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Environmental Data-Plant______________________________________________________

_______________________________________________________________________________________________2 Orient Cement Limited



CONTENTS

Contents 2

List of Tables 2

List of Figures 3

1. Compliance Report 4

2. INTRODUCTION 17

2.1 Location and Accessibility 19

3. PROCESS DESCRIPTION 20

4. ENVIRONMENTAL BASELINE STATUS 23

5. ENVIRONMENTAL MANAGEMENT PLAN 36

6. CONCLUSIONS 40

LIST OF TABLES

1.1 Average Values of online Stack Monitoring Data 5

1.2 Average Values of online Stack Monitoring Data 9

1.3 Average Values Ambient Air Monitoring Data 10

1.4 Average Values of Noise level Data 11

1.5 Average Values of Fugitive Emissions Data 13


2.1Salient features of expansion project 18

4.1 Soil Analysis 24

4.2- 4.4 Water Analysis 25-26



4.5 Weather Monitoring Data-Temperature & Relative Humidity 27

4.6 Average Values Ambient Air quality data 29

4.7 Details of Stack Emissions 30

4.8 Average Values of Stack Monitoring Data (SPM) 31

4.9 Average Values of Stack Monitoring Data (SO2

&NO2) 32


LIST OF FIGURES

1. Process flow diagram of cement manufacturing 22

4.6 Ambient air quality data – Particulate Matter – PM10

29

4.6 Ambient air quality data – Particulate Matter – PM2.5

29

4.6 Ambient air quality data – (SOx) & (NOx) 29

4.8 Stack Monitoring Data – Suspended particulate matter 31

4.9 Stack Monitoring Data – Sulphur dioxide 32

4.9 Stack Monitoring Data – Oxides of nitrogen 32

4.10 Noise Level Data 33



1. COMPLIANCE REPORT: MoEF ENVIRONMENTAL CLEARANCE

Environmental clearances accorded by Ministry of Environment & Forest vide Letter

F. No. J -11011/266/2007-IA II (I) Dated 6th September 2007 for expansion of cement

plant (Cement 3600 to 8900 TPD and clinker 5550 to 10600 TPD) and installation of

Captive Power Plant (50 MW) at Devapur, Adilabad, A.P. by M/s. Orient Cement

Ltd.,The project has been completed and production activities are going on.

A. Specific conditions

(i) On-line continuous stack monitoring facilities for all the stacks and adequate airpollution control systems shall be provided to keep emission levels below 50mg/Nm3 and data submitted to the APPCB and CPCB regularly. ESP to kiln / raw

mill, clinker and CPP shall be provided to control air emissions.

Online continuous monitoring facility for process stacks have been provided along

with main equipments. Online connectivity is given to CPCB and TSPCB Server.

Latest Pollution Control Equipments viz Baghouse (RABH), ESP’S are equipped with

three phase transformers were installed, which are controlling the emissions

within the stipulated levels, data is presented in Table 1.1.



Table 1.1

AVERAGE VALUES OF STACK MONITORING DATA

(October-16 to March-17)

Parameters Particulate Matter (mg/Nm3)

Location of Online Continuous

Stack Monitoring Equipment

PCB Limit as

per Consent

(mg/Nm3)

Avg.

(mg/Nm3)

3600 TPD Rotary Kiln – I & Raw Mill – I 80 45.17

2800 TPD Rotary Kiln – II & Raw Mill – II 80 14.60

4200 TPD Rotary Kiln –III & Raw mill – III 50 17.83

Clinker Cooler – Line 1 80 24.33



FBC Boilers of Capacity 2 X 115 115 81.50

(ii) Total water requirement from the reservoir of abandoned mine pit shall notexceed 1,895 m3/day. No water from other surface or ground water sourcesshall be used. All the treated wastewater shall be recycled and reused in theprocess and/or for ash quenching, dust suppression, green belt developmentand other plant related activities etc. No process wastewater shall bedischarged outside the factory premises and ‘zero’ discharge shall be adopted.



Treated domestic effluent shall be used for green belt development within theplant premises.

Mines reservoir is replenished with rainwater. Water consumption is well

within the permissible limits.

STP is in operation for treatment of i.e domestic sewage water from which

the treated water is being used for green belt development in the colony.

Zero liquid discharge concepts are adopted.

(iii) The fly ash from the power plant shall be stored in silos and pneumaticallytransferred to the cement plant and used in the process itself for manufacturingPozollona Portland Cement (PPC). Bottom ash shall be disposed off inabandoned mines or utilized in road making or given to brick kilnmanufacturers. All the cement dust collected from pollution control devicesshall be recycled and reused in the process and used for cementmanufacturing. Sludge from domestic sources shall be used as manure forgreen belt development. Waste oil shall be sold to authorized recyclers/re-processors only.

Fly ash from the Power Plant is being stored in silos and pneumatically

transferred to cement plant and it is completely utilized in the cement

manufacturing process.

Bottom ash is also meeting the quality parameters and it is completely

utilized in the cement manufacturing process.

The Cement & other raw material dust are collected through Pollution

Control Equipments and are being recycled in the Process.

Sludge from STP (domestic sources) is used as manure in township for

colony plantation.

Waste oil is being sold to Authorize Recyclers/Re-processors only.



(iv) High calorific value hazardous waste shall be utilized in the cement kiln from

Ranga Reddy, Medak and Patancheru Districts.

Alternate & Biomass fuels (Rice Husk, Cotton Stalk, Black Carbon, Pet coke) are

being used in the plant. We have applied for co-processing Permission of

various hazarders waste at TSPCB, Hyderabad.

(v) Out of total 425.89 acre, green belt shall be developed in 216.09 acres (51%) asper the CPCB guidelines to mitigate the effects of air emissions in consultation

with local DFO.

Green belt was further increased during this financial year. About 5020 saplings

were planted till March- 2017 including mines. We have developed green belt in

plant & Colony areas which is well above 51% as prescribed by TSPCB,

Hyderabad

(vi) Green Belt shall be developed along the boundary of the cement plant.

Green belt is already developed as per the guidelines. About 5020 saplings were

planted till September 2016 including mines.

(vii) Regular annual medical examination of all the employees shall be carried outfrom the occupational health point of view and records should be maintained.

Annual Medical Examination for all the employees and contract workmen was

done.



B. General Conditions

(i) The project authority shall adhere to the stipulations made by A.P. PollutionControl Board (APPCB) and State Government.

The stipulations made by various state government departments including

TSPCB will be adhered strictly.

(ii) No further expansion or modification of the plant shall be carried out withoutprior approval of this Ministry.

No expansion/ modification will be carried out without permission from MoEF.

(iii) The gaseous and particulate matter emissions from various units shall conformto the standards prescribed by the A.P.Pollution Control Board. At no time, theparticulate emissions from the cement plant shall exceed APPCB limit.Interlocking facility shall be provided in the pollution control equipment, so thatin the event of the pollution control equipment not working, the respective unit(s)is shut down automatically.

SPM Standards prescribed by the Telangana State Pollution Control Board are

being followed and automatic tripping system of equipment is installed and

data is presented in table1.2.



Table 1.2

AVERAGE VALUES OF STACK MONITORING DATA


Parameters Particulate Matter (mg/Nm3)

Stack attached to PCB Limit as

per Consent

(mg/Nm3)

Avg.

(mg/Nm3)

3600 TPD Rotary Kiln – I & Raw Mill – I 80 45.17

2800 TPD Rotary Kiln – II & Raw Mill – II 80 14.60

4200 TPD Rotary Kiln –III & Raw mill – III 50 17.83




FBC Boilers of Capacity 2 X 115 115 81.50

All Results are within the limit.

(iv) One Ambient Air Quality Monitoring Station shall be installed in downwinddirection. Ambient air quality including ambient noise levels shall not exceed thestandards stipulated under EPA or by the State authorities. Monitoring of



Ambient Air Quality and Stack Emissions shall be carried out regularly inconsultation with APPCB and report submitted to the TSPCB quarterly and to theMinistry’s Regional Office at Bangalore half-yearly.

Two Online Ambient Air Quality Monitoring Stations are installed and connected

to Central and State Pollution Control Boards. We are also getting it done once in

a month by MoEF approved third party. The same are submitted to RO MoEF&CC

in half yearly reports.

Table 1.3

AMBIENT AIR QUALITY DATA(October16 to March-17)

Parameter

Location

Particulate Matter –

PM10

(µg/m3)


PM2.5

(µg/m3)

Sulphur dioxide(µg/m3)

Nitrogen Dioxide(µg/m3)

Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg.

Near Timeoffice. 51 66 58.67

12 25 17.17

8 14 10.33 16 22 19.50

Near MinesOffice

59 72 65.17 7 13 9.67 18 23 21

NearStores

54 68 58.83 6 13 9.50 15 21 18.50

Near GuestHouse

41 63 50.67 5 11 8.50 14 58 51.50

All Results are within the Limit.

Noise level: Noise in general is sound which, is composed of many frequency

components of various loudness distributed over the audible frequency range. The

most common and heavily favored of these scales is the A-weighted decibel [dB (A)].



This scale has been designed to weigh the various components of noise according to

the response of the human ear; loud noise may damage hearing or health; interfere

with work tasks, speech communication and sleep; affect inter-room privacy; cause

annoyance. The impact of noise depends on its characteristics (instantaneous,

intermittent or continuous in nature), time of day (day or night) and location of noise

source. The noise levels at various locations in and around plant area were measured

and tabulated in table 1.4.

Table 1.4

AVERAGE VALUES OF NOISE LEVEL DATA


Location NOISE LEVEL in Leq dB(A)Day Time Night Time

Min Max Avg Min Max Avg

Near Kiln 67.60 71.50 69.54 61.80 65.40 63.96Near Raw Mill 70.80 73.50 72.20 65.30 68.70 67.04

Near Compressor House 71.30 73.90 72.72 64.70 68.10 66.94Near Cement Mill 68.90 70.50 69.72 62.10 65.40 64.34Near D.G.Set 68.10 73.60 71.04 63.30 68.20 65.98Near Limestone Crusher 70.90 74.10 72.84 65.20 69.60 65.70

Near Work Shop 65.70 69.30 67.06 59.50 60.90 61.20Near Line-III 66.40 70.70 68.86 61.10 65.70 64.12

All the Values are within the Range

All the equipment are being operated from Central Control Room. Exposure of the employees

near the machines is limited. If at all required to be exposed, they are using ear plugs / ear

muffs.



Monitoring of Ambient Air Quality and Stack Emissions are carried out regularly and

report is submitted to the TSPCB Monthly and to the Ministry’s Regional Office at

Chennai half-yearly.

(V) The company shall install adequate dust collection and extraction system to

control fugitive dust emissions at various transfer points, raw mill handling(unloading, conveying, transporting, stacking), vehicular movement, bagging andpacking areas, etc. Asphalting/concreting of road and water spray all around thestockyard and loading / unloading areas shall be carried out to control fugitiveemissions. Covered sheds for storage of raw materials and pneumatic conveyingsystem for fly ash and bed ash for conveying ash from boiler shall be provided.Coal, cement, fly ash and clinker shall be stored in silos.

We have installed number of bag filters. Total Number of Pollution Control

Equipments is as follows: ESPs – 7, Bag Filters – 99.

All the transfer points are equipped with bag filters.

Dump hoppers are equipped with water sprinkler system.

Venting systems are available for pneumatic Conveying System.

All the circuits are having venting system.

Truck mounted Water Spraying system arranged in the plant to control fugitive

emissions.

Concrete roads were laid down.

Covered Sheds are available for storing raw materials & fuel.

Pneumatic conveying system provided for fly ash from CPP to Fly ash Silo.

Storage silos are available for in process materials and finished products.



(v) Secondary fugitive emissions shall be controlled and regularly monitored as perguidelines issued by the CPCB.

Concrete Roads are available, which minimizes the fugitive emissions. Road sweeping machine is used for roads cleaning inside the plant. Regular water spray is being carried out to control the secondary fugitive

emissions.

Fugitive emissions analysis data is presented in table 1.5

Table 1.5

AVERAGE VALUES OF FUGITIVE EMISSIONS DATA

(October to March-17)Parameter

Location

(PM10)Average (µg/m3)

(PM2.5 )Average (µg/m3)

Min. Max Avg. Min. Max. Avg.

On top ofTechnicalbuilding

44 58 51.50 16 21 17.83

PCB Limit: PM10 – 100 (µg/m3): PM2.5 - 60(µg/m3).

All Values are Within the Range.

(vi) The company must harvest the rainwater from the rooftops and storm waterdrains to recharge the ground water and use the same water for the variousactivities of the project to conserve fresh water.

Rain water is stored in mines abandoned reservoir and is utilized for various

activities in the plant thus reducing the consumption of ground water.



(vii) The company shall undertake eco-development measures including communitywelfare measures in the project area.

Various welfare schemes are being adopted for the development of the

surrounding village people & area under CSR.

(viii) The overall noise levels in and around the plant area shall be kept well within thestandards (85 dBA) by providing noise control measures including acoustichoods, silencers, enclosures, etc. on all sources of noise generation. Theambient noise levels shall conform to the standards prescribed underEnvironmental (Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) 70 dBA(night time).

We have Provided various noise control measures like acoustic enclosure in CPP,

Silencers and low noise old blower and compressor

The values are recorded and are well within the limits.

Table 1.6AVERAGE VALUES OF NOISE LEVEL DATA




Near Kiln 67.60 71.50 69.54 61.80 65.40 63.96Near Raw Mill 70.80 73.50 72.20 65.30 68.70 67.04

Near Compressor House 71.30 73.90 72.72 64.70 68.10 66.94Near Cement Mill 68.90 70.50 69.72 62.10 65.40 64.34Near D.G.Set 68.10 73.60 71.04 63.30 68.20 65.98Near Limestone Crusher 70.90 74.10 72.84 65.20 69.60 65.70

Near Work Shop 65.70 69.30 67.06 59.50 60.90 61.20Near Line-III 66.40 70.70 68.86 61.10 65.70 64.12



All the Values are within the limits.

(ix) All recommendations made in the ‘Corporate Responsibility for EnvironmentProtection (CREP) for cement plants shall be implemented.

We are complying with the CREP Guidelines.

(x) Proper housekeeping and adequate occupational health programmes shall betaken up.

Good Housekeeping is maintained in all areas of the plant with better management

Road sweeping machine has been provided for maintaining good Housekeeping

Regular health checkups, awareness programs are continued.

(xi) A separate environmental management cell to carry out various management andmonitoring functions shall be set up under the control of Senior Executive.

Environmental management cell is formed with a team of qualified engineers

& chemists to carry out various management and monitoring functions under

the control of senior executive.(xii) As proposed in EIA/EMP, Rs.24.50 Crores and Rs.1.86 Crores earmarked towards

the capital cost and recurring cost/annum for environmental pollution controlmeasures shall be suitably used to implement the conditions stipulated by theMinistry of Environment and Forests as well as the State Government. The fundsso provided shall not be diverted for any other purpose.

a. Major control equipments installed in the Up gradation of the plant. The funds

have been utilized for installing and maintenance of Pollution Control

Equipments & to keep up the green belt and an amount of Rs. 2756 Lakhs has

been spent for construction of limestone stockpile and CPP coal storage

sheds. All pollution control equipments will be in operation during running of

the plant. In order to comply with new emission norms of less than 30

mg/Nm3 for stacks, all existing single phase transformers are replaced with



b. 2. INTRODUCTION

M/s. ORIENT CEMENT LIMITED has expanded the cement unit and also 50MW coal

based Captive Power Plant (CPP). The total cost of the project is Rs.531.72 Crores.

These units are located in existing Cement Plant premises of M/s. ORIENT CEMENT

LIMITED at Village: Devapur, Mandal: Kasipet, District: Adilabad of State: Telangana.

The salient features of the expansion project are presented.

At present we have three production lines (Line-1 & Line-2 & Line-3) with a installed

capacity of 10,600 TPD Clinker. Cement production capacity is 8,900 TPD. The

modifications & retrofitting was carried in Raw Mills, Kilns & Cement Grinding line 1 &

2.

A 50 MW Coal based power plant is installed to meet the power requirement of the

plant operations.



Table2.1SALIENT FEATURES OF THE EXPANSION PROJECT

Built-up area includes buildings, utilities like roads, storage yards, watertanks etc.

Existing Plant Total

Cement Unit1. Clinker Production (TPD)

a) Line – 1b) Line – 2c) Line – 3d) Overall production

1. Cement Production (TPD)2. Built-up Area (Acres)3.Project Cost (Rs. in

Crores)

3600 TPD2800 TPD4200 TPD

10,6008,90054.42- - -

Captive Power Plant1. Power Production (MW)2. Built-up Area (Acres)3. Project Cost

(Rs. in Crores)

- - -- - -- - -

5011.06213

5011.06- - -

1. Plant Area (Area in acres)a) Built-up Areab) Green belt Area

2. Town Shipa) Built-up Areab) Green belt Area

3. Total Project Areaa) Total Built-up Areab) Greenbelt Areac) % Greenbelt Area

4. Total Project Cost (Rs. inCrores)

168.5645.5667.74257.3520.07148.35425.8965.63216.0950.74- - -

No Change19.923.50No ChangeNo Change7.5No Change19.9211.00- - -531.72

168.5665.4871.24257.3520.07155.85425.8985.55227.0953.32- - -



2.1 Location and Accessibility

M/s. Orient Cement Ltd is located in Devapur (V), Kasipet (M), Adilabad (Dist) of

Telangana. The area is between 19°00’15” - 19°03’16” North Latitude and

between 79°18’30”-79°21’44” East Longitude. Fig2.1 shows location map. Mean

sea level of the place is in between 240 – 260 m.

The site can be reached from the State Highway between Mancherial and

Bellampalli using a connecting tar road via Kasipet. The plant area is about 35

km from Mancherial and 22 km from Bellampalli.



3. PROCESS DESCRIPTION

MANUFACTURING PROCESS:Materials:

Lime stone + Additives → Raw meal95% 5%

Raw meal (1.48 Ts) → Clinker (1.00 T)(Burning with Coal at 14000C - 14500C)

Clinker + Gypsum → Ordinary Portland cement (OPC)97% 3%

Clinker + Fly Ash + Gypsum → Portland Pozzolana Cement (PPC)

Stage wise Operations:

Limestone Mining: Mechanized mining of limestone is done by deep hole drilling, blasting,excavation and hauling. The blasted limestone of size less than 1000 mm will be transportedto Limestone Crusher for crushing.

Limestone Crushing: Limestone crushing is done in Hazemag type Double rotor impactcrusher (1200 TPH capacity). The size reduction in crusher will take place from 1000 mm toless than 40 mm.

Stacking & Reclamation: Crushed limestone will be stacked with Stacker (CIMMCO Birlamake – 1500 TPH capacity) as per the required quality. Capacity of the stockpile is 50000 Ts.After forming the stocking (with the required quality as well as quantity), the reclamation(Reclaimer – CIMMCO Birla make – 800 TPH capacity) will be started. The total process ofstacking and reclamation is called Chevron method.

Raw material grinding: Blended Limestone will be reclaimed and will be filled into rawmaterial hopper in the respective raw mill section. Laterite -1 and Alumina Laterite (outsourced material) will be filled into respective Laterite hoppers. Lime stone with Laterite -1 andAlumina Laterite in required ratios will be conveyed through weigh feeders and belt conveyorto Polycom, HIC, Roller Press, where grinding will take place. The product, called raw meal,is entrained with air/gases to Electrostatic precipitator, Bag House where the total raw meal iscollected and further conveyed to Continuous Flow Silo’s.

Coal Crushing & Grinding: Raw coal, received from Singareni collieries, is crushed in coalcrushers, where the size reduction of coal from 100 mm to 30 mm size takes place; this isconveyed to Raw Coal hoppers. Ball Mill, VRM will grind raw coal to fine powder and will becollected in bag filter. The fine coal will be further conveyed mechanically to fine coal bins.



Pyro-processing: The system consists of Rotary Kilns (3600 TPD, 2800 TPD, 4200 TPD)with 5, 6 stage suspension pre-heater and in-line calciners. Raw meal from respective CF silowill be conveyed to Preheater. Fine coal will be fired through burner pipe in kiln and throughnozzles in precalcinator. The material will be 90% calcined at kiln inlet and balanceCalcination, pre burning and sintering reactions will take place in kilns. Temperature of 1400 -14500C will be maintained in kiln for the completing the reactions. Clinker will be formed and iscooled in Clinker coolers. The clinker after cooling will be transported mechanically to CSP,Silo’s.

Cement grinding: Clinker from CSP, Silo’s will be conveyed to clinker hopper. Gypsum (outsource material) will be filled into gypsum hopper. Closed circuit ball mill with dynamicseparator and Pregrinding Roller Press System will grind clinker and gypsum fed to it in fixedratios. The product, called Ordinary Portland Cement, is conveyed mechanically to OPCstorage silos.

Similarly clinker, flyash and gypsum at a fixed ratio will be ground in the Roller Press and ballmill system. The product, called Portland Pozzolana Cement, will be conveyed mechanically toPPC storage silos.

Cement Packing: Six packers (Electronic packers) are available for packing of cement in tobags and dispatching.

Plant (Raw Mills to Cement Grinding section) is operated from CCR based on PLC systems.

Captive Power Plant: Two boilers with 25 MW capacities are installed within the CementPlant premises to cater the Power requirement of the Plant.



4. ENVIRONMENTAL BASELINE STATUS

The base line data for Soil, Water, Micrometeorology, Ambient air quality; Stack

monitoring Data and Noise levels in and around plant area was generated from

April’16 to September’16.

4.1 Soil Environment

During plant operations top soil is removed. Presently topsoil whenever removed

is being spread on the mined out areas for reclamation & plantation. Soil samples

were collected from various locations and analyzed for different parameters,

which are presented. The soils in the plant area are mostly varying between silty

clay to mixed soil (Loamy sand) analysis data is presented in table 4.1.

4.2 Water requirement

Water is drawn from Bore wells in the company area and Jack wells in the nearby

for different utilities. At present 2,070 m3/day of water is used for gas

conditioning for ESP’s and for cooling of bearings, gearboxes and dust

suppression at raw material etc. Additional 430 m3/day of water is required for

up-gradation and another 450 m3/day is required for proposed expansion as

makeup water for cooling of bearings, gearboxes and dust suppression etc. After

proposed expansion the total water requirement for plant will be 2,950 m3/day.

About 641 m3/day of water is used for domestic purposes (township) at present,

which will increase, by 20m3/day after the expansion. The water quality data &

drinking water data is presented in tables 4.2 & 4.3 and drinking water data is

presented in table 4.4.



Table4.1

SOIL ANALYSIS(October-16 to March-17)

Location 1 2 3 4

pH 7.74 7.92307 7.37 7.87E.C. µ mhos/cm 431 49.5 253 369.5Calcium as Ca m eq/100g 68 15.8 41.5 35.5Magnesium as Mg m eq/100g 17.35 43 9.85 10.9Sodium as Na m eq/100g 55.5 54.5 26.5 17.5Potassium as K Kg/ha 64.5 9 112.5 120.5Phosphorous as P Kg/ha 13.5 142.5 15.5 19.5Nitrogen as N Kg/ha 119.5 0.58 209 211.5Organic Carbon % 0.46 0.58 0.57 0.56Sulphates as So4 m eq/100g 0.79 0.71 0.21 0.28Chlorides as Cl m eq/100g 0.70 0.56 0.32 0.57Silt & Clay % 66.5 63.5 63.5 62Sand % 33.5 36.5 36.5 38

Textural Classm eq/100g Loamy Sand Loamy

SandLoamy Sand Loamy

SandPhysical Appearance m eq/100g Mixed Soil Mixed Soil Mixed Soil Mixed Soil

Note: a. Soil Sample collected at a depth of 45 cm.b. Soil sampling locations1. Near Crusher site,2. Near Mines Office,3. Agriculture land Devapur4. Near colony.



Table 4.2WATER ANALYSIS

Date of Sample Collection : 31-12-2016, 02-01-2017.Date of Sample Analysis : 16-03-2017, 17-03-2017.

Locations 1 2 3 4 5

Colour (Hazen units) 0 0 0 11 4

Turbidity (NTU) 0.1 0.65 0.9 3.35 0.35

pH 7.675 7.56 7.5 7.48 7.65

E.C. (Micromhos/cm) 295 1082.5 592.0 788.50 998.5

Total dissolved solids 161 698 360.0 498.00 619

Phenolphthalein alkalinity as CaCo3 0 0 0.0 0.00 0

Methyl orange alkalinity as CaCo3 79 255 108.0 230.00 324

Total hardness as CaCo3 111 318 245.5 300.50 363.5

Calcium as Ca 22.5 87 78.0 88.50 109.5

Magnesium as Mg 13.31 24.43 12.3 20.26 21.82

Sodium as Na 15.5 105.5 32.0 48.00 38.5

Potassium as K 0.905 3.515 1.2 1.90 1.10

Chloride as Cl 30 157 55.0 85.50 62

Sulphate as So4 23 57.5 42.5 43.50 53

Nitrate as NO3 5.215 20.5 14.5 17.50 25

Carbonates as CaCO3 0 0 0.0 0.00 0

Bicarbonates as CaCO3 96.5 311.5 132.0 280.00 395.5

Residual Chlorine 0 0 0.0 0.37 0

Copper as Cu <0.05 0.045 <0.05 0.17 <0.05

Manganese as Mn <0.02 <0.05 <0.02 0.06 <0.02

Iron as Fe 0.17 0.275 0.2 0.40 0.315

Fluoride as F 0.33 0.635 0.3 0.72 0.955

1. Bore well (Near Crusher) 2. Bore well (Maddimadugu Village)3. Bore well (Factory Premises) 4. Open well (Devapur village)5. Bore well Water (Devapur Village)

Note: All the values except pH are expressed in mg/L.



Table 4.4DRINKING WATER ANALYSIS DATA

(October -16 to March-17)

S.NO PARAMETERS min max AVERAGE1 Turbidity (NTU) 0 0 0.002 pH 6.9 7.54 7.243 E.C (micromhos/cm) 101 162 131.334 Total dissolved solids 62 96 77.505 phenolpthalene alkalinity as CaCO3 0 0 0.006 Methylorange alkalinity as CaCO3 40 62 49.507 Total alkalinity as CaCO3 40 62 49.508 Total hardness as CaCO3 32 52 42.009 Calcium as Ca 5 11 7.24

10 Magnesium as Mg 4.04 9 5.8111 Sodium as Na 8.94 13.95 11.2612 Potassium as K 0.56 0.9 0.7313 Copper as Cu 0.013 0.016 0.0114 Iron as Fe 0.03 0.07 0.0515 Managanese as Mn 0 0 0.0016 Chlorides as Cl 9.03 14.8 11.8917 Sulphates as SO4 1.86 3.1 2.4618 Flourides as F 0.16 27 4.7219 Phenolic compounds as c6h5OH <0.001 <0.001 <0.00120 Mercury as Hg <0.001 <0.001 <0.00121 Cadmium as Cd <0.001 <0.001 <0.00122 Selenium as Se <0.01 <0.01 <0.0123 Cyanide as CN <0.01 <0.01 <0.0124 Lead as Pb <0.01 <0.01 <0.0125 Zine as Zn 0.01 0.02 0.0226 Resifual chlorine <0.04 <0.04 <0.0427 Silver as Ag <0.01 <0.01 <0.0128 Mineral Oil <0.01 <0.01 <0.0129 Hexavalent chromium as Cr+6 <0.01 <0.01 <0.01

Note: All the values except pH, Turbidity and E.C. are expressed in mg/L



4.2.1 Water pollution

There is no wastewater generated from cement plant. Different effluents except

DM plant regeneration water generated from utilities of power plant will be

diverted into cooling water tank of cement plant. DM plant regeneration water is

separately collected, neutralized and used for ash quenching. Sewage from

township etc. is to be treated in the proposed sewage treatment plant and used

for green belt.

4.2.2 Solid waste management

There are no prominent solid wastes generated from cement plant. Fly ash from

power plant will be safely collected and used in cement manufacturing. Bed ash

from power plant will be used for reclamation of abandoned mine pits

Table 4.5

WEATHER MONITORING DATA(Temperature & Relative Humidity)

DateTemperature (0C) Relative Humidity (%)

Min. Max. Avg. Min. Max.

29-12-2016 16.50 27.30 21.90 52 58

15-03-2017 29.60 40.70 35.20 39 46



4.3 Air Environment

The pollutant emissions from sources and atmospheric interactions determine

the quality of air at a receptor (any object affected adversely by the quality of air

to which it is exposed and include human beings, vegetation and materials), is

determined by the type and amount of pollutants emitted upwind and the extent

of atmospheric interaction.

The base line data for major pollutants like particulate matter (PM10), Particulate

Matter (PM2.5), Sulphur dioxide (SO2), Nitrogen Dioxide (NOX) and Carbon

Monoxide were collected by judiciously designed ambient air quality stations

network in and around the plant area.

Note: The Ministry of Environment and Forests (MOEF) New Delhi has given

amendment on 16th November 2009 for revised standards for Ambient Air

Quality Standards. M/s. Orient Cement has following the same Standards.

At each station 24 hr continuous sampling in every month was carried out. From

August 2010 onwards they are following as per MOEF Notification i.e. Particulate

Matter (PM10), Particulate Matter (PM2.5), SO2 & NO2 were monitored on 24 hourly

basis. The method of sampling and analysis were carried out vis-a-vis following

the Central Pollution Control Board guidelines. The average values of ambient air

quality data is presented in table 4.6 and graphical data are presented in figs.4.7

to 4.10.



Table 4.6

AVERAGE VALUES OF AMBIENT AIR QUALITY DATA

(October-16 to March-17)Parameter

Location


PM10

(µg/m3)


PM2.5

(µg/m3)

Sulphur dioxide(µg/m3)

Nitrogen Dioxide(µg/m3)

Min. Max Avg. Min. Max. Avg. Min Max. Avg. Min Max. Avg.

Near D.G.Set 51 66 58.67

12 25 17.17

8 14 10.33 16 22 19.50

Near TimeOffice

59 72 65.17 7 13 9.67 18 23 21

Near GuestHouse

54 68 58.83 6 13 9.50 15 21 18.50

Near MinesOffice

41 63 50.67 5 11 8.50 14 58 51.50

4.3.2 Air Pollution Sources and Control Measures

The sources of air emissions are from Kiln with Raw Mill, Cement Mill, Coal Mill

and Cooler. The stack details are furnished in Stack emissions monitoring are

carried out once in a month for the parameter Particulate matter (PM). It is

noticed from the collected emissions data that the parameters monitored are

within the limits prescribed by TSPCB. The stack details are furnished in table 4.7

and results are presented in tables 4.8 to 4.9.



Table 4.7

DETAILS OF STACK EMISSIONS

(October 16 to March-17)

SI.NO.

Stack attached to Height(Meters)

Dia(Meters)

Flow rate(Nm3/hr)

Concentrationof particulate

matter(mg/Nm3)

1. Kiln –I & Raw

mill – I85.0 3.34 340632 45.17

2. Kiln-II & Raw mill – II 82.5 3.00 276780 24.33

3. Kiln – III & Raw mill – III -- 3.76 400488 17.83

4. Cooler –I 30 3.00 191508 24.33

5. Cooler-II 31 3.80 230748 22.33

6. Cooler – III -- 3.50 237936 19.50

7. Coal Mill-I 36.0 0.85 18906 31.17

8. Coal Mill-II 45.5 1.00 20718 38.67

9. Coal Mill – III -- 1.80 90060 28

10. Cement Mill-I 39.0 1.00 25905 21

11. Cement Mill-II 38.7 1.50 53106 21.33

12. Crusher -- 1.20 35544 55

13. Packing Plant-I -- 0.75 14886 45.33

14. Packing Plant-II -- 0.75 14068 45

15. Packing Plant-III -- 0.75 9408 43

16. Packing Plant-IV -- 0.75 14700 42.67

17. CPP 90.0 5.00 346464 81.50



Table 4.8AVERAGE VALUES OF STACK MONITORING DATA


S.No Parameters PCB Norms(In mg/Nm3)

Particulate Matter(mg/N m3)

Location Min Max Avg.

1 3600 TPD Rotary Kiln – I & Raw Mill – I 80 41 49 45.172 2800 TPD Rotary Kiln – II & Raw Mill – II 80 22 27 24.333 4200 TPD Rotary Kiln –III & Raw mill – III 50 14 26 17.834 FBC Boilers of Capacity 2 X 115 115 71 89 81.505 Cement mill – Line 1 80 17 25 216 Cement mill – Line 2 80 17 25 21.338 Coal mill – Line 1 50 22 39 31.179 Coal mill VRM – Line 1 80 24 42 32.3310 Coal mill – Line 2 80 29 45 38.6711 Coal mill – Line 3 50 25 32 2812 Clinker Cooler – Line 1 80 20 29 24.3313 Clinker Cooler – Line 2 80 19 25 22.33

14 Clinker Cooler – Line 3 50 16 23 19.5015 Packing plants - 5 Nos. 80 25 59 46.8

16 Attached to 4 X 4. 2 MW &1 x 4.0 MWD.G.sets

115 Not Running



Table 4.9AVERAGE VALUES OF STACK MONITORING DATA

(October -2016 to March-2017)

Parameter

Location

Sulphur dioxide(mg/N m3)

Oxides of Nitrogen(mg/N m3)

Min. Max. Avg. Min. Max. Avg.

Kiln – I 1.60 2.50 2.13 829 947 897.83

Kiln – II 26 34 29.33 610 767 704.33

Kiln – III 1.20 2.10 1.75 705 745 728.33

4.4 Noise Environment

Noise in general is sound which, is composed of many frequency components of

various loudness distributed over the audible frequency range. The most

common and heavily favored of these scales is the A-weighted decibel [dB (A)].

This scale has been designed to weigh the various components of noise

according to the response of the human ear; loud noise may damage hearing or

health; interfere with work tasks, speech communication and sleep; affect inter-

room privacy; cause annoyance. The impact of noise depends on its

characteristics (instantaneous, intermittent or continuous in nature), time of day

(day or night) and location of noise source. The noise levels at various locations

in and around plant area were measured and tabulated in table 4.10.



Table 4.10AVERAGE VALUES OF NOISE LEVEL DATA




Near Kiln 67.60 71.50 69.54 61.80 65.40 63.96Near Raw Mill 70.80 73.50 72.20 65.30 68.70 67.04Near Compressor House 71.30 73.90 72.72 64.70 68.10 66.94Near Cement Mill 68.90 70.50 69.72 62.10 65.40 64.34

Near D.G.Set 68.10 73.60 71.04 63.30 68.20 65.98Near Limestone Crusher 70.90 74.10 72.84 65.20 69.60 65.70Near Work Shop 65.70 69.30 67.06 59.50 60.90 61.20Near Line-III 66.40 70.70 68.86 61.10 65.70 64.12

4.5 Green belt development:

Development of water bunds in the plant water drains and reuse of wastewater

for maintaining green belt commenced. Further it is planned to build bunds

upstream of the drains to meet additional requirement for new green belt area in

the plant.

The already developed greenbelt enhances environmental quality through:

Mitigation of fugitive emissions including odor

Attenuation of noise levels

Creation of aesthetic environment

Balancing Eco-environment

Prevention of soil erosion



Recharging oxygen into environment

Spatial and compositional design of greenbelt for environmental management is

done after considering the topography, climate, soil quality of the area and flora

spread over the area.

4.5.1 Township

For township wastewater treatment plant is proposed for reuse of treated

wastewater for maintaining large green belt developed in colony. This will also

cater to propose green belt in the township.

4.5.2 Other measures

Further construction of water reservoir in township in an area of 23,600

sq. m with a volume of 87,000 m3 was developed for storage of water.

Water is used for watering the plantation & improves ground water

recharge.

Development of water bunds in the plant water drains and reuse of

wastewater for green belt development will be undertaken.

STP Provided in colony along with water filtration system for use in

Green Belt development.

Higher No. of air-cooling fans for cooler installed to reduce water

consumption.

High Pressure water spray system installed for process cooling to

reduce the water consumption.

Reservoir in the mines pit will also add to increasing ground water table

economizing the water intake.



4.6 Land Environment and Solid Waste Management

There is no generation of solid wastes from cement manufacturing process, as all

the dust collected in air pollution control systems is continuously recycled into

process. Different types of solid wastes are generated from the non-process

activities in the unit. They include waste packaging materials, steel scrap, and

empty oil/grease drums, used tyres, used batteries etc. All the non-process solid

waste materials are disposed for further processing as per the directions of TS

Pollution Control Board.

4.7 Waste Management

The used oil is used as fuel in the Kiln calcining system. The Precalciner is

designed to use waste fluids from the plant for utilizing the heat value of the

waste. The required feeding system shall be part of the main equipment.



5.ENVIRONMENTAL MANAGEMENT PLAN

Effective pollution control measures, greenbelt development and adequate safety

measures and post project monitoring facilities for pollution, implementation of the

same form the strategy for Environmental Management Plan. The environmental

management plan is prepared for operation phases.

5.1 Operation phase

Effective pollution control measures to abate various types of pollution generated in

the plant are installed. Major pollution after up gradation and expansion (3rd line) of

Cement plant and new captive power plant is air pollution in the form of flue gas and

dust emissions from kiln, crushers, material handling systems etc., of cement plant

and boilers, coal crusher and coal and ash handling systems of power plant. Waste

water generated from DM Plant, RO Plant & other waste water and solid waste in the

form of ash due to coal burning from power plant.

5.2 Air Environment:

Different types of air pollution control equipment are installed/modified along with

up gradation/new plant installation in concurrence with installation of other process

equipment and control equipment is commissioned simultaneously along with process

plant.

5.3 Water Environment:

There is no wastewater generation from the cement plant except domestic discharge.

From power plant waste water generated from blow-downs of cooling tower & boiler,

DM plant regeneration, RO plant reject and sanitary effluent. The blow-down from

boiler & cooling tower is sent to cement plant’s cooling water tank. The DM Plant re-



generation water about 100 m3/day collected separately collected and neutralized

effluent is directly used for quenching of ash. The above waste water management

facilities created along with process plant installation and the same functions from the

day of commissioning of plants.

About 550 m3/day of sanitary effluent is generated from township and industry. In the

expansion program sewage treatment plant to treat the sewage and use the same for

green belt is installed.

5.4 Land Environment and solid waste Management:

There is no generation of solid wastes from cement manufacturing process as all the

dust collected in air pollution control systems is continuously recycled into process.

Different types of solid wastes are generated from the non-process activities in the

unit. They include waste packaging materials, steel scrap, and empty oil/grease drums,

used tyres, used batteries etc. All the non-process solid waste materials are disposed

to scrap vendors for further processing. The present disposal and management

practices are continued.

Solid waste generation is ash from the boilers of CPP. All the Fly ash that is generated

is used to produce Pozollona Portland Cement.

5.5Noise Environment:

The noise generating equipment is covered with sound proof enclosures. The noise

generating sources in captive power plant is Turbine generator, high pressure boiler

and compressor. The noise generating equipment is covered and acoustic noise

suppression measures implemented under the guidance of equipment manufactures.

Personnel safety equipment like earmuffs provided to the staff working near high noise

generating sources. There are no human habitations in the vicinity of the unit so there



no impact on the surroundings. The greenbelt help in the reduction of noise levels

outside the plant.

5.6 Hazardous Materials Management

There are no hazardous materials used in the process. Used lead acid batteries at

present are sent to suppliers on buy back basis. Non-ferrous metal scrap is disposed

to nonferrous metal scrap recyclers authorized by TSPCB. Waste oil generated from

various manufacturing equipment is disposed to agencies authorized by TSPCB. The

additional waste generated after up gradation/expansion is disposed in the same

manner.

5.7 Safety Systems

The company maintains safety of the equipment as well as the employees with well-

defined procedures, which is also spelt out in ISO-14000 and OHAS-18000. For

emergency control fire hydrant system is available along with maintenance

Schedule for the firefighting equipments. We have mobile fire hydrant also. A well-

defined on site emergency plan is also made and regular monitories are conducted.

Mock drills are conducted regularly Ambulance is available of the plant.

Water spraying system is provided for coal yard to control coal burning. Flame proof

motors are installed wherever required. Electric sub-stations are sufficiently ventilated.

Electrical fittings like switches, lamps, starters etc. are provided with flameproof

components. Smoking is strictly prohibited and vehicles are to be allowed only near

storage yards and utility places in the industry premises.



a) Fire Hydrant System:

The fire protection system provided is capable of achieving a non-combustible

atmosphere in less than one minute, which meets the requirements of National Fire

Protection Association (NFPA). This system shall include sprinkler systems and CO2

based fire suppression equipment. Fire hoses & tools cabinet, Fire alarm and required

Fire pumps are provided as part of fire safety system.

b) Fire Extinguishers:

Fire extinguishers are provided wherever necessary. 158 no. DCP fire extinguishers, 94

no. CO2 fire extinguishers, 48 no. Mechanical Foam type extinguishers and 7 no. ABC

type extinguishers are provided at various locations throughout the plant. Additional

fire extinguishers are procured and provided wherever required.

Necessary safety and preventive measures avert any possible hazards and fire

accidents which may cause human suffering, property loss/ damage to equipment and

detrimental effect on environment.

5.8 House Keeping:

Proper housekeeping and cleanliness is being maintained both inside and outside the

industry. The process areas are cleaned regularly. Internal roads are water sprayed to

avoid dust emissions. Signboards are provided in the work areas and all the road and

building highlighting the safety and occupational aspects.



6. CONCLUSIONS

The compliance report is enclosed. The monitoring data generated is presented

and critical analysis is carried out. Necessary control equipments have been

added in the up gradation of clinker transportation belt & Cement Storage silo’s

For the new 3rd Line all control equipments have been installed and well

maintained. We have installed 2 No’s of Online Ambient Air Quality Monitoring

Stations, 7 No’s of stack monitoring Stations and these are connected to TSPCB

AND CPCB Servers. The Emission levels are found to be in the specified limits.

There is no wastewater generation in the process. Sewage treatment plant is

provided to treat the sewage water. STP is maintained in good condition.

Adequate green belt has been developed and every year we are planning 2000-

4000 new saplings. Two new rose gardens were developed inside the plant.

Adequate measures are taken to maintain the Environmental conditions

stipulated by MoEF and Telangana State Pollution Control Board.

Environmental Monitoring facilities:

The industry already procured AAQ samplers - 2 Nos. PM10 and PM 2.5 each, stack

monitoring kit 1 no. and noise level meter - 1 no., Continuous ambient air quality

monitoring stations – 2 Nos. and stack emission monitoring – 7 Nos. are installed.

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