Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
EXECUTIVE SUMMARY
1. Proposed Project: Maihar Cement is situated at Sarlanagar, Maihar, Distt. Satna in the State of Madhya Pradesh with licensed production capacity of 5 Million TPA (3 MTPA Clinker & 5 MTPA Cement). Maihar Cement at Sarlanagar Madhya Pradesh, currently operates 2 Units : Unit 1 consists of 2 Kiln lines each producing around 2350 TPD clinker and unit 2 has one kiln producing ~ 4500 TPD clinker whereas present Cement production is 5 Million TPA.
It is proposed to increase the clinker production capacity of the plant from 3.0 Million TPA to 4 Million TPA by upgrading Kiln No.1 & Kiln No.2. Slight modifications will also be carried out in Kiln No.3 to reach its maximum potential. The existing cement mills will be optimized and bottlenecks will be removed to obtained the desired increased production in cement production from 5 Million TPA to 6 million TPA.
Maihar Cement is proposing to upgrade the existing pyro processing lines in Unit 1 to enhance clinker productivity along with improved fuel and power efficiency to reduce variable cost of clinker production and also to capitalize on the projected improved cement demand. Both existing kiln lines in Unit-1 consist of dry kiln with 4 stage pre-heater. The project cost of existing project is 989.11 crores which will be increased by Rs. 80 Crore
1. Objective Of The Study: The Environmental Impact Assessment has been carried out to assess the existing base line environmental scenario of the area and probable impacts on various components of the proposed activities. Based on the activities of existing and proposed cement manufacturing unit, an environmental management plan has been suggested. The plan will identify and address the impacts and design mitigative measures to manage such impacts in a manner as to conserve environment and ecology of the area. The EMP has been prepared with a view to ultimately ensure that the adverse impacts can be minimized if these cannot be prevented altogether. The main objectives of the study are listed as below: • To anticipate & avoid, minimize or offset biophysical, social, and other relevant adverse effects of project • To ensure environmental consideration are explicitly addressed and incorporated in to the development decisions making process • To protect the productivity and capacity of natural system and ecological processes which maintain their functions. • To establish the present environmental scenario ES - 1
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• To anticipate the impacts of proposed operations on the environment. • To suggest preventive and mitigating measures to minimize adverse impacts and to maximize beneficial impacts. • To prepare a detailed action plan for implementation of mitigating measures. • To suggest a monitoring program to evaluate the effectiveness of mitigating measures. • To suggest the formation of a core group responsible for implementation of environmental control and protective measures and monitoring of such implementation. • To suggest a feedback mechanism enabling to make mid course corrections. • To prepare a capital cost estimate and annual recurring cost for Environmental Management Plan.
2. Environmental Setting: The environmental setting of the proposed plant is given in Table .
Table 1 S. No. Particulars Details 1 Location Sarla Nagar, Maihar Dist Satna (MP) Toposheet No. 63D/16 2 Latitude Longitude S. No. Latitude Longitude 1 24°11'29.17"N 80°47'52.45"E 2 24°11'33.30"N 80°47'56.52"E 3 24°11'45.66"N 80°48'7.99"E 4 24°12'8.54"N 80°48'29.34"E 5 24°12'22.10"N 80°48'12.57"E 6 24°12'23.14"N 80°48'13.24"E 7 24°12'23.96"N 80°48'12.43"E 8 24°12'25.27"N 80°48'11.50"E 9 24°12'26.80"N 80°48'8.43"E 10 24°12'29.62"N 80°48'2.61"E 11 24°12'15.29"N 80°47'48.24"E 12 24°12'3.52"N 80°47'25.47"E 13 24°11'59.63"N 80°47'22.32"E 14 24°11'57.67"N 80°47'22.85"E 15 24°11'53.62"N 80°47'26.91"E 16 24°11'51.31"N 80°47'24.51"E
1. General ground level 441-341m above MSL 2. Nearest National/ State Highway NH-7- 6km SH-11 - Adjacent 3. Nearest Railway Station Maihar – 6.50km - NW 4. Nearest Airport Khajuraho- 116km 5. Nearest Tourist Place Maihar – 6.50km 6. Archaeological Important Place None within 10km radius ES - 2
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
7. Ecological Sensitive Areas (Wild Life None within 10km radius Sanctuaries) 8. Reserved / Protected Forest within PF- Adjacent 10km radius PF – 6.50km – W PF- 7.50km - E 9. Nearest major city <50000 Maihar – 6.50km - NW population 10. Nearest Town / City within 10km Maihar – 6.50km - NW radius 11. Surrounding village within 1 km Delha – 1.0km - N area of the project. Sarla Nagar- Adjacent 12. Nearest village Delha – 1.0km - N Sarla Nagar- Adjacent 13. Nearest River within 10km radius Tons or Tamas River–0.50 km– WNW 14. Nearest Lake/ Ponds within 10km Seasonal nallah – 0.75km- N radius Ghusru N – 1.75km- NW Serainji Nalla – 6.15km- NEN Andhayari Nalla- 3.15km – SE Godin Nalla – 7.00km – ESE Lilji Nalla – 8.50km – NW Kanindari N - 6.25km- S Chakdahi Nalla – 8.50km - SWS 15. Nearest Hill Ranges within 10km Kaymore Hill radius 16. Other industries within 10km KJS Cement – 5.50km- N radius Reliance Cement – 9.00km – WSW 17. Mines within 10km radius Maihar Cement, Bhadanpur Limestone mine Sadera Limestone mine, Reliance Cement Amaliya & Girgita Limestone mine, KJS Cement, Maihar Cement, Tiloura Limestone Mines No. of other mines 18. Seismic Zone Zone – II as per IS: 1893 (Part-I) : 2002
3. Details About The Project Site Maihar Cement is situated at Sarlanagar (Maihar), Dist. Satna in the State of Madhya Pradesh. Maihar Cement Plant lies at Longitude: 24° 10’ N to 24° 15’ N and Latitude: 80° 45’ E to 80° 50’ E and is covered under Topo sheet No.63-D16 The area lies in the region of Kymore Hill range. The terrain of the area is partly hilly and partly plain. The elevation of the area above the mean sea level is 600 meter where as cement plant lies on 460 m contour. The main basin of the area is Mahanadi. The area is drained by the Tamus river, which flows along north eastern foot hill of Kymore range. Another Andhari nala which is a seasonal stream and gets dry in summer. Maihar is 45 Kms South - East of Satna on Howrah - Mumbai Central Railway Main Line. Distance from Satna to Maihar is approximately 45 km, south of Satna by metalled tar district road via Uchehara (part of the road is national ES - 3
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
highway no. 7 Maihar to Sarlanagar is 8 km south of Maihar by metalled tar road. Maihar Cement Plant is a working unit and expansion of Clinker capacity is within the existing cement plant complex. The entire land is in possession of Group and no additional land is required for the project. 4. Salient Features Of The Project Salient Features Of The Project Particular Existing Details Proposed Details Capacity 3 MTPA Clinker 4 MTPA Clinker 5 MTPA Cement 6 MTPA Cement Cost of Project 989.11 crores Increased by 80 Croes (Approx) Total area of project 477.36 acres Remain same Type of Fuel Coal and Pet Coke Remain same Source of Fuel Linkage and purchase Linkage and Purchase Water Requirement 3200 KLD Increased by 25 KLD Source of Raw water River Tamas and water River Tamas and water reservoir developed at reservoir develop ed at Mines Mines and Plant and Plant Pollution control Hybrid Filters, RABH, APCE shall be same with equipment ESP, Bag filter certain modification Level of particulate Matter 30 Mg/nm3 30 Mg/nm3 Cost of Pollution Control 82.75 Crore 10 Crore Equipments Recu rring Cost on 6.03 Crore Increased by 1 Crore Pollution Control measures (2016-17) Total Employment 340 Increased by 10-15 number generation Ash Generation 225 TPD Remain same Fly Ash Silo Capacity 8000 MT Remain same Green Belt area 149 acres Increased by 05 acres No of plants 10,78,000 numbers Increased by 5,000 numbers
• The principal raw materials required for the production of clinker are Limestone and Laterite. Limestone is being sourced from Captive four limestone mines of Maihar Cement which are located adjacent to the plant. Coal and Pet Coke are being used as fuel. • The proposed modifications will be carried out within the existing plant; no additional land is required . Existing infrastructure will be utilized for the
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
proposed modifications. • Total power requirement for simultaneous running of the complete plant is about 46 - 47 MW which is being sourced through MPSEB, as well as two Thermal Power Plant with a capacity of 15.7 MW each. • About 3200 KL/ day of water is required for cement plant complex inclusive of power plant section, which is being sourced from a perennial river "Tamus" (River Pump House -at a distance of about 2 Km from the plant) during the rainy season only ,whereas during non monsoon season, water is sourced from water reservoir having capacity of 20,40,000 KL developed at Mine leases. Marginal increase of 25 KL per day is envisaged during the proposed expansion. • Maihar Cement has also developed a reservoir in the Cement Plant having capacity of 5,75,000 KL and is capable of meeting about 100 days water requirements of the Cement Plant • There is no wild life sanctuary, national park, eco-sensitive area within the 10 km radius of the project site. • Existing infrastructure includes railway siding, roads, storm water drains, adequate storage space for clinker and flyash and parking area , which have been developed over the years. All social infrastructure facilities such as education, health and others have also been developed in the area. • Green belt has already been developed within the existing operational premises & mines with 10,78,000 number of trees. Total area (within plan and colony ) covered under plantation is about 149 acres with 8,23,000 number of trees. • Maihar Cement has well-defined CSR policy for carrying out social development and welfare measures in the surrounding villages. Under CSR activity Maihar Cement is executing community development projects, in the fields of health, education and environmental conservation.
5. Process Of Optimization For Increased Capacity • Mining of Limestone: Limestone is mined from existing mines. • Crushing: The two common existing limestone crushers of 1200 tph and 650 tph capacity are sufficient for the proposed up-gradation • Stacker & Reclaimer: The Existing raw material handling system for Unit 1 consists of one stacker of 650 tph and one reclaimer operating at 350 tph. Reclaimer will be upgraded to 450 tph. • Raw Mill: Existing Raw Mill system being used. • Continuous Blending Silo: Existing 3 nos. Raw Meal Silos each with a blending compartment of 3000 T and storage compartment of 5000 T common to both Kiln Lines. • Pre Heater, Kiln, Cooler: Maihar Cement unit-1, consists of 2 Dry process Kilns of 2350 TPD Clinker Production capacity. Both the existing Kiln Lines consist of 4 Stage suspension Pre-Heater. Maihar Cement Kiln No.3 Clinker
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Production capacity is around 4500 TPD Clinker. For up-gradation, the two Kilns of unit-1 will be upgraded to 3000 TPD each. • Preheater & Calciner: For the proposed up-gradation, the Existing Top Stage Twin Cyclone in the Pre-Heater Structure would be modified and replaced by single Cyclone of 7.2 dia. A new Top Stage Single Cyclone of 6.9 m dia is envisaged. A new Modified Inline Calciner (U-Shape) of 56 m Effective Length and 4.6 m effective dia is also envisaged. • For Both, the Calciner and 5th Stage Cyclone a new structure would be erected over Kiln Pier. • Kiln: For the up-gradation of each of the Kilns of unit-1 to 3000 TPD, both the existing kiln will be able to cater to upgraded capacity. • Cooler: The Up-gradation would require modification and extension of existing cooler and cooler hood. Cooler length is envisaged to increase from existing 50.79 m 2 to 60 m 2. • Coal Mill: Mixture of Coal and Pet coke in 50:50 ratio is used as fuel for the generation of heat and clinkerization. The coal mill section consists of a VRM with a capacity of 40 tph for coal grinding but currently grinding a 50-50 mixture of coal and petcoke at a rate of 27 tph with 2.5 % residue on 90 microns. This is sufficient for running the two kilns. • Along with coal mill VRM, one ball mills would also have to operate to meet the additional requirement if any of around 29 TPH fuel after up-gradation. • There is a fine coal bin of 100 m3 for main kiln firing and a 90 ton bin for secondary firing. The main firing FK pump has a capacity of 15 tph and the secondary firing is at a rate of 4 tph to the smoke chamber. A system for fuel firing to the Calciner will have to be included in the up-gradation project. • Coal Handling: No new Crusher is envisaged • Cement Mill: Maihar cement having five Cement Mills and existing cement mills are close circuit mills. Two mills are supplied by L&T, these are close circuited with Sepax separator and producing cement about 115 TPH supplied by L&T, where as third one supplied by Fuller KCP, Madras and producing about 140 TPH cement. Cement mill 1, 2, & 3 are run with PLC and equipped with HAG’s. All three mills are vented through ETS Elex. Hybrid filters with design outlet emission 25 mg/nm3. Cement mill 4 & 5 with a capacity of 165 TPH each. The Cement Mill system is provided with High Pressure Rolls (HRC) and Sepax separator to get the required fines. The existing circuit of the Cement mill gases vented to the atmosphere through Hybrid Filters with design outlet emission below 25 mg/nm 3. The cement so produced is being transported to 4 silos in Unit-1 having total capacity of 20,000 tonnes and three silos in Unit-2, the cement is stored in
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
three silos, having the capacity 10,000 M.T. each. The storage capacity of cement is 30,000 M.T. • Packing and despatch of cement : ‹ Maihar Cement has four Electronic Rotary Packers in Unit-1; two are having single discharge with a capacity of 100 TPH, where as other two is double discharge with capacity of 180 TPH. ‹ In Unit-2, alsohave four Electronic Rotary Packers; two are having single discharge with a capacity of 100 TPH, where as other two is double discharge with capacity of 180 TPH ‹ The cement stored in the silo is transported to the packer hopper through screw conveyor and elevators. Cement from the packer hopper is flushed through the spouts in each packer to self sealing 50 Kgs HDPE bags. The cement bags from the packer are transported through conveyor belt system and loaded in Railway Wagon / Trucks at different platform exclusively built for such task. It is ensured that HDPE bags do contains minimum 50 Kgs of Cement. ‹ For up-gradation of packing house Electronic Rotary Packers of 100 TPH (four Nos.) to be converted into double discharge with capacity of 180 TPH and venting bag filters to be replaced. ‹ There are four concrete silos for storage of dry fly ash, each having a capacity of 2000 MT, dry fly ash received through bulkers is pneumatically unloaded in these silos and fed to cement mills day hoppers through PD pumps. In addition to this, Maihar Cement has commissioned two Truck tippler during year 2013 for the dry fly ash unloading (coming through trucks) system along with dense phase conveying system, to minimize fugitive emission which occurs during truck unloading and transportation of material through belt conveyors. ‹ For clinker dispatch, Maihar Cement has a clinker loading facility with static weigh bridge at their railway siding. They have M/s DCL make clinker loading & dust control system. Specific Consideration For Upgardation In Pyro Process System • Since the total production increase is 1300 tpd, all the existing raw mills (2 ball mills and one VRM) would have to be operated simultaneously and yet may fall a little short of the requirement of 9000 tpd . (410 tph kiln feed requirement, total raw mills production is 390 tph). It will be required to improve the ball mills circuit and a Pre-grinder/ Pre-crusher system can also be considered. The raw material hoppers may have to be augmented for the simultaneous operation of 2 ball mills. • Along with coal mill VRM, one of the ball mills would also have to operate to meet the requirement of around 29 tph fuel. Plant may also consider separate grinding of pet coke and coal to get higher fineness in pet coke. • It will be necessary to increase the reclaimer capacity to achieve 450 tph instead of existing 350 tph. The extraction from the silo would also need to be augmented to achieve around 200 tph x 2 from existing 136 tph x 2(design) operating at 160 tph. ES - 7
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Raw Meal Extraction from Silo and Kiln feed system This system will have to be augmented to meet the requirement of around 200 tph per kiln line. This will entail replacement of existing air slides and bucket elevators. The kiln feed bin will be resized to 60 m3. • Kiln The kiln has a dimension of 4.35 m diameter by 65 m length. Operating the kiln at 3000 tpd level would be feasible with some modifications to Kiln drive system The specific loading would go from 3.0 tpd/ m2 at 2350 tpd to 3.95 tpd/m3 at 3000 tpd. Since ILC kilns are designed to operated upto much higher specific loadings of ~5 tpd/m3, kiln size is Ok for the proposed throughput. • The kiln drive system would need slight modification so kiln speed increases from 2.7 rpm to around 3.5 rpm • Kiln refractory lining will have to be changed Preheater /Calciner • In order to produce 3000 tpd clinker with better energy efficiency and stable operation, it is proposed to install a precalciner and one more preheater stage. • New Calciner and TA duct to be installed • Preheater modification can be carried out as follows • New structure has to be built for for calciner and one top stage new cyclone. • Replace the existing top stage twin cyclone of 4 stage preheater with with single cyclone . • Alternately, use existing PH building for one calciner and 1/2 new cyclones, new structure for 3 top stage cyclones to get a new single string ILC system however this would require more downtime and would be more expensive • New structure can be constructed over kiln pier and Calciner and new top stage cyclone on this new Structure • Provision for WHR system will be kept • The existing kiln feed system would have to be modified to go from 155 tph to 200 tph. • Based on ERCOM’s past projects and interactions with OEM, the following key modifications are suggested • Existing top stage twin cyclone to be modified – replaced by single cyclone of 7.2 dia • New Top stage single cyclone proposed of 6.9 m dia • Modified Inline Calciner (U shape) of 56 m effective length and 4.6 m effective dia. These dimensions are tentative and will have to be confirmed during procurement stage by OEM. • The proposed location of the new structure for Calciner and 5th stage cyclone is as shown in photo below: It is proposed to make a new structure over kiln. Cooler • In order to upgrade from 2350 to 3000 tpd it would be necessary to modify and extend existing cooler and cooler hood
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Cooler length extension required with area increase to 60 m2 m for 3000 tpd production (50 tpd/m2) • Cooler fans will have to be replaced to meet the design requirements of the new cooler. • Expansion may be carried out without touching the coal mill building. Cooler vent location will have to be towards coal mill building • Cooler hood would have a larger area and new TA duct to be installed • Kiln Burner modifications may not be required. • Cooler vent volume can be handled by existing ESP and ESP fan Exhaust Gas Handling • The PH exhaust gas will be at about 320 C. It can be cooled to about 240 C using a down comer spray or by retaining the existing GCT. In case the GCT is removed, new down comer will be installed of around 3 m diameter. • The waste gas fan will fall slightly short of its volumetric capacity to handle the flows at 3000 tpd. It may be possible to reach the desired capacity by tipping of fan blades. While it is estimated around 880 mm pressure drop, will determine the suitability of existing fans. Otherwise new Waste Gas fan will have to be procured. • The hybrid ESP will fall short of its capacity and it will have to be extended by one more compartment. ESP fan will be sufficient since reduced exhaust gas temperatures will ensure that gas volumes to do not increase considerably at the increased production rates. Specific Consideration For Up-grdation In The Existing Cement Mills For up-gradation from 5 MTPA to 6 MTPA in Cement grinding section following jobs are proposed. In the existing Cement Mill No.1&2 from 115 TPH to 150 TPH following modification and upgradation are: • In the existing cement mill Drag peb liners to be replaced by thinner classifying liners. • Dynamic separator to be installed and cyclones to be modified for high efficiency cyclones. • Existing fan to be replaced for higher flow capacity with keeping high efficiency fan. • Pregrinder (VRPM) output rate is to be increased by modifying existing V- separator. • Additional module to be added in Existing Hybrid Filter for control of dust emission from cement mill stack. In the existing Cement Mill No.3 from 140 TPH to 160 TPH following modification and upgradation are: • In the existing cement mill Drag peb liners to be replaced by thinner classifying liners. • Dynamic separator to be installed and cyclones to be modified for high efficiency cyclones. ES - 9
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Existing fan to be replaced for higher flow capacity with keeping high efficiency fan. • Pregrinder (HRC) output rate is to be increased by modifying the existing HRC. • Additional module to be added in Existing Hybrid Filter for control of dust emission from cement mill stack. In the existing Cement Mill No. 4&5 from 165 TPH to 200 TPH following modification and up-gradation are proposed : • In the existing cement mill Drag peb liners to be replaced by thinner classifying liners. • Dynamic separator to be installed and cyclones to be modified for high efficiency cyclones. • Existing fan to be replaced for higher flow capacity with keeping high efficiency fan. • Pregrinder (HRC) output rate is to be increased by modifying the existing HRC. • Installation of static V-separator in place of existing Deagglomerator. • Additional module to be added in Existing Hybrid Filter for control of dust emission from cement mill stack. Environmental Consideration • The proposed up-gradation will not effect the particulate emission since it is proposed to extend the existing Hybrid Filter to take care of Preheater gas volume increase. Moreover addition of an efficient top-stage cyclone will reduce the specific dust losses with the preheater gases. The existing cooler ESP will be able to handle the slight increase in quantity of cooler vent gases. Adequate dedusting filters will be provide at material transfer points to take care of fugitive emissions if any. • Up-gradation in APC at Cement Mill and packing house additional supporting bag filters (03 no.) to be installed to control dust emission etc. • In the Hybrid Filter of Cement Mills additional module to be added in Existing Hybrid Filter for control of dust emission from cement mill stack
• Since petcoke is being used along with coal as fuel there is a concern on NO X
emission. In order to reduce the NO X emission to below acceptable range of 800
mg/ Nm3, low NO X system for the Calciner shall be installed. It is proposed to
replace the kiln burner with a low NO X burner. The SOX emission is usually taken care of in the cement process based on the raw material alkali content.
6. Raw Material Details & Storage Facility: TABLE Details Of Raw Material Material Sources Transportation Existing Proposed Requirement Requirement (LMT) (LMT) Limestone Captive OLBC 44.4 59.2 mines/purchase ES - 10
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Bauxite Purchase OLBC 0.444 0.592 Laterite Captive OLBC 1.332 1.776 mines/purchase Gypsum Purchase Wagon 1.50 1.80 Flyash Own Generation/ Bulker/trucks 17.0 20.40 Purchase box type Coal/ Linkage/e- Wagon/trucks 4.74/2.9625 6.32/3.95 Pet Coke auction/purchase
TABLE Storage Details Existing Details Proposed Details S. Storage Capacity in Days Storage Capacity Days No Department MT in MT Limestone Pre- 1 blending covered 100000 6 100000 6 Stockpile
2 Laterite 27000 90 27000 90 4 Raw meal Silo 30000 2.5 30000 2.5 5 Clinker Silo 70000 8 70000 8 Coal stock pile/ pet 6 64000 40 96000 60 coke 8 Cement storage 50000 4 50000 4 9 Fly ash storage 38000 13 38000 13 10 Gypsum storage 20000 70 20000 70 11 L/s Additives 8000 20 8000 20
7. Base Line Environment i. Ambient Air Quality Status
Station PM -10 PM -2.5 SO 2 NOx CO Avg. 98 th Avg. 98 th Avg. 98 th Avg. 98 th PPM Delha 67.83 70.44 27.07 21.54 5.69 <4.00 11.15 5.49 <1 Sonwari 53.84 58.84 26.56 29.05 5.59 <4.00 8. 85 20.87 <1 Bhadanpur 66.75 71.94 21.43 21.04 <4.00 <4.00 6.19 10.37 <1 Harnampur 72.90 74.97 18.48 24.94 <4.00 <4.00 6.32 10.37 <1 Amgar 53.65 56.98 24.76 21.58 <4.00 <4.00 6.09 8.57 <1 Hinotiya 52.45 55.68 28.08 23.26 5.06 <4.00 13.49 6.20 <1 Kothi 46.12 48.89 28.53 29.90 5.02 <4.00 9.70 25.42 <1 Material gate 62.20 67.76 22.97 22.41 <4.00 <4.00 6.40 11.49 <1 Main gate 62.07 67.67 19.33 27.36 <4.00 <4.00 6.89 11.44 <1 Maihar 54.06 58.87 27.19 23.41 <4.00 <4.00 6.63 10.36 <1 Cement ES - 11
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Hospital ii. Surface Water & Ground Water Quality
Surface Water Quality Monitoring Stations S. No. Location Location No. Direction Distance in km 1 SW-01 WNW 0.50 Tamas River 2 SW-02 SE 5.25 Bhadanpur Mine pit- C 3 Bhadanpur Mine pit- D SW-03 ESE 5.00 4 Bhadanpur Mine pit- E SW-04 ESE 6.50 5 Bhadanpur Mine pit- B1 SW-05 SES 6.25 6 Recharge Pit – A SW-06 NWN 0.10 7 Piparhat Mine pit water SW-07 SWS 7.50 8 Andhayari Nalla SW-08 SE 7.00
Surface Water Quality Results Surface Water Quality Status of the Study Area Sr. No Test Parameters Unit Minimum Maximum Standard limit IS:2296 Physical Parameter 1 Temperature oC 19.20 21.50 # 2 Color Hazen Clear # 3 Odour - UN # 4 Taste - AG # Chemical parameter 1 pH - 7.06 8.34 6.5-8.5 2 Electrical Conductivity mhos/cm 345.60 3884.00 # at 25 0C 3 Turbidity NTU 0.80 15.10 # 4 Total Solid mg/lit 190.00 3360.00 # 5 Total Dissolved Solid mg/lit 168.00 3095.00 1500.00 6 Total Suspended Solid mg/lit 5 265.00 # 7 Total Alkalinity mg/lit 116.00 200.00 # 8 Total Hardness as mg/lit 114.00 1608.00 # CaCO 3 9 Ca Hardness as CaCO 3 mg/lit 24.00 680.00 # 10 Mg Hardness as mg/lit 54.00 928.00 # CaCO 3 11 Calcium as Ca mg/lit 9.62 272.54 # 12 Magnesium as Mg mg/lit 13.12 225.50 # 13 Sulphates as SO 4 mg/lit 20.84 171.49 400.00 14 Chlorides as Cl mg/lit 5.00 203.93 600.00 ES - 12
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
15 Iron as Fe mg/lit <0.05 50.00 16 Nitrate as NO 3 mg/lit 0.01 11.49 50.00 17 Nitrite as NO 2 -N mg/lit <0.01 0.53 # 18 Phosphate as PO4 mg/lit <0.01 # 19 Fluoride as F mg/lit <0.10 0.15 1.50 20 Copper as Cu mg/lit <0.03 1.5 21 Chromium as Cr +6 mg/lit <0.10 0.05 22 Manganese as Mn mg/lit <0.20 # 23 Zinc as Zn mg/lit <0.05 15.00 24 Total Chromium as Cr mg/lit <0.05 0.05 25 Cadmium as Cd mg/lit <0.05 0.01 26 Lead as Pb mg/lit <0.05 0.1 27 Mercury as Hg mg/lit <0.05 28 Nickel as Ni mg/lit <0.05 # 29 Arsenic as As mg/lit <0.05 30 Sodium as Na mg/lit 7.34 173.48 # 31 Potassium as K mg/lit 2.96 60.14 # 32 Boron as B mg/lit <0.10 33 Selenium as Se mg/lit <0.05 0.05 34 Dissolve Oxygen mg/lit 4.20 5.30 4.00 35 COD mg/lit <4.00 70.00 # 36 BOD mg/lit <2.00 7.00 3.00 37 Coliforms MPN per 22.00 94.00 5000.00 100ml
Ground Water Quality Results
Ground Water Quality Monitoring Locations Sr. Location Name of Station Source of Direction Distance No. No. sample in km 1. GW-01 Delha Hand pump NNE 2.75 2. GW-02 Sonwari Hand pump NNW 2.50 3. GW-03 Bhadanpur Hand pump SE 5.00 4 GW-04 Harnampur Hand pump NNW 5.50 5 GW-05 Amgar Hand pump S 6.50 6 GW-06 Hinotiya Hand pump WSW 5.25 7 GW-07 Kothi Hand pump E 5.50 8 GW-08 Hospital Bore well 1.0
SN Test Parameters Unit Minimum Maximum Desirable Permissibl limits e limits Physical Parameter 1 Temperature oC 2 Color Hazen Clear Clear 5 25 3 Odour - UN UN UN
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
4 Taste - Agreeable Agreeable Agreeable Chemical parameter 1 pH - 6.37 8.28 6.5-8.5 6.5-8.5 2 Electrical Conductivity at mhos /cm 202.00 1277.00 - - 25 0C 3 Turbidity NTU 0.40 11.50 5 10 4 Total Solid mg/lit 98.00 696.00 - - 5 Total Dissolved Solid mg/lit 84.00 681.00 500 2000 6 Total Suspended Solid mg/lit 8.00 70.00 - - 7 Total Alkalinity mg/lit 84.00 388.00 200 600 8 Total Hardness as CaCO3 mg/lit 76.00 452.00 300 600 9 Ca Hardness as CaCO3 mg/lit 56.00 272.00 - - 10 Mg Hardness as CaCO3 mg/lit 20.00 180.00 - - 11 Calcium as Ca mg/lit 22.44 109.02 75 200 12 Magnesium as Mg mg/lit 4.86 43.74 - - 13 Sulphates as SO4 mg/lit 89.36 198.09 200 400 14 Chlorides as Cl mg/lit 5.99 127.96 250 1000 15 Iron as Fe mg/lit <0.05 0.3 1.0 16 Nitrate as NO 3 mg/lit 5.27 23.87 45 100 17 Nitrite as NO 2 -N mg/lit <0.01 3.57 - - 18 Phosphate as P mg/lit <0.10 0.54 - - 19 Fluoride as F mg/lit <0.10 1.00 1 1.5 20 Copper as Cu mg/lit <0.03 0.05 1.5 21 Chromium as Cr +6 mg/lit <0.01 0.05 0.05 22 Manganese as Mn mg/lit <0.20 0.10 0.30 23 Zinc as Zn mg/lit ˂0.05 5 15 24 Total Chromium as Cr mg/lit ˂0.05 - - 25 Cadmium as Cd mg/lit ˂0.05 0.01 0.01 26 Lead as Pb mg/lit ˂0.05 0.05 0.05 27 Mercury as Hg mg/lit ˂0.01 0.001 0.001 28 Nickel as Ni mg/lit ˂0.05 - - 29 Arsenic as As mg/lit ˂0.05 0.05 0.05 30 Sodium as Na mg/lit 5.79 160.36 - - 31 Potassium as K mg/lit <1.00 24.74 - - 32 Boron as B mg/lit <0.10 1 5 33 Selenium as Se mg/lit <0.05 0.01 0.01 34 COD mg/lit <4.00 20.00 - - 35 BOD (3 day 27degree) mg/lit <2.00 3.00 - - 36 Coliforms MPN per 100ml <2.00 Absent 10/100ml iii. AMBIENT NOISE LEVEL Ambient Noise Location Sl. No. Code Stations Distance Direction Zone 1. N1 Delha 2.75 NNE Residential 2. N2 Sonwari 2.50 NNW Residential 3 N3 Bhadanpur 5.00 SE Residential 4 N4 Harnampur 5.50 NNW Residential 5 N5 Amgar 6.50 S Residential 6 N6 Hinotiya 5.25 WSW Reside ntial
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
7 N7 Kothi 5.50 E Residential 8 N8 Maihar Cement Hospital 1.00 Silence zone
The prevailing noise level of villages has been shown in table No. 3.10 (A). Ambient Noise Level at Villages S. No. Location Code Leq day Leq night 1. Delha 72.71 54.34 2. Sonwari 63.68 38.37 3. Bhadanpur 76.54 42.00 4. Harnampur 75.37 40.77 5 Amgar 57.35 35.60 6 Hinotiya 54.83 33.72 7 Kathi 53.76 32.84 8 Maihar Cement 53.71 33.48 Hospital
Units are in dB(A). Analysis by: M/s CES, Bhopal Noise level at sources S.N. Location Distance from Maximum Minimum 1. Packing Plant 68.0 58.0 2. CCR 71.0 64.2 3. Raw Mills 0.0mt. 90.5 85.3 5.0mt. 83.6 80.0 10.0mt 76.0 71.4 4. Kiln feed 0.0mt. 81.0 75.0 5.0mt. 80.2 76.0 10.0mt 75.6 71.0 5 Coal Mills 0.0mt. 90.0 88.0 5.0mt. 87.3 84.2 10.0mt 76.8 74.0 6. Compressor 0.0mt. 88.0 84.0 5.0mt. 80.0 76.0 10.0mt 72.0 68.0 7 Thermal Power 0.0mt. 84.5 78.0 5.0mt. 76.3 73.0 10.0mt 71.0 69.0 Note: Units are in dB(A)
ES - 15
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
8. IDENTIFICATION OF IMPACTING ACTIVITIES
Activity Environmental Cause Impact Characteristics Attribute Nature Duration Reversibility Significance Wastewater Water Quality Generation of Waste Minor Negative Short Term Reversible STP is be provided Discharge Water Emissions from Air Quality Unit operations, Vehicle Negligible Long Term Reversible Low as ambient and stack various unit (SPM, SO2, Operation and fuel Negative monitoring , is be performed processes and NOx, CO,) Combustion Adequate . APC has been provided vehicular traffic PUC certified vehicles are used. Noise levels Noise generation From Minor Negative Short Term Reversible Low, due to noise protection machinery and Vehicles measures, periodical vehicle maintenance Solid & Hazardous Land and Soil Generation of Solid Waste Minor Negative Short Term Reversible Low, proper collection and Disposal Waste Disposal Green Belt Ecology Planting of Trees Positive Long Term Reversible High Positive Impact Development Socio- Economic Employment Direct and Indirect Positive Long Term Irreversible High, new Opportunities of income Generation employment for many families Quality of Life In flow of funds in the Positive Long Term Irreversible High, the project region/nation will generate employment
S No Aspects/Activities Impact without measures Proposed Management/Mitigation Impact with Measures EMP Construction Phase 1. Air Environment Uncontrolled dust emission/source emission During construction NA air shall lead to change in air quality, visibility, • Provision of spraying water to reduce During construction deposition of dust over soil. Such emission dust emission. Dust emission due to the will have secondary impact as : • The amount of exposed ground and minor construction, movement • Adverse impact over human health, stockpiles will be minimized so that of vehicles, concrete mixing • Adverse impact over crop production , re-suspension due to wind and machinery, emission from DG • Adverse impact over flora & fauna subsequent dust fall is prevented. set • Adverse Impact over the climate Heights of stock piles should control dust fall in nearby areas. ES - 16
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
During Operation • Ensuring all vehicles, generators and Emission from various stacks The above secondary impact will have compressors are well maintained and of kiln, cooler, cement mills, tertiary impact with respect to loss of regularly serviced. raw mills etc economy and ill socio cultural environment • DG set will be kept as stand by. Emission from material During Operation handling / coal • Adequate height to various stacks crushing/conveying and fly ash and adequate control system have emission been provided with emission limit of 25 mg per normal cum. • Dust collectors shall be provided at various material transfer points • Dense phase conveying system for flyash has been provided. 2 Water Environment Uncontrolled withdrawal of water from river During construction NA water During construction and release of un treated waste water will • Local workers will be employed to SB Requirement of 4-5m 3/day of give primary adverse impact over avoid excess water consumption. socioeconomic water during construction • Change in ground water quality • Waste water from domestic sanction Accumulation of water in • Change in surface water quality has been taken to STP located within excavation • Decreased water level & flow pattern the premises. • Disturbance to drainage pattern of the area • Care will be taken to prevent water Release of waste water from • Leaching of toxic substance from entering excavations though GI m3/day from domestic sheets and other measures activities These primary impact will lead to adverse impact on the agricultural production, water During Operation
During Operation borne diseases to human beings and • No discharge of water from outside of Requirement of 3200 (+ 25 ) animals, loss of land scape, flora and fauna plant will take place m3/day of water ( if proposed) etc. which ultimately results in loss of • The drain along the boundary wall aquatic life, negative impact on amenity & (inside the premises) is proposed to Discharge of treated waste recreation, hydraulics of water courses prevent to meet any runoff from water from STP on land economy and ill socio cultural environment premises. • Ground water table is anticipated to be rise by creation of water harvesting structure and water body ES - 17
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Ground water recharge system have been developed which further help in recharging of ground water. • Unit has also developed a reservoir in the Cement Plant having capacity of 5,75,000 KL and is capable of meeting about 100 days water requirements of the Cement Plant apart from the water reservoir developed within mine premises. 3 Noise Environment Higher Noise may cause impacts as below : • Equipment like compressor shall be NA noise • Change in ambient noise level installed with acoustic enclosure During construction • Annoyance • The vehicles used will be with the Higher noise level during • Interference with communication standard limiting noise output. construction due to excavation, • • Health risk Online vibration monitoring of high plying of vehicles, operations of • speed and vital equipments shall be construction machinery, Impact on work output and efficiency planned • operation of DG set etc. Migration of birds, reptiles and • Noise shield shall be provided population wherever required During Operation • Risk of accident with high vibration • Employees and others would be • Generation of noise due to scenario guided properly with sign board operation of steam turbine, Strict compliance of maintenance boiler, equipments, conveyer schedule have been done of all belt, etc. transportation and plant equipment • Regular monitoring of noise level will be carried out and corrective measures in concerned area have been adopted accordingly. • The adverse impact on occupationally exposed workers will not be envisaged, as noise protection devices have been provided • Rotation of workers working in high ES - 18
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
noise prone area 3 Land Environment Soil contamination is envisaged through • Spillage of oil from NA land construction/operational vehicles and NA ground During construction • Heavy metals and other pollutants equipments is avoided. These should water • Leakage of oil from vehicles • Change in Soil moisture, permeability be inspected by supervisor for any & equipment. • Leaching of toxic substance leakage of oil. • Spillage of concrete mixture • Change in structure of Soil • The contamination of soil is avoided containing additives and by soil conservation measures. Good plasticizers. The above primary impact will result in less plantation has been developed which • Contamination of land/soil agricultural production, affected fodders for help in soil conservation also. Spillage of construction animals, health effect on human being and • Care hass been taken to compact the material containing heavy animals. soil after refilling so that, soil erosion metals, paints, coating, liners and consequent soil import is etc. Change in land use is not anticipated as avoided. • Storage and handling of expansion is proposed within the premises of • Cement powder, concrete retarding concrete existing unit. will be stored in areas away from During Operation Phase storm water, grids, channels and Contamination of soil due to watercourses or adequate measures spillage of oil from machinery will be taken to protect against Contamination of soil pollution. Release of waste water over the • Storage of all potentially polluting land substances will be located on impermeable surfaces with controlled drainage. • Storage areas is fenced off • No discharge of water will take place • The drain along the boundary wall (inside the premises) is m to prevent to meet any runoff from premises to nalla 6 Solid & Hazardous Waste Improper handling and disposal of solid and • Recyclables like Cements bags, waste 0- land, Environment hazardous waste shall give impact over paper, unusable steel scrap and During construction cardboard packing material sold to ES - 19
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Generation & disposal of • Soil profile and characteristic of the area vendors/recyclers waste like Cements bags, • Contamination of ground water and • Inert material will be used as much waste paper, unusable steel surface water courses of the area as possible for the internal road scrap and cardboard packing construction and leftover is/will be material and excavated earth Contaminated soil and water will sold to road contractor and concrete debris subsequently provide adverse impact over • Waste oil is/will be stored in HDPE • Waste oil from DG set agricultural production and quality of crops, drums and is/will be sold to During Operation Phase affected fodders for animals, health effect on authorized recyclers Generation & disposal human being and animals. • Waste resin, carbon and discarded Waste paper, broken bottles, drums is/shall be disposed off at Plastics, Bio-degradable – Common TSDF Pithampur Dist Dhar kitchen waste, Sludge, Inert (MP) –Waste Resin and carbon • Waste oil is/will be sold to authorized from ACF Discarded Drums recyclers Used Oil • Ash will be given to local brick manufacturer • DDGS shall be sold as cattle feed 7 Socio Economic environment Most of activities pertaining to socio • Proper implementation of EMP to SB on socio During construction economic aspects will have positive impacts. prevent impact on social segment economy • About 50-75 number of However uncontrolled discharge of air, water, • Direct & indirect employment workers shall be deployed at solid & hazardous waste will give impacts on opportunity. site during construction social segment as tertiary impact. Following • Positive impacts since the employees • Air, water, land, noise are the impacts envisaged : are from different culture and pollution through various • Net Income Output religion. construction activity • • Change in Economic Base of the Region Positive impact due to change in zonal economy. • During Operation Development Of ancillary industries • Positive impact due to health care’s • Generation of direct and • Employment Opportunity facilities for workers & villages. indirect employment • Demand For Communication Facilities • Better medical facilities through
• Air, water, land, HSW, noise • Demand for infrastructural facilities in regular medical camps
pollution through various terms of water supply, sewerage & waste • Execution of various need base operational activity management, educational, medical and programme under CSR, which
• Gross economic product recreational facilities, ultimately resulted in development of ES - 20
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Medical facilities area
• Execution of CSR programme Uncontrolled discharge of air, water, solid & hazardous waste will give impacts in terms of aesthetic risk, Effect on Human health, Effect on agriculture, & fisheries, Effect on Building Materials Monuments Biological Environment Uncontrolled discharge of air emission , • Thick Plantation of trees in and NA on flora & During construction waste and treated water , will give impacts around premises. Total 147 acres of Fauna • Disturbance of flora and in terms of Aesthetic risk, Effect on area has been planted with more fauna due to illumination, & Human/animal health, Effect on than 10,00,000 no of trees, which unexpected fluctuations in agriculture, & fisheries. will throw positive sign towards lighting Uncontrolled dust emission/source emission healthy environment. • Disturbance of flora & fauna shall lead to change in air quality, visibility, • As no wastewater/treated water from due to noise generation from deposition of dust over soil. Such emission the proposed project is/will be various machineries and will have secondary impact as : discharged outside the premises, transportation activities • Adverse impact over human health, there is insignificant impact on the • Adverse impact over crop production , ecology of the study area. During Operation • Adverse impact over flora & fauna • Disturbance of flora & fauna The provision of adequate stack due to emission to ambient air Uncontrolled discharge of waste or treated height with pollution control because of burning of Fuel water over the land or any surface water equipment at various point of siyrce body will lead to adverse impact on the emission, water spraying system and Disturbance of flora & fauna agricultural production, water borne diseases dust collector system at various due to noise generation from to human beings and animals, loss of land material transfer points is/shall various machineries scape, flora and fauna etc. which ultimately results in loss of aquatic life. restrict the probable disturbance to Disturbance of flora & fauna the biological environment of the due to release of waste water High noise level and significant illumination area. create disturbance the habitats of animals.
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
9. Environment Management Plan The project will be implemented with environment friendly technology.
a. Air Pollution Control • All pollution control equipment is designed for less than 25mg/Nm 3 dust on dry basis, though SPCB has given limits of 30 mg/Nm3 . Covered sheds/Silos have been provided for raw materials and finished products • Stacks at various points with adequate height for wider dispersion of gaseous emissions have already been provided. • In line with proposed up-gradation, the control equipments at Kilns, Cooler section, Cement mill and coal mill shall also be upgaraded by providing additional compartment to ESP and additional module to Bag Filetrs to meet out the given norms. • Four Closed silo system for storage of fly ash with capacity of 8000 MT have been provided. • Two covered limestone stacker re-claimer having Capacity of 60000 MT & 40000 MT, covered laterite storage having Capacity of 27000 MT, Coal Stacker re-claimer having capacity of 14000 MT, Coal covered shed having Capacity of 50000 MT, Three Clinker silo having Capacity of 50000X2 MT and 20000 MT, one Clinker Covered shed with capacity of 20000 MT, One Covered gypsum shed having capacity of 20000 MT have been provided. • Water sprinkling system is provided at the limestone crushing system. The same arrangement shall be maintained all the time. • Pucca road from Maihar to Dhanwari via Plant have been made to control the fugitive dust emission. The same shall be maintained all the time. • Transportation of clinker to clinker silo is done through covered conveyor to prevent fugitive emission. • Transportation of fly ash to silo is done pneumatically from tanker to avoid fugitive emission. The same shall be maintained all the time • Fly ash transportation has been transported by closed tankers. The same arrangement shall be continued all the time. • Covered unloading hoppers with atomized water spray system have been provided. • Greenbelt has been developed 5 m all around the periphery of the plant to arrest the fugitive emissions. Total 10,78,000 trees are in survival stage within Plant, colony and mines. • Online emission monitors have been provided for major stacks and same arrangement shall be maintained all the time. • Preventive maintenance of valves, flanges, joints, roof vents of storage vessels in practice. The fugitive dust emissions is controlled by installation of closed conveyor system along with suitable dust suppression measures: • Dust collectors systems have been provided at various material transfer points. ES - 22
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Dust collected from air pollution control equipments is being totally recycled in the process. • Roads and floors inside the plant are cleaned by vacuum sweeping machine. • Low NOx burners are already provided for NOx control from Kilns stack. • The guideline issued by CPCB on measures for controlling of source and fugitive emission in cement plant is being followed. • The stack emission control system shall be regularly monitored and maintained. • Better process control shall also help to keep the emission within the limit • Proper record of monitoring report of existing stacks, and ambient air shall be maintained. • In order to control the fugitive dust emissions due to transportation activity, major roads within the plant area has been asphalted. The road nearby the fly ash silo shall also be asphalted.
To keep the PM emissions from stack below 30 mg/Nm3, all major sources of air pollution (i.e. kiln, cooler, cement mill etc.) have been provided with RABH / Bag filters / ESP.
Air Pollution Control Equipment Emission Proposed Details of modification proposed Proposed Stack Stack Source APCE Designed Dia (mt) Height Emission level ( mg/nm 3) Kiln No. 1 Hybrid Additional module to be added & 25 3.9 80.0 Filter converted into bag house Kiln No. 2 Hybrid Additional module to be added & 25 3.9 80.0 Filter converted into bag house Kiln No. 3 RABH Additional module to be added 25 4.6 102.0 Coal Mill No. 4 Bag Filter No change 30 1.8 40.0 (VRM) Coal Mill No. 5 Bag Filter No change 30 1.8 60.0 (VRM) Clinker Cooler ESP To be upgraded 30 2.0 40.0 no.1 Clinker Cooler ESP To be upgraded 30 2.0 40.0 no.2 Clinker Cooler ESP To be upgraded 30 4.8 50.0 no.3 Cement Mill Hybrid Existing Hybrid Filter is to be 25 1.5 40.0 No. 1 & 2. Filter used for CM-1& new bag house to be installed for CM-2 Cement Mill Hybrid Additional module to be added & 25 1.8 40.0 no. 3 Filter its ESP is to be upgraded Cement Mill Hybrid Additional module to be added & 25 1.3 31.0 no. 4 &5 Filter its ESP is to be upgraded Thermal Power Hybrid - 25 2.5 70.0 ES - 23
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Plant Filter ( 15.7 MW-I) Thermal Power Hybrid - 25 2.5 72.0 Plant Filter ( 15.7 MW-II)
b. Noise Control Following are the measures proposed to control the higher noise level. Noise generating sources in a plant are identified as steam release valves, compressors, Various mills, turbine and DG set etc. No person is required to remain constantly at the above-mentioned units and will go occasionally to check the systems. Noise attenuating devices like earplugs and earmuffs shall be provided to workers exposed to high noise levels. Noise barriers, silencer and enclosures shall be incorporated in the equipments, which emit high noise level. All basic equipments and various machineries should be kept well maintained. Green belts are good noise barriers and same will be developed around the plant. The sufficient green belt may be proposed to control noise levels. Following are the measures proposed to control the higher noise level. • Provision of acoustic enclosure for STG, DG set • Provision of lining with sound absorbing materials for walls and ceilings of the concerned buildings. • Provision of insulated enclosures at area close to the high noise sources. • Provision of noise attenuating devices like ear plugs and ear muffs to the workers exposed to high noise level. • Development and maintenance of sufficient green belt. • Regular monitoring of noise level followed by corrective measures in concerned machinery. • Maintenance of machinery & vehicles will be done in a sustainable manner to ensure best performance and less noise. • Disallowing vehicles for parking at villages property and towards highway. Provision shall made for specified parking area for vehicle • Continues exposure to workers in higher noise prone area shall be avoided. Workers will be subjected to regular medical examination for any symptoms of hearing loss. • Provision of training to workers to generate awareness about effects of noise and importance of using PPEs.
c. Water Management The cement manufacturing process is not water intensive unit and manufacturing process does not require water and water being used in cooling towers and other utilities. ES - 24
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Present water consumption is approximately 3200 m3/day for Cement Plant, TPP, Mines and Colony which is sourced from a perennial river "Tamus" (River Pump House located at a distance of about 2 Km from the Cement Plant) as well as from reservoir developed in the captive mines/ plant. After the debottlenecking project , the requirement will be increased by 25 KLD and shall be sourced from the same as above. water is sourced from water reservoir having capacity of 20,40,000 KL developed at Mine leases. Marginal increase of 25 KL per day is envisaged during the proposed expansion.Maihar Cement has also developed a reservoir in the Cement Plant having capacity of 5,75,000 KL and is capable of meeting about 100 days water requirements of the Cement Plant. Mine water reservoir is located at a distance of approximately 9 KM from the plant. Water from river and mines is drawn and passed through a filtration plant for purification and chlorination. The chlorinated water is then pumped to two overhead tanks of 4.5 lacs liters capacity each in the colony and the two ground level tanks with 4.5 lacs liters capacity each in the plant. The waste water generated from cement plant and CPP is treated in the neutralization tank followed by treatment plant. The domestic waste water is provided treatment at STP of 800 KLD capacity.
Water Balance of Existing & Proposed Plant Water Balance Unit Water Consumption KLD Waste water generation KLD Existing (Additional) Existing Proposed Cooling Tower 525 -- 5 00 DM water 75 -- 10 00 Others (Cement Plant 1550 25 00 00 process) Domestic/colony 800 385 -- Total (A) 2950 25 400 Mines Process 150 -- -- Mines Domestic 100 60 -- Total (B) 250 - 60 - Total 3200 25 460 --
• Water conservation plan will be carried out by recycling and reuse of treated domestic waste water in gardening, dust suppression which will reduce the fresh water demand. Rainwater harvesting has been done to increase the water table of the area • Rain water of all catchment area of colony & plant has been collected and same is diverted through the proper system of storm drains into the reservoir which is located behind the administrative building. The overflow of reservoir
ES - 25
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
and water from remaining part of plant is also collected through the proper system of drains, which lead to the reservoir named as part-A, C & part-D connected by the open RCC channel Rain water harvesting reservoir – Part A : (Cap. 175 million litres), Part B&C – Capacity : 80 millon litres and Part Capacity : D-320 million litres • No effluent generation from process. Blow down from TPP is being neutralized and is/will used for various ancillary purposes within the plant . • Proper spill control measures for stored chemicals, raw material is/ will be done. • Regular monitoring of water is/will be done. • Proper and covered storage area have been provided to avoid leakage and spillage. • Daily inspections are carried out, on each site, and general housekeeping are often checked on a daily or weekly basis. • Zero discharge condition is/will be maintained. PTZ camera with connectivity to server of MPPCB has been provided to monitor the condition. • A drain along the boundary wall shall be made, which joins the settling tank to protect the flow of contaminant outside the premises if any. • Oil spills and leaks from vehicle parking lots and washing area.
Proposed Rainwater harvesting in Plant and Colony area
Proposed RWH Scheme in the Project Area S. Type of Number of Dimensions of RWH Location Of the RWH No Structure structures structures (LxWxD) structures 1 Recharge Trench 5 5 m x 2 m x 2 m Near 30 bed Hostel 2 Recharge Pit 5 2 m x 2 m x 2 m Near Club House Total 10
Estimation of Annual Rainfall-Runoff Potential
Rainfall is only source of water for rainwater harvesting. The surface run-off available in the plant area will be used for this propose. The total area is21,27,000m 2. The normal monsoon rainfall is 1.066 m. The coefficient of run-offdepends on land use Additional Recharge Structures To accommodate the additional water i.e. 8,55,652 m3available from mines pits, it is proposed to construct a large pond of approximately 20,000 sq. m. area with average depth as 10 m having capacity of 2,00,000 cum or increase the capacity of existing pond-C by third year of mining period. It is proposed to ES - 26
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
construct 2 additional number of recharge shafts by end of third year and additional 1 number after 4 th year having depth of 20 m with diameter of 12 to 15 inches. The collar height of recharge shafts may be maintained at least half of the depth of proposed recharge/storage pond. The existing pond shall be able to accommodate the surplus water available in mine pits by second yea
Water Requirement & Available Rainwater For Recharge
The existing and additional water requirement of Cement Plant is source of water is Tamas River. From the table given below; it is seen that, theavailable rainwater for artificial rechargeis 794703m3/year. Thus, the quantum of rainwater available within Cement plant for artificial recharge with respect to total water requirement is 67%.
Water Requirement Total Water Available % Availabl e m3/ day Requirementm 3/ Rainwater for Rainwater for Existing Additional Total Annum Artificial Artificial Recharge Recharge wrt (m 3/Annum) Water Requirement 3200 25 3225 1177125 794703 67%
d. Solid & Hazardous Waste Management Details of Solid & Hazardous Waste Generation/Management Description Unit Existing Proposed Mode of Disposal Quantity Quantity Used Oil KL 27.74 Remain Same Disposed off to authorized recyclers Lead Acid batteries Number 159 Remain Same Exchanged with OEMs Metal Scrap MT 1870 Remain Same Recycled through PCB approved Agencies Rubber Belt Scrap MT 80 Remain Same Consumed in Kiln Flyash TPD 225 Remain Same Used for Manufacturing of MT/day PPC Transformer Oil KL 4 KL Remain Same Giving to PCB approved Agencies STP Sludge Kg/Day 20 Kg/Day Remain Same Used as Manure and used for Plantation
Use of High Calorific Hazardous Waste in Cement Plant The co-processing of waste in cement industry is much beneficial option, whereby wastes are not only incinerated at a higher temperature of around 1400°C and longer residence time but its inorganic content gets fixed within the clinker apart from using the energy content of the wastes. ES - 27
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Apart from this, no residues are left, which in case of incineration still requires being land filled as incinerator ash. Further the acidic gases, if any generated during co-processing gets neutralized, since the raw material is alkaline in nature. Such phenomenon also reduces resource requirement such as coal and limestone. Plastic waste stored in the shed, and planned for co-processing . Plastic waste co-processing is being carried out manually; a hopper (Capacity around 500 kg) is installed at Kiln Riser duct. In the hopper, plastic waste packets of 300 to 350 mm size is filled in manually and at the end point of the hopper a slide gate is provided, when slide gate is get opened packets gets entered in the raiser duct where the operating temperature is in the range 1050 to 1100 0C and where co- processing takes place the kiln temp. is maintained more than 1400 0C. Year wise quantity of plastic waste used as co-fuel in the cement kiln are given below:
Details of Incineration of High Calorific Waste SN Year Quantity (MT) 1 2008 - 09 76.6 2 2009 -10 101.50 3 2010 -11 99.20 4 2011 -12 112.45 5 2012-13 106.80 6 2013-14 97.50 7 2014-15 122.7 8 2015-16 119.0 9 2016-17 80.2 10 2017-18 35.0 Total 950.95
E. Green Belt Development Plan Green belt has already been developed within the existing operational premises & mines with 10,78,000 number of trees. Total area (within plan and colony ) covered under plantation is about 149 acres with 8,23,000 number of trees. The green belt development will be carried out as per CPCB guidelines and local species would be preferred. Further development of green belt over 5 hactare of area is also proposed around the plant periphery and open space. Area-Wise Plant Surviving Till Date Jura Nalla Colony Plant Name Quantity(Nos) Remark ES - 28
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Kopic 130 Peepal 8 Kathal 13 Mango 9 Jamun 14 Neem 7 Shisam 2 Kaitha 15 Uk Liptis 9 Amrood 5 Bargad 350 Ashok 20 Kunji 4 Kesia Semia 4 Reunja 4 Jangal Jalebi 4 Ber 4 Niboo 5 Karhi 5 Total 612
Mangal Niketan Dasman 27 Peepal 10 Kathal 2 Mango 43 Jamun 3 Neem 20 Shisam 34 Uk Liptis 2 Amrood 26 Bargad 4 Ashok 48 Ber 3 Khareefa 40 Karhi 6 Anaar 4 Amla 3 Munga 3 Sindoor 1 Chikoo 7 ES - 29
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Niboo 16 Karonda 6 Kadam 3 Kaila 25 Papita 10 Mithi Neem 1 Bogan Belia 2 Bel 2 Gulmohar 1 Mor Pankhi 7 Chmeli 1 Ratrani 1 Khajoor 3 Sagaun 704 Mausami 1 Kapaas 1 Gulab 1 Kaner 7 Mogra 4 Gul Chandni 3 Total 1085
Plant Area Dasman 170 Peepal 85327 Kathal 40 Mango 10 15 Jamun 90 Neem 45896 Shisam/Kala Shisam 65423 Uk Liptis 1877 Amrood 1125 Bargad 63215 Ashok 8257 Ber 140 Karhi 5680 Anaar 30 Amla 433 Munga 5
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Niboo 65 Kadam 70 Kela 356 Mithi Neem 50 Kopic 14 Badam 55 Imli 30 Pheltafarm 3760 Sagaun 512 Nasriyal 40 Paam 725 Molsree 60 Gurja 13589 Chmpa 750 Kesia Semia 1253 Gulmohar 1267 Semar 112 Bel 80 Bahera 350 Jungal Jalebi 2635 Sau Babool 189655 Kaner 2569 Bogan Belia 28576 Kesia Flora 14 Amaltaas 64 Sitafal 67 Morpankhi 75 Reunja 35603 Kachnaar 514 Laxmitaru 10 Mahua 20 Kahua 10 Lichi 15 Halikhuli Parfemia 15 Khamer 15 Chilla 27363 Kopic 20 Kunji 58655 Egjora 190 Morpanchi 75
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Baans 1272 Total 649293
Hathikund Area Peepal 215 Mango 75 Jamun 45 Neem 1225 Shisam 1545 Amrood 165 Bargad 25 Ashok 665 Ber 85 Amla 56 Munga 18 Niboo 115 Kadam 2 Kopic 345 Pheltafarm 15 Sagaun 310 Gurja 135 Kesia Semia 4568 Jungal Jalebi 325 Kaner 3512 Bogan Belia 456 Kesia Flora 65 Amaltaas 690 Sitafal 15 Morpankhi 64 Vakain 2 Gulauchi 175 Kopic 1 Kunji 165 Egjora 325 Morpanchi 236 Ratanjot 1356 Babool 2815 Ber 117 Gulchandni 345 Umar 6
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Chameli 12 Gudhal 56 Gulab 25 Gudhal 356 Total 20728
Staff Colony Area Peepal 5097 Kathal 6 Mango 1045 Jamun 218 Neem 26015 Shisam 2766 Uk Liptis Amrood 367 Bargad 56 Ashok 1152 Ber 7 Karhi 55 Anaar 16 Amla 575 Munga 46 Niboo 175 Mithi Neem 78 Kopic 275 Pheltafarm 695 Sagaun 69 Paam 196 Molsree 11 Chmpa 22 Kesia Semia 345 Gulmohar 11 Bel 56 Jungal Jalebi 25 Sau Babool 70554 Kaner 6544 Bogan Belia 5056 Kesia Flora 255 Sitafal 95 Vakayn 175
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Reunja 8789 Kopic 578 Kunji Egjora 95 Morpanchi 3436 Baans 535 Babool 14556 Gulchandni 145 Umar 45 Chameli 114 Gudhal 215 Gulab 185 Tendu 55 Harsingar 127 Krotan 163 Gudhal 186 TOTAL 1,51,282 G.TOTAL 8,23,000
Plantation Programme M/s. Maihar Cement has further proposed to develop 5 ha (for greenbelt / plantation though 60 ha area out of 199 ha of area has already been developed with good green belt of 8,23,000 number of trees , however 65 ha are required to meet out the norms of 33% criteria . Green belt has already been developed within the existing operational premises & mines with 10,78,000 number of trees. Total area (within plan and colony ) covered under plantation is about 149 acres with 8,23,000 number of trees. Proposed Action Plan for Greenbelt development / plantation at Maihar Cement is given in Table
Proposed Action Plan for Greenbelt development/Plantation Year Plantation location Area Total Nos. of Plant (Ha) Existing At various paces as given above 60 8,23,000 2018-19 Boundary between Colony and plant 2 4000 2019-20v Plantation in plant area at 9 locations 3 6000 Total 65 8,33,000
Proposed Plantation Detail Description Qty Location Forest Trees ES - 34
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Neem 500 Boundary Wall Putran Jeeva 200 Boundary Wall Pulp Trees Eucalyptus 700 STP site & Western Side Bamboo 1000 Along With boundary of back side Ornamental Trees Amaltash 400 Road Main Gate - Admin Block Gulmohar 400 Road Main Gate - Admin Block Ficus Benjamina 200 Around Admin Block Satparni 200 Around Admin Block Around Admin Block and around boundary limit ( Backside of the Ashoka Tree 200 abandoned site) Palm 200 Out Side Main Gate Out Side Main Gate along periphery of Kaner 250 plant Fruit Trees Papaya 500 Near Main Gate Near water reservoir and along Mango 500 approach road Around raw material storage area and Mahua 500 near to kiln, along road etc. Guava 500 Near water reservoir Lemon Grafted 500 Near water reservoir Jamun 500 Near water reservoir Emly 500 Boundary wall and along approach road Jack Fruit 500 Boundary wall Amaltash/Gulmohar 1000 All along internal road Bushes Bugun Velia 500 Boundary Wall Medicinal Trees Drum Sticks and Jamun 250 Near pump house
TOTAL 10,000
F. Health and Safety Occupation safety and health is very closely related to productivity and good employer-employee relationship. Occupational health of workers may be affected by fugitive emission, dust and noise. Safety of employee during operation and maintenance of equipment and handling of materials are proposed to be taken care as per regulations. To avoid any adverse affects on the health of workers due to dust, heat, and noise sufficient measures shall be provided as per requirement . Periodical medical check up is necessary. Provisions of pure and clean drinking water, safety provisions, training of all personnel to deal with accidents are required for an effective environmental management.
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
A dispensary has been established within the premises and services of the qualified Doctor shall be hired on regular basis. It is also to mention here that Maihar Cement is operating a good hospital also in the Sarlanagar area. Monitoring at work place will be done regularly. Each group of worker has been monitored at regular intervals. The analysis of the same need to be conducted by a specialist. However, to adhere to safety measures safety helmets, safety boots, safety goggles has been provided to the workers. Occupational health survey of the employees should be carried out at regular intervals. The following measures is/will be taken to prevent occupational diseases and health hazards. • Pre - employment and periodic medical examination of employees. • Regular monitoring of working environment and implementation of safety and control measures. • Use of protective equipment, clothing, helmets, gas mask, shoes, etc. • Provision of rest shelters for workers/staff with amenities like drinking water, fans, toilets etc. • Rotation of workers exposed to high noise area • Dust suppression of road • First-aid facilities in the plant area. • Emergency Plan duly approved by the Director, Industrial Health and Safety shall be prepared and will be updated periodically. • Compulsory use of PPE like dust mask, safety shoes, helmets during the working hours. • Provision of Medical check up as per statutory provision • Provision of Training programme on OHS aspect every year for the workers to educate them the importance of the impacts. • Evaluation of health of workers need to be made through pre-designed format, for chest X-ray, Audiometry, Spirometry Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre placement and periodical examinations.
Plan and Fund allocation for Occupational and Safety Hazards Plan and fund allocation actually incurred to ensure the occupational health and safety of all contracts and subcontract workers is given in Table as below:
Expenses incurred on OHS Aspects Occupational health and Safety Expenses (Rs.) Health Expenses Year Grand Total This includes, PPE 2015-16 6,126,462 with fire extingshers. 2016-17 6,094,320 2017-18 7,351,403
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
G. Socio Economic Welfare Activities Maihar Cement / Maihar Cement Unit No.2 CSR Expenses-Head wise (Tentative-Unaudited) 2017-18 Amount (in Rs.) S.No. Description Unit-1 Unit-2 Total A Community Welfare/Development 1 Arrangement of Drinking Water at Maihar 477140.00 477140.00 Railway Station, nearby villages of mines etc. 2 Transport handling, tentage and other 120391.00 120391.00 arrangements during Navratri Mela at Devi Ji 3 Steel Plates and Spoons for Mukhyamantri 162750.00 162750.00 Kanyadan Yojna, Dindori 4 Hospital and College area Road Cleaning 56155.00 56155.00 5 Deepening of Vishnu Sagar Pond at Maihar 1199989.00 1199989.00 6 Contribution to amalgamated Special Fund 50000.00 50000.00 Ärmed Forces Flag" 7 Repairing of Ramp at Old Age House at Devi Ji, 27565.00 27565.00 Maihar 8 Tent arrangement for Divya Maihar Mela 118000.00 118000.00 9 Painting at Police Station-Nadan 12913.00 12913.00 10 Misc. community welfare work at Mines Villages. 211041.00 211041.00 11 Drilling, hand pump installation, water tank ect. 543425.00 543425.00 At vill. Umrour,piprabarband, Godin,Patehra & Jhhirahat. 12 Cremation shed at Muktidham, Bhadanpur 491535.00 491535.00 13 Cement Supply (48 MT) for village. Sagmania 108532.00 108532.00
Road. 14 Water Proofing,Painting & other Civil Jobs at 388944.00 388944.00 Mangal Niketan for devotees comfort. Outside Road Repairs 455980.00 510650.00 966630.00 Total 4935010.00 B Health 1 Medicines Purchased 948785.00 266601.00 1215386.00 2 Hospital & Dispensary Expenses 1503256.00 1503256.00 3 Medical Charges Paid to Seva Trust 5700000.00 5700000.00 4 Yoga & Naturopathy Camp at Gorraiya 14998.00 14998.00 Total 8433640.00 C Promotion of Sports/Culture/Sprituality 1 Shri Hanuman Temple 230617.00 230617.00 Ganesh Pooja/Durga Pooja/Navratri/ Dasahra/ 189262.00 189262.00
2 Dhanteras etc.
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
FA in organising All India Independence Club 31000.00 31000.00
3 Football Tournament at Nagod, Satna FA in organising All India Late Capt. Pratap Singh 15000.00 15000.00 Memorial Football Tournament at Amarpatan, 4 Satna FA in organising Distt. Level Kabbadi Tournament 25000.00 25000.00
5 in Satna FA in organising 21st All India Football 200000.00 200000.00
6 Tournament in Maihar 7 FA to Religious event "Ram Katha" at vill. Sonwari 15000.00 15000.00 Hoarding for Baba Alluddin Khan Sangeet 42000.00 42000.00
8 Samaroh at Maihar, Katni. Total 747879.00 D Skill Development 1 VTC (Running Expenses) 593843 593843.00 2 W.E. Training Stipend 6265921 6265921.00 Total 6859764.00
G. Total 20976293.00
Proposed Expenditure For CER Activities In line with the OM of MoEFCC dated 1 st May 2018, following additional provision has been proposed towards the CER which is altogether does not include the cost of implementation of EMP, conservation plan, etc. The existing cost being incurred pertaining to CER aspect shall continue as per requirement.
Total Cost of proposed Project : 80 Crores CSR Budget @ 1 % : 0.80 Crores This amount Rs 80 lacs per year will be spent over a period of 5 years ( @ Rs 16 Lacs per Year) in addition to the existing activities being carried out commencing after commercial production. PROPOSED BUDGET FOR CER S. Need Identified For Activities Budgetary Budgetary no CSR Plan Provision Provision on (Rs. In lacs ) yearly basis (Rs. In lacs ) 1 Skill Development Facilitating self-employment skill generation 30 6.0 Programmes for youths vocational training programmes for creating 10 person per year as per the requirement of better self employment ventures through @ Rs 5000/- per the Unit inducing skill among the youths as per the month requirements of the cement unit. A Apprentice type training in association with ITI. 2 Ensuring Safe drinking For ensuring this Awareness generation 15 Toilets at two water and healthy campaign, wall writing, village level theme villages every year Sanitation Practices camps. Construction of toilets to stop open with supporting defecation at Delha, Sonwari , Bhadanpur, like water tanks etc Harnampur, Amgar, Hinotiya, Kathi . Provision ( Rs 2.0) of supply of drinking water or payment of bills of Drinking water water supply of villages. facility in terms of bore well, water ES - 38
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
cooler, etc , for two villages every year ( Rs 1.0) 3 Rainwater harvesting in Rain water harvesti ng in the villages Delha, 5 Provision of water the villages Sonwari , Bhadanpur, Harnampur, Amgar, harvesting Hinotiya, Kathi structure in terms, roof water of community building, deepening of ponds , stop and check dams etc Rs 1.0 lacs per year ) 4 Agriculture improvement Facilitate youths & farmers of selected villages 7.5 Rs 1.5 lacs per camps. both on on-farm and off-farm activities based on year per villages Promotion of drip need, interest and market potential. It will create irrigation amongst better employment opportunities for the Farmers , aid to the community. Promotion of advanced agriculture farmers practices and water efficient farming practices. 5 Provision of solar lights Solar light, at common property of surrounding 10 Rs 2.0 lacs per year in the villages villages at Delha, Sonwari , Bhadanpur, per villages Harnampur, Amgar, Hinotiya, Kathi etc enable to reduce the dependency on the Govt electric supply 7 Infrastructure Infrastructure facilities at schools of nearby 7.5 Rs. 1.50 Lac per development at School villages in terms of provision of computers, year teachers, facility of safe drinking water, separate toilets for girls and boys etc. 9 Need base assistance to In consideration and with recommendation of 5 Rs 1 Lac per Year villages/ individual basis gram panchayat Total 80 Lacs 16 Lacs per year
10. ENVIRONMENTAL MONITORING PROGRAMME Suggested Monitoring Programme Attributes Sampling Network Frequency Measurement Method A. Air Environment Meteorological Project impact area Continuous Hourly Mechanical/automatic • Wind speed weather station • Wind direction • Dry bulb temperature • Wet bulb temperature • Relative humidity • Rainfall Pollutants 4 locations in the Once in Month As per IS : 5182 and Revised PM-10 project impact area. National Ambient Air Two stations along the Quality Standards boundary of unit in (NAAQS) vide MoEF circular, upwind and down dated 16.11.2009 wind direction and ES - 39
M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
two station at village – Delha and At Village- Sonwari PM-2.5 As Above Gravimetric SO 2 As Above EPA Modified West & Gaeke method NO x As Above Arsenite modified Jacob & Hochheiser CO As Above NDIR technique Stack Emission - • Online monitoring • As per CPCB Guide Line from various system and Indian Standard major stack • Under direction of 11255 (1985). SPCB/CPCB • As Per IS-11255 part (2) 1985 (Absorbing • Solution of H2O2, Isopropanol Reagent) • As Per IS-11255 part (7) 2005 with NOx flask assembly Stack emission - quarterly ------from DG set
Attributes Sampling Network Frequency Measurement Method
Water Parameters for • Set of grab samples Pre and post- Samples for water quality water quality during for ground and monsoon should be collected and surface water for 5km analysed as per : • pH, turbidity, distance (06 ground 1. IS : 3025 methods for magnesium water sample at village- Methods of sampling hardness, total Delha, Sonwari, and test (physical and alkalinity, chloride, Bhandanpur, Harnampur chemical) for water sulphate, nitrate, , Hinotia, Kathi ) and wastewater fluoride, sodium, • 02 surface water sample 2. Standard methods for potassium, total at upstream and examination of water phosphorus, DO, downstream side) of and wastewater BOD, COD, Phenol, River Tamas analysis published by Heavy metals, Total • American Public coli forms, faecal coli Two Sample of mine Health Association. forms water reservoir, and Plant water Reservoir
Attributes Sampling Network Frequency Measurement Method Noise • Hourly At premises of Quarterly Instrument : Noise level equivalent boundary (04 meter noise levels samples) IS:4954-1968 as adopted by CPCB
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
• Hourly (1.5 meter from Quarterly Instrument : Noise level equivalent noise machinery) ( 04 meter levels samples) CPCB/OSHA • Soil • Soil 06 locations around Yearly As CPCB protocol the plant For parameters viz pH, conductivity, Organic matter, organic C, NPK, , WHC, moisture, particle size distribution, Fe, Cu, Zn,
Socio Economic Environment Attributes Sampling Frequency Measurement Method Socio-economic • Economic resource Socio-economic Regular meeting with base survey is based local gram Panchayat • Health status on proportionate, Need base programme stratified and may be prepared with • Cultural and random sampling the help of Gram aesthetic attributes method panchayat under CSR • Education activity. Land Land Use Pattern Once in - three year
Project Cost of Existing and Proposed Unit Investment Investment SN Particulars Existing (Up to Proposed 31.03.2018) (2018-19) Capital cost of Plant & Machinery, land & 1 97549 8443 Building Cost incurred on environmental measures inclusive of APC, Online monitoring system, web camera , 8369 2 543 STP , RWH OHS Dust supression etc Recurring cost on environmental measures inclusive of 3 monitoring of environmental parameters, green belt development,
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
Maintenance of 403 440 APC, Online monitoring system, web camera , STP , RWH OHS Dust supression etc
11. COST OF MEASURES UNDER EMP Sufficient fund allocation will be made towards environmental management and monitoring program. Following provisions are proposed to be taken for improving, control and monitoring of environment protection measures
Total Cost (EMP + CSR+ Plantation + Monitoring ) for proposed project Sn Particular Amount (Rs in Amount (Rs in Lacs) Capital Lacs) per annum – Recurring 2B Maintenance of Plantation (@ Rs 45/- per - 490 plant 2c Plantation (Capital cost) within plant 14.87 @ 15 - Sub Total 14.87 @ 15 490 4 CSR cost 80 16 Sub Total 80 16 Remark : This amount Rs 80 lacs per year will be spent over a period of 5 years ( @ Rs 16 Lacs per Year) in addition to the existing activities being carried out commencing after commercial production. 5 Occupational health and safety exp. 195.70 50 ( avg) Sub Total 196 50 ( Avg) 6 Environmental Monitoring cost 843 46.12 @ 47 Sub Total 843 46.12 @ 47 Grand Total 1134 603
27 CONCLUSIONS It can be seen from the foregoing chapters that air emission due to proposed activity of capacity utilization and optimization will not be increased significantly . The TPM emission from the boiler stack will be below the 30mg/nm3. Adequate stack height and control measures have been provided. Zero discharge effluent treatment system have been provided. No significant impacts is envisaged on other environmental aspects such as meteorology, topography and geology, mineral resources, archaeology, cultural, religious and land use.
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal
Capacity expansion in clinker/cement production Executive Summary through upgradation and optimization of Parameters
As discussed, it is safe to say that the proposed expansion project will not be likely to cause any significant impact on the environment & ecology of the area, as adequate preventive measures will be adopted to contain various pollutants within the permissible limits. Green belt development around the area would also be taken up as an effective pollution mitigative technique, as well as to control the pollutants released from the premises of Maihar cement
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M/s Maihar Cement , Sarlanagar M/s CES, Maihar, Dist Satna (MP) Bhopal