Mombasa Cement Ltd Vipingo EIA Study Report for Proposed Expansion MOMBASA CEMENT LTD (VIPINGO UNIT)

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Mombasa Cement Ltd Vipingo EIA Study Report for Proposed Expansion MOMBASA CEMENT LTD (VIPINGO UNIT) Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion MOMBASA CEMENT LTD (VIPINGO UNIT) P.O. BOX 83594-80100 MOMBASA Email: [email protected]; [email protected] GPS coordinates UTM X-0593567 & UTM Y- 9586780 PROPOSED EXPANSION OF MOMBASA CEMENT VIPINGO CLINKER AND CEMENT PRODUCTION PLANT ENVIRONMENTAL IMPACT ASSESSMENT STUDY REPORT PROJECT REPORT REF NO: NEMA/PR/5/2/13,587 Compiled by: J.Morumbasi Mong’oni EIA/EA Lead Expert Reg. No.0357 Philip. Manyi Omenge EIA/EA Lead Expert Reg. No. 1559 Dr. George Eshiamwata EIA/EA Lead Expert Reg. No 1781 P.O. Box 569-80100 Mombasa Kenya 0722 493 772 [email protected] DECEMBER 2015 Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page i Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion MOMBASA CEMENT LTD (VIPINGO UNIT) P.O. BOX 83594-80100 MOMBASA Email: [email protected]; [email protected] PROPOSED EXPANSION OF MOMBASA CEMENT VIPINGO CLINKER AND CEMENT PRODUCTION PLANT ENVIRONMENTAL IMPACT ASSESSMENT STUDY REPORT PROJECT REPORT REF NO: NEMA/PR/5/2/13,587 Compiled by: J.Morumbasi Mong’oni EIA/EA Lead Expert Reg. No.0357 Philip. Manyi Omenge EIA/EA Lead Expert Reg. No. 1559 Dr. George Eshiamwata EIA/EA Lead Expert Reg. No 1781 Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page ii Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion Environmental Audit Report Submitted by MOMBASA CEMENT LIMITED P.O BOX 83594-80100 MOMBASA Tel 041 3434486 Email: [email protected] HASHUMUKH PATEL ........................................ Director Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page iii Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion EXECUTIVE SUMMARY This report presents finding of an environmental impact assessment study carried out for the proposed expansion of Mombasa Cement Limited Vipingo Unit. The EIA was carried out as provided for in the Environmental Management and Coordination Act, 1999 and the Environmental (Impact Assessment and Audit) Regulations 2003. Other relevant national legislations that were reviewed include; The Environmental Management and Coordination (Water Quality) Regulations, 2006, The Environmental Management and Coordination (Waste Management) Regulations, 2006, The Environmental Management and Coordination (Noise and Excessive Vibration Pollution) (Control) Regulations 2009, The Public Health Act, The Water Act of 2002, The Employment Act 2007, The Work Injuries Benefits Act 2007, The Labour Institutions Act 2007, The Occupational Safety and Health Act 2007, The Environmental Management and Coordination (Conservation of Biological Diversity and Resources, Access to Genetic Resources and Benefit sharing) Regulations , he Environmental Management and Coordination (Wetlands, River Banks, Lake Shores and Sea Shore Management) Regulations 2009, The Environmental (Impact Assessment and Audit) Regulations 2003, The Land Act 2012, The Energy Act 2006, The Environmental Management and Co-Ordination (Amendment) Act, 2015, The Environmental Management and Co-Ordination (Air Quality) Regulations, 2009. Proposed project location Mombasa Cement Limited Vipingo factory is located in Kilifi County, Kikambala Division, Takaungu /Mavueni Location at Vipingo off Mombasa-Kilifi Road on two parcels of land namely MN/III/291/2 and MN/III/4391 the GPS coordinates of the proposed expansion are UTM X-0593567 & UTM Y- 9586780. The project components The proposed expansion will involve construction of two new cement factories for the manufacture of clinker and cement. The components of the expansion will include construction of a boundary wall to enclose each new cement factory, limestone crusher, limestone pre- blending stockpile, additive storages, raw material hoppers, raw mill building & bag house, Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page i Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion blending silo, kiln feed, preheater tower, rotary kiln, clinker cooler building, clinker transport conveyer, clinker storage, gypsum storage, pozzolana storage, coal stockpile, coal mill building, cement mill hoppers, cement Mill building, cement silos, cement packing plant, cement loading for dispatch, clinker dispatch station, main sub-station, central control room, laboratories, engineering offices, stores, weighbridges, dispatch offices, water reservoirs and water treatment plant. Project cost The proposed expansion is estimated to cost KSH 7, 360,000,000.00 (seven billion, three hundred and six million Kenya Shillings only. Raw materials to be used MCL will grind, mix and burn in a kiln coral limestone, shale and iron ore in a clinkerization process to produce clinker. Coal will be the source of energy in firing the kiln during clinkerization. To produce cement, MCL will mix and grind in a cement mill clinker, pozzolana and gypsum. Sources of raw material The limestone that will be used in clinker production will be sourced from existing limestone deposits that MCL is currently extracting for use in clinker and cement production for the existing plant. MCL has an EIA licence for extracting these limestone deposits namely application reference number EIA/217 (registration number 0000337) and application reference number CP/PR.0495 (registration number 0007709). Shale that will be used in clinker production will be sourced from existing shale quarry owned by MCL at Vyambani within Kilifi County. MCL has an EIA licence for the shale quarry application reference number CP/PR/0682 (registration number 0007707). Iron ore and pozzolana will be bought from people who have their own quarries of pozzolana and iron ore while gypsum will be imported as currently is the practice. Envisaged positive impacts Potential positive impacts likely to result from the proposed expansion may include:- Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page ii Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion Increased exploitation of minerals used in cement production Increase in cement production in Kenya Reduction in cement imports Increase in Cement exports Employment opportunities Support of local businesses Increased revenue to government Potential negative impacts Increased gaseous emissions Increased dust emissions Increased noise disturbance Occupational injuries and or accidents Waste (liquid and solid) related pollution Negative impacts on local fauna Negative impacts on local flora Negative impacts on avifauna Proposed mitigation measures Emission of sulfur dioxide from clinker production process can be mitigated by using the following technologies; inherent scrubbing, oxygen control (increase), fuel substitution (lower total sulfur), raw material substitution (lower sulfide sulfur), raw material alkali/sulfur balance, in-line raw mill, peheater upper stage hydrated lime injection, calcined feed recirculation, cement kiln dust internal scrubber, preheater upper stage trona injection and calcium-based internal scrubber. Emission of Nitrogen Oxides from clinker production process can be mitigated by using the following technologies; oxygen control (decrease), indirect firing, low-NOX burner, mid-kiln firing, process improvements, process control improvements, low-NOX Compiled by Philip M. Omenge, J. Morumbasi Mong‘oni, & Dr. George Eshiamwta, EIA/EA Lead Experts 2015 Page iii Mombasa Cement Ltd Vipingo EIA Study Report for Proposed expansion calciner, staged combustion, semi-direct firing, mixing air fan and cement kiln dust insufflation. Emission of carbon monoxide from clinker production process may be mitigated using the following technologies; good combustion practice, excess air (increase), raw material substitution, pyroprocessing system design and mixing air fan. Emission of carbon dioxide from clinker production process can be controlled using the following technologies; improved thermal efficiency, clinker substitution, improved electrical efficiency, raw material substitution and mineralizers. Emission of ammonia from clinker production process can be mitigated through raw material substitution and tailpipe scrubber technologies. Dust emission from clinker and cement grinding can be mitigated by use of bag filter technology and electrostatic precipitators‘ technology. Fugitive dust from clinker and cement production can be mitigated by application of dust suppressant such as water sprinkling and enforcement of the use of appropriate personal protective equipment such as dust masks. Noise can be mitigated by developing and implementation of a comprehensive noise management programme that include assessing the risks, protecting employees, maintaining and equipment use, raining and sensitising of workers, health surveillance and work reviews. Measures that can be put in place to mitigate solid waste generation may include appropriate management practices and deliberate innervations aimed at minimization of waste generation. Impacts on flora, fauna and avifauna can be mitigated by continuous planting of trees and other vegetation in and around the cement plant open areas and undertaking comprehensive quarry rehabilitation in all mined areas. Traffic related negative impacts can be mitigated by developing a comprehensive traffic marshal plan. Compiled by Philip M. Omenge, J. Morumbasi
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