT<br />
There is no generation of solid wastes from cement manufacturing<br />
process as all the dust collected in air pollution control systems is<br />
continuously recycled into process. Different types of solid wastes are<br />
generated from the non-process activities in the unit. They include waste<br />
packaging materials, steel scrap, and empty oil/grease drums, used tires,<br />
used batteries etc. All the non-process solid waste materials will be<br />
disposed for further processing as per the directions of <strong>Meghalaya</strong><br />
<strong>Pollution</strong> control <strong>Board</strong>.<br />
All ash will be utilized in the Cement Plant.<br />
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5.9 OCCUPATIONAL SAFETY & HEALTH SYSTEM<br />
For occupational safety in the proposed Plant, the following will be<br />
provided:<br />
• Electrical interlocking of ESP inspection doors.<br />
• Inspection and maintenance of <strong>Pollution</strong> <strong>Control</strong> Systems only after<br />
getting official shut down or with the permission of authorized Officer.<br />
• Immediate cleaning of any coal dust accumulated on floors, road,<br />
rooftops, conveyor galleries and other places.<br />
• Heat insulation of hot surfaces.<br />
• Provision of rubber mats around the electrical panels.<br />
• Fire barriers at appropriate places.<br />
• Provision of all safety measures like use of safety appliances, safety<br />
training, safety awards, posters, slogans related to safety etc.<br />
• Training of employees for use of safety appliances and first aid.<br />
Hill Cement will take utmost care for occupational health to help reduce<br />
absence rates and improve employee welfare. Good quality Occupational<br />
Health advices enhance business benefits of reduced short and long-term<br />
absence rates as well as improved employee welfare.<br />
The purpose of an Occupational Health assessment is:<br />
1) To offer advice and support<br />
2) To assess fitness to work<br />
3) To ensure health and safety at work.<br />
Regular medical examination as well as periodical medical examination of<br />
employees will be done. Qualified medical officer will carry out the medical<br />
examination.<br />
The following measures relating to safety and health shall also be<br />
practiced:<br />
• Provision of rest shelters for plant workers with amenities like drinking<br />
water etc.<br />
• All safety measures like use of safety appliances, safety awards, posters,<br />
slogans related to safety etc.<br />
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• Training of employees for use of safety appliances and first aid.<br />
• Regular maintenance and testing of all equipment as per manufacturers’<br />
guidelines.<br />
• Periodical Medical Examination (PME) of all workers by a medical<br />
specialist so that any adverse effect may be detected in its early stage.<br />
• First Aid organization in plant including training and retraining for First Aid.<br />
• Close surveillance of the factors in working environment and work<br />
practices, which may affect environment and worker’s health.<br />
• Monitoring of various factors, which may lead to occupational health<br />
hazards.<br />
Surrounding population<br />
Periodical medical camps will be arranged for detection of occupational<br />
diseases and minor diseases in the near by rural population, wherein the<br />
local people can take free medicines and health check ups. Treatments for<br />
their chronic illnesses will be provided free of cost with referral services<br />
and treatment at well-equipped hospitals with financial assistance.<br />
The assessment may include a physical examination. Once all the<br />
necessary information is gathered a written report will be prepared and the<br />
reports will advice on one’s work capacity and make recommendations on<br />
work place adjustments, if necessary. The company will maintain<br />
Occupational safety & Health of the employees with well defined<br />
procedures, which are also spelt out in ISO-14001 and OSHA-18001.<br />
Medical Surveillance:<br />
The industry will have a dispensary within the premises and all the<br />
employees will be tested for medical fitness at the time of recruitment.<br />
Factory Medical officers will medically examine all employees once in two<br />
years to ascertain the health status of all workers in respect of<br />
Occupational Heath hazard to which they are exposed.<br />
Medical officer will prepare a list of hazardous area both area wise and<br />
trade wise Specific tests are performed for identification of such<br />
occupational hazard. No person is employed to operate a crane,<br />
locomotive or work-lift or give signals unless qualified ophthalmologist has<br />
examined his eyesight and color vision.<br />
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List of general tests to be conducted and recorded:<br />
1. Eyes 8.Chest X- ray<br />
2. Ears 9. Audiogram<br />
3. Respiratory system 10. Circulatory system (Blood Pressure)<br />
4. Abdomen 11. Nervous System<br />
5. Skin 12.Hernia<br />
6. Hydrocele 13. Urine<br />
7. Blood for ESR Report<br />
Medical examinations:<br />
The following medical check up/examinations will be done:<br />
1. Comprehensive Pre-employment medical check up for all employees.<br />
2. X-ray of chest to exclude pulmonary TB, Silicosis etc.<br />
3. Lung function test.<br />
4. Sputum Test to detect Asbestos bodies.<br />
5. Audiometer test to find deafness.<br />
The following occupational safety and health measures are being adopted<br />
to ensure that the employees are not exposed to pollutants; operation<br />
controls, work practices, protective equipment and medical surveillance.<br />
i) Engineering <strong>Control</strong>s:<br />
The manufacture of cement is mainly size reduction and sintering<br />
the material to form clinker and grind the clinker along with gypsum<br />
and fly ash to make cement. The manufacture of cement involves<br />
processing of limestone & additives for clinker manufacture and<br />
handling of finished product cement while grinding with gypsum and<br />
fly ash and packing of cement. Gypsum a byproduct received from<br />
fertilizer units are stored in lined floor. The storage area is also<br />
covered on all sides. This is to ensure that washed gypsum<br />
received from fertilizer unit does not contaminate the soil. The<br />
gypsum will be transported in closed trucks.<br />
The waste heat from kiln is used for drying the raw material. The<br />
process temperature and exhaust system is controlled from<br />
programmable logic control. Occupational Safety and Health<br />
Administration (OSHA) ensure the dust emission from process to<br />
be within the prescribed limits.<br />
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Table 5.3<br />
DETAILS OF VENTILATION SYSTEM<br />
S. No Location Operating <strong>Control</strong><br />
1.<br />
2.<br />
3.<br />
4.<br />
Limestone Crushing<br />
Operator<br />
Air conditioned control room with peeping window<br />
Site Attendant Pressurized room and Personal Protective<br />
Equipments<br />
Raw Mill– Millers<br />
Site Operator<br />
Kiln – Burners<br />
Site operator<br />
Cement Mills<br />
Site operator<br />
Air conditioned central room<br />
Pressured room with required PPE for site work<br />
Necessary to visit site with required PPE. Provision<br />
of CC TV for observation of process<br />
Air conditioned control room.<br />
Pressured room with required PPE for site work<br />
Air conditioned control room with peeping window<br />
Pressured room with required PPE for site work<br />
5. Maintenance Crew Ventilated Room with required PPE and tools for<br />
attending maintenance<br />
ii)<br />
Work Practices:<br />
Mechanical sweepers will remove surface accumulations from<br />
floors. Use of compressed air will be prohibited for personal<br />
cleaning and equipments. Brushing will be adopted. Employees will<br />
be provided with canteen facilities for consumption of food.<br />
Smoking will not be allowed within the work area. All employees will<br />
be trained periodically about proper house keeping and hygiene<br />
practices. Employees will be provided with ample wash areas.<br />
iii)<br />
Protective Equipment:<br />
Nose Mask Respirators of reputed company / brand as prescribed<br />
by OSHA will be provided by the industry to the employees. The<br />
Nose mask will be changed whenever the employee notices an<br />
increase in breathing resistance.<br />
The industry will provide work clothing, gloves, hats, shoes, face<br />
shields, vented goggles, and other appropriate protective<br />
equipment. The industry will replace the required protective clothing<br />
or equipment as needed to maintain their effectiveness.<br />
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iv)<br />
For emergency control well set up fire hydrant system will be made<br />
available. Maintenance schedule for the fire fighting equipments<br />
shall be observed. Provision of mobile fire hydrant will be made. On<br />
site emergency plan, monitoring and mock drills will be conducted<br />
regularly. Ambulance will be available round the clock for the plant.<br />
Employee Information and Training:<br />
The industry will provide training program for the employees to<br />
inform them of the following aspects; hazards of operations, proper<br />
usage of nose mask and earplugs, the importance of engineering<br />
controls and work practices associated with job assignment(s).<br />
5.10 SOCIO-ECONOMIC DEVELOPMENT<br />
The proposed project would generate direct employment for about 300<br />
staff and workers. There will be economic boost in the nearby villages.<br />
Also there will be generation of secondary employment opportunities in<br />
the form of transportation facilities, service sector, material supply etc. The<br />
infrastructure facilities in the area will be improved. The education,<br />
medical and other facilities will be developed in the area, which will also<br />
be beneficial for the local people.<br />
The project authority will carry out following peripheral development in the<br />
nearby villages.<br />
1. Education: -<br />
Supply of study materials, construction/ extension of village school<br />
buildings, financial aid to village schools<br />
2. Health & Hygiene: -<br />
One ambulance; mobile health camps, free supply of medicine,<br />
insecticides, etc. will be provided for the villagers.<br />
3. Promotion of cultural and social welfare activities: -<br />
Construction of community hall, extension of village club, supply of<br />
furniture, financial aid to encourage local cultural heritage, regular<br />
film shows<br />
4. Training to villagers through self-help group: -<br />
Tailoring, knitting, & pickle making etc for women<br />
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5.11 ENVIRONMENTAL MANAGEMENT OF MINING<br />
To control the adverse impacts of the mining activities well in time, a<br />
suitable environmental management plan is formulated. The<br />
environmental management plan in respect of mining project includes the<br />
following actions to preserve the healthy environment-<br />
• Restoration of the landscape by way of reclamation as near to its previous<br />
status as possible, and to have an effective waste rock disposal<br />
management.<br />
• Avoidance of damage to the flora and fauna of the area.<br />
• Minimization of the pollution of land, air, water and surrounding<br />
environment by dust, smoke, gases and noise.<br />
• Protection of water sources, water bodies and drainage patterns of the<br />
area.<br />
Abatement measures to reclaim the land-<br />
Reclamation of degraded land due to mining is necessary. The<br />
abandoned pit will be filled back with the already generated waste. But<br />
some area will remain unfilled and such parts of the abandoned pit will act<br />
as a water reservoir in which rainwater collected. This water is to be used<br />
for irrigation of cultivated land in nearby vicinity.<br />
Plantation of green plants in the surrounding area will also increase the<br />
aesthetic value of the area.<br />
Abatement measures to improve flora and fauna-<br />
Plantation of suitable species of plants improves the floral growth in the<br />
area. It will also provide opportunities to house fauna. Thus the<br />
deteriorated condition due to mining automatically improves. The locally<br />
available shrubs, bushes and grasses are proposed to be spread over the<br />
surface during rainy season. Mine water, which is being pumped out from<br />
the mine would get accumulated in tank for regular watering to the plants.<br />
Abatement measures for Air pollution –Air pollution due to increase in<br />
SPM load is expected in the present proposed mining operations under<br />
study. Suitable control measures are required to be taken but the quality<br />
of air in the area is natural clean air. Hence no special management would<br />
be required.<br />
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There are 4 points where the dust will be generated:<br />
• .Drilling<br />
• .Blastng<br />
• .Transportation<br />
• .Waste dumping places<br />
Although these are on so minor scale that they will not generate much<br />
dust. Air pollution is anticipated during blasting and movement of trucks.<br />
Regular water spray over the transportation road as well as wet drilling is<br />
proposed to minimize the dust generated during drilling and blasting. This<br />
water spraying over the road is to be done twice a day during summer and<br />
once a day during winter. The following monitoring schedule is<br />
recommended for regular check to ensure the SPM level and Ambient Air<br />
Quality-<br />
Ambient Air Monitoring :Once in six Months in the mine area.<br />
Ambient Air Monitoring :Once in a year in the surrounding area.<br />
Noise Nuisance Abatement-<br />
Proper maintenance of machineries and transport vehicles should be done<br />
to reduce the noise and keep the same within permissible limits. Noise<br />
level measurements in the mine area should be carried out once in every<br />
six months.<br />
Measures to improve natural resources-<br />
The project will lead to permanent depletion of non –renewable mineral<br />
resources. While this adverse impact is inevitable in case of all mining<br />
activities, the damage can be ameliorated to an appreciable extent by<br />
reclamation of mined area in the shape of back filling of the exhausted pits<br />
and plantation on maximum area of back filled pits and dumps.<br />
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Measures to improve Socio-Economic Environment<br />
Socio Demographic Profile<br />
The socio-demographic profile of the area shall improve, as the mining<br />
activities will create additional employment facilities for the habitats of the<br />
nearby villages.<br />
Occupational Health and Safety Measures<br />
The mining operations will be carried after observing the safety measures<br />
laid down in mines regulations and Mines Act. The workers shall be<br />
provided footwear and safety helmets during working hours. Regular<br />
medical checkup of workers will be done to check occupational diseases.<br />
The following schedule for medical checkup is recommended-<br />
1. Persons working in the mining operations: once in a year<br />
2. Residents of nearby villages: Once in 2 years.<br />
Abatement measures to improve water regime<br />
a. Surface water-No surface water will get affected due to mining.<br />
However water would get accumulated at the lowest level of the<br />
pits during monsoon will be pumped out and stored in a artificial<br />
pond where it remain stored for sometime. All the suspended<br />
particles get settled at the bottom of the pond and fresh water is<br />
utilized for irrigation purposes and watering of the trees. The water<br />
thus pumped out does not have any toxic effect because mineral<br />
limestone is inert type of rock. It will only increase little percentage<br />
of Cao, which act as a cleaning agent of water instead of polluting<br />
it.<br />
The rainwater is collected in pits and from where it is recharged to<br />
the ground through cracks in the rocks created by blasting actions.<br />
Work is suspended during rainy season and all the rainwater is<br />
collected in the large pits. This collected rain water is used in<br />
different purposes in the plant and irrigation purposes etc.<br />
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5.12 CONCEPTUAL MINING PLAN-<br />
It is necessary to select the sites for waste dump, site service,<br />
plantation etc, so that these sites do not disturb during life of the<br />
mine.<br />
EMPLOYMENT POTENTIAL-<br />
Management and supervisory personnel:-The following supervisory<br />
personnel are proposed with management chart:<br />
General Manager(Degree Holder)<br />
with min 15 years experience<br />
--One<br />
Mining Engineer (Degree Holder) -----2<br />
Mines Foreman (Certificate Holder) ----4<br />
Mining Mate Store Keeper Timekeeper<br />
Mine Labours –As per Requirement<br />
Drivers Watchman<br />
”/DERXUVVNLOOHGVHPL-skilled and unskilled :-The following<br />
laboures are proposed:<br />
Skilled -2<br />
Semi-skilled -3<br />
Unskilled -25<br />
Features existing within the leasehold and adjoining area (with<br />
in 10 Km of the proposed site)<br />
National Park/Sanctuary<br />
Nil<br />
Biosphere/Wetland<br />
Nil<br />
Historic Monuments<br />
Nil<br />
Tourist spot/Religious Place<br />
Nil<br />
Tribal Settlement<br />
Nil<br />
5.13 ENVIRONMENT MANAGEMENT CELL (EMC)<br />
A competent person of experience shall be made exclusively responsible<br />
to ensure the execution the environment management proposals. Services<br />
of the mines manager shall be utilized for dump creations, safeguarding<br />
the dumps, plantation & its care and maintenance.<br />
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Ambient air quality in the vicinity of the mining unit at selected locations<br />
from time to time shall be carried out. Proper record of money spent on<br />
suggested pollution control measures and any competent authority should<br />
properly record the related quarterly progress of implementation for<br />
reference, guidance and inspection.<br />
Waste Management<br />
Nearly 1,40,000 tonnes of waste will come across during first five<br />
years and around 3,50,000 tonnes during the present life of the<br />
mine. The waste will be of calc silicate and limestone having foreign<br />
intrusions. Two sites of 0.7hectare and 0.9 hectare are proposed<br />
for waste dump. A part of waste will be used for construction and<br />
maintenance of haul roads time to time.<br />
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CHAPTER 6<br />
ENERGY EFFICIENCY IN CEMENT PLANT<br />
Energy Efficiency Technologies and Measures for cement Industry<br />
Improving energy efficiency at a cement plant should be approached from<br />
several directions.<br />
First, plants use energy for equipment such as motors, pumps, and<br />
compressors. These important components require regular maintenance,<br />
good operation and replacement, when necessary. Thus, a critical<br />
element of plant energy management involves the efficient control of<br />
crosscutting equipment that powers the production process of a plant.<br />
(i) A second and equally important area is the proper and efficient<br />
operation of the process. Process optimization and ensuring the most<br />
efficient technology is in place is a key to realizing energy savings in a<br />
plant’s operation.<br />
(ii) Finally, throughout a plant, there are many processes simultaneously.<br />
Fine-tuning their efficiency is necessary to ensure energy savings are<br />
realized.<br />
Though changes in staff behavior, such as switching off lights or closing<br />
windows and doors, often save only small amounts of energy at one time,<br />
taken continuously over longer periods they may have a much greater<br />
effect than more costly technological improvements. An energy<br />
management program will see to it that all employees actively contribute<br />
to energy efficiency improvements.<br />
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6.1. RAW MATERIALS PREPARATION<br />
1. Efficient Transport Systems (Dry Process) - Transport systems are<br />
required to convey powdered materials such as kiln feed, kiln dust,<br />
and finished cement throughout the plant. Mechanical conveyors use<br />
less power than pneumatic systems & the average energy savings are<br />
estimated at 2.0-kWh/tonne raw materials with a switch to mechanical<br />
conveyor systems. Conversion to mechanical conveyors is costeffective<br />
when replacement of conveyor systems is needed to<br />
increase reliability and reduce downtime.<br />
2. Use of roller mills (Dry Process)- Traditional ball mills used for grinding<br />
certain raw materials (mainly hard limestone) can be replaced by highefficiency<br />
roller mills, by ball mills combined with high-pressure roller<br />
presses, or by horizontal roller mills. The use of these advanced mills<br />
saves energy without compromising product quality.<br />
3. High-efficiency classifiers/separators- A recent development in<br />
efficient grinding technologies is the use of high-efficiency classifiers<br />
or separators. Classifiers separate the finely ground particles from the<br />
coarse particles. The large particles are then recycled back to the mill.<br />
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High efficiency classifiers can be used in both the raw materials mill<br />
and in the finish-grinding mill.<br />
4. Standard classifiers may have a low separation efficiency, which leads<br />
to the recycling of fine particles, and results in to extra power use in<br />
the grinding mill. In high-efficiency classifiers, the material stays longer<br />
in the separator, leading to sharper separation, thus reducing over<br />
grinding. Electricity savings through implementing high-efficiency<br />
classifiers are estimated at 8% of the specific electricity use.<br />
6.2. FUEL PREPARATIONS<br />
1. Coal is the most widely used fuel in the cement industry. Fuels<br />
preparation is most often performed onsite. Fuels preparation may<br />
include crushing, grinding and drying of coal. Coal is shipped “wet” to<br />
prevent dust formation and fire during transport. Passing hot gasses<br />
through the mill combines the grinding and drying. Waste heat of the<br />
kiln system (e.g. the clinker cooler) is used to dry the coal if needed.<br />
6.3. CLINKER PRODUCTION – ALL KILNS<br />
(i) Process <strong>Control</strong> & Management Systems – Kilns- Heat from the kiln<br />
may be lost through non-optimal process conditions or process<br />
management. Automated computer control systems may help to<br />
optimize the combustion process and conditions. Improved process<br />
control will also help to improve the product quality and grind ability,<br />
e.g. reactivity and hardness of the produced clinker, which may lead to<br />
more efficient clinker grinding.<br />
(ii) Expert control systems do not use a modeled process to control<br />
process conditions, but try to simulate the best human operator, using<br />
information from various stages in the process.<br />
(iii) An alternative to expert systems is model-predictive control using<br />
dynamic models of the processes in the kiln. A model predictive<br />
control system can reduce energy needs by 4%, while increasing<br />
productivity and clinker quality.<br />
(iv) Additional process control systems include the use of on-line<br />
analyzers that permit operators to instantaneously determine the<br />
chemical composition of raw materials being processed in the plant,<br />
thereby allowing for immediate changes in the blend of raw materials.<br />
(v) A uniform feed allows for steadier kiln operation, thereby saving<br />
ultimately on fuel requirements.<br />
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(vi) Energy savings from process control systems may vary between 2.5%<br />
and 10%, and the typical savings are estimated at 2.5-5%.<br />
(vii) Process control of the clinker cooler can help to improve heat<br />
recovery, material throughput, and improved control of free lime<br />
content in the clinker and reduce NOx emissions. Installing a process<br />
perfecter has increased cooler throughput by 10%, reduced free lime<br />
by 30% and reduced energy by 5%, while reducing NOx emissions by<br />
20%.<br />
Kiln Combustion System Improvements. Fuel combustion systems in<br />
kilns can be contributors to kiln inefficiencies with such problems as poorly<br />
adjusted firing, incomplete fuel burnout with high CO formation, and<br />
combustion with excess.<br />
Improved combustion systems aim to optimize the shape of the flame, the<br />
mixing of combustion air and fuel and reducing the use of excess air.<br />
Various approaches have been developed:<br />
a. One technique is developed for flame control, which results in fuel<br />
savings of 2-10% depending on the kiln type.<br />
b. Another one is advancements from combustion technology that<br />
improve combustion through the use of better kiln control.<br />
Eg.<br />
The Gyro-Thermo burner uses a patented "precessing jet" technology.<br />
The nozzle design produces a gas jet leaving the burner in a gyroscopiclike<br />
precessing motion. This stirring action produces rapid large scale<br />
mixing in which pockets of air are engulfed within the fuel envelope<br />
without using high velocity gas or air jets. The combustion takes place in<br />
pockets within the fuel envelope under fuel rich conditions. This creates a<br />
highly luminous flame, ensuring good radiative heat transfer. It results in<br />
fuel savings between 2.7% and 5.7% with increases in output between 5<br />
and 9%.<br />
Indirect Firing- Historically the most common firing system is the directfired<br />
system. Coal is dried, pulverized and classified in a continuous<br />
system, and fed directly to those kiln. This can lead to high levels of<br />
primary air (up to 40% of stoichiometric). These high levels of primary air<br />
limit the amount of secondary air introduced to the kiln from the clinker<br />
cooler. Primary air percentages vary widely, and non-optimized matching<br />
can cause severe operational problems with regard to creating reducing<br />
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conditions on the kiln wall and clinker, refractory wear and reduced<br />
efficiency due to having to run at high excess air levels to ensure effective<br />
burnout of the fuel within the kiln.<br />
In more modern cement plants, indirect fired systems are most commonly<br />
used. In these systems, neither primary air nor coal is fed directly to the<br />
kiln. All moisture from coal drying is vented to the atmosphere and the<br />
pulverized coal is transported to storage via cyclone or bag filters.<br />
Pulverized coal is then densely conveyed to the burner with a small<br />
amount of primary transport air. As the primary air supply is decoupled<br />
from the coal mill in multi-channel designs, lower primary air percentages<br />
are used, normally between 5 and 10%. The multi-channel arrangement<br />
also allows for a degree of flame optimization. This is an important feature<br />
if a range of fuels is fired. Input conditions to the multi-channel burner<br />
must be optimized to secondary air and kiln aerodynamics for optimum<br />
operation. The optimization of the combustion conditions will lead to<br />
reduced NOx emissions, better operation with varying fuel mixtures, and<br />
reduced energy losses. This technology is standard for modern plants.<br />
Excess air infiltration is estimated to resort in heat losses equal to 65<br />
kBtu/ton. Assuming a reduction of excess air between 20% and 30% may<br />
lead to fuel savings of 130 – 190 kBtu/ton of clinker. The advantages of<br />
improved combustion conditions will lead to a longer lifetime of the kiln<br />
refractories and reduced NOx emissions. These co-benefits may result in<br />
larger cost savings than the energy savings alone.<br />
The disadvantage of an indirect firing system is the additional capital<br />
cost.<br />
Oxygen Enrichment- Several plants have experimented with the use of<br />
oxygen enrichment in the kiln to increase production capacity any energy<br />
savings will depend on the electricity consumed for oxygen generation<br />
approximately 0.01 kWh/scf. Oxygen enrichment may result in higher NOx<br />
emissions, if the injection process is not carefully managed. Oxygen<br />
enrichment is unlikely to result in net energy savings.<br />
Seals- Seals are used at the kiln inlet and outlet to reduce false air<br />
penetration, as well as heat losses. Seals may start leaking, increasing the<br />
heat requirement of the kiln. Most often pneumatic and lamella-type seals<br />
are used, although other designs are available (e.g. spring-type). Although<br />
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seals can last up to 10,000 to 20,000 hours, regular inspection may be<br />
needed to reduce leaks. Upgradation of the inlet pneumatic seals at a<br />
relatively modern plant in India has reduced fuel consumption in the kiln<br />
by 0.4%.<br />
Kiln Shell Heat Loss Reduction- There can be considerable heat losses<br />
through the shell of a cement kiln, especially in the burning zone. The use<br />
of better insulating refractories can reduce heat losses. Refractory choice<br />
is the function of insulating qualities of the brick and the ability to develop<br />
and maintain a coating. The coating helps to reduce heat losses and to<br />
protect the burning zone refractory bricks. Estimates suggest that the<br />
development of high temperature insulating linings for the kiln refractories<br />
can reduce fuel use by 0.1-0.34 MBtu/ton. costs. Structural considerations<br />
may limit the use of new insulation materials. The use of improved kilnrefractories<br />
may also lead to improved reliability of the kiln and reduced<br />
downtime, reducing production costs considerably, and reducing energy<br />
needs during start-ups.<br />
Refractories- Refractories protect the steel kiln shell against heat,<br />
chemical and mechanical stress. The choice of refractory material<br />
depends on the combination of raw materials, fuels and operating<br />
conditions. Extended lifetime of the refractories will lead to additional<br />
energy savings due to the relative reduction in start-up time and energy<br />
costs. The energy savings are difficult to quantify, as they will strongly<br />
depend on the current lining choice and management.<br />
Kiln Drives- A substantial amount of power is used to rotate the kiln. The<br />
highest efficiencies are achieved using a single pinion drive with an air<br />
clutch and a synchronous motor. The system would reduce power use for<br />
kiln drives by a few percent, or roughly 0.5 kWh/ton clinker at slightly<br />
higher capital costs (+6%).<br />
More recently, the use of AC motors is advocated to replace the<br />
traditionally used DC drive. The AC motor system may result in slightly<br />
higher efficiencies (0.5 – 1% reduction in electricity use of the kiln drive)<br />
and has lower investment costs. Using high-efficiency motors to replace<br />
older motors or instead of re-winding old motors may reduce power costs<br />
by 2 to 8%.<br />
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Adjustable Speed Drive for Kiln Fan- Adjustable or Variable Speed<br />
Drives (ASDs) for the kiln fan result in reduced power use and reduced<br />
maintenance costs.<br />
The replacement of the damper by an ASD was driven by control and<br />
maintenance problems at the plant. The energy savings may not be typical<br />
for all plants, as the system arrangement of the fans is different from<br />
typical kiln arrangements.<br />
Use of Waste-Derived Fuels- Waste fuels can be substituted for<br />
traditional commercial fuels in the kiln. The trend towards increased waste<br />
use will likely to increase after successful tests with different wastes. New<br />
waste streams include carpet and plastic wastes, filter cake, paint residue<br />
and (dewatered) sewage sludge. Cement kilns also use hazardous<br />
wastes.<br />
Since the early 1990’s cement kilns burn annually almost 1 million tons of<br />
hazardous waste. The revenues from waste intake have helped to reduce<br />
the production costs of all waste-burning cement kilns, and especially of<br />
wet process kilns. Waste-derived fuels may replace the use of commercial<br />
fuels, and may result in net energy savings and reduced CO 2 emissions.<br />
The carbon dioxide emission reduction depends on the carbon content of<br />
the waste-derived fuel, as well as the alternative use of the waste and<br />
efficiency of use (e.g. incineration with or without heat recovery). The high<br />
temperatures and long residence times in the kiln destroy virtually all<br />
organic compounds, while efficient dust filters may reduce any potential<br />
emissions to safe levels.<br />
Conversion to Reciprocating Grate Cooler- Four main types of coolers<br />
is used in the cooling of clinker: shaft, rotary, planetary and traveling and<br />
reciprocating grate coolers.<br />
The grate cooler is the modern variant and is used in almost all modern<br />
kilns. The advantages of the grate cooler are:<br />
• Its large capacity (allowing large kiln capacities) and efficient heat<br />
recovery (the temperature of the clinker leaving the cooler can be as low<br />
as 83°C, instead of 120-200°C, which is expected from planetary coolers.<br />
• Grate coolers recover more heat than do the other types of coolers.<br />
• For large capacity plants, grate coolers are the preferred equipment. For<br />
plants producing less than 500 tonnes per day the grate cooler may be too<br />
expensive.<br />
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• Replacement of planetary coolers by grate coolers is not uncommon.<br />
• Grate coolers are standard technology for modern large-scale kilns.<br />
• Modern reciprocating coolers have a higher degree of heat recovery than<br />
older variants, increasing heat recovery efficiency to 65% or higher, while<br />
reducing fluctuations in recuperation efficiency (i.e. increasing productivity<br />
of the kiln).<br />
• When compared to a planetary cooler, additional heat recovery is possible<br />
with grate coolers at an extra power consumption of approximately 2.7<br />
kWh/ton clinker. The savings are estimated to be up to 8% of the fuel<br />
consumption in the kiln.<br />
Cooler conversion is generally economically attractive only when installing<br />
a precalciner, which is necessary to produce the tertiary air (see above),<br />
or when expanding production capacity.<br />
Optimization of Heat Recovery/Upgrade Clinker Cooler- The clinker<br />
cooler drops the clinker temperature from 1200°C down to 100°C. The<br />
most common cooler designs are of the planetary (or satellite), traveling<br />
and reciprocating grate type.<br />
All coolers heat the secondary air for the kiln combustion process and<br />
sometimes also tertiary air for the precalciner. Reciprocating grate coolers<br />
are the modern variant and are suitable for large-scale kilns (up to 10,000<br />
tpd). Grate coolers use electric fans and excess air. The highest<br />
temperature portion of the remaining air can be used as tertiary air for the<br />
precalciner. Rotary coolers and planetary coolers do not need combustion<br />
air fans and use little excess air, resulting in relatively lower heat losses.<br />
Grate coolers may recover between 1.1 and 1.4 MBtu/ton clinker sensible<br />
heats.<br />
Improving heat recovery efficiency in the cooler results in fuel savings, but<br />
may also influence product quality and emission levels. Heat recovery can<br />
be improved through reduction of excess air volume, control of clinker bed<br />
depth and new grates such as ring. <strong>Control</strong> of cooling air distribution over<br />
the grate may result in lower clinker temperatures and high air<br />
temperatures. Additional heat recovery results in reduced energy use in<br />
the kiln and precalciner, due to higher combustion air temperatures.<br />
A recent innovation in clinker coolers is the installation of a static grate<br />
section at the hot end of the clinker cooler. This has resulted in improved<br />
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heat recovery and reduced maintenance of the cooler. Modification of the<br />
cooler would result in improved heat recovery rates of 2-5% over a<br />
conventional grate cooler.<br />
6.4. CLINKER PRODUCTION - DRY PROCESS PREHEATER<br />
KILNS<br />
Low Pressure Drop Cyclones for Suspension Preheater- Cyclones are<br />
a basic component of plants with pre-heating systems. The installation of<br />
newer cyclones in a plant with lower pressure losses will reduce the power<br />
consumption of the kiln exhaust gas fan system. Installation of the<br />
cyclones can be expensive, & new cyclone systems may increase overall<br />
dust loading and increase dust carryover from the preheater tower.<br />
However, if an inline raw mill follows it, the dust carryover problem<br />
becomes less of an issue.<br />
Heat Recovery for Cogeneration- Waste gas discharged from the kiln<br />
exit gases, the clinker cooler system, and the kiln pre-heater system all<br />
contain useful energy that can be converted into power. Only in long-dry<br />
kilns is the temperature of the exhaust gas sufficiently high, to costeffectively<br />
recover the heat through power generation. Cogeneration<br />
systems can either be direct gas turbines that utilize the waste heat (top<br />
cycle), or the installation of a waste heat boiler system that runs a steam<br />
turbine system (bottom cycle). The steam turbine systems have been<br />
installed in many plants worldwide and have proven to be economic.<br />
Heat recovery has limited application for plants with in-line raw mills, as<br />
the heat in the kiln exhaust is used for raw material drying.<br />
Dry Process Conversion to Multi-Stage Preheater Kiln- Installing multistage<br />
suspension preheating (i.e. four- or five-stage) may reduce the heat<br />
losses and thus increase efficiency. Modern cyclone or suspension<br />
preheaters also have a reduced pressure drop, leading to increased heat<br />
recovery efficiency and reduced power use in fans. By installing new<br />
preheaters, the productivity of the kiln will increase, due to a higher degree<br />
of pre-calcination (up to 30-40%) as the feed enters the kiln. Also, the kiln<br />
length may be shortened by 20-30% thereby reducing radiation losses. As<br />
the capacity increases, the clinker cooler may have to be adapted to be<br />
able to cool the large amounts of clinker.<br />
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Energy savings depend strongly on the specific energy consumption of the<br />
dry process kiln to be converted as well as the number of preheaters to be<br />
installed.<br />
Installation or Upgrading of a Preheater to a Preheater/Precalciner<br />
Kiln- An existing preheater kiln may be converted to a multi-stage<br />
preheater precalciner kiln by adding a precalciner and, when possible an<br />
extra preheater. The addition of a precalciner will generally increase the<br />
capacity of the plant, while lowering the specific fuel consumption and<br />
reducing thermal NOx emissions (due to lower combustion temperatures<br />
in the pre-calciner). Cooler replacement may be necessary in order to<br />
increase the cooling capacity for larger production volumes. Fuel savings<br />
will depend strongly on the efficiency of the existing kiln and on the new<br />
process parameters (e.g. degree of precalcination, cooler efficiency).<br />
Older calciners can also be retrofitted for energy efficiency improvement<br />
and NOx emission reduction.<br />
Average savings of new calciners can be 0.34 MBtu/ton clinker.<br />
Conversion of Long Dry Kilns to Preheater/Precalciner Kiln- If<br />
economically feasible a long dry kiln can be upgraded to the current state<br />
of the art multi-stage preheater/precalciner kiln. Energy savings are<br />
estimated at 1.2 MBtu/ton clinker for the conversion. These savings reflect<br />
the difference between the average dry kiln specific fuel consumption and<br />
that of a modern preheater, pre-calciner kiln.<br />
6.5. FINISH GRINDING<br />
Process <strong>Control</strong> and Management – Grinding Mills- <strong>Control</strong> systems<br />
for grinding operations are developed using the same approaches as for<br />
kilns. The systems control the flow in the mill and classifiers, attaining a<br />
stable and high quality product.<br />
Similar results have been achieved with model predictive control (using<br />
neural networks).<br />
Advanced Grinding Concepts- The energy efficiency of ball mills for use<br />
in finish grinding is relatively low, consuming up to 30-42 kWh/ton clinker<br />
depending on the fineness of the cement. Several new mill concepts exist<br />
that can significantly reduce power consumption in the finish mill to 20-30<br />
kWh/ton clinker, including roller presses, roller mills, and roller presses<br />
used for pre-grinding in combination with ball mills. Roller mills employ a<br />
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mix of compression and shearing, using 2-4 grinding rollers carried on<br />
hinged arms riding on a horizontal grinding table. In a high-pressure roller<br />
press, two rollers pressurize the material up to 3,500 bar, improving the<br />
grinding efficiency dramatically.<br />
Air swept vertical roller mills with integral classifiers are used for finish<br />
grinding, whereas a recent offshoot technology which is not air swept is<br />
now being used as a pre-grinding system in combination with a ball mill.<br />
A new mill concept is the Horomill, first demonstrated in Italy in 1993. The<br />
Horomill is a compact mill that can produce a finished product in one step<br />
and hence has relatively low capital costs. In the Horomill a horizontal<br />
roller within a cylinder is driven. The centrifugal forces resulting from the<br />
movement of the cylinder cause a uniformly distributed layer to be carried<br />
on the inside of the cylinder. The layer passes the roller with a pressure of<br />
700-1000 bar. The finished product is collected in a dust filter.<br />
Today, high-pressure roller presses are most often used to expand the<br />
capacity of existing grinding mills, and are found especially in countries<br />
with high electricity costs or with poor power supply. The electricity<br />
savings of a new finish grinding mill, when replacing a ball mill is<br />
estimated at 25 kWh/ton cement.<br />
High Efficiency Classifiers- A recent development in efficient grinding<br />
technologies is the use of high efficiency classifiers or separators.<br />
Classifiers separate the finely ground particles from the coarse particles.<br />
The large particles are then recycled back to the mill. Standard classifiers<br />
may have a low separation efficiency, which leads to the recycling of fine<br />
particles, resulting in extra power use in the grinding mill. In high-efficiency<br />
classifiers, the material is more cleanly separated, thus reducing over<br />
grinding. High efficiency classifiers or separators have had the greatest<br />
impact on improved product quality and reducing electricity consumption.<br />
Newer designs of high-efficiency separators aim to improve the separation<br />
efficiency further and reduce the required volume of air (hence reducing<br />
power use), while optimizing the design. The actual savings will vary by<br />
plant and cement type and fineness required.<br />
Improved Grinding Media- Improved wear resistant materials can be<br />
installed for grinding media, especially in ball mills. Grinding media are<br />
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usually selected according to the wear characteristics of the material.<br />
Improved balls and liners made of high chromium steel is one such<br />
material but other materials are also possible. Other improvements include<br />
the use of improved liner designs, such as grooved classifying liners.<br />
These have the potential to reduce grinding energy use by 5- 10% in<br />
some mills, which is equivalent to estimated savings of 1.8 kWh/ton<br />
cement.<br />
6. 6 PLANT-WIDE MEASURES<br />
1. Preventative Maintenance-<br />
2. High-Efficiency Motors and Drives- Adjustable or Variable Speed<br />
Drives<br />
3. Compressed Air Systems-<br />
Maintenance of Compressed Air Systems-<br />
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lowest possible inlet temperature.<br />
• &KHFNEHOWs for wear and adjust them. A good rule of thumb is to adjust<br />
them every 400 hours of operation.<br />
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Rotary screw compressors generally start with their air lubricant<br />
separators having a 2 to 3 psid pressure drop at full load. When this<br />
increases to 10 psid, change the separator.<br />
• &KHFNZDWHU-cooling systems for water quality (pH and total dissolved<br />
solids), flow, and temperature. Clean and replace filters and heat<br />
exchangers per manufacturer’s specifications.<br />
4. Reduce Leaks-<br />
5. Reducing the Inlet Air Temperature- Maximize Allowable Pressure<br />
Dew Point at Air Intake<br />
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6. Compressor <strong>Control</strong>s<br />
Start/stop, load/unload, throttling, multi-step, variable speed and<br />
network controls are options for compressor controls and described<br />
below:<br />
• Start/stop (on/off) is the simplest control available and can be applied to<br />
reciprocating or rotary screw compressors. They are used for applications<br />
with very low duty cycles. Applications with frequent cycling will cause the<br />
motor to overheat.<br />
• Load/unload control, or constant speed control, allows the motor to<br />
run continuously but unloads the compressor when the discharge<br />
pressure is adequate. In most cases, unloaded rotary screw compressors<br />
still consume 15 to 35% of full-load power while delivering no useful work.<br />
Hence, load/unload controls can be inefficient.<br />
• Modulating or throttling controls allow the output of a compressor to be<br />
varied to meet flow requirements by closing down the inlet valve and<br />
restricting inlet air to the compressor. Throttling controls are applied to<br />
centrifugal and rotary screw compressors. Changing the compressor<br />
control from on/zero/off to a variable speed control can save up to 8% per<br />
year.<br />
Heat Recovery for Water Preheating<br />
As much as 80 to 93% of the electrical energy used by an Industrial air<br />
compressor is converted into heat. In many cases, a heat recovery unit<br />
can recover 50 to 90% of this available thermal energy for space heating,<br />
industrial process heating, water heating, makeup air heating, boiler<br />
makeup water preheating, industrial drying, industrial cleaning processes,<br />
heat pumps, laundries or preheating aspirated air for oil burners.<br />
7. Lighting<br />
• Lighting <strong>Control</strong>s (manual and automatic controls)<br />
• Replace T-12 Tubes by T-8 Tubes<br />
• Replace Mercury Lights by Metal Halide or High Pressure Sodium Lights<br />
• Replace Metal Halide HID with High-Intensity Fluorescent Lights<br />
• Replace Magnetic Ballasts with Electronic Ballasts<br />
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8. Product & Feedstock Changes<br />
Alkali Content<br />
Reducing the alkali content from the cement is achieved by venting (called<br />
the by-pass) hot gases and particulates from the plant, loaded with alkali<br />
metals. The bypass also avoids plugging in the preheaters. This becomes<br />
cement kiln dust (CKD). Many customers demand lower alkali content, as<br />
it allows greater freedom in the choice of aggregates. The use of fly ash or<br />
blast furnace slags as aggregates (or in the production of blended cement)<br />
may reduce the need for low alkali cement. Low alkali cement production<br />
leads to higher energy consumption. Savings of 2-5 Kcal/kg per percent<br />
bypass are assumed. The lower figure is for precalciner kilns, while the<br />
higher figure is for preheater kilns. Typically, the bypass takes 10-70% of<br />
the kiln exhaust gases. Additionally, electricity is saved due to the<br />
increased cement production, as the CKD would otherwise end up as<br />
clinker.<br />
There are no investments involved in this product change, although<br />
cement users may need to change the type of aggregates used (which<br />
may result in costs). Hence, this measure is most successfully<br />
implemented in coordination with ready-mix producers and other large<br />
cement users.<br />
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CHAPTER- 7<br />
DISASTER MANAGEMENT PLAN<br />
“Disaster” is defined as a catastrophic situation that causes damage,<br />
economic disruptions, loss of human life and deterioration of health and<br />
health services on a scale sufficient to warrant an extraordinary response<br />
from outside the affected area or community. Disasters occasioned by<br />
man are factory fire explosions and release of toxic gases or chemical<br />
substances, etc.<br />
All types of industries face certain types of hazards which can disrupt<br />
normal activities abruptly and lead to disaster like fires, inundation, failure<br />
of machinery, explosion to name a few. Disaster management plan<br />
formulated with an aim of taking precautionary step to control the hazard<br />
propagation and avert disaster and also to take such action after the<br />
disaster which limits the damage to the minimum.<br />
7.1 SCOPE OF STUDY<br />
Emergency planning, i.e. recognizing that accidents are possible,<br />
assessing the consequences of such accidents and deciding on the<br />
emergency procedures, both on site and offsite that would need to be<br />
implemented in the event of an emergency.<br />
Emergency/ disaster planning is just one aspect of safety and cannot be<br />
considered in isolation. M/s Hills Cement Co. Ltd. fully endorses this fact<br />
and hence a disaster management plan is prepared for construction &<br />
operation phase to ensure that the necessary standards appropriate to<br />
their safety legislation are followed.<br />
The important elements of disaster planning are broadly classified as<br />
follows.<br />
• Identification of various scenarios<br />
• Advance planning to overcome the problem<br />
• Actions in case of disaster phase, which includes warning, evacuation of<br />
personnel, rescue relief operations to people affected in mishappening &<br />
containment of disaster.<br />
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7.2 TYPE OF DISASTER AT CEMENT PLANT AND CPP<br />
Disaster may occur due to following hazards at the cement plants.<br />
- Fire<br />
- Explosion<br />
- Electrocution<br />
- Loose fitting<br />
In any cement plant along with the CPP, there are various activities or<br />
area which pose substantial threat to the workers and hence hazardous in<br />
nature. The potential hazardous areas and the likely accidents with the<br />
concerned area have been enlisted below:<br />
TABLE 7.1<br />
HAZARDOUS AREA WITH CONCERNED ACCIDENTS<br />
Sl. No. Hazardous Area Likely Accident<br />
1. Boiler Area Explosion<br />
2. Electrical rooms Fire and electrocution<br />
3. Transformer area Fire and electrocution<br />
4. Cable tunnel Fire and electrocution<br />
5. Storage yard Sliding<br />
6. Crushing and grinding unit Fatal accident<br />
7. Chimney Air pollution<br />
8. Coal/ fuel storage area Fire and spillage<br />
9. Turbine room Explosion<br />
7.3 ACCIDENT LEVEL<br />
The nature of accidents and areas, which may be affected in case of any<br />
disaster in any part of plant/work place due to any reason can classified as<br />
follows:<br />
1 Level I Operator level<br />
2 Level II Local community level<br />
3 Level III Regional/National level<br />
4 Level IV International level<br />
Out of the above, only level-I and level - II class of accidents can be<br />
considered applicable for cement plant.<br />
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Level- I Accidents<br />
Under this level disaster may happen due to electrocution, fire, explosion,<br />
and breakage due to loose fitting and spontaneous ignition of combustible<br />
material. This level has probability of occurrence affecting persons inside<br />
the plant.<br />
Level-II Accidents<br />
Disaster of this level can occur in case of sabotage and complete failure of<br />
all automatic control/warning systems, and also due to failure of ESP, Bag<br />
filter and other pollution control devices. However probability of<br />
occurrence of this is very low due to adequate security, training and<br />
education of persons of plant responsible for operating such systems.<br />
7.3.1 DISASTER PREVENTIVE MEASURES<br />
In order to prevent disaster due to fire, explosion, electrocution and other<br />
accidents following preventive measures shall be adopted.<br />
i) Design, manufacture and construction of all plant and machineries<br />
building will be as per national and international codes as<br />
applicable in specific cases as laid down by Statutory Authorities.<br />
ii)<br />
iii)<br />
iv)<br />
Provision of adequate access way for movement of equipment and<br />
personnel shall be kept.<br />
Minimum two no. of gates shall be provided in any enclosure for<br />
escape during disaster shall be provided.<br />
Fire hydrants system of comprising electrical motor division and<br />
diesel engine driven fire pumps with electrical motor driven jockey<br />
pump for keeping the fire hydrant system properly pressurized for<br />
all important suspected places.<br />
7.4 SITE EMERGENCY CONTROL ROOM<br />
A site emergency control room (SECR) shall be established at the plant<br />
site in order to control the disaster more effectively. The facilities proposed<br />
to be provided are given in following sections:<br />
• Plant Layout<br />
• Area map of surrounding village<br />
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• Plant Layout with inventories and locations of fuel oil/furnace oil storage<br />
tanks, etc<br />
• The blown up copy of Layout plan showing areas, where accident has<br />
occurred<br />
• Hazard identification chart,<br />
• Maximum number of people working at a time, assembly points etc.<br />
• Population around factory<br />
• Internal telephone connections<br />
• External telephone connections<br />
• Hotline connection to district collector, police control room, fire brigade,<br />
hospital etc.<br />
• Public address system<br />
• Torch-lights<br />
• List of dispensaries and registered medical practitioners around factory<br />
• Note pads and ball pens to record message received and instructions to<br />
be passed through runners.<br />
7.5 SAFETY DEPARTMENT<br />
Senior level manager having 15-20 year experience in safety practices<br />
and operations shall manage the safety department supported by<br />
experienced engineers and other staff who shall bring safety<br />
consciousness amongst the work force of plant.<br />
The safety department will conduct regular safety awareness courses by<br />
organizing seminars and training of personnel among the various working<br />
levels.<br />
SAFETY EQUIPMENTS / DEVICES<br />
To make the services more effective, the workers and rescue team will be<br />
provided with the safety equipments and items like-<br />
Gas mask,<br />
Respirators,<br />
Fire entry suits,<br />
Fire blankets,<br />
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Rubber shoes or industrial shoes,<br />
Rubber glove,<br />
Ladders,<br />
Ropes,<br />
Petromax,<br />
Lamp torches etc.<br />
MISCELLANEOUS PREVENTIVE MEASURES<br />
• Alarm system to be followed during disaster<br />
On receiving the message of “Disaster” from Site Main <strong>Control</strong>ler, fire<br />
station control attendant will sound SIREN FOR 5 MINUTES. Incident<br />
controller will arrange to broadcast disaster message through public<br />
address system.<br />
On receiving the ‘ message of “Emergency Over” from Incident <strong>Control</strong>ler<br />
the fire station control room attendant will give “All Clear Signal, by<br />
sounding alarm straight for two minutes.<br />
The features of alarm system will be explained to one and all to avoid<br />
panic or misunderstanding during disaster.<br />
• Actions to be taken on hearing the warning signal<br />
On receiving the disaster message following actions will be taken:<br />
- All the members of advisory committee, personnel manager, security<br />
controller, etc. shall reach the SECR.<br />
- The process unit persons will remain ready in their respective units for<br />
crash shutdown on the instruction from SECR.<br />
- The persons from other sections will report to their respective officer.<br />
- Residents of township will remain alert.<br />
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7.6 CONTINGENCY PLAN FOR MANAGEMENT OF<br />
EMERGENCY<br />
SITE MAIN CONTROLLER (SMC)<br />
Plant Manager shall be head of the emergency organization. He shall be<br />
emergency leader- site main controller (SMC). In his absence senior most<br />
people available at plant shall be emergency leader till arrival of plant<br />
manager.<br />
Rest of the employees shall be divided into three action teams namely A,<br />
B, C, and a Non-action Group D.<br />
Action team 'A' will consist of staff of section, in which accident has<br />
occurred.<br />
Action team ‘B’, will consist of staff of non-affected sections and<br />
maintenance department.<br />
Action team 'C' will consist of supporting staff i.e. Security supervisor,<br />
Ware house Supervisor, Shift Supervisor etc.<br />
Group ‘D’ will consist of people not included in those teams like contractor,<br />
labour, security men etc,<br />
Team 'A' comprising staff of affected section will be taking up the action in<br />
case of an emergency.<br />
Team 'B' will help team 'A' by remaining in their respective sections ready<br />
to comply with specific instructions of SMC.<br />
Team 'C' of supporting staff will help team ‘A’ as required and directed by<br />
Team 'B’.<br />
Group ‘D’ will be evacuated to safe region under supervision of Team 'C'.<br />
A multichannel communication network shall connect SECR to control<br />
rooms of plant, various shops and other departments of plant, fire station<br />
and neighboring industrial units.<br />
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Co-ordination among key personnel and their team is shown below:<br />
SITE EMERGENCY TEAM MEMBERS COORDINATION<br />
EMERGENCY LEADER<br />
PLANT MANAGER/HEAD OF<br />
OPERATIONS/ENGINEERING/MAINTENANCE<br />
COMMUNICATION<br />
TEAM<br />
1. Administrative Head<br />
2. Personnel Officer<br />
3. Telephone Operator<br />
4. Time Office Staff<br />
ADVISORY TEAM<br />
1. Head of Operation<br />
2. Head of Maintenance<br />
3. Head of Engineering<br />
4. Head of Administration<br />
ADMINISTRATIVE HEAD/<br />
PERSONNEL MANAGER<br />
EMERGENCY<br />
COORDINATOR<br />
ACTION TEAM ‘A’<br />
1. SHIFT SUPERVISOR OF<br />
AFFECTED SECTION<br />
2. PLANT<br />
OPERATORS/TECHNICIA<br />
NS OF AFFECTED<br />
SECTION<br />
3. SHIFT SECURITY<br />
SUPERVISOR DUTY<br />
ACTION TEAM ‘B’<br />
1. HEAD OF MAINTENANCE<br />
2. WARE HOUSE/SPARE<br />
PARTS SUPERVISOR/<br />
MAINTENANCE<br />
SUPERVISOR/I/C<br />
SUPERVISOR<br />
3. MECHANICS/<br />
ELECTRICIAN<br />
ACTION TEAM ‘C’<br />
1. SECURITY<br />
SUPERVISOR<br />
2. WARE HOUSE STAFF<br />
3. SHIFT SUPERVISOR<br />
ENVIRONMENTAL<br />
COMPLIANCE SAFETY<br />
4. INCHARGE OF FIRST<br />
AID CENTRE<br />
ACTION TEAM ‘D’<br />
1. OTHER STAFF<br />
NOT<br />
LISTED IN<br />
EMERGENCY<br />
TEAMS INCLUDING<br />
CONTRACTOR<br />
WORKERS AND<br />
SUPERVISORS<br />
7.7 OUTSIDE ORGANISATIONS INVOLVED IN CONTROL OF<br />
DISASTER<br />
In case of occurrence of fire population inside and outside plant<br />
boundaries, vegetation and animal etc may be affected. Secondary fire<br />
may also take place in such conditions. In such an event help shall also be<br />
taken from outside agencies.<br />
The organizations that shall be involved are as follows:<br />
(a)<br />
<strong>State</strong> and local authorities: District Collector, Revenue Divisional<br />
Officer, etc<br />
(b)<br />
Factory Inspectorate, Chief Inspector of factories, Joint Chief<br />
Inspector of factories, Inspector of factories.<br />
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(c)<br />
Environmental agencies: Member Secretary of <strong>State</strong> <strong>Pollution</strong><br />
<strong>Control</strong> <strong>Board</strong>s, District Environmental Engineer<br />
(d)<br />
Fire Department: District Fire Officer<br />
(e)<br />
Police Department: District Superintendent of Police, SHOS of<br />
nearby Police Stations<br />
(f)<br />
Public Health Department:<br />
- District Medical Officer<br />
- Residential medical officers of PHCs around plant site<br />
(g)<br />
Local Community Resources<br />
- Regional Transport officer<br />
- Divisional Engineer Telephones<br />
The outside organizations shall directly interact with district magistrate<br />
who in consultation with SMC shall direct to interact with plant authorities<br />
to control the emergencies.<br />
7.8 HAZARD EMERGENCY CONTROL PROCEDURE<br />
The onset of emergency will in all probability, commence with a major fire<br />
or excess stack emission.<br />
The following activities will immediately take place to interpret and take<br />
control of emergency.<br />
1. Staff member on duty will go to nearest fire alarm call point and<br />
trigger off the fire alarm.<br />
2. On site fire crew led by fire man will arrive at the site of incident<br />
with fire foam tenders and necessary equipments.<br />
3. Site main controller will arrive at SECR, from where he will receive<br />
information continuously from incident controller and give<br />
decisions and direction to the incident controller, plant control room,<br />
and emergency security controllers to the site medical officer to<br />
take care of casualties.<br />
Site main controller will direct and decide following desperate issues.<br />
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In particular SMC has to decide and direct.<br />
- Whether incident controller requires reinforcement of manpower<br />
and facilities<br />
- Whether plant is to be shut down or more importantly kept running.<br />
- Whether staffs in different locations are to remain indoor or to be<br />
evacuated and assembled at designated collection center.<br />
- Whether missing staff members are to be searched or rescued.<br />
- Whether off-site emergency plan to be activated and a message to<br />
that effect is to be sent to the District Headquarter.<br />
When the incident has been brought under control as declared by the<br />
Incident <strong>Control</strong>ler, the SMC shall send two members of his advisory team<br />
as inspectors to incident site for:<br />
- An assessment of total damage and prevailing conditions with<br />
particular attention to possibility of re-escalation of emergency<br />
which might, for the time being, be under control.<br />
- Inspection of other parts of site which might have been affected by<br />
impact of incident.<br />
- Inspection of personnel collection and roll call centers to check if all<br />
persons on duty have been accounted for.<br />
- Inspection of all control rooms of plant to assess and record the<br />
status of respective plants and any residual action deemed<br />
necessary.<br />
Post emergency, the inspectors will return to SECR with their observations<br />
and report of finding and will submit the same to SMC.<br />
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CHAPTER - 8<br />
PROJECT BENEFITS<br />
The proposed project coupled with the ancillary industries would contribute to the<br />
overall<br />
socio-economic development of the region.<br />
8.1 DIRECT BENEFITS TO THE NATIONAL AND STATE<br />
EXCHEQUER<br />
• Income tax from individual as well as corporate taxes from cement<br />
company and ancillary units,<br />
• Income by way of registration of trucks, payment of road tax and payment<br />
of tax for interstate movements<br />
• Cess on power generation<br />
• Royalty on limestone<br />
• Excise duty<br />
• <strong>State</strong> sales tax or VAT<br />
8.2 INDIRECT BENEFITS<br />
• The project has an employment generation prospect on skilled manpower.<br />
It is assumed that the generation of indirect employment would be multiple<br />
of direct employment.<br />
• Most of the work force required for construction and operation of the<br />
proposed project will be drawn from the surrounding villages.<br />
• During the construction phase, no family is required to rehabilitate from<br />
the core zone.<br />
• With the establishment of colony, not only will there be requirement of<br />
food and commodities but also service providers such as servants, maids,<br />
gardeners, sweepers, maintenance people etc.<br />
• The direct beneficiaries in this process would be the local producers and<br />
local people providing services.<br />
Significant positive impact on employment and occupation is envisaged on<br />
account of<br />
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- Better economic status of the community due to better earnings,<br />
- Higher inputs towards infrastructural facilities due to establishment<br />
of plant and colony,<br />
- Enhancement of literacy due to educational facilities available in<br />
township.<br />
• The general social development of the area is expected<br />
due to the improvements in infrastructure and<br />
communication system.<br />
• New facilities will be created to meet growing demand of<br />
the population. This will have impact on the current literacy<br />
level, primary and middle level education and on existing<br />
health facilities.<br />
• Awareness generated will have positive impact on the<br />
social pattern, which is caste and community oriented.<br />
• The long-term implications of this change are definitely<br />
progressive.<br />
-skilled employees and the managerial/supervisory personnel<br />
• The Due to cement plant project including the CPP, there will be<br />
development of communication facilities in the area. In the plant area,<br />
accommodation has been planned for the skilled/ semi plant site area will<br />
be equipped with sufficient infrastructural facilities including drinking water,<br />
toilets, sanitation facilities, health centre etc.<br />
• During operation, plant will generate direct employment.<br />
• The preference will be given for local population for employment in the<br />
semi-skilled and unskilled category.<br />
• Indirect employment is created by the plant for supply of daily domestic<br />
goods<br />
• Permanent supply of electricity in the area will support to improve other<br />
type of industries.<br />
• Housing accommodation for 60% of total manpower is proposed.<br />
• Employees from local villages commute from their own homes.<br />
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HEALTH AND SAFETY MEASURES<br />
The workers working near pollution generation sources will be equipped<br />
with appropriate protective equipments.<br />
Following measures will be adopted in the plant to keep check on the<br />
safety measures and health:<br />
• Inspection and maintenance of pollution control systems regularly<br />
• All safety measures such as provision of safety appliances, imparting<br />
training, giving-of safety awards, display of posters with slogans related<br />
to safety will be taken<br />
• The workers exposed to noisy sources will be provided with ear<br />
muffs/plugs<br />
• Adequate facilities for drinking water and sufficient toilets will be provided<br />
to the employees<br />
• Regular medical checkup of workers shall be arranged. A full time<br />
dispensary shall be provided at site/colony. The medical facilities will also<br />
be extended to the neighboring villagers.<br />
SOCIAL WELFARE MEASURES AND CORPORATE RESPONSIBILITY<br />
The company has already earmarked funds for social development and<br />
welfare measures in the surrounding villages.<br />
These measures will include funding for:<br />
a) Medical camps<br />
b) Women and child development programs<br />
c) Drinking water availability efforts if needed for the local people<br />
d) Awareness programs<br />
e) Repair and improvement of existing schools<br />
f) Repair and improvement of health centers<br />
g) Repair and improvement of community centers, building such as<br />
Panchayat halls, Barat ghars etc<br />
h) Competitions and prizes distribution<br />
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Hills Cement Co. Limited.<br />
CORPORATE RESPONSIBILITY<br />
The<br />
management of HCCL has strong belief in business development<br />
along with peripheral development of nearby areas to the project site.<br />
Peripheral development plan including development in infrastructure,<br />
health, education and socio cultural aspects being carried out are as<br />
follows:<br />
1. The company has one dispensary with qualified doctors and nursing<br />
staff, where free medicines and treatment to the employees and local<br />
villagers is provided.<br />
2. The company has provided an ambulance on free of cost for the<br />
benefit of the above villagers.<br />
3. The company has provided free cement and donations to temples and<br />
churches in the surrounding villages. Cement at discounted rate shall<br />
be provided to villagers for the purpose of house construction etc.<br />
4. The company organizes free medical camps for the benefit of the<br />
villagers.<br />
5. The company organizes cultural programme in connection with<br />
Christmas for the sake of local villagers.<br />
6. The company has plans to construct a 20 bed Hospital and a school<br />
up to 10th standard.<br />
7. The company shall built a children park for the benefit of employees'<br />
and villager’s children.<br />
8. The company shall construct a community hall with a capacity of 1000<br />
personnel with the required infrastructure like chairs, audio system etc.<br />
9. Cultural activities shall be organized on important occasions.<br />
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Hills Cement Co. Limited.<br />
CHAPTER 9<br />
DISCLOSURE OF CONSULTANTS ENGAGED<br />
TEAM OF POLLUTION CONTROL CONSULTANTS (I) Pvt. Ltd<br />
INVOLVED IN EIA PREPARATION<br />
Position Expert Name Qualifications Experience<br />
Team leader Dr. M.K.Jain M.E., Ph.D (Env.<br />
Mgmt)<br />
Over 30 years experience in<br />
environmental impact<br />
assessment, management and<br />
planning with over 200 projects<br />
executed over last 20 years. Air<br />
and Water pollution <strong>Control</strong><br />
Systems. Also experienced in<br />
wastewater treatment,<br />
resettlement and rehabilitation<br />
studies. Environmental Engineer<br />
designing of Cement plant ESP/<br />
BAG Filters<br />
Hydrogeologist R. K. Agrawal M.Sc. (Geo.) 40 years work experience in<br />
hydrogeology and geology<br />
Ex. Sr. Manager MEC Ltd. (Govt.<br />
of India Undertaking)<br />
Ecology and<br />
data collection<br />
Dr. Abha Garg<br />
Dr. Swati Jain<br />
along with field<br />
staff<br />
Ph.D. (Chemistry)<br />
Ph.D.<br />
(Chemistry),MBA<br />
10 years of work experience in<br />
Ecology<br />
5years of work experience in<br />
Laboratory testing work<br />
Suresh Kumar B.Sc (Chemistry) 10 years of work experience in<br />
ecology Environmental and<br />
Social Planning<br />
Navodita M. Sc. (Env. Sc.) -<br />
Kanchan M. Sc. (Env. Sc.) -<br />
J. M. Sharma Engineer<br />
Aheet Kumar<br />
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Hills Cement Co. Limited.<br />
10.0 CONCLUSION<br />
CHAPTER – 10<br />
The process of manufacturing adopted by M/s Hills Cement Co. Limited is<br />
among the most modem and designed on the principles of “Zero<br />
Discharge and Minimum Emissions”. All the solid waste and the<br />
industrial wastewater are being reused I recycled in the product<br />
manufacture. The industry does not pose significant risk hazards even<br />
under the most severe constraints/ stresses conceivable, due to severe<br />
meteorological conditions. Elaborate safety measures and a stringent<br />
code of practice shall be adopted to protect the health of the workers.<br />
Cement Plant, Thermal Power Plant and Limestone mining activities<br />
expected to have no adverse impact on the surrounding environment<br />
with the proposed abatement measures in terms of proper handling of raw<br />
materials , green belt plantation, control of fugitive emissions, control<br />
systems at source, zero waste disposal, complete recycling of solid waste<br />
and water, good housekeeping as proposed in the EIA report.<br />
For Hills Cement Co. Limited<br />
For <strong>Pollution</strong> <strong>Control</strong> Consultants (I) Pvt. Ltd.<br />
Director<br />
( Dr. M. K. JAIN)<br />
Director<br />
<br />
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