NATIONAL INSTITUTE OF FOUNDRY AND FORGE TECHNOLOGY

HATIA, RANCHI

PRESENTATION ON ENVIRONMENTAL IMPACT ASSESMENT

OF
Cement plant with a capacity of clinker 3 MTPA, cement 7
MPTA
Bhimnagar village, Sedam taluka, Gulbarga district,
Karnataka

PRESENTED BY : GUIDED BY:

PRAVEEN KUMAR BHARTI PROF. ABHILASH T. NAIR
 TABLE OF CONTENT
• INTRODUCTION
• LOCATION
• SITE SELECTION CRITERIA
• OUTLINE OF THE MANUFACTURING & PRODUCTION PROCESS
• PROJECT REQUIREMENTS
• BASELINE ENVIRONMENT
• ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
• ENVIRONMENT MONITORING PLAN
• CONCLUSION
 INTRODUCTION
 JSW CEMENT ONE OF INDIA'S FASTEST GROWING CEMENT COMPANIES IN INDIA,
MANUFACTURES WORLD CLASS PORTLAND SLAG CEMENT & GROUND GRANULATED BLAST
FURNACE SLAG (GGBS).

 THE COMPANY PROPOSED TO SET UP A GREENFIELD CEMENT PLANT ADJOINING ML AREA

WITH A PRODUCTION CAPACITY OF 3.0 MILLION TPA OF CLINKER AND 7.0 MILLION TPA OF
CEMENT LOCATED AT BHIMNAGAR VILLAGE, SEDAM TALUKA IN GULBARGA DISTRICT OF
KARNATAKA.
 LOCATION

M/S JSW CEMENT LIMITED ( JSW) SITUATED AT BHIMNAGAR VILLAGE, SEDAM

TALUKA, GULBARGA DISTRICT, KARNATAKA STATE.

THE PLANT IS LOCATED ABOUT 5.6 KMS, SW FROM CHITAPUR. THE NEAREST
RAILWAY STATION IS AT MALKHAID AT A DISTANCE OF 3.4 KMS, ESE FROM THE
PROJECT SITE AND THE NEAREST AIRPORT IS LOCATED AT HYDERABAD, AT A
DISTANCE OF 135 KM, NE FROM THE PROJECT SITE
Vicinity Map showing the earlier cement plant site, mining area and the proposed site
for cement plant
 
 
 SITE SELECTION CRITERIA

• Availability of adequate plain barren land

• Well connected to Market
• Poor yielding rain fed agricultural lands
• Non Mineral bearing area
• No forest area in the total identified land
• Power evacuation facility
• The Rail Siding feasibility
• No homestead land
• No National Parks, Wildlife sanctuaries in 10-km radius
 S. No Item Details
1 Name of the Project Proposed Capacity of Clinker 3.0 Million TPA Cement 7.0 Million TPA (0.70 MTPA
OPC, 3.50 MTPA PSC & 2.80 MTPA PPC)
  Location of Project
2 Village Village : Bhimnagar; Taluka : Sedam
3   District : Gulbarga
District & State  
State : Karnataka
4 Toposheet No 56 G/4
5 Extreme Coordinates of the 179’30.72”N 778’43.04”E
   
Plant site 179’9.70”N 778’43.66”E
 
179’18.06”N 777’52.52”E
 
179’42.07”N 777’46.90”E
6 Elevation 410-420 m aMSL
7 Type of land Single crop land
  General Climatic Conditions (IMD, Gulbarga)
8 Mean Maximum Temperature 15.9 °C (December)
9 Mean Minimum Temperature 40.0 °C (May)
10 Relative Humidity 19-82
11 Annual Rainfall 834 mm
12 Predominant Wind Direction East
13  
Road Connectivity State Highway – 126 (1.4 km, NW) State Highway – 10 (4.6 km, NE)
14  
Rail Connectivity Malkhaid (3.4 km, ESE) Chitapur (5.6 km, SW)
15 Airport Hyderabad (135 km, NE)
S. No Item Details

16 Archaeological/Historically Ruins of Malkhaid Fort (Protected Monument)

   
Important Site located at 4.4 km NE

17  
  Kagna river (2.2 km, NW) Benithora river (5.8 km, N)
Water bodies Ivni Halla stream (9.1 km, NW)

18 Forest Area None within 10 km radius

19 Sanctuaries / National Parks None within 15 km radius

20   Captive limestone ML area (adjacent to the site);

   
  Existing cement plant and mines of Rajshree Cement Works,
Industries Ultratech Cement Ltd. (3.5 km, SE);
Orient Cement Ltd (4.5 km, S)

21 Seismic Zone Zone-II as per IS:1893-2002, GoI

 OUTLINE OF THE MANUFACTURING & PRODUCTION PROCESS

 Cement Plant
The cement plant will adopt Dry Process Technology for Cement manufacturing with Pre Heating
and Pre-Calciner Technology.

 Clinker Section
The main steps involved in the process are:
• Limestone Crushing
• Limestone Storage
• Raw Mill Feeding
• Raw Mill Grinding
• Homogenizing and Storage Blending Silo
• Cyclone pre-heater
• Kiln
• Cooler
• Coal Grinding
• Clinker Storage
 Cement Manufacturing
The main steps In the Process of the cement Manufacturing are
• Cement Grinding
• Cement Blending
• Cement Storage and Packing

PROJECT REQUIREMENTS

Raw Materials:
The major raw material requirement for proposed plant will be limestone, bauxite, iron ore, gypsum,
slag, fly ash and coal.
 RAW MATERIALS AND SOURCE

Raw Materials Quantity in MTPA Source Mode of Transportation

Limestone 4.50 Captive Mine Tipper/Dumper

Bauxite 0.182 Belgaum Road/rail

Iron Ore 0.182 Bellary Road/rail

Gypsum 0.367 RCF Mumbai Road/rail

Fly ash 0.612 Toranagallu & Ratnagiri Road/rail

Slag 3.019 Toranagallu Road/rail

Coal 0.395 Imported from Indonesia Sea/rail

 UTILITIES
 Water

The total water requirement for proposed plant is about 3500 m 3/day which will be met from
borewell. The permission for ground water abstraction from CGWA/water resource department is
under process. JSW Cements Ltd. has also proposed Rain water harvesting measures for
improving the ground water table.

 POWER
The total power requirement for Cement Plant will be met from 67 MW from Gulbarga
Electricity Supply Company Limited (GESCL)/Karnataka Power Transmission Corporation
Limited (KPTCL)
 MANPOWER

Total no. of persons will be 141 in implementation phase out of which 56 person may be taken
from contractor viz fabrication, erection & commissioning etc. In operation phase the total no. of
persons will be 478 persons, which of 136 person may be taken from contractor works viz
Maintenance, Packing etc. JSW Cement Ltd. will provide employment to the local populace and
also labor of unskilled and semi-skilled categories will be taken from the nearby villages and
towns.

 LAND

JSW Cement Ltd. is in the process of acquiring 303.19 acres of land from the private land
owners for the proposed integrated cement plant. About 100 acres of land will be
developed into greenbelt.
 BASELINE ENVIRONMENT
 STUDY PERIOD

Baseline environmental studies were carried out during the period March 2013 to May
2013. Study area of 10 km radial distance around the site has been considered for the
EIA study.

 METEOROLOGY

Meteorological data for summer season have been generated close to project site. The
predominant wind direction during the study period is from East direction. The average
wind speed is 0.7 m/s. daily mean temperature varied from 11.8 °C to 38.0°C. The
relative humidity varied from 15 % to 85 %.
Windrose Diagram During Baseline Study Period (Summer season 2013)
 OBSERVED METEOROLOGICAL DATA

   
Period Temperature Relative Wind Pattern
(oC) Humidity (%)

         
2013 Min Max Min Max Predominant Average Wind
Direction Speed (m/s)

March 13.4 35 21 85    
East 0.69
April 11.8 34 18 80

May 14.6 38 15 75
 AMBIENT AIR QUALITY

The PM2.5, PM10, SO2, NOx and PAH levels were monitored at ten locations during the summer
season. Predominant upwind and downwind direction, population zone and location where
maximum GLC is anticipated have been selected for air quality measurement. The minimum level
of PM10 recorded in the study area was 24.9 μg/m3 at Huda and the maximum level recorded was
62.2 μg/m3 at Kanganhalli. The minimum level of PM2.5 recorded in the study area was 10.1 μg/m 3
at Udgi and proposed Plant site and the maximum level recorded was 27.4 μg/m3 at Chitapur. The
minimum level of SO2 recorded in the study area was 6.7 μg/m3 at Proposed plant site and the
maximum level recorded was 13.3 μg/m3 at Murgal. The minimum level of NOx recorded in the
study area was 8.8 μg/m3 at Digaon and the maximum level recorded was 19.9 μg/m 3 at Margul. The
Poly Aromatic Hydro Carbons (PAH) including benzene and pyro benzene were found below
detectable limit.
Ambient Air Quality Stations
  
Station Name of the Station Direction w.r.t. plant Distance w.r.t. plant Wind Pattern w.r.t. wind
Code site site rose

A1 Chitapur 5.6 SW Downwind

A2 Margul 2.1 SW Downwind

A3 Mudbol 4.7 W Downwind

A4 Proposed plant site 0.0 -- --

A5 Huda 1.4 E Upwind

A6 Kanganhalli 4.9 E Upwind

A7 Udgi 8.0 E Upwind

A8 Digaon 7.1 S Cross wind

A9 Itgi 3.7 S Cross wind

A10 Mogla 1.5 S Cross wind

 
Ambient Air Quality Monitoring Stations
            
  Air Quality Code Particulars PM10 PM2.5 SO2 NOx   CO in
Station mg/m3

    Minimum 32.0 15.1 9.0 13.5 0.5

Chitapur A1
Maximum 54.8 27.4 10.8 15.3 1.0

    Minimum 35.0 11.0 11.1 16.6 0.6

Margul A2
Maximum 51.8 13.3 13.3 19.9 1.1

    Minimum 30.8 11.3 9.2 12.3 0.3

Mudbol A3
Maximum 49.0 13.1 11.7 15.1 0.7

  Minimum 25.6 10.1 6.7 9.2 0.5

Proposed plant A4
site Maximum 43.0 13.0 11.5 13.1 1.0

Huda A5 Minimum 24.9 10.8 7.8 11.6 0.5

Ambient Air Quality in the Study Area (All values are in g/m3)
            
Air Quality Station Code Particulars PM10 PM2.5 SO2 NOx CO in
mg/m3

    Maximum 39.2 13.2 10.2 13.8 1.0

    Minimum 32.2 14.3 8.4 10.7 0.6

Kanganhalli A6
Maximum 62.2 16.6 10.3 14.8 0.9

    Minimum 25.9 10.1 8.6 13.4 0.4

Udgi A7
Maximum 43.2 19.3 10.0 14.9 0.7

    Minimum 26.8 10.9 7.1 8.8 0.5

Digaon A8
Maximum 44.6 13.5 9.0 14.2 0.8

    Minimum 28.4 11.2 7.4 10.2 0.4

Itgi A9
Maximum 47.8 14.5 12.8 14.6 0.9

    Minimum 28.3 11.3 7.1 10.5 0.7

Mogla A10
Maximum 45.6 13.4 9.3 14.5 1.3

Ambient Air Quality in the Study Area (All values are in g/m3)
 AMBIENT NOISE QUALITY

The minimum noise level during day time Ld 44.8 dB (A) at Mudgol and maximum Ld was recorded
55.2 dB(A) at Kanganhalli while the minimum noise level during night time Ln 41.7 dB(A) at Mudgol
maximum Ln 52.8 dB (A) was recorded at Huda.

 WATER QUALITY

Sample of surface water and samples of ground water have been collected from surrounding
villages. The water quality is found to be satisfactory. No metallic contamination or significant
pollutants has been found in the surface and ground water samples.
 SOIL QUALITY

Soil samples from surrounding agriculture fields were collected for analysis. The soil texture is clay
type. The soil contains moderate amount of organic matter, nitrogen, potassium and phosphorus

 SENSITIVE ECOSYSTEM

No ecologically sensitive area like national park, wildlife sanctuary, wetland, archaeological
monuments, marine ecology are present within 10 km radius of the project site. There are no
threatened species or endangered animals present in the 10 km study area.
SOCIO-ECONOMIC ENVIRONMENT
    Description Numbers
Demography
Total Villages 15
Total no. of House Hold 80792
Total Population 445977
Total Male Population 223304
Total Female Population 222673
Total ST Population 8241
Total Sc Population 137511
Literacy Level
Total Literate Population 223915
Employment Pattern
Cultivators 34203
Agricultural Labour 20774
House Hold Workers 3202
Other Workers 60570
Total Main Workers 141102
S. No. Particular Population

1 Total Population 445977

2 Total Literates 223915

3 Total Literacy Rate 50%

4 Male Literates 130114

5 Male Literacy Rate 58%

6 Female Literates 93801

7 Female Literacy Rate 42%

Status of Literacy and Details

S. No. Particular Details of Study Area

1 Total Population 445977

2 Total SC Population 137511

3 % of SC Population 31%

4 Total ST Population 8241

5 % of ST Population 2.00%

6 Others Population 300225

7 % of others 67%

Vulnerability Groups
 S. No. Particulars Land Use pattern (In Ha) Area %

1 Agriculture Double Crop 9247.42 29.44

2 Agriculture Single Crop 15374.07 48.94

3 Agricultural plantation 549.36 1.75

4 Agriculture Fallow land 1662.3 5.29

5 Land with scrub/ without scrub 3454.2 11.00

6 Barren Land 81.76 0.26

7 Built up Land 509.5 1.62

8 Industrial Establishments / Mine 316.26 1.01

9 River/water body 302.31 0.96

  Total Area 31497.18 100

Land Use Pattern of the Study Area as per satellite Imagery IRS P6 LISS III
Landuse Pattern of the Study Area
 
 ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

AIR

 The emissions generated from Cement Plant process are particulate matter, Oxides of Nitrogen (NO2)
and Sulphur dioxide (SO2). High efficiency ESP will be installed for cooler, Bag House for Raw Mill
and kiln, bag filters/ESP for coal mill and cement mill to control the Particulate Matter emissions to
less than 30 mg/Nm3.

 Fugitive emission shall be controlled by covered storage facilities for raw material & product.
Installation of bag filters and water sprinkling shall be carried out at the material transfer points.
    Stack Stack    
S. No. Stack attached to Velocity Temperature (oC) Emission rate (g/s)
height Diameter (m)
(m) (m/s)

PM SO2 NO2

               
1 Limestone 30 2 17 45 1.5 - -
crusher

2 Raw Mill/ Klin 120 5.5 20 120 10.8 36 216.2

3 Cooler 60 4 18 280 3.7 - -
4 Coal Mill 75 2.5 17 63 2.2 - -
5 Cement Mill – I 60 2 11 78 0.9 - -
6 Cement Mill – II 60 2 12 76 1.0 - -
7 Packer I to III 35 1 16 46 0.4 - -
  Total emissions 20.5 36.0 216.2

Stack & Emission Details

WATER

 No industrial waste water will be generated from cement manufacturing process. However,
approx. 50 M3/day waste water will be generated from the cooling tower as blow down. This
waste water will be suitably treated and shall be used for dust suppression.

 Waste water generated from domestic utilities will be treated and used for plantation. Sludge
will be used as manure for green belt development within the plant premises.
NOISE

During operational phase noise will be generated from compressors, motors, blowers, grinding
mills, crushing units etc. in the cement plant. Noise will be controlled by providing silencers,
acoustic enclosures and providing sound barriers wherever feasible, Ear plugs/ muffs will be
provided to persons working in high noise zone.
ENVIRONMENT MONITORING PLAN

The main attributes for which monitoring shall be carried out are:
• Ambient air Quality
• Stack Emission
• Wastewater Quality
• Noise Level
• Hazardous Waste
• Online monitoring of meteorological parameters
• Health Check-up for workers
CONCLUSION

By considering the entire baseline data collected during March-2013 to May-2013 as part of the EIA
study conducted in the study area and by evaluating all the possible environment impacts of the project,
it can be concluded that project activities during construction and operation phase of this proposed
Project by JSW Cement Ltd. will not have any significant negative impact on environment if all the
environment management plan, Disaster management plan given is strictly followed. More over this
project will have a positive impact on the socio economy of this region as source of employment.
THANK YOU