JAYPEE SIDHI CEMENT PLANT (A UNIT OF JAIPRAKASH ASSOCIATES LIMITED)

JAYPEE VIHAR, SIDHI (M.P)

2012-2013

SUBMITTED TO M.P.POLLUTION CONTROL BOARD

BHOPAL (M.P.)

Jaypee Sidhi Cement Plant (A Unit of Jaiprakash Associates Limited)

Jaypee Group is 3 rd largest cement producer in the country. The group produces special

blend of Portland Pozzolana Cement under the brand name Jaypee Cement (PPC) and

Ordinary Portland Cement brand name Jaypee Cement (OPC). Its cement division has

currently operates modern, computerized process control system, Jaypee Sidhi cement plant

(JSCP) and with an aggregate capacity of 3.5 MTPA Cement production.

The Group is committed towards the safety and health of employees and the public. Our

motto is Work For Safe, Healthy, Clean & Green Environment.

Jaypee Sidhi Cement Plant (JSCP) is a unit of Jaiprakash Associates Limited (JAL) groups of

Companies with Corporate & Registered office in Noida (U.P), a leading Business House

with its presence in core industries like Cement industry, Construction division, Hydropower

division, Education, I.T., a chain of hotels in major cities of India, which has been at the

vanguard in generating wealth for the nation.

Jaypee Sidhi Cement Plant is located near Majhigawana village in Rampur Naikin Tehsil

Sidhi District of Madhya Pradesh state at an aerial distance of about 50 km North-East of

Sidhi & about 24km aerial distance from Rewa in Southern direction. Geographically, it is

located at Latitude 240 19’ 35” North and Longitude 810 19’ 08” East.

Jaypee Sidhi Cement Plant has come into operation in year 2009 and Expansion Jaypee Sidhi

Cement Plant has come into operation in year 2013. The plant is pyro-processing technology

with Make-L&T- Separate Line Calciner (SLC) Rotary kiln, Coolex cooler modified duoflex

low NOx burner with capacity 6-stages low pressure cyclones preheater. The cement

production process is based on dry process. Present production capacity of integrated Cement

plant is 3.5 million Cement, 3.0 million Clinker tonne per annum & 35 MW Captive Power

Plant.

FORM- V

(See rule 14)

ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE

31st MARCH 2013

PART- A

(i) Name and address of the owner/ : Jaypee Sidhi Cement Plant Occupier of the Industry, operation Vill. Majhigawan P.O-Bharatpur, or process Thesil –Rampur Naikin Distt-Sidhi ( M.P.) – 486776

(ii) Industry category : Red Category and Large Industry Primary-(STC Code) (Primary STC Category) Secondary-(SIC Code) (iii) Production Capacity Unit : 3.0 MTPA (Clinker)

3.5 MTPA (Cement)

35 MW (Captive Power)

(iv) Year of Establishment : Unit-I February, 2009

: Unit-II January, 2013

(v) Date of last Environment Statement Submitted : 30.09.2012

PART- B WATER AND RAW MATERIAL CONSUMPTION

(i) Water consumption m3 /d Cooling: (Spraying) : 2179.83

Domestic : 155.57

Process : Nil

Name of Products Process water consumption per unit of Product output During the previous Financial

Year (2011-12) During the Current Financial

Year (2012-13) Cement 0.27 M3/MT 0.28 M3/MT

Electricity 0.026 M3/Kwh 0.038 M3/Kwh

(ii) Raw Material Consumption

Name of raw material consume

Name of products

Consumption of raw material Per unit of output MT/ MT of Cement and MT/ Kwh for Electricity

During the Previous Financial Year (2011-12)

During the Current Financial Year (2012-13)

Limestone Laterite Iron ore Coal Bauxite Gypsum Flyash

Pet Coke

Cement

1.0408 0.0285 0.0101 0.1010 0.0016 0.0252 0.2542 0.0014

1.0533 0.0176 0.0213 0.0975 0.0064 0.0223 0.2453 0.0094

Coal Electricity 0.970 0.970

(iii) Production of Cement(MT)

Production During the Previous Financial Year(11-12)

During the Current Financial Year(12-13)

Clinker 1160440 MT 1404840 MT Cement 1098830 MT 1135755 MT

Electricity 154193000 Kwh 110915000 Kwh

PART- C Pollution discharges to environment/ unit of output.

(Parameter as specified in the consent issued)

(i) Pollution Quality of Pollutants Discharged (Mass/day) Tons/day

Concentration of Pollutants discharges (mass/volume) (mg/Nm3)

Percentage of variation from prescribed standards

(a) Water

i)Domestic

ii)Industrial

Zero discharge is maintained. Treated domestic water is being

used in horticulture and plant process

(b)Air RSPM parameter within limit and report attached as Annexure-I

Stack emission(Unit-I) 1) Raw mill & Kiln Bag House 2) Cooler ESP Stack 3) Coal Mill Bag House stack 4) Cement mill Bag House stack 5) Cement Packer Bag filter 6) L .S crusher Bag filter 7) CPP ESP Stack Stack emission(Unit-II) 1) Raw mill & Kiln Bag House 2) Cooler ESP Stack 3) Coal Mill Bag House stack 4) Cement mill Bag House stack 5) Cement Packer Bag filter

0.2267 0.0980 0.0598 0.0503 0.0113 0.0095 0.1764

0.2253 0.1409 0.0668 0.0700 0.0095

20.26 18.08 35.71 30.49 38.22 36.66 37.97

21.17 33.31 38.80 33.68 34.61

Within the permissible limit

PART- D

(HAZARDOUS WASTES) (As specified under hazardous waste (Management, Handling & Transboundry

Movement) Rules, 2008)

Hazardous Wastes Total Quantity (Kg.)

During the previous financial Year (2011-12)

During the current financial Year (2012-13)

(a) From process (i) Used Oil(5.1) (ii) Waste Oil(5.2)

Nil Nil

7980 Nil

(b) From pollution Control Facilities

Nil Nil

PART- E SOLID WASTES

TOTAL QUANTITY (Ts)

Solid Waste During the Previous Financial Year (2011-12)

During the Current Financial Year (2012-13)

(a) From Process

No solid waste is generated from the cement manufacturing process

No solid waste is generated from the cement manufacturing process.

(b) From Pollution Control Equipment

All the collected material is

recycled in the process.

All the collected material is

recycled in the process.

(c) (i) Qty. recycled or reutilized within the unit.

(ii)Sold (iii)Disposed

All the collected swept solid waste is reused in the process Nil Nil

All the collected swept solid waste is reused in the process Nil Nil

PART- F

Please specify the characterizations (in terms of composition of quantum) of Hazardous as well solid waste and indicate disposal practice adopted for both these categories of wastes. Hazardous waste: Analysis Report of Used Oil is attached as Annexure-II Note-Used Oil = 7.98 KL generated in period of 2012-13 but sold on 20.04.2013

PART- G

Impact of the pollution abatement measures taken on conservation of natural resources and on the cost of production. of the pollution abatement measures taken on cost of prodution. The plant is equipped with best available technology for Air Pollution Control devices such as Bag House, ESP, Bag Filters etc designed to control the emission level below 50 mg/Nm3 from any of the stacks installed at our plant. Covered belt conveyors, water sprinklers of raw material & coal conveyors and concreted roads for vehicular movement inside the plant premises. The company has undertaken various energy efficiency improvement measures & process modifications which helped to significantly reduce the overall energy consumption to enable us to achieve our ultimate goal of GHG emission reduction and positive contribution towards reversing the effects of Climate Change. Thus, the pollution abatement & other energy conservation practices adopted by us save precious raw material/ product and greatly help in conserving valuable natural resources.

PART- H Additional measures/ investment proposal for environmental protection including abatement of pollution, prevention of pollution

1. Replacement of damaged filter bags in Bag House to effectively control the dust emission during material transport to improve the air quality inside the plant premises.

2. Green belt development in and around the plant premises

3. Construction of concrete roads in and around factory premises.

4. Continuous water spraying on roads for controlling the fugitive emission.

5. Water sprinkler installed at L/S Crusher and haulage road plant premise.

6. Good housekeeping practices being followed to avoid dust deposition on roads.

7. Extension of Covered shed for coal shed, gypsum shed , latrite shed.

8. Installed two nos. of CAAQMS(Continuous Ambient Air Quality Monitoring Station)

9. Construction of additional Gypsum shed Storage capacity 1500 MT

10. Procurement of operated sweeping machine for good housekeeping

11. Installation of online CEMS (Continuous emission monitoring system).

PART- I

Any other particulars for improving the quality of the environment. Following measures have been adopted for abatement of pollution, conservation of natural

resources:

1. Conservation of Limestone:

Limestone is being used for the manufacturing of cement by the proper blending of different

grade of limestone for preparation of proper raw mix design which can be produced a good

quality of cement. The raw mix design has been prepared in such a way that it reduce the

limestone stone saturation factor by which substantial quality of limestone has been

conserved. In the same manner as per the Regulation of Bureau of Indian Standard.

2. Energy conservation

a. Utilization of Pet Coke-

The pet coke which is petroleum refinery industry by product is a waste in nature and have

very high calorific value. This refinery by product is used as alternate fuel in cement kiln,

almost 1.31% (18357 MT) of total fuel consumption during the 2012-2013 was in the form of

pet coke.

b. Reduction in Thermal energy consumption-

The raw mix quality and process parameters have been maintained which resulted to

reduction in Specific Heat per kg of clinker production. The last three years trend of specific

heat is depicted as under:

3. Utilization of fly ash for the manufacturing of cement-

Captive Power Plants were having capacity of 35 MW CPP which fly ash generation about

55378.90 MT for period FY-2012-13 which is being stored in closed silos from where it has

been pneumatically conveyed to cement plant and directly to the cement mill for the cement

grinding process. Apart from this we are also consuming approx 24.53% (278649 MT) fly

ash for PPC cement manufacturing which is being collected from the different thermal power

675

690

705

720

735

750

765

2009-10 2010-11 2011-12 2012-13

Kcal

/Kg

clin

ker

F.Y Period

Sp Heat Consumption on NCV

Sp Heat Consumption on NCV

plant and being transported in closed container and being directly feed in the cement grinding

through pneumatic feeding system.

4. On line real time Ambient Air Quality Monitoring Station (AAQMS)

Commissioned two no. of CAAQMS as per the approved location by RO, MPPCB, Rewa.

The transmission of real time data started displaying in CPCB website & plant main gate

w.e.f. 20.07.2012 & On line Continuous Emission Stack Monitoring Station (CEMS)

work order has been placed ESA India.

AAQM STATION NO. 1 & 2

2021222324252627282930

2009-10 2010-11 2011-12 2012-13

% F

ly A

sh C

onsu

mpt

ion

F.Y Period

%FLY ASH CONSUMPTION

FLY ASH CONSUMPTION

5. Use of STP treated water for the plant purpose-We have latest and advance aerobic

technology based Sewage Treatment Plant which comprises of:

1. Screen Chamber with Oil & Grease Trap-800 KLD 2. Equalization Tank-69.60 m3/hr 3. Aerator I&II-64.0 m3/hr 4. Tube Settlers Tank-75.0 m3/hr 5. Primary Sand Filter (PSF)-33.30 m3/hr 6. Activated Carbon Filter-33.30 m3/hr 7. Chlorine Contact Tank-34.20 m3/hr 8. Treated Water Tank-188.10 m3/hr 9. Sludge dry beds-15.0-unit 4 m3

Sewage Treatment Plant – 800KLD

The capacity of sewage treatment plant is 800 KL per day. The sewage collected from the

different part of colony and plant is being collected in raw sewage tank where blowing is

being done for homogenization of raw sewage water. Then this homogenized sewage water

comes to Aeration tank for sufficient aeration of sewage and then conveyed to clarifier where

the suspended particle is being settle through mechanical clarification system. After this

clarified water collected in intermediate holding tank and sludge settled at the bottom of

clarifier is transported to sludge drying beds. Now the water from the intermediate tank is

passed through pressure sand filter and then activated carbon filter and ultimately collected in

the final holding tank.

6. Water conservation:

3.0 km garland drain constructed around the plant for rain water harvesting in colony and

plant premises. This harvested rain water is stored in our own man made reservoir. The total

rain water is collected and stored in this reservoir, the stored water will be used for cement

manufacturing process and cooling purpose. The full study for rain water harvesting is done

by Hydrominvirion Consultancy Pvt. Ltd. It helps us in preservation of precious rain water

and recharging of ground water.

Water Harvesting

7. Solid Waste Management: The Collected bio-degradable Waste of colony and plant canteen waste is used for the biogas

generation. The basic concept of our design on process known as up flow Anaerobic Sludge

Blanket (USAB), with Capacity of 400 kg/day. The produced is used in our Annapurna Mess

that will help in reduction in Green House Gases emissions.

8. Noise Abatement

Installed 25 No. blower silencers, 15 No. of compressor silencer and 12 nos. of high speed

cooling fans attached with silencer at clinker cooler area. The noise level has been come

down up to 7.0% in impulsive noise monitoring. A. cylindrical drum size silencer is hooked

after cooling fan and exist Ambient Air to reduce machine impulsive noise.

SILENCER AT CLINKER COOLER FAN

9. Extensive plantation in and around the plant- We have complete dedicated a team of

skilled horticulturists for the a forestation and greenery development program at our plant and

mines under the supervision of senior experienced person.

We are on fast progress to achieve the full target of development green belt in 40 ha. (33%)

area of the plant. The areas for the plantation have already being earmarked. We have already

planted 29367 trees in plant area of 14.5 ha. up to March, 2013.

* Development of plantation and greenery along the road and unused areas

PLANT & COLONY SITE PLANTATION

10. Good housekeeping- Following measures have been taken for good housekeeping at

Jaypee Sidhi Cement Plant.

* All the raw material is being stored in the covered sheds.

* The conveyor belts are fully covered.

* Clinker and cement is being stored in the concrete silos.

* Auto workshop and CPPs treated water is being utilized for the regular road water spraying.

11. Concreting of kachcha roads- All the kachcha roads of plant and colony has been

concreted as well as flowers and plantation has been done side by the roads for the

beautification.

CONCERETE ROAD

12. Treatment of Auto workshop effluent- A gravity settler oils separator has been installed

for treatment of auto workshop effluent. The treated water is used for spraying on mines

haulage road for dust suppression & collected oil is sold out to authorized recycler. The basic

concept of oil and grease trap is to separate the oily water generated during washing and

cleaning of the Heavy Earth Moving Equipment. Gravity settler oil separator compartments

are made to give retention time to water to separate oil from water and oil will be collected

from the upper surface manually in empty oil drum and water will be collected in last

compartment will be used for haul road dust suppression. No water will be allowed to

discharge outside the mine premises. Zero discharge is maintained. The treated water is used

for spraying on mines haulage road for dust suppression & collected oil is sold out to

authorized recycler.

Oil & Grease Separator

I. Air Pollution Control Measures Adopted:

Water spraying at Limestone Yard & Late rite Yard dump hopper to control fugitive

emission.

Covering of all belt conveyors to control fugitive emission.

Storage of Laterite, Fly ash, and Coal & Gypsum are being stored under covered shed.

Cement Plant is equipped with modern pollution control devices, to mitigate the

pollution.

Major pollution control devices: 03 Nos of ESP, 06 Nos of bag house, 04 Nos. Major

capacity bag filter.

97 nos. of bag filters equipped at all transfer points for control of dust emission.

All internal roads are concreted.

37 Energy meter installed for bag filters at transfer points.

III. Noise Pollution Control Measures:

Installed Silencers at Blowers/Compressors / Clinker cooling fans.

25 no. of blower silencers installed.

15 no. of compressor silencers installed.

12 no. of cooler fan silencers installed.

IV. PROPOSAL TO CARRYOUT THE ACTIVITIES IN FUTURE:

Installation of fog type water sprinkler.

Online monitoring system (CEMS) for stack emissions.

Use of Alternative fuels & alternative raw material in kiln.

Peripheral tree plantation in plant boundary.

Installation of RO plant at colony area.

Polythene Incineration

Vermi-composting of biodegradable matter Prepared By Environment Cell Dated: 26.08.2013

For Jaypee Sidhi Cement Plant

(Authorized Signatory) S.C. Shrivastava

Sr. Vice President (Tech)

JAYPEE SIDHI CEMENT PLANT

AMBIENT AIR QUALITY MONITORING REPORT APRIL- 2012 TO MARCH- 2013

LOCATION -> Near CPP Near office complex Near L/S Crusher Near Autowork shop

PARAMETERS ->

PM2.5

µg/M³

PM10

µg/m3

SO2 µg/m

3

NOX µg/m

3

CO µg/m

3

PM2.5

µg/M³

PM10

µg/m3

SO2 µg/m

3

NOX µg/m

3

CO µg/m

3

PM2.5

µg/M³

PM10

µg/m3

SO2 µg/m3

NOX µg/m3

CO µg/m

3

PM2.5

µg/M³

PM10

µg/m3

SO2 µg/m

3

NOX µg/m

3

CO µg/m

3

Apr-12 - 57.31 10.0 23.0 130.0 - 56.21 9.0 24.0 125.0 - 58.19 10.0 22.0 128.0 - 57.17 11.0 25.0 132.0

May-12 - 62.75 8.0 25.0 138.0 - 60.11 7.0 27.0 132.0 - 57.27 8.0 28.0 130.0 - 58.15 9.0 30.0 142.0

Jun-12 - 63.50 7.0 22.0 154.0 - 61.24 6.0 24.0 148.0 - 58.38 7.0 25.0 145.0 - 57.42 8.0 27.0 158.0

Jul-12 - 47.5 8.0 22.0 162.0 - 48.5 6.0 21.0 160.0 - 43.2 5.0 18.0 148.0 - 45.2 7.0 20.0 158.0

Aug-12 - 46.5 7.0 28.0 165.0 - 47.6 5.0 23.0 172.0 - 44.9 4.0 18.0 152.0 - 46.3 6.0 21.0 163.0

Sep-12 23.10 47.7 6.0 25.0 190.0 25.1 48.7 6.0 24.0 180.0 22.3 46.3 4.0 20.0 175.0 24.4 47.2 5.0 22.0 184.0

Oct-12 28.5 50.6 5.0 26.0 190.0 27.4 52.5 6.0 24.0 192.0 24.8 53.8 5.0 21.0 183.0 25.1 51.4 7.0 23.0 198.0

Nov-12 55.26 74.2 7.0 26.0 198.0 54.3 75.3 8.0 24.0 192.0 57.2 78.3 6.0 27.0 190.0 56.3 78.3 6.0 25.0 193.0

Dec-12 58.25 50.6 5.0 25.0 180.0 53.2 52.5 7.0 24.0 190.0 55.3 53.8 6.0 21.0 182.0 54.2 51.6 7.0 22.0 196.0

Jan-13 28.5 50.6 5.0 26.0 190.0 27.4 52.5 6.0 24.0 192.0 24.8 53.8 5.0 21.0 183.0 25.1 51.4 7.0 23.0 198.0

Feb-13 55.26 74.2 7.0 26.0 198.0 54.3 75.3 8.0 24.0 192.0 57.2 78.3 6.0 27.0 190.0 56.3 78.3 6.0 25.0 193.0

Mar-13 58.25 50.6 5.0 25.0 180.0 53.2 52.5 7.0 24.0 190.0 55.3 53.8 6.0 21.0 182.0 54.2 51.6 7.0 22.0 196.0

AVERAGE -> 43.88 56.36 6.67 24.92 172.9

2 42.10 56.90 6.75 23.92

172.08

42.42 56.68 6.00 22.42 165.6

7 42.22 56.18 7.17 23.75

175.92

MPPCB LIMIT 60 100 80 80 2000 60 100 80 80 2000 60 100 80 80 2000 60 100 80 80 2000

Min 23.10 46.48 5.00 22.00 130.0

0 25.12 47.58 5.00 21.00 125.0

0 22.30 43.21 4.00 18.00 128.0

0 24.35 45.23 5.00 20.00 132.0

0

Max 58.25 74.24 10.00 28.00 198.0

0 54.29 75.26 9.00 27.00 192.0

0 57.20 78.26 10.0

0 28.00 190.0

0 56.27 78.34 11.00 30.00 198.0

0

Annexure-II