ANDHRA PRADESH POLLUTION CONTROL BOARD Regional Office, 1st Floor, Shankar Shopping Complex,Krishna Nagar Main Road, Kurnool – 518 002

K. RAVI KUMAR ., Phone No. 08518 - 235800. Environmental Engineer. Fax No. 08518 – 233619 E-mail: ro_knl@yahoo.com

Lr. No. 33-R-1023/PCB/RO/KNL/CFO & HWA/2008 Date: -04-2008

ToThe Joint Chief Environmental EngineerA.P.Pollution Control Board,Zonal Office, Kurnool

The Joint Chief Environmental Scientist (HWM)

A.P.Pollution Control Board,Board Office , Hyderabad.-

Sir ,

Sub: PCB – RO – KNL – CDCC - CFO application of M/s Penna Cement Industries Ltd, Talaricheruvu(v), Tadipatri(M), Anantapur District – Verification report – Regarding.

Ref: 1) CFE Order No. APPCB/KNL/KNL/193/CFE/HO/2007-1699, dt: 26-10-20072) Lr.No.12-2-7-2143-3383-ID, dated: 10-12-2007 from Commissioner of

Industries, Hyderabad received on 13-12-20073) Clarification sought on 18-12-20084) T.O.Lr.No.32-R-1023/PCB/RO/KN/CFO/2007 – 1476, dt: 21-02-20085) Industry resubmitted application on 02-04-2008

The details of the industry and inspection report are submitted as below:

General Details:1 Name and Address of the industry

With Tel. No,

E-mail.

M/s Penna Cement Industries Ltd, Talaricheruvu(V), Tadipatri(M), Anantapur Dt.

08558 – 286055, 286066

pennaworks@gmail.com

2 Status of Consent and HWA.

I Fresh / Renewal (Copy of CFE / CFO and HWA orders shall be enclosed).

Fresh (expansion)

II Date of receipt of application / Additional information if any.

13-12-2007 & resubmitted on 02-04-2008

III Details of Consent Fee paid.

(Period upto)

66,000/- vide D.D. NO.253340, dt:19-11-07

The industry has Paid consent fee for the period of one year i.e., upto 30-11-2008 for an investment of Rs.22.0 crores.

3. Project cost.(including modification / expansion without depreciation, as per balance sheet)

Rs.22.0 crores.

Total investment on pollution control measures and recurring cost and percentage.

Rs. 2.2 Crores

Latitude &Longitude

E 78003’50” - E 78008’50”N 15056’00” & N 15059’00”

Total Area of the plant: 100.95 Acres (plant & Township including existing)

Extent of Greenbelt 50.0 acres

Surroundings of the Industry East : Agricultural landsWest : Neem gardenNorth : MinesSouth : Colony

4. Date of commissioning. Yet to commission

5 Status of E.C

I Line of Activity as per EIA Notification. Cement Plant II Environmental Clearance order No.

and date

(Copy shall be enclosed).

Lr.No. F-No.J-11011/819/2007-IA-II(I), dt: 13-03-2008

III Violations of EIA Notification, If any. ---

6 I Inspection conducted by A.E.E-II

II Representative of Industry present Sri M.Subba Reddy, Manager

III Date of Inspection 08-02-2008

CFO Details7 Raw materials / Fuels required for production at Consented capacity per Day / Month.

Note : Should not be mentioned as “ enclosed with the application “

S.No Name of the Major Raw material / material used in the

Activity

Existing

(TPD / KLD)

Million Tonnes Per Annum

Total (TPD / KLD)

1 Lime stone 1.35 MTPA 0.75 MTPA 2.10 MTPA

2 Coal 0.158 MTPA 0.0092 MTPA 0.25 MTPA

3 Iron ore 0.022 MTPA 0.028 MTPA 0.850 MTPA

4 Gypsum 0.074 MTPA 0.036 MTPA 0.06MTPA

5 Slag 0.524 MTPA 0.308 MTPA 0.850 MTPA

6 Bauxite 0.022 MTPA 0.038 MTPA 0.06 MTPA

8 Products & By Products manufactured / Storage capacity of Petroleum products / Mining capacity etc per Day / Month. As per CFE order dt: 26-10-2007

S.No Products / Line of Activity Consent capacity

(Existing) MTPA

Consent capacity (Expansi

on) MTPA

Total capacity

MTPA

Applied

(as per the

application)

MTPA

1 Clinker 0.85 0.6 1.45 ---

2 Cement (OPC + PPC + PSC) 1.5 0.7 2.2 2.2

9 Water consumption. I Source of water supply

(River / Bore wells / Public supply)Borewell

S.no

Purpose Quantity in KLD

Existing Proposed Total 1. Process / Scrubbing --- --- ---2. Washings --- --- ---3. Boiler Feed --- --- ---

4 Cooling 176 KLD 50 KLD 225 KLD5 Gardening / Irrigation. --- --- ---6 Others (to be specified) --- --- ---7 Domestic 280 KLD --- 280 KLD

II. Status of Functioning of Water Meters Provided

10 Waste Water Generation:

S.No Effluents Quantity in KLD

Existing Proposed Total

1. Process --- --- ---

2 Washings --- --- ---

3 Boiler Feed --- --- ---

4 Cooling 10 KLD 3 KLD 13.0 KLD

5 Domestic 225 KLD --- 225 KLD

11 Out let – as per CFE order dt.26-10-2007

Outlet No. Outlet Description Max Daily Discharge Point of Disposal1 Cooling 13 KLD Re-used2 Domestic 215 KLD On land for

gardening after treatment in STP.

12. a) ETP Details & Mode of Disposal:

I. Outlet No. 1a. Stream Details:b. Treatment units details.c. Point of disposal

Cooling---Re-used

ii. Outlet No. 2 :a. Stream Details:b. Treatment units details.

c. Point of disposal

DomesticExisting STP – Bar screen, grit chamber, equalization, aeration, clarifier, Aerobic digestor & filteration

Proposed for on land for gardening

b) Standards as per CFO / CFE. Board Monitoring Data--- Not yet commissioned

13 Water Cess

I Returns filed upto (Month & Year) February 2008 for the existing plant

II Assessment issued upto (Month & Year)

31-10-2007

III Assessment paid upto (Month & Year) ---

IV Assessment amount due (In Rs.) ---

14 Air pollution:

S.No. Source of Pollution( Boiler / Furnace / Kiln / Cupola /

Incinerator / Process emissions with Characteristics / Fugitive emissions

with Characteristics / DG set )Note:

Capacity should be mentioned for each unit

Control equipment provided

Flow rate in m3/hr.

Stack height in

Mts - above GL

Existing 1 Attached to lime stone crusher bag house Bag house --- ---2 Attached to coal mill – I & II house Bag filter --- 40mts3 Attached to Kiln-I and Raw mill ESP ESP 334980 74mts4 Attached to Kiln-II and Raw mill Bag house Bag house 322500 74 mts5 Attached to vertical Roller mill bag house Bag house --- 30mts6 Attached to Cooler – I ESP ESP 220000 30mts7 Attached to Cement Mill – I ESP ESP 70000 36mts8 Attached to packing plant bag house Bag filter --- 32mts9 Attached to Coal mill – II Bag house Bag filter --- 40mts10 Attached to cooler – II ESP ESP 220000 30mts11 Attached to 2 x 1250 KVA D.G set --- --- ---

Proposed1 Raw mill – III Bag house 1,00,000 34mts

15. Emissions from chimneys – as per CFE order dt. 26-10-2007 for expansion

Chimney No.

Description of Chimney

*Quantity of Emissions

at peak flowm3/hr.

Limiting Standard

Board Monitoring Data

1 Raw mill – III 1,00,000 50mg/Nm3 ---

16 Compliance of the industry on CFE (Schedule- A & B) Conditions for Fresh

CFO / Schedule – B conditions for renewal.

CFE Order No. APPCB/KNL/KN/184/CFE/HO/2007-1699, dt: 26-10-2007

Compliance on Schedule – A conditionsS.

No.Condition Compliance

1 Progress on implementation of the project shall be reported to the Regional Office, Kurnool, A.P Pollution control Board one in six months

: ---

2 Separate energy meters shall be provided for Effluent Treatment Plant (ETP) and Air pollution Control equipments to record energy consumed.

: Not Complied

3 The proponent shall obtain Consents for operation from APPCB, as required under Sec. 25/26 of the Water (P&CP) Act, 1974 and under sec. 21/22 of the Air (P&C of P) Act, 1981, before commencement of the activity

: Complied

4 Not withstanding anything contained in this conditional letter or consent, the Board hereby reserves its right and power Under Sec.27(2) of Water (Prevention and Control of Pollution) Act, 1974 and under

: ---

sec. 21(4) of Air (P & C of P) Act, 1981 to review any or all the conditions imposed herein and to make such alternation as deemed fit and stipulate any additional conditions by the Board.

5 The consent of the Board shall be exhibited in the factory premises at a conspicuous place for the information of the inspecting officers of different departments

: Complied

6 Compensation is to be paid for any environmental damage caused by it, as fixed by the Collector and District Magistrate as civil liability.

: ---

7 Floor washing shall be admitted into the effluent collection system only ad shall not be allowed to find their way in storm drains or open areas. The industry shall maintain a good housekeeping.

: ---

8 Rain Water Harvesting structure(s) shall be established on the plant site. The proponent shall esure that effluent shall not enter the Rain Water harvesting structure.

: Complied

9 The rules and regulations notified by ministry of Law and Justice, GOI, regarding the Public liability insurance Act, 1991 shall be followed

: ---

10 This order is valid for period of 5 years from the date of issue

: ---

Compliance on Schedule – B conditionsS.

No.Condition Compliance

1 The source of water is bore-wells and mine pits and the maximum permitted water consumption after expansion is 506.0 KLD.

: ---

2 Air Pollution control equipment shall be installed along with the commissioning of the activity. All the units of the ETP shall be impervious to prevent ground water pollution

: Complied

3 The effluents shall be treated to the on land for irrigation standards, stipulated under Environment (Protection) Rules, 1986, notified and published by Ministry of Environment and Forests, Government of India as specified in schedule VI vide G.S.r.422(E), dt.19.05.1993 and its amendments thereof, and additional standards / conditions stipulated by APPCB.

: Complied

4 The maximum waste water generation after expansion shall not exceed the following

: Industry not yet commissioned

5 Separate meters with necessary pipe-line shall be provided for assessing the quantity of water

: Not complied

Sl.No.

Description Qty Mode of final disposal

1 Cooling 13 Reused2 Domestic 215 Onland for

gardening after treatment in STP

Total 228

used for each of the purposes mentioned below:a) Spraying in mine pitsb) Domestic purposes

6Air:The existing control equipment shall be upgraded to control air pollution even after expansion to meet the standards prescribed by he Board.

: Industry not yet commissioned

7 The proponent shall comply with the following for controlling air pollution

Details of fugitive emissions :

: Complied

Water sprinklers not provided

8 SPM Concentration in emission from the Kiln including grinding units shall not exceed 50mg/Nm3. SPM concentration from all the sections shall not exceed 250 mg/Nm3.

: Not yet commissioned

9 A sampling port with removable dummy of not less than 15 cm diameter shall be provided in the stack at a distance of 8 times the diameter of the stack from the nearest constraint such as bends etc. A platform with suitable ladder shall be provided below 1 meter of sampling port to accommodate three persons with instruments. A 15 AMP 250V point shall be provided on the platform.

: ---

10 The proponent shall provide interlocking system for air pollution control equipments provided with raw material feeding system so that the feeding of raw material would be stopped incase the air pollution control equipments fail.

: ---

11 The generator shall be installed in a closed area with a silencer and suitable noise absorption systems The ambient noise level shall not exceed 75dB(A) during day time and 70dB(A) during night time.

: Complied

Source Control EquipmentRaw mill – III Bag filters followed by 34m

stack

Source Control EquipmentCoal yard, lime stone stock pile, transfer points, vehicular movement

Bag filters shall be provided at transfer points, cement road laid down in the premises.

Material handling Dust suppression by water sprinklers

12Solid Waste:The proponent shall comply with the following:

: ---

13 Provisions shall be made in the kiln to burn high calorific hazardous waste

Complied

14 The following rules and regulations notified by the MoE&F, GOI shall be implementeda) Hazardous Waste (Management &

Handling) Rules, 1989b) Manufacture, storage and import of

hazardous chemicals Rules, 1989.

: ----

15Other conditions:Green belt shall be maintained along the boundary of the industry and in all vacant places.

: Partially complied

16 The recommendations / commitments made during the Public Hearing held on 06-05-2007 at Talaricheruvu(V), Tadipatri(M), Anantapur Dist. shall explicitly be followed from pollution control point of view.

: ---

17 The proponent shall obtain Environmental Clearance from MoE&F, GOI as per EIA Notification, 2006.

: Complied

17 Compliance of the industry on EC Special conditions : N.A

S. No.

Condition Compliance

1 The stack emissions from various sources shall not exceed 50mg/Nm3.

: Partly complied

2 Bag house / filters shall be provided to control the fugitive emissions during loading and unloading. The project authorities shall store all the raw materials except limestone in the covered sheds to control fugitive emissions

: Complied

3 The locations of ambient air quality monitoring stations shall be set up as per statutory requirements in consultation

: complied

Sl.No.

Solid waste generated from

Quantity Method of disposal

1 D.G sets mill gears & gear boxes

7 TPA Oil & oil sludge is fired in the kiln and waste grease used for conveyor wheel and chains

2 STP 5 TPM Used as manure

3 Dust collected in air pollution control equipments

2 TPA Recycled in the process

with the A.P.Pollution Control Board (APPCB) and additional stations shall be installed, if required, in the down wind direction as well as where maximum ground level concentrations are anticipated

4 Total ground water requirement shall not exceed 505 m3/day and prior ‘Permission’ for the drawl o ground water shall be obtained from the SGWB/ CGWA and copy of the permission shall be submitted to Ministry’s Regional Office at Bangalore within 3 months from the date of receipt of this letter. The project authorities shal install sewage treatment plant for minimum 225 m3/day capacity to treat domestic sewage and treated sewage shall be utilized for the green development. No waste water shall be discharged outside the premises and ‘zero’ discharge shall be ensured.

: Complied

5 The project authorities shall make all out effort to use high calorific value hazardous waste in the kiln and accordingly, necessary provision in the kiln shall be made.

: Complied

6 The project authority shall transport the raw material and the product in covered means

: Complied

7 Out of total 40.40 Ha, 14.14 Ha shall be developed as greenbelt as per the guidelines of Central Pollution Control Board to mitigate the effect of fugitive emission

: Complied

8 The project authorities shall provide a health centre with all emergency medicines and ambulance along with full time doctor. Occupational health surveillance of the workers shall be carried out on regular basis and records shall be maintained as per the Factories Act.

: Complied

9 The project authorities shall obtain all other necessary statutory clearances from the concerned departments including ‘No Objection Certificate’ from the A.P.Pollution Control Board (APPCB) prior to commencement of construction

: Complied

10 All the recommendations mentioned in the CREP guideline shall be followed and complied

: ---

11 Measure shall be taken to prevent impact of particulate emission / fugitive emission, if any, from the proposed plant on the surrounding reserve forests viz., Dobbudaballe & Dhodiyam which is located within 10 Km radius of the project. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department shall be prepared and implemented.

: ---

B.

1.

General ConditionsThe project authorities shall strictly adhere to the stipulations of the SPCB / state Government or any other Statutory body

: ---

2. No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. In case of deviations or alterations in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any.

: Complied

3 The gaseous emissions (SO2, NOx) and particulate matter levels from various process units shall conform to the standards prescribed by the concerned authorities from time to time. At no time, the emissions shall exceed the prescribed limits. In the event of failure of any pollution control system adopted by the unit, the unit shall be immediately put out of operation and shall not be restarted until the desired efficiency has been achieved.

: ---

4 The company shall undertake following Waste Minimization measures

Reuse of by-products from the process as raw materials or as raw material substitutes in other processes.

Use of “Closed pneumatic” system for transport of fine material

All venting systems shall be connected with dust arresting equipments

Dust collect in pollution control equipments shall be reused.

: Complied

5 Fugitive emissions in the work zone environment, product, and raw materials storage area shall be regularly monitored. The emissions shall conform to the limits imposed by the State Pollution control Boards / Central Pollution Control Board.

: ---

6 The overall noise levels in and around the plant area shall be kept well within the standards by providing noise control measures including acoustic hoods silencers, enclosures etc. on all sources of noise generation. The ambient noise levels shall conform to the standards prescribed under Environment (Protection Act, 1986 Rules, 1989 viz., dBA (day time) and 70 dBA (night time)

: Complied

7 The project authorities shall strictly comply with the rules and guidelines under manufacture, storage and import of hazardous chemicals rules, 1989 as

: Complied

amended and hazardous waste (Management and Handling) Rules, 1989 as amended from time to time. Authorization from the SPCB shall be obtained for collection, treatment, storage, and disposal of hazardous wastes.

8 Rainwater harvesting shall be done within the premises Ground water recharge structures shall be installed around the plant area in consultation with local authorities to contain the ground water table

: Complied

9 The company shall undertake eco-developmental measures including community welfare measures in the project area for the overall improvement of the environment. The eco-development plan should be submitted to the SPCB within three months of receipt of this letter for approval.

: Complied

10 As proposed, the project authorities shall earmark Rs.30.00 Lakhs to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State Government along with the implementation schedule for all the conditions stipulated herein. The funds so provided shall not be diverted for any other purpose. The cost of environmental protection measures for expansion wil be Rs.30 Lakhs.

: Complied

11 A separate Environmental Management Cell equipped with full fledged laboratory facilities shall be set up to carry out the Environmental Management and Monitoring functions

: Complied

12 The implementation of the project vis-à-vis environmental action plans shall be monitored by he concerned Regional Office of the Ministry / SPCB / CPCB. A six monthly compliance status report shall be submitted to monitoring agencies and shall be posted on the website of the company.

: Complied

13 The project proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the SPCB and may also be seen at Website of the Ministry at http://envfor.nic.in. This shall be advertised within seven days from the date of issue of the clearance letter, at lest in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the concerned Regional Office of the Ministry

: Complied

14 The project authorities shall inform the Regional Office as well as the Ministry the date of financial closure and final approval of the project by the concerned

: ---

authorities and the date of start of the project.

18 Compliance of the industry on Task Force Directions : N.A

S. No.

Condition Compliance

--- ---

19 Compliance of the industry on CREP Recommendations. N.A

S.No.

CREP Recommendations Compliance

1 Cement plants who are not complying the notified standard shall do the following to meet the standards; Augmentation of existing APCD – by July 2003 Replacement of existing APCD – by March, 2004

: N.A

2 Cement Plants located in critically polluted or urban areas (Including 7 Km distance outside urban boundary) will meet 50mg/ Nm3 limit of particulate matter by December 2004.

: Industry designed APCE for 50mg proposed

3 For new cement plants and expansion cases, the limit of particulate matter emission will be 50mg/Nm3

: Industry designed APCE for 50mg proposed

4 CPCB will evolve load-based standards .

: ---

5 CPCB and NCBM will evolve SO2 and NO2 emission standards.

: ---

6 Cement Industries will control fugitive emissions.

: Partly complied

7 CPCB, NCBM, BIS and Oil refineries will jointly prepare the policy on use of petroleum coke as fuel in cement kiln by July, 2003

: ---

8 After performance evaluation of various types of continues monitoring equipment, Industries will install the continuous monitoring equipment by December 2003.

: Not complied

9 Tripping in Kiln ESP to be minimized by July, 2003.

: ---

10 Industries will submit the target date to enhance the utilization of waste material by April 2003.

: ---

11 NCBM will carryout a study on hazardous waste utilization in cement Kiln by December 2003.

: ----

12 Cement Industries will reduce CO2 emission to 0.75 t/t of cement production by July, 2004

: ---

13 Cement Industries will carryout feasibility study and submit target dates to CPCB for co-generation of power by July, 2006.

: ---

20 Hazardous chemicals used and their storage facilities:Existing facility is having CFO

21. HWA Details:i) Particulars of Authorisation obtained under

HW(M&H) Rules, 2003 (No. & Validity date) N.A

ii) Authorization issued for(Transportation, reception, storage, treatment and disposal)

*remarks shall be furnished if the industry is receiving Haz.Waste at the site and using as a raw material.

N.A

iii) Process in which the industry is covered (Please give Sl. No of process as per HW Rules)

---

iv) Description of Hazardous waste with quantities and Stream No. as per HWM Rules, 2003

---

v) Particulars of on-site Secured Storage (Capacity with dimensions) and mention period for which secured storage is sufficient.

---

vi) Quantity of Haz Waste stored on-site presently.

*Furnish specific remarks on the storage of Haz.waste for more than 90 days.

Nil

vii) Quantity of Hazardous waste disposed for last six months as per the following break-up:

Common TSDF –Common HW Incinerator – For recycle / reused -

N.A

viii) Whether industry has submitted annual returns, date of latest submission.

N.A

ix) Whether industry has installed incinerator or sending to common HW Incinerator

Not submitted

x) Particular of own incinerator (if applicable) ---xi) Whether log books are maintained for

incinerator. (if applicable)---

xii) Whether industry has taken adequate steps to prevent contaminated runoff from storage areas of Hazardous Waste.

---

xiii) Steps taken by industry towards waste minimization and cleaner production.

---

xiv) Future plan for waste minimization. ---xv) Facilities available with, industry for waste

characterization.---

xvi) Overall House Keeping within the factory premises.

---

xviii) Details of disposal of lead acid batteries along with nos and agencies to whom they are disposed

---

22 Compliance of the industry on previous Hazardous Waste Authorisation conditions. : N.A

23 Inspection Officer’s Remarks:

M/s Penna Cement Industries Ltd, has applied CFO for expanded capacity of 2.2million TPA by increasing the capacity from 1.5million TPA to 2.2million TPA through optimization and upgradation of existing unit by installing one more raw mill –III with project cost of Rs.22.0 Crores for which the industry has obtained CFE vide order dated: 26-10-2007 and also obtained E.C vide order dated: 13-03-2008 (copy enclosed). The industry has installed bag filters as a control equipment followed by stack of height 34mts.

I Maintenance of ETP / APC : Industry has not proposed any new STP for treatment of sewage. The air pollution control equipment are in the erection stage.

II Records Maintained

ETP Log Book.: ---

Stack Monitoring Report.: Stack monitoring of the existing plant (Phase-I) is herewith enclosed.

Ambient Air Quality Monitoring report.: AAQ monitoring of the existing plant (Phase-I) is herewith enclosed.

Energy consumption records.: ---

Water meter readings.: ---

(Signature of the Inspecting Officer)

24 Regional Officer’s Remarks:

I Compliance of the industry with reference to Notifications under E(P) Act & Rules.

a) Fly Ash Notification.

b) PLI Act Policy.

c) Environmental Statement in Form – V.

d) Other if any.

---

II Complaint / Legal action taken against the industry.

---

III. Mitigation Measures (Where significant adverse effects are identified, description of the measures to be taken to avoid, reduce or remedy those effects).

---

25 Remarks: He may remark on case history of illegal dumping of hazardous waste :

M/s Ultra tech cement Ltd has been issued CFE for expansion from existing clinker -

2.0 MTPA to 5.0 MTPA, blended cement – 2.7MTPA to 7.6 MTPA and CPP from

4MW to 54MW. The industry has been issued directions by the CPCB as the SPM

levels for the existing plant for phase-I are exceeding the limits. After that the

industry had rectified the defects to the RABH provided to the kiln. The latest

monitoring report of the existing plant are herewith enclosed. The industry is at the

verge of the completion of the construction activity and it is informed that it may take

trial runs within one month. The industry was instructed to inform this office as

soon as industry takes trial production of Phase-II.

26 Recommendation (Specific comment whether to issue consent or not).

The issue of CFO to the unit may be considered upto 30-09-2008

duly stipulating necessary conditions.

This is submitted for favour of kind information and taking necessary action.

Yours faithfully,

ENVIRONMENTAL ENGINEER

- Copy submitted to the JCEE (Cess & Planning) APPCB, Board Office, Hyderabad for favour of kind information and for taking necessary action.

- Copy submitted to the GIS Section, APPCB, Board Office, Hyderabad for favour of kind information and for taking necessary action.