Environmental Statement Chaibasa Cement Works

ACC Limited
CHAIBASA CEMENT WORKS

ENVIRONMENTAL STATEMENT
(FINANCIAL YEAR ENDING MARCH 31st, 2016)

PREPARED BY

ACC Limited
CHAIBASA CEMENT WORKS
P.O. – JHINKAPNI -833 215
DIST. – WEST SINGHBHUM, JHARKHAND

SEPTEMBER, 2016

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INDEX

PART PARTICULARS PAGE

INTRODUCTION 03

A GENERAL STATEMENT 07

B CONSUMPTION STATEMENT 08

C POLLUTION GENERATED 11

D HAZARDOUS WASTE STATEMENT 13

E SOLID WASTE STATEMENT 14

F CHARACTERISATION STATEMENT 15

G IMPACT STATEMENT 16

H ADDITIONAL INVESTMENT STATEMENT 17

I MISCELLANEOUS 18

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INTRODUCTION

ACC (ACC Limited) is India's foremost manufacturer of cement and concrete. ACC's
operations are spread throughout the country with 16 modern cement factories, 19
Ready mix concrete plants, 19 sales offices, and several zonal offices.

ACC is among the first companies in India to include commitment towards

environmental protection as one of its corporate objectives, long before pollution
control norms and regulatory act came into existence. ACC is committed to provide a
safe and healthy working atmosphere and maintaining harmony with its surrounding
environment. Apart from corporate division of Environment, each manufacturing unit
has a fully functional Environmental Management Cell having experienced
environmental engineer and horticulturist etc.

This Environmental Statement has been prepared by the ACC Ltd. Chaibasa Cement
Works. All data necessary for the preparation of environmental statement have been
collected from the existing records available in the works.

REGULATORY FRAMEWORK

For maintaining better environment in and around industry Government of India has
made it statutory to submit an Environmental Statement every year for the financial
year ending 31st March to the concerned State Pollution Control Board, with reference
to the notification issued by the Ministry of Environment and Forest on March 13,
1992 (amended vide notification N0. G. S. R. 386 (E) dated 22.04.1993) under
environmental (Protection) Rules 1986 that all those persons carrying an industry,
operation or process requiring “Consent” to operate under section 25 of the Water (
Prevention and Control of Pollution ) Act, 1974, ( 6 of 1974) or under section 21 of
the Air (Prevention and Control of Pollution) Act, 1981(14 of 1981), or authorization
under the Hazardous Waste ( Management & Handling ) Rules, 1989, and amended
rules 2000 issued under the Environment ( Protection ) Act, 1986 ( 29 of 1986).

Environmental statement is a tool approved by the government to the industries for

making environmental self-introspection and setting environmental goals. It provided
an opportunity to select options for waste minimizations which in turn could even
benefits the industry in economic terms. It is for the industry to use the tool
effectively.

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LOCATION

The Chaibasa Cement Works is located near Jhinkpani in Chaibasa Tehsil of West
Singhbhum district in Jharkhand. The plant is about 180 km from Ranchi airport and
2.2 km from Jhinkpani railway station. The plant is about 20 km by road from
Chaibasa. The plant falls in the survey of India toposheet No. 73F/15 and can be
located Latitude (N 22˚ 25’ 30”) and Longitude (E 85˚ 45’ 30”).

TOPOGRAPHY

Area around CCW is fairly plain topography with no hill or valleys in the immediate
vicinity. Area around CCW is drained by the Gumua Nala.

CLIMATIC CONDITION

The Climate at Jhinkpani (Chaibasa Cement Works) is Semi – Arid. Winds are light to
moderate in summer and winter season, whereas its speed increases towards the
end of the summer and beginning of the monsoon.

Meteorological parameter recorded at CCW is given in table no. 1.

Table no. 1

Meteorological parameter during financial year 2015-2016

Month Temperature (˚C) Relative humidity (%) Rainfall

Min. Max. Min. Max. (mm)
Apr. – 15 18.9 43.9 66 92 235
May – 15 22.2 46.7 56 89 78
Jun. – 15 23.9 44.4 70 92 244
Jul. – 15 21.1 37.8 70 92 480
Aug. – 15 22.8 36.7 68 88 218
Sep. – 15 21.7 38.3 70 88 99
Oct. – 15 17.2 36.7 70 87 42
Nov. – 15 13.9 32.8 66 90 0
Dec. – 15 8.3 32.2 68 90 27
Jan. – 16 7.8 32.2 66 88 12
Feb. – 16 13.3 37.8 61 96 10
Mar. - 16 17.8 40.6 66 92 12

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MANUFACTURING PROCESS

Low and high-grade limestone raised in the mine is crushed in a crusher located at
the mine. Primary crushing of calcareous shale is also done at the mine and
secondary crushing is done in the hammer crusher in the plant. Limestone is
transported from mine to plant by tube conveyer.

Stacker reclaimer is used for stockpiling of limestone in the plant. High grade
limestone, low-grade limestone, bauxite and iron ore is dry ground in Vertical Roller
Mill (VRM). The calcareous shale is wet ground in ball mills and subject to floatation.

Dry limestone along with corrective materials and slurry is ground in VRM and stored
in a blending cum storage silo. Raw mill gases along with pre-heater gas are de-
dusted in Bag house, where dust concentration reduces to less than 50 mg/Nm3 in
discharge gas.

The homogenized raw meal is passed through 5 stage pre-heater and pre-calciner
and has 90% calcination before entering the kiln. Coal is fired in pre-calciner and
kiln. The material is move from one end of kiln to the other end coming in contact
with hot gases of combustion completing the Clinkerisation process with clinker
coming out from other end of kiln. The clinker is cooled in reciprocating grate cooler
and transported by deep pan conveyor to clinker storage silo. The clinker from the
silo is transported by belt conveyor to the clinker storage bins.

Clinker is taken to cement mill, where it is ground along with slag and gypsum to
produce Portland Slag Cement, while ground with fly ash and gypsum to produce
Portland Pozzolana Cement. The Cement is then transported to cement storage silos.
Dust Collectors have been installed to control particulate emission from the cement
mill.

There are 12 cement silos of 14000 tons total capacity. Cement is extracted from the
silos by pneumatic gravity conveyors and packed in bags by four Roto Packer
machines of 100 TPH capacity each. Cement is packed in 50-kg bags and is loaded in
trucks/ wagons for dispatch. Each packing unit is provided with individual dust
collectors.

Coal/Pet coke required for plant is crushed in crusher. The crushed coal/petcoke is
ground in VRM. Bag filter is used for de-dusting gases from the VRM.

Captive power plant power generation is based on thermal power generation process.
21 MW captive power plant is consisting of two nos. of TG sets comprises of 15MW,
6MW with four nos. of coal based boilers having three nos. of AFBC type water tube
boilers and one nos. of stoker fired water tube boilers.

Crushed coal/petcoke is fed into boiler furnace for the steaming process and the
rated steam quality is given to turbine for mechanical rotation of the generator.
Burnt coal ash is collected in a silo and further it is utilized as a filling material in our
mines pit. All boilers are equipped with Electrostatic Precipitators to control dust
emission. Accumulated fly ash through ESP is utilized in manufacturing of PPC
cement.

Desired quality of water is a prime factor for the economical use of fuels and life of
the thermal power plant equipments. Deminerlized water is generated by ion
exchange process to give as a make up water to boiler for steam generation.

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Hardness free water is also generated by sodium ion exchange process in order to
maintain heat exchanger equipments performance optimum level. Effluent water
generated during water treatment process is neutralized before disposal. Water
conservation is done by reutilization of power house drain water in dust suppression,
gardening and as process waster in the thickener of our cement plant.

Heat exchangers are utilized for the condensation of turbine exhaust steam to make
it recycled in boiler as a boiler feed water.

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[FORM-V]

Environmental Audit Report

for the financial year ending the 31st March 2016

PART-A
General Statement

1. (a) Name of the industry : ACC Limited,

Chaibasa Cement Works

(b) Address of the industry : ACC Limited,

Chaibasa Cement Works
P.O.- Jhinkpani - 833 215,
Dist.- Singhbhum West
Jharkhand

(c) Registered Office : Cement House,

121, Maharshi Karve Road,
Mumbai 400 020

Name of the Managing Director : Mr. Harish Badami

Name of the Chief Executive at : Dr. Arun Kumar Saxena

Chaibasa Cement Works Director Plant

2. Industry Category : Cement Manufacture

N.I.C. CODE (1987) 324.1(Clinker Manufacture)
324.2 (Cement Manufacture –all
Grade)

3. Production Capacity : Clinker – 1.20 MTPA

Cement – 1.20 MTPA
Power - 21 MW

4. Year of Establishment : 1947 & Expansion and

modernization in the year 2005

5. Date of Last Environmental : 28.09.2015

Statement

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PART -B
Consumption Statement

Water Consumption

Water requirement of the factory and colony of CCW is met from the abandoned
mines pits and natural drains.

Water drawn from quarry pits and natural drains is treated at CCW water treatment
plant employing sand filtration and chlorination before being sent to the plant and
colony. At Chaibasa cement works, Water is used in Cement Manufacturing process
for preparation of lime stone slurry, power generation, and for cooling of shells of
grinding mills and compressor etc. Cooling water is recycled and pumped back to
the system after making up for evaporation losses.

Quantity of Water consumed in process, power house, cooling purpose and for
domestic use during the financial year 2015 - 2016 is presented in Table no. - 2

Table no. 2

Water Consumption

Water Used Water Consumption in KL KL Per ton of Cement

2015-2016
Process 556940 0.60
Domestic 735030 0.79
Cooling 609900 0.66
Total 1901870 2.06

Note: 1. per unit consumption has been calculated considering Cement as Product.
2. On line Flow meter has been provided in water supply line.
3. Source of water supply: Water requirement of CCW & colony are met from
the water reservoir in abandoned quarry, Gumua nala and from working mines
pits.

Raw Material Consumption

The major raw materials and fuels used for manufacturing of cement at CCW are
Limestone, Iron ore, Coal, Gypsum, Slag, Fly ash, Bauxite & Petcoke. The amount of
Clinker and Cement produced in the current and previous financial year is given in
Table no.4.

The quantity of Raw material used in the current and previous financial year with
corresponding amounts used per unit production are given in Table no. 5.

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Table no. 4

Production in Tonnes

Name of the product Quantity produced for the financial year

2014-2015 2015-2016
Clinker 634561 727123
Cement
1. PSC 741969 735818
2. PPC 149188 187909
Total 891157 923727

Table no. 5

Raw material consumption

Sr. Name of Raw Consumption of raw material

No. materials

During financial year Per Tonnes of Product*

2014-2015 2015-2016 2014-2015 2015-2016

1. Limestone 777212 1058593 1.22 1.45

2. Iron ore 634 0 0.001 0
3. Bauxite 0 17328 0.00 0.02
4. Laterite 43457 25129 0.07 0.03
Fuel
Consumption
5. 143863 161858 0.23 0.18
(Pet Coke +
Coal)**
6. Gypsum 20878 30347 0.02 0.03
7. Slag 264139 348334 0.29 0.38
8. Fly Ash 34724 43160 0.04 0.05

*Per unit consumption for raw materials No. 1 to 4 has been calculated
considering clinker as product and for raw materials 5 to 8 cement produced
is considered as product.

** - Fuel consumption in Kiln, Slag Dryer & Captive Power Plant

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PART - C
Pollution generated

Water pollution statement

Industrial Effluent : Avg. water consumption is around 158490 KL/Month.

As stated earlier in this statement, CCW uses water

for preparation of limestone slurry, power
generation, cooling of various equipments such as
grinding mill shells, bearings, compressor etc. and
for domestic use. Cooling water is recycled back into
the system after making up for evaporation losses.
Water used for making limestone slurry gets
evaporated in the kiln. Effluent generated from
Power house is used as process water in thickener.

Treatment : Neutralization pit and settling chambers have been

provided for the recycling of water.

Domestic Effluent : On an average of 1685 KL/day water is consumed for

residential colony and office building for domestic
activity during day period & then discharged for
treatment.

Treatment : Effluent generated from the domestic is treated

in STP with a capacity of 600 meter cube per day
within the colony premises.

Effluent is sampled and analyzed regularly and

utmost care is taken to ensure that its quality
remains below the norms, prescribed by the PCB.
Results are shown in Table no. 6.

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Table no. 6

Effluent Quality during the financial year 2015-2016

Cement Plant Power Plant Domestic

Parameter Min. Max. Avg. Min. Max. Avg. Min. Max. Avg.

pH 7.0 7.2 7.1 6.5 8.2 7.3 6.8 7.9 7.2

Temp 0C 24 30 27 25 32 29 20 27 24

T.D.S. (mg/l) 89 98 93 92 125 111 101 130 123

T.S.S. (mg/l) 68 95 78 70 95 82 18 25 21
Chloride as Cl
31 36 34 18 22 20 19 24 22
(mg/l)
B.O.D. (mg/l) 6 12 8 4 9 6 5 10 7

C.O.D. (mg/l) 24 33 28 18 25 20 18 25 20

Air pollution statement

Source of particulate : Source of particulate emission at the plants while

matter manufacturing cement are – (a) Crushing, (b) Raw materials
storage, (c) Raw meal preparation, (d) Kiln (e) Cement mills
(f) Packing Plant (g) Slag dryer & (h) Boilers. Fugitive
emissions include dust generation at transfer points, wind
blown dust from the storage piles, dust generated due to
movement of vehicles on plant roads.

Treatment : CCW has provided Reverse Air Bag House, ESPs, Bag filters
and dust suppression systems as air pollution controlling
device to control the particulate emissions from the process
and for controlling fugitive emission from handling of
materials. Fugitive emissions of finish product are control by
adopting pneumatically conveying system instead of
traditional conveying system. The fugitive emissions of
particulate matter from road transporting activity in the
plants are also controlled by water sprinkling system and by
using vacuum road sweeping machines.

CCW Regularly monitors and analyzes the point sources and

ambient air quality in and around process activity. Result of
which are shown in table no.7 & 8.

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Table no. 7

Average SPM emission from point sources during the financial year 2015-
2016

Sr. Source APCD SPM (mg/Nm3)

No.
1. Kiln- VRM RABH 15
2. Cooler ESP 18
3. Coal VRM Bag filter 32
4. Cement Mill No. 1 Bag filter 43
5 . Cement Mill No. 2 Bag filter 31
6. Cement Mill No. 5 Bag filter 26
7. Cement Mill No. 6 Bag filter 31
8. Cement Mill No. 7 Bag filter 41
9. Slag Dryer Bag filter 47
10. Boiler # 1 (6 MW)
11. Boiler # 2 (6 MW) Hybrid-ESP 38
12. 15 MW ESP 30

Table no. 8

Ambient Air Quality (SPM) during the financial year 2015-2016

Sr. Location
No. Min. Max. Average
1. Guest House no. 2 35 56 45
2. Water treatment
24 53 39
Plant
3. Guest House no. 1 40 55 32
4. Eastern Gate 24 41 36

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PART - D

Hazardous Waste as specified under Hazardous Waste (Management and

Handling and Transboundary Movement) Rules, 2008

Hazardous waste generated at CCW includes small quantity of used oil from gear
boxes, compressor and transformers etc. Used oil is generated during oil changes in
such equipment. It is collected in drums and reused for lubrication of bearings and
other mechanical parts. This reused oil is once again recollected in drums and sold to
the venders who are authorized by the Central Pollution Control Boards. Hazardous
waste generated in the current and previous financial year is given in Table no. 9.

Table no. 9

Hazardous waste generation

Total Quantity
(liters)
Hazardous
Sr.
waste During financial year Per Ton of Product (Clinker)
No.
category
2014 – 2015 2015-2016 2014 – 2015 2015-2016

1. Used Oil 6720 4620 0.010 0.006

(5.1)

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PART - E
Solid wastes statement
Table no. 10

Solid waste generation & disposal facility

Type of Waste Source Disposal Facility

Dust Dust Collectors, ESPs 100% Recycled back into the system.
Garbage Colony, Canteen, Co-processed in kiln and landfilled.
Factory, office building

Flotation Rejects From Lime stone Used for reclamation of worked out
flotation tank mines/ cement manufacturing.
Cinder From Captive Power Used for reclamation of worked out
Plant mines/ Bricks manufacturing.
Fly Ash From Captive Power Manufacturing of Portland Pozzolana
Plant Cement/ Bricks manufacturing/ Used for
reclamation of worked out mines.
Lead Batteries Vehicle, Plant Return to dealer/ Sold to the private
parties duly authorized by Pollution
Control Board.

Quantity of solid waste generated during the financial year 2014 – 2015 and 2015 –
2016 is given in Table No. 11.

Table no. 11

Solid waste generation at CCW

Sr. No. Type of Solid Quantity produced in Tonnes Status of waste

waste for the financial year
2014-2015 2015-2016

1. Cinder/ 1830 6430 Used for Mine

bottom ash reclamation
2. Fly ash 36865 43533 Used for PPC
manufacturing/ Mine
reclamation
3. Float Rejects 70642 84256 Used for Mine
reclamation

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PART - F
Characterization statement of hazardous / solid waste

Used Oil:

Sr. No. Parameter Results

1 Polychlorinated biphenyls (PCBs) Below Detection Limit
2 Lead <0.5 PPM
3 Arsenic <0.10 PPM
4 Cadmium + Chromium + Nickel <1.0 ppm
5 Polyaromatic hydrocarbons (PAH) 0.17 %

Solid Waste from Process : Dust Collected in Bag filters equivalent to

the product quality.

Solid Waste from Pollution Control
Facility
: Septic tank sludge collected during
cleaning of septic tank is completely
biodegradable in nature and it is being
used as manure or disposed off as a land
filling material.

Solid Garbage : Dry garbage collected from canteen,

colony is totally biodegradable in nature.

Garbage collected from Offices and

factory is totally combustible in nature,
which mainly contains waste paper etc.

Flotation Rejects and Cinder :

Sr. No. Parameter Composition in % in sample of

L/S Flotation Rejects Power House Cinder
1. SiO2 48-52 55 – 60
2. Al2O3 4.4-4.8 18 – 25
3. Fe2O3 2.0-2.2 6–8
4. CaO 19.5-20.5 1–2
5. MgO 0.8 – 1.0 0.4 - 1.0
6. Alkali Traces Nil
7. Combustible matter Nil 10 – 13

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PART - G
Impact of pollution control measure on the conservation of natural resources
and consequently on the cost of production.

IMPACT STATEMENT:

Water : In CCW water is required mostly in process of

preparation of limestone slurry, power generation and for
the cooling purpose. Occurrence of contamination in industrial
process water is negligible; hence quality of water is not
drastically changed with respect to inlet characterization. It
has only thermal effect in terms of the rising water
temperature, which subsequently reduced in cooling
devices. Fresh water is only added in cooling tanks as a make
up quantity against evaporated water quantity as per
requirement. Used water is recycled back to the system
continuously, which in terms reduces the fresh water
consumption.

Air : Cement manufacturing activity is basically air pollution prone

activity but by providing better quality of pollution
control equipment like Reverse Air Bag House, ESPs, Pulse jet
dust collector etc., CCW has sustained the impact of cement
manufacturing activity nicely. From the results of ambient
air quality which is being monitored regularly in and around
of the plants, clearly shows that the pollutant concentration
is well within the limits prescribed by the Pollution control
board.

Noise : CCW has well controlled its industrial operation by

lubrication,regular maintenance of machinery and by
providing shielding between machinery in such way that
there is very negligible generation of noise. Apart from
this plantation shielding is helping in controlling the
work environment noise, if any generated.

Hazardous Waste : Used oil is sold to the private venders, authorized by the
Central Pollution Control Board.

Social : The Awareness level towards environmental aspects has

increased amongst the employees as well as local people
through various social activities and program conducted by
the CCW on regular basis.

Economic : Standard of living of the people has been increased due to the
various activities of CCW.

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PART - H

Additional measure / investment proposal for environmental protection.

Additional Investment Statement

The management of M/s ACC is fully conscious about their responsibilities for
environmental protection and pollution control abatement. These activities are
always given top priority in the annual budget of Chaibasa Cement Works.

The following Budget was allocated for the financial year 2015 - 2016.

Expenditure in
Sl. No. ITEM Lac INR
Revenue
1 Environmental monitoring
Payment of fees for renewal of Consents to
operate to State Pollution Control Board. 2.00
Payment of water cess to State Pollution
Control Board.
1.20
Environmental monitoring 12.00
Sub-total 15.20
2 Environment Management System
Renewal of Certification of IS 14001:2004 EMS
by the BSI, Government of India 0.75
3 Awareness development
Celebration of World Environment Day,
Environment Week & awareness generation 0.40
4 Development of Green belt and Green cover
New plantation, maintenance of old plantation
and maintenance of gardens 57.85
5 Pollution Control
O&M of bag filters & ESP 20.50
Water tanker for water sprinkling 24.00
Sub-total 44.50
6 CSR & Rural development
Education,Health,Infrastructure and livelihood
programmes 155.63
Grand Total 274.33

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PART - I

Any other particulars for improving quality of environment.

Green Belt Development

5250 Sapling of various species like – Teak, Kathsagwan, Casia, and Sheesham etc.
has been planted inside and around the cement plant, mines & colony.

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