Andhra Cements Limited DCW

56 Pages·2015·3.6 MB·English

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DURGA CEMENT WORKS

A Unit of Andhra Cements Limited
Gamalapadu (V), Dachepalli (M)
Guntur District, Andhra Pradesh.

Six monthly compliance report for the period October 2014 to March 2015 to the
conditions specified in Environment Clearance granted by MoEF Vide letter no. J-
11011/719/2007-IA II (I) dated 2012.2007.

Sl.No. Condition Compliance
A. Specific Conditions:
i Continuous monitoring system to monitor Continuous monitoring system to
gaseous emissions shall be provided and monitor gaseous emissions through
limit of SPM shall be controlled within 50 stacks has been working and online real
mg/Nm3 by installing adequate air time monitoring data is being
pollution control system and data transmitted to APPCB Server & Display
submitted to the Ministry's Regional Office board at factory gate regularly. Air
at Bangalore, A.P. Pollution Control pollution control equipments like RABH
Board (APPCB) and CPCB regularly. installed in Kiln & Raw mill, Bag filter
installed in coal mill, ESP installed in
cooler. Bag filters installed in cement
mills. PM level is maintained below 30
mg/Nm3. Data is being submitted to
Ministry's Regional Office at Chennai,
A.P. Pollution Control Board (APPCB)
and CPCB regularly. Stack emission
report is attached as Annexure-A(i).
CEMS installed at all majar stacks
exhibit at Annexure-A(ii) Photographs
of the APCDs are also attached as
Annexure-A(iii)
ii The company shall install adequate dust Dust collection and extraction system
collection and extraction system to control (Bag filters) have been installed to
fugitive dust emissions at various transfer control fugitive dust emissions at
points, raw mill handling (unloading, various transfer points i.e raw mill
conveying, transporting, stacking), handling (unloading, conveying,
vehicular movement, bagging and transporting stacking) bagging and
packing areas etc. Crusher shall be packing areas etc. Crusher has been
operated with high efficiency bag filters. provided with high efficiency bag filters.
All conveyers shall be covered with Gl All conveyers are covered. Covered
sheets. Covered sheds for storage of raw sheds are provided for storage of raw
materials and fully covered conveyers for material such as laterite, coal, gypsum.
transportation of materials shall be Cement, Clinker and Fly ash are stored
provided besides coal, cement, fly ash in silos. Pneumatic system shall be
and clinker shall be stored in silos. used for fly ash handling. List of the
Pneumatic system shall be used for fly APCDs are given in Annexure-
ash handling. A(iv).Fugitive control measures exhibit
at Annexure-A(v)
iii Secondary fugitive emissions shall be The secondary fugitive emission is
controlled within the latest permissible being controlled by providing dust
limits issued by the Ministry and regularly collectors at transfer points, water
monitored. Guidelines / Code of Practice spray, covered storage and silo etc as
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issued by the CPCB shall be followed and per the guidelines of CPCB and is being
data submitted to the Ministry's Regional regularly monitored. The ambient air
Office at Bangalore, CPCB and APPCB. monitoring data is being submitted to
APPCB, CPCB and MOEF regularly.
iv Digital processing of the entire lease area IBM (Regional Office) and State Mining
using remote sensing technique should department have been approached for
be done regularly once in three years for the details and they have been
monitoring land use pattern and report requested to forward us the name of the
submitted to Ministry of Environment and approved agencies who have been
Forests and its Regional Office, conducting Digital processing of Mining
Bangalore. area using remote sensing technique.
We are committed for compliance.
v Regular water sprinkling shall be carried Regular water sprinkling is being carried
out in critical areas prone to air pollution out at all pollution prone areas,
and having high levels of SPM and RPM conforming the air quality norms as
such as haul road, loading and unloading prescribed by the CPCB. Ambient Air
points, transfer points and other Monitoring data are enclosed as per
vulnerable areas. It shall be ensured that Annexure-A(vi)
the ambient air quality parameters
conform to the norms prescribed by the
Central Pollution Control Board in this
regard.
vi Vehicular emissions shall be kept under Being complied by taking suitable
control and regularly monitored. measures for maintenance of Mine’s
Measures shall be taken for maintenance vehicles. The vehicles are not
of vehicles used in mining operations and overloaded and are covered with
in transportation of mineral. The vehicles tarpaulin as at Annexure-A (vii).
shall be covered with a tarpaulin and shall
not be overloaded.
vii Asphalting/concreting of roads and water Being complied. Photographs are
spray all around the stockyard and attached at Annexure-A(viii).
loading/unloading areas in the cement
plant shall be carried out to control
fugitive emissions.
viii Total ground water requirement for Water consumption is maintained as
cement plant and mining shall not exceed per the APPCB limits.
420 and 60 m3/day (including 56 m3/day No process waste water is discharged
mine water) respectively. All the treated outside the factory premises and 'zero'
wastewater shall be recycled and reused discharge is maintained.
in the process and/or for ash quenching,
dust suppression, green belt development
and other plant related activities etc. No
process wastewater shall be discharged
outside the factory premises and 'zero'
discharge shall be adopted.
ix 'Permission' for the drawl of ground water Permission for the drawl of ground
from SGWB / CGWA shall be obtained. water obtained. Copy of the letter is
Mined out area shall be developed as provided at Annexure-A (ix). Mined
artificial reservoir. The water stored in the area have been developed as artificial
artificial reservoir made in the mine pit water reservoir as per Annexure-A (x).
shall be used maximum to reduce ground Water collected in artificial reservoir in
water consumption. the mine pit is being used to minimize
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ground water consumption.
Sewage treatment plant (STP) shall be Sewage Treatment Plant of capacity
x installed for the colony. Treated domestic 300 KLD has been installed for the
effluent shall be used for green belt treatment of sewage water of colony
development within the plant premises. and plant. . Quality of treated water is
Domestic waste from colony and STP within the norms. Treated water is being
shall be segregated into bio-degradable used in gardening and dust
and non-biodegradable. Bio-degradable suppression. Sludge of STP is being
waste shall be composted and non- used as manure. Bio-degradable and
biodegradable waste shall be land filled at non bio-degradable waste is being
identified sites. ETP should also be treated as directed. STP Photographs
provided for workshop and mineral attached as per Annexure- A(xi)
separation plant wastewater.
xi The project proponent shall ensure that It is ensured that no natural course of
no natural watercourse shall be water get obstructed due to any mining
obstructed due to any mining operations. operation.
xii All the bag filter dust, raw mill dust, coal Systems have been designed and
dust, clinker dust and cement dust from installed for recycling and re-use of the
pollution control devices shall be recycled dust collected through pollution control
and reused in the process and used for devices. Similarly sludge from domestic
cement manufacturing. Sludge from sources is being used for green belt
domestic sources shall be used as development. Waste oil shall be sold to
manure for green belt development. authorized recyclers / pre-processors
Waste oil shall be sold to authorized
recyclers / preprocessors only.
xiii An effort shall be made to use of high System shall be made to use high
calorific hazardous waste in the cement calorific hazardous waste in cement
kiln and necessary provision shall be kiln.
made accordingly.
xiv Efforts shall be made to use low grade We are mixing low and high grade
lime, more fly ash and solid waste in the Limestone to conserve the natural
cement manufacturing. resources. Fly ash will be used for
manufacturing PPC.
xv Action plan for the mining, management There is no overburden present in our
of over burden (removal, storage, mine, as limestone is exposed on the
disposal etc.), reclamation of the mined surface.
out area and mine closure shall be
submitted to the Ministry and its Regional
Office at Bangalore.
xvi The top soil and solid waste shall be There is no top soil and solid waste in
stacked separately at specified dumping our mine.
site with proper safeguards. Top soil shall
be used for the plantation / green belt
development during reclamation and solid
waste for backfilling.

xvii The over burden (OB), inter burden and There is no overburden, inter burden
other waste generated from mines, if any, and other waste generated in our
shall be stacked at the earmarked dump mine.100% limestone being used for
sites only and should not be kept active cement manufacturing.
for long period. Backfilled OB dumps shall
be scientifically vegetated with suitable
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native species to prevent erosion and
surface run off. Monitoring and
management of reclaimed areas shall
continue until the vegetation becomes
self-sustaining. Regular compliance shall
be submitted to the Ministry and its
Regional Office at Bangalore on six
monthly basis.
xviii The area for external over burden dump Noted, however there is no over burden
shall be reduced by suitably increasing in our mine.
the height of the dumps with proper
terracing. It shall be ensured that the
overall slope of the dump does not
exceed 28°.
xix Garland drains shall be constructed to Noted, however there is no wastes
arrest silt and sediment flows from soil. dump generated in our mine.
The water so collected shall be used for
watering the mine area, haul roads, green
belt development etc. The drains shall be
regularly de-silted and maintained
properly.
xx Suitable rainwater harvesting and Rain water is being collected into Mine’s
conservation measures to augment pit for further use in the plant.
groundwater resources in the area on
long term basis shall be planned and
implemented in consultation with
Regional Director, Central Ground Water
Board in cement plant and mining area to
augment ground water resources and use
for dust suppression and horticulture.
xxi Regular monitoring of ground water level Ground water level monitoring has been
and quality shall be carried out by regularly carried out 4 times in a year
establishing a network of existing wells and water quality analyzed. Abstract of
and new peizometers at suitable locations the same is given at Annexure-A (xii).
by the project proponent in and around Peizometer is also being installed.
project area in consultation with Regional
Director, Central Ground Water Board
during the mining operation. The ground
water monitoring shall be carried out 4
times in a year i.e. pre-monsoon (April-
May), monsoon (August), post-monsoon
(November) and winter (January) and
data thus collected shall be regularly sent
to the Ministry, its Regional Office at
Bangalore, Central Ground Water
Authority and State Ground Water Board,
Bangalore.
xxii The project proponent shall take No waste water generated in our
appropriate mitigative measures to process/plant & mines. Zero discharge
prevent pollutions of nearby River and is adopted.
other surface water body, if any.

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xxiii Deep hole wet drilling sequential blasting Wet drilling and sequential blasting
method shall be adopted and provision for methods are being applied. The charge
the control air emissions during blasting per hole is also adjusted to minimize
using dust collectors/ extractors etc. shall ground vibration and to control fly rocks.
be made. Blasting operation shall be We are monitoring Ground vibration and
carried out during the daytime only and air blast with the help of 'Minimate'
one bench at a time shall be blasted. The instrument and keeping records of the
mitigative measures for control of ground same. The results are well within the
vibrations and to arrest fly rocks and permissible limits specified by DGMS.
boulders shall be implemented. 'No We have obtained no objection
objection certificate' from the Chief certificate from Chief controller of
Controller of Explosives shall be obtained. explosives, in form LE-3 for Explosive
Possession and Use. Enclosed copy of
License No.E/HQ/AP/22/93(E1673) as
Annexure –A(xiii)

xxiv Out of total 141.574 ha., green belt shall Cement plant area has already 48 ha of
be developed in at least 36 ha. (25 %) in green belt. Tree plantation work in
and around the cement plant as per the additional area including Mines is under
CPCB guidelines to mitigate the effects of progress. An action plan for green belt
air emissions in consultation with local development of Plant and Mines area is
DFO. In mining, out of 170.22 ha., given at Annexure –A (xiv) ,
plantation shall be raised in an area of photographs of tree plantation enclosed
46.72 ha. By planting the native species as per annexure-A(xv)
around mining lease area, over burden
dumps, around water body, roads etc. in
consultation with the local DFO /
Agriculture Department. At least, 1,500
trees per year shall be planted with a tree
density of 2,000 trees per ha. An action
plan shall be submitted in this regard.
xxv The void left unfilled shall be converted Our Mine is running mine which will be
into water body. The higher benches of converted into water body after
excavated void/mining pit shall be completion of life. The maximum bench
terraced and plantation done to stabilize height is 8 m which is as per Mining
the slopes. The slope of higher benches plan approved by IBM.
shall be made gentler for easy
accessibility by local people to use the
water body. Peripheral fencing shall be
carried out along the excavated area.
xxvi The project proponent shall take all As per the study made, there is no
precautionary measures during mining endangered fauna around the Plant and
operation for conservation and protection
Mines area. State Forest and Wild life
of endangered fauna. Action plan for
department, Guntur have been
conservation of flora and fauna shall be
requested as per Annexure –A (xvi)
prepared and implemented in consultation
to kindly issue a Certificate mentioning
with the State Forest and Wildlife
Department. Necessary allocation of that there is no endanger to fauna due
funds for implementation of the to our Cement plant and Mining
conservation plan shall be made and the
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funds so allocated shall be included in the activities.
project cost. Copy of action plan may be
submitted to the Ministry and its Regional
office within 3 months from the date of
issue of this letter.

xxvii A final Mine Closure Plan along with Agreed. Shall be complied.
details of Corpus Fund shall be submitted
to the Ministry of Environment & Forests 5
years in advance of final mine closure for
approval.
xxviii Mechanized open casting shall be Agreed. Mechanized open cast mining
adopted and no change in mining is adopted and we will take prior
technology and scope of working shall be approval of MOEF for any change in
made without prior approval of the technology or scope.
Ministry of Environment & Forests.
xxix Consent to Operate shall be obtained Consent to Operate the mining
from APPCB before starting enhanced operation for enhanced production has
production from the mine. been obtained & renewed. Mines CFO
validity is up to 30 June 2016.
Renewed copy of CFO enclosed as
Annexure- A (xvii)
xxx 'Permission' of the State Forest There is no adverse impact of cement
Department shall be obtained regarding plant operation and mining activities on
impact of cement plant and mining the surrounding 6 reserve forests. The
activities on the surrounding 6 reserve plant and Mines have been running
forests viz. Gamalapadu RF (0.1-0.4 km.), since 1984. State Forest department
Madinapadu RF (1.2-1.8 km.), Daida RF have been requested to kindly issue
(4.7-4.9 km.), Saidulnam RF (3.8-5.0 NOC as per Annexure A (xviii) .
km.). Ravipahad RF (5.3-6.6 km.) and
Warivabad RF (6.2-6.8 km) and all the
recommendations shall be followed.
xxxi The company shall obtain necessary Necessary permissions obtained from
clearances / approval from the concerned IBM. Letter from IBM enclosed as
Departments i.e. Indian Bureau of Mines, Annexure – A (xix).
State Government, MoEF etc. for the
linked mining component before
undertaking any construction activity at
the project site.
xxxii Rehabilitation and Resettlement Plan for There is no Rehabilitation and
the project affected population as per the Resettlement involved in this Project.
policy of the State Govt. shall be prepared
and implemented.
xxiii Acoustic enclosures shall be provided to All Mining machineries provided with
control noise wherever necessary. Mine silencers. Sharp bits are being used
machine shall be provided with silencers. with wet drilling to reduce noise of
Noise shall also be controlled from cooler drilling machine. Drill operators are
fans, compressor house, cement mill and provided ear plug. Bottom initiation with
raw mill, cement plant and drilling the help of shock tubes and use of
machines, excavator, blasting at mine site millisecond delay to reduce noise by
using appropriate noise control measures. blasting. Acoustic enclosures in the
plant area are used where ever
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applicable.
xxxiv All the safety norms stipulated by the We are implementing all the safety
Director General, Mine & Safety (DGMS) norms stipulated by DGMS
should be implemented.

B General Conditions :
i The project authority shall adhere to the Agreed.
stipulations made by Andhra Pradesh
Pollution Control Board (APPCB) and
State Government.
ii No further expansion or modification of Agreed.
the plant shall be carried out without prior
approval of this Ministry.
iii The gaseous and particulate matter Being complied. Stack emissions are
emissions from various units shall within the norms and inter locking
conform to the standards prescribed by facility also provided.
the A.P. Pollution Control Board. At no
time, the particulate emissions from the
cement plant shall exceed APPCB limit.
Interlocking facility shall be provided in
the pollution control equipment so that in
the event of the pollution control
equipment not working, the respective
unit(s) is shut down automatically.
iv One ambient air quality monitoring station Three (3) nos. On line real time
shall be installed in downwind direction. CAAQM stations have been installed in
Ambient air quality including ambient upwind, downwind and crosswind
noise levels shall not exceed the directions. 3rd CAAQM Station is at
standards stipulated under EPA or by the Mines area, Online real time
State authorities. Monitoring of ambient monitoring data is transmitted to
air quality and stack emissions shall be APPCB server & display board at
carried out regularly in consultation with factory gate continuously. Four (4) nos
APPCB and report submitted to the AAQM stations installed at different
APPCB quarterly and to the Ministry's locations & regular ambient air quality
Regional Office at Bangalore half-yearly. monitoring done. 3 nos On line real time
CAAQM stations exhibited as per
Annexure-B (i). Ambient air, Stack
emission level monitoring data is
regularly submitted to APPCB, CPCB &
MoEF.
v The company must harvest the rainwater All the water from the roof tops, storm
from the rooftops and storm water drains water drains lead to main drains
to recharge the ground water and use the connecting to the mines water reservoir.
same water for the various activities of Photographs of Rain water harvested at
the project to conserve fresh water. mine pit enclosed Annexure-B(ii)
The company shall undertake eco A list of eco development measures
vi development measures including including community welfare measures
community welfare measures in the in the project area is given at Annexure
project area. B (iii).
vii The overall noise levels in and around the Noise control measures including
plant area shall be kept well within the acoustic hoods, silencers. Enclosures
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standards (85 dBA) by providing noise have been provided. Noise level
control measures including acoustic monitoring data enclosed as Annexure
hoods, silencers, enclosures etc. on all –B(iv)
sources of noise generation. The ambient
noise levels shall conform to the
standards prescribed under
Environmental (Protection) Act, 1986
Ruies, 1989 viz. 75 dBA (day time) and
70 dBA (night time).
viii. All recommendations made in the Compliance report of CREP is given at
Corporate Responsibility for Environment Annexure B (v)
Protection (CREP) for cement plants shall
be implemented.

ix. Proper housekeeping shall be taken up. Medical checkup camp was organized
Regular annual medical examination of all in January’15 & February’2015.
the employees shall be carried out from Photographs enclosed at Annexure-
the occupational health point of view and B(vi)
records maintained.
x. A separate environmental management An organization chart of the
cell to carry out various management and Environmental Management Cell is
monitoring functions shall be set up under given at Annexure B (vii).
the control of Senior Executive.
xi. As proposed in EIA/EMP. Rs. 28.00 As on date, about Rs. 52.11 crores
Crores and Rs. 0.95 Crores earmarked already invested on the air pollution
towards the capital cost and recurring equipments which were installed for
cost/annum respectively for environment expansion (ie RABH, ESP, Bag House
pollution control measures for the cement and nuisance bag filters).Capital cost &
plant and Rs. 35.00 Lakhs and Rs. 23.2 Recurring cost data of Plant and Mines
Lakhs earmarked towards the capital cost from October 2014 to March 2015 are
and recurring cost/annum respectively for attached as Annexure-B (viii) Funds
environment pollution control measures provided for the maintenance of the
for the mine shall be suitably used to above equipment shall not be diverted
implement the conditions stipulated by the for any other purpose.
Ministry of Environment and Forests as
well as the State Government. The funds
so provided shall not be diverted for any
other purpose.
xii. The Regional Office of this Ministry at Agreed. Six monthly compliance reports
Bangalore / CPCB / APPCB shall monitor are regularly being submitted.
the stipulated conditions. A six monthly
compliance report and the monitored data
along with statistical Interpretation shall
be submitted to them regularly.
xiii. The Project Authorities shall inform the Complied.
Regional Office as well as the Ministry,
the date of financial closure and final
approval of the project by the concerned
authorities and the date of commencing
the land development work.
xiv. The Project Proponent shall inform the Complied.
public that the project has been accorded
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environmental clearance by the Ministry
and copies of the clearance letter are
available with the A. P. Pollution Control
Board / Committee and may also be seen
at Website of the Ministry of Environment
and Forests at http:/envfor.nic.in. This
should be advertised within seven days
from the date of issue of the clearance
letter at least in two local newspapers that
are widely circulated in the region of
which one shall be in the vernacular
language of the locality concerned and a
copy of the same shall be forwarded to
the Regional office at Bangalore.

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