ultra tech - plant - expansion - 08 - phase-ii

22
ANDHRA PRADESH POLLUTION CONTROL BOARD Regional Office, 1 st Floor, Shankar Shopping Complex,Krishna Nagar Main – 518 002 K. RAVI KUMAR ., Phone No. 08518 - 235800. Environmental Engineer. Fax No. 08518 – 233619 E- mail: [email protected] Lr. No. 33-R-1027/PCB/RO/KNL/CFO & HWA/2007 Date: - 03-2008 To The Joint Chief Environmental Engineer A.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 Ultra Tech Cement Ltd, A.P.Cement Works, Bhogasamuram(V), Tadipatri(M), Anantapur District Verification report – Regarding. Ref : 1) CFE Order No. APPCB/KNL/KNL/184/CFE/HO/2006-1087, dt: 07- 09-2006 2) CFE order No. APPCB/KNL/KNL/184/CFE/HO/2006-2579, dt: 21- 03-2007 (amendment order) 3) Lr.No.12-2-6-0385-0197-ID, dated: 23-01-2008, received through Commissioner of Industries, Hyderabad on 01-02- 2008 4) Clarification sought on 8-02-2008 5) Industry letter dated: 13-03-2008 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 Ultra Tech Cement Ltd, (Formerly known as M/s Larsen & Toubro Ltd) (Waste Heat Recovery), A.P. Cement Works, Bogasamudram (V), Tadipatri(M), Anantapur Dist. 08558- 288847 [email protected] 2 Status of Consent and HWA.

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Page 1: Ultra Tech - Plant - Expansion - 08 - Phase-II

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: [email protected]

Lr. No. 33-R-1027/PCB/RO/KNL/CFO & HWA/2007 Date: -03-2008

To

The 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 Ultra Tech Cement Ltd, A.P.Cement Works, Bhogasamuram(V), Tadipatri(M), Anantapur District – Verification report – Regarding.

Ref: 1) CFE Order No. APPCB/KNL/KNL/184/CFE/HO/2006-1087, dt: 07-09-20062) CFE order No. APPCB/KNL/KNL/184/CFE/HO/2006-2579, dt: 21-03-2007

(amendment order)3) Lr.No.12-2-6-0385-0197-ID, dated: 23-01-2008, received through

Commissioner of Industries, Hyderabad on 01-02-20084) Clarification sought on 8-02-20085) Industry letter dated: 13-03-2008

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 Ultra Tech Cement Ltd, (Formerly known as M/s Larsen & Toubro Ltd) (Waste Heat Recovery), A.P. Cement Works, Bogasamudram (V), Tadipatri(M), Anantapur Dist.

08558- 288847

[email protected]

2 Status of Consent and HWA.

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

Fresh

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

01-02-2008 & 13-03-2008

III Details of Consent Fee paid.

(Period upto)

1,87,500/- vide D.D. NO.257045, dt:28-12-07 1,87,500/- vide D.D. NO.257046, dt:28-12-07

The industry has Paid consent fee for the period of 9monthsfrom Jan.2008 to sept. 2008 i.e., upto 30-09-2008 for an investment of Rs.1268.93 crores.

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

Rs.1268.93 crores.

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

Rs. 100 Crores

Latitude &Longitude

E 78000’59” & E 78002’58”N 15001’29” & N 15003’29”

Page 2: Ultra Tech - Plant - Expansion - 08 - Phase-II

Total Area of the plant: 207.9 Ha. (existing Phase-I)

Extent of Greenbelt 67.5 Ha.

Surroundings of the Industry East : Township followed by vacant land West : Agricultural land North : Agricultural landSouth : Vacant land followed by Bogasamudram village

4. Date of commissioning. Yet to commission

5 Status of E.C

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

and date

(Copy shall be enclosed).

Lr.No.3-11011/324/2006-IA II(I) dated: 05-03-2007

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

6 I Inspection conducted by A.E.E-II & Analyst Gr-II

II Representative of Industry present Sri K.V.Reddy, DGM

III Date of Inspection 07-02-2008

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 ActivityTonnes Per Annum for each

product

1 Lime stone 60,00,000

2 Al. laterite 128438

3 Iron ore 64,220

4 Gypsum 9600

5 Fly ash 28880

6 Slag 3,12,170

7 Coal for Cement plant 3,22,170

8 Coal for Power plant 4,43,478

8 Products & By Products manufactured / Storage capacity of Petroleum products / Mining capacity etc per Day / Month. As per CFE order dt: 21-03-2007

S.No Products / Line of Activity Consent capacity (Phase-I MTPA

Consent capacity (Phase-II

MTPA

Total capacity

MTPA

Applied

(as per the

application)

1 Clinker 2.0 3.4 5.4 3.4 MTPA

2 Cement (blended) (OPC + PPC + PSC)

2.7 4.9 7.6 4.9 MTPA

3 Electricity 4MW (Waste heat recovery system is under construction) 2 x 12.27 MW D.G sets (standby)

2x25MW (coal based captive power plant with sulphur content 0.6%)

54.0 MW 4140 Lak. K.W

Page 3: Ultra Tech - Plant - Expansion - 08 - Phase-II

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 480 980 14602. Washings 5 50 553. Boiler Feed --- --- ---4 Industrial Cooling (Makeup) /

Humidification / Water spraying).380 500 880

5 Gardening / Irrigation. --- --- ---6 Others (to be specified) --- --- ---7 Domestic 350 250 600

Total: 1230 1780 2995 KLD

II. Status of Functioning of Water Meters Provided

10 Waste Water Generation:

S.No Effluents Quantity in KLD

Existing Proposed Total

1. Process & Washings

(specify stream wise i.e., LTDS, HTDS, High COD etc.--- brake up shall be given)

--- --- ---

2 Boiler Blow Down - ---- --- ---

3 Captive power plant --- 98 98

4 Vehicle washing 5 -- 5

5 Domestic 300 167 345

Total: 305 265 440

11 Out let – as per CFE order dt.07-09-2006 and amendment on 21-03-2007

Outlet No. Outlet Description Max Daily Discharge Point of Disposal1 Captive power plant 90 Sprinkling on roads

, dust suppression, greenbelt

development2 Vehicle wasing 5 On land for

gardening3 Domestic 345 On land for

gardening.

12. a) ETP Details & Mode of Disposal:

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

Captive power plantProposed - Neutralization and settling tankProposed to sprinkling water on roads for dust suppression.

ii. Outlet No. 2 :a. Stream Details:b. Treatment units details.c. Point of disposal

Vehicle washingsOil & grease separation tank, settling tankProposed for on land for gardening

iii. For Domestic waste water:

Mode of disposal

Screen chamber, Grit chamber, aeration tank / secondary clarifier & sludge drying bedsOn land for gardening

Page 4: Ultra Tech - Plant - Expansion - 08 - Phase-II

b) Standards as per CFO / CFE.

Board Monitoring Data

--- ---

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) Paid

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 Kiln - 6900 TPD RABH 1191,372 141.5mts2 D.G set – 12MW x 2 Nos. Silencers --- 68mts

Proposed4 Kiln - 12550 TPD Bag filters 13,75,000 141.5mts5 CPP – 2 X 25 MW ESP 2,41,920 110mts.

15. Emissions from chimneys – as per CFE order dt. 07-09-2006 for Phase-II cement plant

Chimney No.

Description of Chimney

*Quantity of Emissions

at peak flowm3/hr.

Limiting Standard

Board Monitoring Data

1 Kiln / raw mill 1375000 50 The control equipment are under erecting

stage

2 Cooler 1125000 1003 Coal 320000 504 Cement mill – III 600000 505 Cement mill - IV 506 Limestone crusher 95700 1007 Packer – I

30340100

8 Packer – II 1009 Packer – III 10010 Packer – IV 10011 Packer – V 10012 Packer – VI

As per this application the industry has shown on more cement mill – pipe.*The flow rates were not mentioned in the CFE order. The data submitted as per the application.

Page 5: Ultra Tech - Plant - Expansion - 08 - Phase-II

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/2006-1087, dt: 07-09-2006

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.

: ETP - Complied APCE – 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

: ---

Page 6: Ultra Tech - Plant - Expansion - 08 - Phase-II

Compliance on Schedule – B conditionsS.

No.Condition Compliance

1 The source of water is Penna river bed, bore-wells and seepage water from min and the maximum permitted water consumption after expansion is 296o KLD.

: Industry not yet commissioned

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

: ---

3 The effluents shal 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.

: ---

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 used for each of the purposes mentioned below:

a) Spraying in mine pitsb) Domestic purposes

: Not complied

Purpose Total (KLD)A Captive power

plant90

B Vehicle washing 5C Domestic 345

Source of

Effluent

Existing Treatment

Mode of final disposal

Domestic STP consists of screen chamber, Grit chamber, aeration tank / secondary clarifier & sludge drying beds

On land for gardening

Vehicle Oil & grease separation tank, settling tank

Onland for gardening

Captive power plant

ETP (Neutralisation and settling tank)

Sprinkling on roads, dust suppression, greenbelt development

Page 7: Ultra Tech - Plant - Expansion - 08 - Phase-II

6Air:The proponent shall comply with the following for controlling air pollution

Existing:

Proposed:

Source of emissions – proposed Phase-II cement plant

The proponent should provide dust control equipment to control fugitive emissions as mentioned at page No. C2-23 of EIA.

: Industry not yet commissioned

Sl.No.

Details of stack Stack 1 Stack 2

a Attached to Kiln D.G setb Capacity 6900 TPD 12MW x

2 Nos.c Fuel quantity Coal –

1150 TPDHF/LFO – 2700 LPH

d Stack height 141.5 68me Diameter / size

in m5.1m 2m

f Control equipment

RABH Silencers provided

Sl.No.

Details of stack Stack 1 Stack 2

a Attached to Kiln CPPb Capacity 12,550

TPD2 x 23MW

c Fuel quantity Coal – 2669 TPD

Coal – 1200TPD

d Stack height 141.5 110me Diameter / size

in m5.1m 5.1m

f Control equipment

Bag filters ESP

Sl.No.

Stack attached

to

Stack height

(m)

Control equipment

Emissions rate-SPM (mg/Nm3))

A Kiln / rawmill

141.5 Bag house

50

b Cooler 50.0 ESP 100

c Coal mill 75.0 Bag filters 50d Cement

Mill-III60.0 Bag

house

50

e Cement Mill-IV

60.0 50

f Lime stone crusher

30.0 Bag filter 100

g Packer-I 32.0 Bag filter 100h Packer-II 32.0 Bag filter 100i Packer-III 32.0 Bag filter 100j Packer-IV 32.0 Bag filter 100k Packer-V 32.0 Bag filter 100l Packer-IVI 32.0 Bag filter 100

Page 8: Ultra Tech - Plant - Expansion - 08 - Phase-II

7 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.

: ---

8 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.

: ---

9 The generator shall be installed in a closed area with a silence4r and suitable noise absorption systems The ambient noise level shall not exceed 75dB(A) during day time and 70dB(A) during night time.

: Complied

10Solid Waste:The proponent shall comply with the following:

: ---

11 The fly ash from the power plant shall be fully utilized in the cement plant and bottom ash which will be generated shall be used for forming haulage roads at the existing and proposed mining area as committed vide lr.dt. 12.8.2006. The proposal shall be submitted while applying for CFO.

---

12 The Hazardous waste (Management and Handling), Rules, 1989 and regulations notified by the MOE&F, GOI shall be implemented.

---

Sl.No.

Waste Esisting phase-I

Proposed Phase-II

Mode of disposal

1 Tank bottom sludge

42.5 Kl/year

35.5 Kl/year

For internal use for lubrication of scraper chains

b Waste oil

25.6 kl/yr. 45.0 Kl/year

PCB approved

c Used Grease

11700 Kg/yr

12500 Kg/yr.

50

d Lead acid batteries

228 Nos/yr

300Nos/yr To authorized parties

e STP sludge 10 MT/yr.

10MT/year 10MT/yr As manure for plantation

f Ball Mill 20 TPA 20 TPA To authorized parties

g Gears (grease)

12 TPA 12.5 TPA To authorized parties

Page 9: Ultra Tech - Plant - Expansion - 08 - Phase-II

Other conditions13 The proponent shall develop greenbelt in an

area of 60.2 Ha. Green belt of width 10m shall be developed along the boundary of the industry. Green belt development shall be started along with the constructions activity.

: New plantation taken up in an area of 10.0 acres

14 The community facilities, such as parks shall not be affected by the proposed new building as committed in lr.dt.12.8.2006

: Complied

15 The sources and consumption of water needed to be reviewed, in particular with regard to recycling of water. It was noted that water was proposed to be recycled for suppression of dust and horticulture. The demand for both these items may suddenly drop during the wet weather. However, the demand for process water would remain unchanged. Therefore, the proponent shall submit a comprehensive water balance while applying CFO, keeping in view that drawal of water from the river and borewells should be minimized and utilization of mine water and recycled water should be maximized.

: Not complied

16 The propone tshall harvest rain water from the roof of the cement plant (As also the captive power plant). A comprehensive proposal on rain water harvesting should submitted whie applying for CFO.

: No new proposals for RWH submitted

17 The project proponent shall install continuous monitoring instruments to monitor important parameters such as particulate matter as assured in lr.dt. 12.8.2006.

: Not complied

18 The recommendations / commitments made during the Public Hearing held on 6.7.2006 at Gram Panchayath office, Bhogasamudram (V), Tadipatri(M), Anantapur District shall explicity be followed from pollution control point of view.

: ---

19 The proponent shall not undertake any activity without obtaining Environmental Clearance from MOE&F, Govt. of India as per MOE&F, Govt. of India Notification No.S.O.60(E) dt.27.01.94 and the amendments issued thereof.

: ---

20 The proponent shall obtain clearance from Central Ground Water Authority to draw ground water.

: Complied

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

S. No.

Condition Compliance

1 The gaseous emissions from various units shall conform the standards prescribed by the A.P.State Pollution Control Board (APPCB) or by the

: Industry not yet commissioned

Page 10: Ultra Tech - Plant - Expansion - 08 - Phase-II

Ministry, whichever is stringent . Reverse Air Bag House will be installed with the Kiln and Raw Mill to limit particulate emission to 50 mg/Nm3. The emissions levels from the cooler and CPP stack will be below 100mg/Nm3. the CPP will be based on CFBC technology.

2 The height of the stack for kiln and raw mill be 141.5 and for CPP, it will be 110m. Bag house will be installed at all other emission points except the cooler exhaust. Bag filters will be provided at all material handling and transfer locations. Low NOx burner shall be installed to control NOx

emissions and lime injection shall be carried out to reduce SO2 emissions, if required.

:

Stack of height prescribed providedControl equipment not yet installed in total

3 Continuous on-line monitors for particulate emissions, SO2 and NOx in Raw Mill / Kin, clinker cooler, coal mill, cement mill etc. shall be provided and shall make necessary arrangements for submission of on-line real time emission data to CPCB website. Interlocking facility shall be provided between pollution control equipment and the process operation so that in the event of the pollution control equipment not working, the respective unit(s) is shut down automatically

:

Control equipment not yet installed in total

4 Acoustic enclosures will be provided at all high noise equipment and place to limit the noise levels is below 85 dBA.

:---

5 Regular monitoring of ground water level and quality shall be carried out by establishing a net work of existing wells and constructing new piezometers during the mining operation. The monitoring shall be carried out four times in a year – pre-monsoon (April-May), monsoon (August), post-monsoon (November) and winter (January) and the data thus collected may be sent regularly to MOEF, Central Ground Water Authority and Regional Director Central Ground Water Board.

:

---

6 Raw material will be stored in covered yards and clinker in Silos to control fugitive emissions. Fugitive emissions from cement mill, packing area and coal yard shall also be controlled.

:

Complied

7 Vacuum dust cleaning system will be provided to evacuate dust on floors. All roads will be swept with sweeping machines. Material will be transported in tippers, covered trucks, covered containers, covered rail wagons etc. dust collectors and e4xtraction system (suction apparatus) shall be installed to control fugitive emissions at coal and lime stone unloading points, at all the transfer points, stockpiles to arrest free

: Complied

Page 11: Ultra Tech - Plant - Expansion - 08 - Phase-II

release of dust.

8 Windbreakers will be installed to restrict fugitive dust.

:Not complied

9 Water sprinkling arrangement should be made in the raw material stock yard. Regular water sprinkling shall be carried out at all areas where fugitive dust can be generated.

:

Complied

10 For cooling towers of CPP will have Air Cooled Condensers.

:---

11 No wastewater will be generated in cement manufacture. The wastewater from CPP and domestic activities shall be treated in Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP) respectively and recycled / reused in cement plant for make-up, in CPP for cooling, dust suppression, other plant related activities and green belt development. O wastewater will be released outside the premises. ‘Zero’ discharge shall be strictly adopted. During monsoon, the waste water will be stored in the mine pit. Separate storm water drains will be provided and storm water from CPP area ill b e stored in settling tank before discharging into the nallah.

:

---

12 Solid waste generated shall be 100% recycled and reutilized in the process and no solid waste shall be disposed off outside the plant premises. 540 TPD of fly ash generated from CPP will be 100% utilized in Portland Pozzolana Cement production. Bottom ash shall be used for development of haul roads in mines area and bak filling in abandoned mines. Treated STP sludge shall be used as manure for green belt development Waste oil sludge shall be reused in the plant and finally burnt in the kiln or sold to authorized recyclers / re-procesors.

:

---

13 The company shall strictly follow all the recommendations mentioned in the charter on corporate responsibility for Environmental Protection (CREP)

:

---

14 As agreed, green belt shall be developed in 20 Ha area in addition to the existing 60.21 Ha.

:---

15 The company must harvest surface as well as rainwater from the rooftops of the building proposed in the expansion project and storm water drains to recharge the ground water ad use the same water for the various activities of the project to conserve fresh water

:

---

16 Studies on noise audiometry to assess the noise induced hearing loss in case of exosed employees will be carried out and appropriate ameliorative measures ill be taken, wherever necessary.

:

---

Page 12: Ultra Tech - Plant - Expansion - 08 - Phase-II

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

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

:Industry designed APCE for 50mg proposed

4CPCB will evolve load-based standards .

: ---

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

: ---

6Cement 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

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

: ---

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

: ---

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

: ----

12Cement 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: HFO - 2370 KL, LFO – 700KL,

Page 13: Ultra Tech - Plant - Expansion - 08 - Phase-II

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

i) Waste oil – 20 KL/yr .ii) Oil sludge – 35.5Kl/yr.iii) used lead acid batteries – 100 Nos/yr.iv) Waste grease – 7500 Kg/yr. v) HI – Chrome forge steel balls – 20 TPAvi) transformer oil – 5 Kl/yr.

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

---

Page 14: Ultra Tech - Plant - Expansion - 08 - Phase-II

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

23 Inspection Officer’s Remarks:

M/s Ultra Tech. has proposed Phase-II unit adjacent to the existing to the phase-I unit which is almost as a mirror image of the existing unit i.e., Phase-I. Industry has not yet commissioned the phase-II and is still under erection stage. During inspection it was informed that the industry may commission in the month of April 2008. The industry is in the process of erecting connecting lines of the control equipment to the clinker cooler section and at various other points. The proponent was erected to inform this office once the industry is ready for trial production.

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).

---

Page 15: Ultra Tech - Plant - Expansion - 08 - Phase-II

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.