CHAPTER-4 IDENTIFICATION AND ASSESSMENT OF IMPACTgpcb.gov.in/pdf/Satva_Cement_Ind_EIA_Report_Part_III.pdf · Draft Rapid Environmental Impact Assessment M/s. Satva Cement Industries

CHAPTER-4

IDENTIFICATION AND ASSESSMENT

OF IMPACT

____________________________________________________________________________________ Draft Rapid Environmental Impact Assessment M/s. Satva Cement Industries Chapter 4 Identification & Assesment of Impact Page: 1 of 25

CHAPTER-4 IDENTIFICATION AND ASSESSMENT OF IMPACT

4.1 PREFACE

Impact Identification and prediction is a way of ‘mapping’ the environmental

consequences of the significant aspects of the project and its alternatives.

Several techniques and methodologies are in vogue for predicting anticipated

impacts due to projects on natural and social aspects of the environment.

These predictions are superimposed over the baseline (pre-project) status of the

environment to derive the ultimate scenario of environmental conditions. These

conditions are then subsequently evaluated for acceptability by screening

them against standards. Based on results of prediction and evaluation, pollution

abatement and control measures in order to mitigate the adverse impacts on

the environment are delineated in an Environmental Management Plan for

further implementation during the construction and commissioning of the

project activities, as well as during the operational phase.

The detailed list of activities described in this report have been taken into

consideration for generation of cause-condition-effect network, for

identification & prediction of the environmental impacts that would be

stimulated by the proposed activity.

Prediction involves determination of the nature and extent of the probable

impacts due to the proposed activities or the actions involved in the project.

Here it is determined, whether the likely environmental impacts are

Beneficial or Adverse

Long term or Short term

Permanent or Temporary

Caused or Induced

Primary / Secondary / Tertiary

Reversible or Irreversible

Site specific or Project specific

The overall environmental impact is divided into two categories during


Construction Phase and Operation Phase. The environmental impact

assessment is accomplished in three stage actions viz. identification, prediction

and evaluation.

The following project related activities identified as sources having potential to

cause impact upon various environmental attributes;

Transportation and storage of raw materials and finished products

Manufacturing process (Generation of solid waste, wastewater, fugitive

emissions and noise)

Consumption of resources

Emergencies or disaster

Breakdown of critical systems

Maintenance activity

Green Belt Development

The prediction and assessment of impact has been based on the following

data, which has been collected from the project proponent, concerned

agencies or generated on the basis of the field monitoring:

1. Environmental pollution potential from the proposed project

Collected data from industry and Our past Experience

2. Baseline environmental quality status at project site and within the study area of 10 km radius from project site which includes air, water, soil and noise

Monitored data

3. Meteorological data monitored for study area during study period and micro meteorological data

Collected from IMD

4. Socio – economic and ecological environment of the area

Summarized from Census 2001

Potential impacts of the project on the various environmental components or

attributes given below are predicted.

Water Environment

Air Environment

Land Environment


Noise Environment

Ecology

Aesthetics

Socio Economic Environment

The identification of environmental impacts has been made, based on the

understanding of cause-condition-effect relationship between an activity and

the impact component. The following activities identified as sources having

potential to cause impact upon various environmental parameters due to

proposed project during the construction and operation phase are given in

Table – 4.1(A) and Table – 4.1(B)

Table – 4.1(A) Type of Activities and Impact during Construction Phase

Sr. No.

Type of Activities Potential Impacts

1 Level and Road Laying Dust emission, Soil Compaction, Change in traffic pattern

2 Earthwork comprising of excavation, grading, Back-filling

Increase in erosion, soil compaction, increase in transport facilities; increase in employment

3 Foundation Work Dust emission, Noise, Decrease in water table

4 Civil construction Increase in Dust Emission, increase in employment

5 Mechanical erection Generation of noise


Table – 4.1(B) Type of Activities and Impact during Operation Phase

Sr. No. Type of Activities Potential Impacts

1 Trial runs and manufacturing activities

Gaseous emission, Increase in vehicular traffic, Increases in employment.

2 Material Handling Increase in Noise level, visual impact, Dust emission

3 Utilities Increase in traffic, Increases in Services.

4 Green Belt Development Decrease in run off, increase in ground water table.

4.2 PREDICTION & ASSESSMENT OF IMPACTS DURING CONSTRUCTION ACTIVITIES

The project would be installed in phased manner. As the installation of the

cement plant is to be undertaken progressively; the time period of the

construction activities will be elongated. Due to this, following short term

impacts will be incurred on the environment for a period of time. However, due

care will be taken to comply all the applicable rules and regulations to minimize

the negative impacts if any to the environment.

4.2.1 WATER ENVIRONMENT

Ground water from own bore well will be utilized for the constructions phase.

The water consumption during the construction phase is very less and

consumption will be for short period. Hence there will not be any major

impact on availability of natural resources during this stage.

The wastewater generation will be only from the domestic activities; which

will be disposed into soak pit through septic tank.

4.2.2 AIR ENVIRONMENT

The major construction activities from which air emission may occur are;

excavation, loading and unloading of material, etc. Following mitigation

measures are proposed to minimize the air pollution during the construction

stage.

Water will be sprayed for dust suppression.


Wind curtain will be provided at the construction site and dispersible material

construction materials like cement, sand etc will be covered with tarpaulin.

The sand and other such dispersible material will be stored at site for

minimum working period.

The construction equipment will be chosen for least suspension of dust/sand

into atmosphere.

The construction activity will be carried out during day time only.

The emissions are temporary and not expected to contribute significantly to

the ambient air quality and will be within prescribed limits for industrial

regions by National Ambient Air Quality Standards (NAAQS).

4.2.3 LAND AND SOIL ENVIRONMENT

The proposed project will set up on the abandoned agriculture land; there

will not be any significant topographical change.

The construction activity will help in fixation of soil, thereby reducing the soil

erosion.

Some construction activities will disturb the soil profile but that will be

temporary and insignificant impact.

4.2.4 NOISE ENVIRONMENT

The noise generated from construction machinery shall be kept low by

keeping the moving parts serviced and properly lubricated.

The noise impacts will be local; limited to the premises and very short – term.

4.2.5 SOCIO - ECONOMIC ENVIRONMENT

During the constriction activities, there will be positive impact on the socio

economic environment as it will generate employment.

4.3 PREDICTION AND ASSESSMENT OF IMPACTS DURING OPERATION PHASE

4.3.1 WATER ENVIRONMENT

With respect to water environment; three aspects are generally considered in

REIA, availability and consumption of Fresh water, Wastewater generation and

its disposal.


A) FRESH WATER CONSUMPTION

The total water requirement for the proposed cement plant will be

@ 16.0 KL/day including domestic, gardening and industrial. The fresh water

requirement will be satisfied through ground water. The location of proposed

project site falls under the Grey (Semi Critical) zone according to the map of

ground water Categorization published by Gujarat Water Resources

Development Corporation. The unit also proposes to install the rain water

harvesting system to recharge the ground water and to reduce the ground

water withdrawal.

Hence, there will be negligible impact on ground water due to water

consumption of the propose project.

B) WASTE LOAD GENERATION AND DISPOSAL

There will be no industrial wastewater generation from the proposed

activity. Hence there will not be any disposal of effluent and the unit will be

Zero Industrial discharge.

There will be generation of domestic effluent @ 1.6 KL/day from the

proposed project which will be disposed in to the soak pit through septic

tank.

There will not be any significant impact on ground water environment and

surface water environment due to effluent disposal from proposed project.

4.3.2 AIR ENVIRONMENT

A) IDENTIFICATION OF MAJOR AIR POLLUTANTS

The major source of air pollution due to proposed project will be flue gas

emission from the vertical shaft kiln and process gas emissions from raw mill &

cement mill. The considerable pollutants from the flue gas & process gas

emission are PM, SO2 and NOx.


Fugitive dust emissions can arise during the storage and handling of materials

and solid fuels, and also from road surfaces. Particulate releases from

packing and dispatch of clinker/cement can also be significant.

B) ASSESSMENT OF IMPACT

The unit will provide water scrubber to Kiln as air pollution control measures

and the flue gas emission will be well within gaseous emission norms

described by the GPCB.

To reduce fugitive dust emission, the unit has proposed to provide bag filter

type dust extraction system at Raw Mill and Cement Mill.

Adequate Stack height will be provided for proper dispersion of pollutants,

particularly sulfur dioxide (SO2) into the atmosphere as per CPCB guidelines.

Impact of a source or a group of sources on air quality is evaluated using

mathematical models. The model stimulates the relationships between air

pollutants emitted from the source and their impact on surrounding air quality.

The air quality model is prepared based on the stack details and

meteorological data.

The mathematical model based on Gaussian theory, a computer based version

ISCST3, is used to calculate Ground Level Concentrations (GLC) as a function of

wind speed, direction and stability class. The GLC for the parameters like SPM, &

SO2 as emitted from the stack attached to kiln, raw mill and cement mill have

been predicted using above mathematical model.

The likely impacts on air have been studied based on following assumptions,

1. PM & SO2 emission from flue gas stack and process stack were calculated

by considering maximum possible concentrations.

2. Maximum possible computed emission at full capacity utilization,

3. The entire three stacks operated together (Kiln, Raw mill & Cement mil )

The following methodology is adopted for the prediction based on above

model.

1. Input Parameters

The input parameters for the preparation of mathematical model consist of


Meteorological Data viz. ambient temperature, wind speed, wind direction etc.

and potential of the air pollutants viz, physical stack height, inner diameter of

the stack at exit, stack emission, flue gas temperature, flue gas velocity etc. The

details of all the in put parameters are discussed here below.

• Micrometeorological Data

Micrometeorological data required for the mathematical modeling were

collected for the site and the details of which are discussed and elaborated in

Section 3.4 of Chapter - 3 in earlier part of this report.

• Potential of the Air Pollutants

The potential sources of air pollution are gaseous emission from the stack

attached to the vertical Shaft Kiln, Raw mill and Cement mill. The details of stack

emissions considered for the processing of mathematical model are given in

Table - 4.2.

Table – 4.2: Details of Stacks

Sr. No. Particular Unit Details / Value

1. Stack Attached to --- Vertical shaft

Kiln (2 Nos.,

5.0 T/Hr.)

Raw Mill (2 Nos.,

3.0 T/Hr.)

Cement Mill

(2 Nos., 3.5 T/Hr.)

2. Stack Height m 30 20 20

3. Stack Inside Diameter m 1.0 0.5 0.5

4. Cross Sectional Area of Stack m2 0.7854 0.1963 0.1963 oC 80 50 50

5. Gas Exit Temperature

K 353 323 323

6. Gas Exit Velocity m/sec 2.5 5.0 5.0

7. Gas Exit Flow Rate Nm3/Sec 1.658 0.906 0.906

8. Quantity of Pollutant Discharge

a) PM 0.0829 0.0453 0.0453

b) SOx gm/sec 0.4330 --- ---


2. The Receptor Area

The baseline ambient air quality monitoring stations are selected as receptor

area to evaluate the impact of air pollutants from the source and eventually

to find out resultant ambient air quality at above location.

The receptor locations in uniform polar grid within 5.0 Km with flow vector of

22.5 degree (sixteen directions) and 10 polar rings i.e. radial distance at 0.5

km increment from source is selected.

3. Model Output

The output of the model consists of ground level concentration at various

distances and direction from the source. The first three highest 24 hour average

ground level concentration value for SPM & SO2 and is given in Table – 4.3 and

the first highest 24 hourly average ground level concentration value for various

parameters at the ambient air quality monitoring stations is given in Table-4.4.

Table- 4.3: First Three Highest 24-Hourly Average GLC Values

Concentration, µg/m3 Highest Value

Location w.r.t Project Site SPM SO2

1st 0.5 KM @ 135º 4.310 7.469

2nd 0.5 KM @ 135º 2.739 4.564

3rd 0.5 KM @ 135º 2.661 4.039

Table-4.4: First Highest 24-Hourly Average GLC Values at AAQM Stations

Concentration, µg/m3 Station Code Station Name Location w.r.t

Project Site SPM SO2 S2 Jegadva 3.25 km @ 45º 0.484 0.629

S3 Hampar 5.0 km @ 90º 0.089 0.206

S4 Khambhda 4.8 km @ 150º 0.012 0.029

S5 Dholi 4.95 km 195º 0.103 0.240

S6 Vrajpar 2.8 km @ 294º 0.000 0.000


Based on the maximum concentration values observed during the study period

and the first highest 24 hourly average GLC value calculated using

mathematical modeling for the proposed project, the expected level of

maximum GLC for various parameters at the ambient air quality monitoring

stations after the proposed project has been estimated and which is illustrated

in the Table-4.5.

Table- 4.5: Expected level of pollutant at ambient air monitoring locations

SPM SO2 Station Code

Station Name I II III I II III

S2 Jegadva 126 0.484 126.484 16.4 0.629 17.029

S3 Hampar 145 0.089 145.089 17.8 0.206 18.006

S4 Khambhda 168 0.012 168.012 20.2 0.029 20.229

S5 Dholi 134 0.103 134.103 16.2 0.240 16.440

S6 Vrajpar 121 0.000 121.000 16.8 0.000 16.800

Note : I - Maximum Ambient Air Monitoring Results observed during study period(µg/m3) II - 24-Hourly 1st Highest Ground Level Concentration Calculated Using

Mathematical Model ISCST3 ((µg/m3) III - Expected Level of Pollutant After Proposed Project ((µg/m3)

Isopleths Showing 1st highest 24 hourly average GLCs contour plots for the Total

Suspended Particulate Matter (SPM) and Sulphur Dioxide (SO2) after the

proposed project are given in Plate – 4.1 and Plate – 4.2 respectively.

OBSERVATIONS

The maximum 24-hourly average concentration for pollutant due to proposed

project calculated using mathematical model (ISCST3) for SPM and SO2 is 4.310

µg/m3 and 7.469 µg/m3 respectively which is very negligible compared to

NAAQS even for the worst case scenario and will fall at about 0.5 km @ 1350

from the project site, where there is unirrigated and open scrub land and no

population resides.


There is negligible increase in concentration of SPM and SO2 at ambient air

monitoring locations due to proposed project as shown in Table-4.4. Thus,

considering worst-case scenario the ambient air quality at all the monitoring

locations after the proposed project does not exceed NAAQS norms as shown

in Table-4.5.

Hence, there will not be any significant impact on air environment due to

proposed project considering worst-case scenario.


4.3.3 LAND/ SOIL ENVIRONMENT

a) PREDICTION OF IMPACT

The impact on land and soil environment may be due to effluent disposal,

hazardous waste disposal and dust deposition.

b) ASSESSMENT OF IMPACT

Effluent Disposal

There will not be any wastewater generation from the proposed

manufacturing activity.

Only domestic wastewater will be generated and entire quantity of

wastewater will be disposed to septic tank followed by soak pit.

Solid/Hazardous waste Disposal

There will be generation of cement dust, which is considered as non-

hazardous. Moreover, the solid waste collected in different dust collection

system will be recycled in respective sections of the plant.

The only source of hazardous waste generated from plant machineries will

be as spent/used oil which will be reused as lubricant within premises / Sold

to MoEF approved recyclers.

The unit will provide an isolated area for the hazardous waste storage within

premises having pucca floor and roof cover.

Dust Deposition

Adequate air pollution control measures will be provided to collect the

generated dust. There will not be any chances of dust emission so there will

be negligible impact on land.

The solid waste collected in different dust collection system will be recycled

in respective sections of the plant.

Adequate height will also be provided to all the stacks for the proper

dispersion of pollutants.

Hence, there will not be any noteworthy impact on land and soil environment

due to Effluent disposal, disposal of hazardous waste and dust deposition.




Development of Green belt

The unit will developed green belt within the premises which will not only

improve the soil conditioning but will also prevent soil erosion and the

landscape & give slight beneficial impact on the land usage. Greenbelt will

minimize the predicted level of possible air pollutants and to minimize noise

pollution.

In consequence of development of green belt it will create a beneficial impact

on land and soil environment.

4.3.4 NOISE ENVIRONMENT

a) PREDICTION OF IMPACT

Prediction of potential impacts on noise environment from the proposed

project is as important as well as the vital components of the environment. The

impacts of noise depend mainly on the characteristic of the noise generating

sources, topography and atmospheric conditions.

During operational phase the impact on noise environment will be due to

manufacturing activities like Raw Mill, cement mill, crusher etc and due to the

transportation within and outside the premises.

b) ASSESSMENT OF IMPACT

The noise generation will be mitigated by installing noise barriers/absorbers

around stationery noise sources. Adequate noise control measures such as

anti vibration pad for equipment with high vibration will be provided.

Extensive Oiling, Lubrication Preventive Maintenance will be done regularly.

Vehicular movements during operation phase for loading/unloading of raw

and finished materials and other transportation activity may also increase

noise level. However, the volume of transport vehicles to be handled due to

proposed project is very low, as compared to the total vehicular traffic in the

area.


Provision of Noise control measures such as acoustic insulation, enclosures,

hood, air silencers etc. for the Equipments and Machinery generating high

noise.

Adequate noise control measures such mufflers, silencers at the air

inlet/outlet, anti vibration pad for equipment with high vibration, earmuff

and earplugs to the operators etc. will be provided.

Proposed green belt will act as a barrier to the propagation of noise from the

factory premises. This will reduce the noise levels appreciably and it will not

have any impact to the nearby present human settlement.

Therefore, there will be negligible impact on noise environment of surrounding

area due to project activities.

4.3.5 ECOLOGICAL ENVIRONMENT

The impact due to the project activity on the ecological parameters like natural

vegetation, crops, fisheries and aquatic life, forests and species diversity is

summarized in below texts:

The project site will be located at Dhrangadhra village District

Surendranangar on abandoned agricultural land and there will not be any

cutting of natural vegetation due to proposed project. On the contrary, the

industry will develop its green belt area surrounding periphery.

Since the proposed project will be on abandoned agricultural land, it is not

likely to alter the crop production and pattern or the area.

The increment in concentration of SPM and SO2 at seven reserved forest is

less than 0.4953 µg/m3 and 1.1650 µg/m3 respectively, which is almost nil and

thus does not envisage any impact on the reserved forest.

No commercial fishery activities are observed within 10 Km radius of the

proposed site, and hence proposed activities are not envisaged to have any

adverse effect on fisheries and aquatic life.

Also the necessary environmental protection measure have been planned

under EMP for air, water and waste management systems and regular

environmental surveillance will be carried out so as to prevent any short-term

or cumulative effect on the crops and natural vegetation of the area.


Thus, there will not be any significant impact on ecological environment due to

proposed project activities.

4.3.6 AESTHETIC ENVIRONMENT

The plant will be developed in abandoned agriculture land with good

landscape and plantation. Increase in fugitive emission due to increased

vehicular movement for the proposed project may have minimal adverse

impact on the visual quality. However, this impact can be minimized with

implementation of environmental management plan.

Since there will be no discharge of effluent to any water body, there is no

visual adverse impact on quality of water.

The units will develop the green belt area @ 1796.0 m2 which will improve the

overall aesthetic view of the premises.

Thus, there will not be any impact on aesthetic environment due to proposed

project activities.

4.3.7 SOCIO ECONOMIC ENVIRONMENT

a) EMPLOYMENT OPPORTUNITY

Prediction of the socio-economic impacts of site would be totally a positive

main due to the employment opportunities. During operational phase, skilled

and unskilled manpower will be needed. This will increase the employment

opportunity. Secondary jobs are also bound to be generated to provide day-to-

day needs and services to the work force. This will also increase the demand for

essential daily utilities in the local market. The manpower requirement for the

proposed project is expected to generate some permanent jobs and

secondary jobs for the operation and maintenance of plant. This will increase

direct / indirect employment opportunities and ancillary business development

to some extent for the local population. This phase is expected to create a

beneficial impact on the local socio-economic environment. b) INDUSTRIES

During the operation activities, the required raw materials will be sourced

maximum from the local area. In addition to this the required spares and


consumables required for the operation of the plant and machineries will be

procured from the near by area. The increasing industrial activity will boost the

commercial and economical status of the locality, to some extent.

c) PUBLIC HEALTH

During operation activities, workers will be provided with basic amenities like

safe water supply, low cost sanitation facilities, first aid, required personal

protective equipment, etc. Otherwise, there could be an increase in diseases

related to personal hygiene. Hence, there will not be any significant change in

the status of sanitation and the community health of the area, as sufficient

measures have been taken and proposed under the EMP.

The proposed project activities will improve the general environment by

planting more number of trees through a planned green belt development

which will improve Aesthetic value of the region. On the whole the project will

have a favorable ranking with the local inhabitants and will be looked upon as

a blessing for development of the area.

Thus, there will be a slight beneficial impact on socio-economic environment

due to proposed project activities.

The possible beneficial Impacts due to the proposed project is shown in Figure-

4.1


Figure – 4.1 Possible Beneficial Impacts Due To Proposed Project

Project

Development of

Minimize the Noise

Socio Economic

Improve Aesthetic

Probability of temporary

Improve community

Improve sanitation

Improve educational

Improve Soil

Probability of secondary

Probability of permanent

Enhance Commercial

and economical

Prevent Soil erosion and improve the


4.4 ENVIRONMENTAL IMPACT EVALUATION

The matrix system evaluates the impact on the environment both in terms of

quality and quantity. The environmental attributes that have some impact due

to the proposed project activities are considered. The environmental impacts

identify the possible relationship of proposed industrial operations with respect

to environment attributes. These relationships can be beneficial or adverse.

Impact identification matrix for operation phase is given in Table – 4.6. The

potential impact during operational stage along with mitigation measure is

presented in Table – 4.7.

Table-4.6: Impact Identification Matrix (Without EMP)

Project Activities

(Construction Phase)

Project Activities (Operational Phase)

Sr. No. Environmental

Parameters

Exca

vatio

n

Con

stru

ctio

n

Inst

alla

tion

of

Equi

pmen

ts

Wat

er

Requ

irem

ent

Efflu

ent

Disc

harg

e G

aseo

us

emiss

ions

Solid

Was

te

Mat

eria

l Ha

ndlin

g

Man

fg.

Act

ivity

Equi

pmen

t Fa

ilure

Tran

spor

tatio

n

Gre

en B

elt

Deve

lopm

ent

ENVIRONMENTAL POLLUTION i) Water Env. Water Resource √ √

Water Quality √ ii) Air Env. √ √ √ √ √ √ √ √ iii) Land / Soil

Env. √ √ √ √

1.

iv) Noise Env. √ √ √ √ √ √ √ ECOLOGICAL ENVIRONMENT Natural Vegetation √ √ √

Crops √ Fisheries & Aquatic Life

2.

Forests & Species Diversity

3. AESTHETIC ENVIRONMENT


Visual Water / Air Quality √ √ √

Odour

Landscape √ SOCIO-ECONOMIC ENVIRONMENT • Employment

Opportunity & Economic Development

√ √ √ √ √ √

• Public Welfare & Sanitation

4.

• Social Amenities

Table- 4.7: Potential Impacts & Mitigative Measures during Operational Stage

Sr. No.

Environment Components

Project Activity

Impacts predicted Remarks

Cement manufacturing

Operations

Dust and Gases will produce , Increase in SPM level

Adverse

Transportation

Causes dust nuisance as well as gaseous pollutant due to vehicular emission on road transportation of product and Raw material

Adverse 1 Air Quality

Green Belt Development

It serves as a natural screen in reducing the SPM concentration

Beneficial


Operations

Extraction of Ground water and utilized for Industrial, Domestic purpose.

Adverse

2 Water

Table & Quality Rain water

Harvesting

Decrease the Extraction of Ground water and Recharge Ground Water

Beneficial

3 Noise Quality


Operations

Increase in noise level due to use of various Equipment

Adverse


Sr. No.

Environment Components

Project Activity

Impacts predicted Remarks

Transportation Deteriorates health due to air & noise pollution

Adverse

4

Health Green belt

Development

Improves the health of Inhabitants by acting as a barrier to air & noise pollution and imparts pleasant atmosphere

Beneficial

5 Public Utilities Transportation Improved road networks and vehicular movement within the study area

Beneficial

6 Economic

Aspect


Operations

Increase employment opportunities both Direct and Indirect there by increasing economic status of people

Beneficial

7 Economic

Aspect Transportation

Increase employment opportunities both Direct and Indirect there by increasing economic status of people

Beneficial

8 Land use and

soil characteristic

Green Belt development

Beneficial effects on land as it improves aesthetic view

Beneficial

9 Land use and

soil characteristic

Dust Deposition

Impact due to dust deposition on land and soil

Adverse

10 Land use and

soil characteristic

Transportation Impact due to settling of air borne dust and fumes

Adverse

4.4.1 IMPACT EVALUATION

The environmental impact evaluation is based on careful study of project site,

manufacturing operation of proposed activities, surrounding environment

(meteorological conditions, ambient air quality status, water quality status, soil

quality status, ecological environment, socio-economic status, land-use pattern

of the study area) etc.


These can be further classified as short term or long term, reversible or

irreversible, local or regional. The evaluation of the impacts due to proposed

project activities is given in Table – 4.9. While Table - 4.10 show the total score of

the project.

4.4.2 IMPACT QUANTIFICATION

For calculating the severity of the impact on the environmental attributes due

to the various project activities the severity has been divided into impact scores

from 0-4 as under ; Table - 4.8 shows the environmental impact score related to

project activities.

Table: 4.8 Environmental Impact Score

Severity Criteria Impact Score

No Impact : 0

Very Slight : 1

Slight Impact : 2

Moderate Impact : 3

Appreciable Impact : 4

The impact score is (–ve) or (+ve) depending on whether the impact is adverse

or beneficial. The construction phase is not considered in environmental impact

matrix, as impacts due to construction activities are temporary, short-term and

negligible.


Table – 4.9: Environmental Impact Evaluation Matrix

Project Activities (Operational Phase)

Sr. No.

Parameters

Wat

er

Requ

irem

ent

Efflu

ent

Gen

erat

ion/

Di

spos

al

Gas

eous

em

issio

ns

Haza

rdou

s W

aste

G

ener

atio

n

Mat

eria

l Ha

ndlin

g

Man

fg.

Act

ivity

Equi

pmen

t Fa

ilure

Tran

spor

tatio

n

Gre

en B

elt

Deve

lopm

ent

ENVIRONMENTAL POLLUTION • Water Env.

i) Water Resource -1 0 0 0 0 0 0 0 0

ii) Water Quality 0 0 0 0 0 0 0 0 0 • Air Env. 0 0 0 0 -1 -1 0 -1 +2 • Land & Soil Env. 0 0 0 -1 -1 0 0 -1 +2

1.

• Noise Env. 0 0 0 0 0 0 0 -1 +1

Total -1 0 0 -1 -2 -1 0 -3 +5 ECOLOGICAL ENVIRONMENT

• Natural vegetation

0 0 0 0 0 0 0 0 0

• Crops 0 0 0 0 0 0 0 0 0 • Fisheries & Aquatic

Life 0 0 0 0 0 0 0 0 0

2.

• Forests & Species Diversity

0 0 0 0 0 0 0 0 0

Total 0 0 0 0 0 0 0 0 0 AESTHETIC ENVIRONMENT

• Visual Water / Air Quality

0 0 -1 0 -1 0 0 -1 +2

• Odour 0 0 0 0 0 0 0 0 0

3.

• Landscape 0 0 0 0 0 0 0 0 +2

Total 0 0 -1 0 -1 0 0 -1 4 SOCIO-ECONOMIC ENVIRONMENT • Employment

Opportunity & Economic Development

0 +1 0 0 +1 +1 0 +1 0

• Public Welfare & Sanitation 0 0 0 0 0 0 0 0 0

4.

• Social Amenities 0 0 0 0 0 0 0 +1 0 Total 0 1 0 0 1 1 0 2 0


Table-4.10: Environmental impact score of the proposed project activities

Sr. No.

Parameters Evaluation Score

1. Environmental Pollution -3

2. Ecology Environment 0

3. Aesthetic Environment +1

4. Socio-Economic Environment +5

Total +3

Thus, proposed project activities will not have any significant environmental

impact on surrounding environment. On the contrary, there will be beneficial

impact on surrounding environment due to increase in employment

opportunities and economy of the area.

CHAPTER-5

ENVIRONMENTAL

MANAGEMENT PLAN

____________________________________________________________________________________ Draft Rapid Environmental Impact Assessment Report M/s. Satva Cement Industries Chapter-5 Enviormental Mangement Plan Page 1 of 28

CHAPTER- 5 ENVIRONMENTAL MANAGEMENT PLAN 5.1 PREFACE

The main purpose of the EMP is to identify project specific actions that will be

undertaken by the project authority for mitigation of the specific impacts

identified in the project. These actions will be incorporated into project

management system and integrated into the implementation at various stages

of project development. This report pertains to the project activities; the

Environmental Management Plan broadly defined here is concerned with the

impacts identified earlier.

The aim of Environmental Management Plan is to warrant that the industrial

development in an identified particular study area needs to be entangled with

judicious utilization of non-renewable resources and to ensure that the stress /

load on the ecosystem is within its permissible assimilative capacity i.e. its

carrying capacity. In above context assimilative capacity refers to the

maximum amount of pollution load that can be discharged into the

environment without affecting the designated use of various environmental

attributes and is governed by dilution, dispersion and removal due to physico-

chemical and biological process. An effective EMP ensures that these

environmental requirements and objectives are satisfied during all phases of

project.

Environmental Management generally includes protection / mitigation /

enhancement measures as well as delineation of post project monitoring

program. The plan as prepared may suggest revisions in the plant layout or

operational parameters to avoid adverse impacts. Sometimes additional

project operations have to be incorporated in the conventional plan of

operation, as per the actual requirement.


Adopting mitigative measures including incorporation of suitable features in the

planning and design stage can minimize the adverse impacts envisaged during

construction and operation phases. Mitigation measures at the source level and

an overall management plan are elicited to improve the supportive capacity of

the study area and also to preserve the assimilative capacity of the receiving

bodies.

5.2 OBJECTIVE OF ENVIRONMENTAL MANAGEMENT PLAN

The long-term objectives of the Environment Management Plan for all the

environmental attributes are as under:

To comply with all the regulations / applicable laws stipulated by Central /

State Pollution Control Boards.

To create good working conditions (devoid of air and noise pollution for the

employees).

To encourage support and conduct developmental works for the purpose of

achieving environment standards and to improve methods of environment

management.

To reduce fire and accident hazards.

To rationalize and streamline environmental activities to add value in

efficiency and effectiveness.

To encourage and achieve highest performance and response from

individual employees and contractors.

To plan out the complete strategy to take care of stakeholder engagement.

To contribute significantly for sustainable development.

To treat all the pollutants i.e. effluent and hazardous waste with appropriate

technology.

Perspective budgeting and allocation of funds for environment

management expenditure.

Continuous development and search for innovative technologies for a

cleaner and better environment.


To encourage, support and conduct development work for the purpose of

achieving environmental standards and to improve the methods of

environmental management.

The environment Management Plan has been worked out for Operation phase

of the proposed project which has been categorized for:

Water Environment

Air Environment

Land Environment

Noise Environment

Socio Economic Environment

As a part of the efforts for sustainable development, to identify the adverse

impacts, causes and prevention and precaution measures are the most

important part of the development activity of any project. For the purpose of

the prevention/minimization of the adverse impacts the Environmental

Management Plan (EMP) and impact mitigation measures are identified and

implementations of various mitigative measures for environmental impacts

envisaged are discussed.

5.3 WATER POLLUTION CONTROL SYSTEM

Water conservation measures will be taken to optimize the fresh water

requirement. The fresh water requirement for the proposed project will be

satisfied through ground water from own bore well.

Record for water consumption shall be maintained for each usage.

There will be no Industrial wastewater generation. The domestic effluent will

be disposed to soak pit through septic tank.

Separate Disposal system for storm water will be provided so it will not be

mixed with domestic waste water.

Cleaner production technology will be assessed to maximum possible reuse

and recycling of material.


The action sheet for mitigation of water pollution due to storm water is given

Table-5.1

Table – 5.1: Action Sheet for Mitigation of Storm Water Pollution

Source Rain water

Mitigation Measures

1. Identify the potential sources of storm water pollution. 2. Evaluation of non-storm water discharges to determine if

they contaminate storm water.

Methodology of Implementation

1. Good House Keeping – To maintain a clean and orderly working environment.

2. Spill Prevention & Response – Identify location where spill occur and define spill prevention handling practices and response procedures.

3. Visual Inspection – To conduct routine inspection of facility to ensure that all the elements of the plant are in place and working properly.

4. Employee Training-Trained employees in all aspects of storm water management plan.

5.3.1 RAIN WATER HARVESTING

Since the project site falls under Grey (Semi Critical) Category and their water

withdrawal will not exceed the 100 m3/day, according to the same CGWA

guidelines it is not mandatory for the unit to adopt recharging of water

(rainwater harvesting). However, the unit will design and implement the

recharging of ground water (Rainwater harvesting) system voluntarily which will

create positive impact to the water environment.

The following major points will be kept in to consideration while designing the

system;

• Total annual rainfall in the area

• Catchments area with in the project site

• Subsurface geology and aquifer

• Precaution to mitigate and control dust contamination

Well design storm water network will be provided to collect the rain water from

the site area and diverted to the proposed rain water harvesting pits for

recharging the ground water. The storm water drain system in the complex will


be designed with proper slope and direction, considering the catchments area

and intensity of rainfall. The design volume of water harvested through the

percolation well will be 180 m3/hr considering the maximum intensity of rainfall

50 mm/hr. Here, for designing of rain water harvesting system the whole

industrial premises is considered as catchment area, so that all the storm water

produced on site can be harvested for ground water recharge and it will not be

require to discharge it outside the factory premises.

The proper management and pretreatment of rainwater harvested will be done

to ensure that it is free of contamination. The storm water collected will be

passed through multi grade filter to remove the suspended matter before

recharging. The Schematic drawing of percolation well is shown in Figure - 5.1.


Figure-5.1. Schematic Drawing of Percolation Well


Total water requirement per day of proposed project will be 16 KL i.e. 4800

KL/annum (considering 300 working days per annum). Total requirement of

water will be met by bore wells within the factory premises of unit. It can be

shown from Table – 5.2 that total volume of water harvested per annum will be

1810 KL which is 37.72% of annual water requirements.

Table – 5.2: Details of Rain Water harvesting System

Value

Particular unit Roof-Top

Ground Surface

Covering

Untreated Ground

Catchment Annual Rain Fall mm 500

Maximum intensity of rain fall mm/hr 50

Design Volume of Water Harvested through Percolation Well m3/hr 180

Runoff Coefficient -- 0.75 0.6 0.3

Filter Efficiency -- 0.9 0.9 0.9

Catchment Area Sq.meter 1175 3554 3365

KL 397 960 454 Annual Volume of water harvested

Liter 396563 959580 454275

Total Annual Volume of water harvested KL/Annum 1810

Daily Water Requirement KL/Day 16

Working Days per annum Days/Annum 300

Annual Water Requirement KL/Annum 4800 Annual Water Requirement After Harvesting KL/Annum 2990

Annual Recharge of the Ground Water % 37.72


5.4 AIR POLLUTION CONTROL SYSTEM

The source of emission of SO2, NOx and particulate matter from the proposed

activity will be Kiln. The source of emission of particulate matter will include Raw

Mill and Cement mill. There will be chances of fugitive emission / dust emission

from transfer points, storage yard, packing plant etc.

Some generic measures shall be taken to reduce fugitive and gaseous pollutants

emissions, which are as follows:

To control the emissions from the kiln, raw mill and cement mill, Scrubber and

bag filter will be maintained properly and operated continuously.

Adequate Stack height will be provided for proper dispersion of pollutants,

particularly sulfur dioxide (SO2) into the atmosphere.

Stack monitoring facilities like porthole, platform etc. will be provided with all

the stacks in order to facilitate sampling of gases being emitted into the

atmosphere.

In case of failure of any air pollution control equipments, the process

activities will be stopped.

All the transfer points will be connected to the respective bag filter to control

the fugitive emission.

Work area monitoring will be done periodically to check fugitive emissions.

Unit will adopt free water sprinkling method in open Fuel yard, roads, storage

yard and handling area to suppress dust generation and tarpaulin covering

will be used wherever required to prevent the dust spreading into

atmosphere.

The unit will also develop thick plantation around the storage yard to control

the fugitive emission.

Regular ambient air quality monitoring shall be carried out within factory

premises for SPM, RSPM, SO2, and NOx.

Transfer vehicles and construction machinery will be properly maintained so

as keep air emissions in check. Emphasis will be made on EURO II engines.


The action sheet for mitigation of Air pollution from primary source and

secondary source is given Table-5.3.

Table – 5.3: Action Sheet for Mitigation of Air Pollution

Source Primary and secondary source

Mitigation Measures

1. Regular preventive maintenance and overhauling of APCE will be done.

2. Regular check on the content in the fuel and emissions. 3. To maintain proper air to fuel ratio. 4. Regular checking of efficiency of bag filter 5. Regular checking of efficiency of scrubber.

Methodology of Implementation

a. Good House Keeping – To maintain a clean and orderly working environment.

b. Monitoring of source emissions and ambient air quality as per GPCB Norms through reliable testing authority to ensure compliance of air pollution emission standards.

c. All the kaccha roads shall be made pucca or will be asphalted or concreted to avoid dust formation caused by movement of vehicles.

d. The PUC of the vehicles entering the industrial premises will be checked regularly.

5.4.1 GUIDELINES FOR PREVENTION AND CONTROL OF FUGITIVE EMISSION

Guidelines for prevention and control of fugitive emission are listed below in

sections.

A. Unloading Section (All Operations)

Sr.No.

Control Measures to be Provided Guidelines

1. Enclosure should be provided for all unloading operations, except wet materials like gypsum

The enclosures for the unloading sides could be flexible curtain type material covering up to height of dumpers discharge from the roof.

2. Water shall be sprayed on the material prior and during unloading

A dust suppression system should be provided to spray water. The amount of water sprayed should preferably be optimized by employing proper design of spray system. Suitable systems may be adopted to reduce the problems like choking, jamming of the moving parts.


B. Material Handling Section (Including Transfer Points)

Sr.No.


1. All transfer point locations should be fully enclosed.

The enclosures from all sides with the provision for access doors, which shall be kept, closed during operation. Spillages should be periodically removed.

2. Airborne dust at all transfer operations / points should be controlled either by spraying water or by extracting to bag filter.

Either water spray system should be provided for suppressing the air borne dust or dry extraction cum bag filter with adequate extraction volume.

3. Water should be periodically sprayed on the stockpiles so as to retain some moisture in the top layer.

Spray sufficient quantity of water to moist the top layer to avoid wind blowing of fines.

C. Open Coal Yard Section

Sr.No.


1. Coal to be stored in open yard shall be free of fine dust.

Necessary arrangement is provided to extract fines, from various locations. The air borne fines should be extracted and captured in bag filter and sent to last possible destination (coal mill) directly and should not be mixed/recycled with the crushed coal or safely disposed for purposes like land filling along with stabilization such that it doesn’t get re-entrained.

Maximum possible airborne dust could be extracted from various locations like unloading, crusher discharge, and transfer points. The extracted fines should be separated (not recycled) to prevent its re-entrainment.

If it is not possible to separate the fines then the coal shall be stored in closed storage only.

2. The coal yard floor should be paved with concrete.

Open stocking of coal in unpaved area should be avoided. The pathways for vehicle movement should also be paved.

3. Accumulated dust shall be Any deposits of dust on the ground


Sr.No.


removed / swept regularly and water the area after sweeping.

(other than stock piles) should be cleaned regularly either manually or by sweeping machines. Additionally sufficient water should be sprayed on ground frequently to suppress the dust getting airborne.

4. Instead of dust extraction cum bag filter system, If dust suppression measure is used, additional control measures should be provided.

5. Wetting before unloading.

Coal should be sufficiently moistened to suppress fines by spraying minimum quantity of water.

6. Spray water at crusher discharge and transfer points.

Water spray should also be applied at crusher discharge and transfer points.

7. Water stockpiles frequently.

The frequency and quantity of watering may vary from season to season and the area to be covered, which should be decided and recorded, based on average evaporation rate in the region.

D. Closed Coal Storage Section

Sr.No.


1. The air borne fines should be either suppressed or extracted and captured in bag filter and should be separated.

The captured coal dust be sent to last possible destination (fine coal hopper) directly or safely disposed in landfill and should not be allowed to re-entrain.

2. The enclosure should be from all sides and roof so as to contain the airborne emissions.

The access doors or any other openings shall be kept closed at all possible times.


E. Clinker-Closed Stock Piles Section

Sr.No.


1. Enclosure should be complete from all sides and should have a venting arrangement along with a bag filter.

The enclosures should have a venting arrangement located at transfer point where clinker is dropped to the stockpile. The extraction/ venting should be sufficient enough so as to avoid pressurization of the enclosure thereby reducing fugitive emissions from leakages in the sidewalls or doors.

2. The dust extracted and captured in bag filter should not be fed back/recycled to the clinker stockpile.

Extracted dust should be captured in bag filter and the collected dust should not be fed back to the clinker stockpile. It may be recycled at last possible destination i.e., cement mill section through suitable arrangement

F. Clinker Open Storage Section

Sr.No.


1. Air borne fines extracted from clinker cooler shall be separated and sent to last possible destination directly or safely disposed.

The unit may need to add on / install necessary provisions for separating fine particulates. Fines separation may be achieved by passing collected dust through cyclone, the fines escaping cyclone to be separated, cyclone collection (coarse particles) could be recycled. The fines shall be recycled to the last possible destination (like clinker day silo) suitable or safely disposed.

2. Provide cover on stockpiles.

During the period when the stockpile is inactive, it should be covered fully by HDPE or tarpaulin type sheets to prevent wind blowing of fugitive dust.

3. Provide windbreak walls or greenbelt on three sides of open stock piles

Install three sided enclosures with walls with less than 50% porosity, which extend to average height of the stockpile.

4. Provide partial enclosure for retrieving area.

Flexible type wind breaking enclosure should be provided covering the clinker retrieval area as wind barrier to prevent dust carry over by wind.


Sr.No.


The enclosure could be of lightweight material like moulded plastic material or similar, which could be dismantled / assembled and shifted from one place to other.

5. The travel path of pay loaders should be paved and frequently swept and kept sufficiently moistened to prevent emissions.

Travel areas path used by the front – end pay loader shall be paved with concrete. It should be regularly swept manually or by high efficiency vacuum sweeper to minimize the material build – up. In addition, these areas should be watered as necessary.

6. Provide loading of clinker by pay loaders into trucks / trailers be carried out in an enclosure vented to a bag filter.

An enclosure fitted with bag filter could be located at the most central place adjacent to the clinker storage area. The enclosure could be on wheels such that it could be shifted as required.

The pay loader moves to the fixed loading area from one end of the enclosure and the truck/trailer enters the enclosure from other end.

G. Storage of Limestone, Gypsum and other additives:

Sr.No.


1. The storage should be done under covered shed.

The enclosure walls shall cover minimum two sides up to roof level.

2. Fly ash shall be transported by closed tankers.

Fly ash shall be pumped directly from the tankers to silos pneumatically in closed loop or mechanically such that fugitive emissions do not occur.

3. Fly ash shall be stored in silos only.

If the wet fly ash is stored in open temporarily for the purpose of drying, necessary windbreak arrangement to avoid wind carryover of fly ash shall be provided. The fly ash should be removed immediately after drying and send to closed silos.


H. Cement Packing Section:

I. Silo Section:

Sr.No.


1. The silo vent to be provided with a bag filter type system to vent out the air borne fines.

The bag filter should be operated and maintained properly, especially the cleaning of bags to avoid pressurization of silos thereby causing fugitive emissions from leakages etc.

Sr.No.


1. Provide dust extraction arrangement for packing machines.

The packing machines should be equipped with dust extraction arrangement such that the packing operation is performed under negative pressure. The dust may be captured in bag filters.

2. Provide adequate ventilation for the packing hall.

Adequate ventilation for the packing hall should be provided for venting out suspended particulars thereby ensuring dust free work environment.

3. Spillage of cement on floor shall be minimized and cleared daily to prevent fugitive emissions.

The spilled cement from the packing machine should be collected properly and sent for recycling.

The spilled cement on the shop floor should be swept by vacuum sweeping machines periodically.

Proper engineering controls to prevent the fugitive emissions may include arrangements like providing guiding plate, scrapper brush for removing adhered dust on cement bag etc.

4. Prevent emissions from the recycling screen by installing appropriate dust extraction system.

The vibratory screen provided for screening/ recycling spilled cement should be provided with a dust extraction arrangement to prevent fugitive emission from that section.


J. Roads:

Sr.No.


1. All roads on which vehicle movement of raw materials or products take place should be paved.

The paved roads should be maintained as paved at all times and necessary repairs to be done immediately after damages to the road if any.

2. Limit the speed of vehicles. Limit the speed of vehicle to 10 Km/h for heavy vehicles with in the plant premises to prevent the road dust emissions.

3. Employ preventive measures to minimize dust build up on roads.

Preventive measures include covering of trucks and paving of access areas to unpaved areas.

4. Carry out regular sweeping of roads to minimize emissions.

Mitigative controls include vacuum sweeping, water flushing, and broom sweep.

5.4.2 LIST OF DOCUMENTS & RECORDS TO BE MAINTAINED FOR FUGITIVE DUST

CONTROL

Title of Record to be maintained

Frequency of Recording Information to be recorded

Documents:

List of Fugitive Emission Management Systems (FEMS) installed

To be up-dated once in a year

Location of FEMS, marked on process flow diagram,

Identity Number

Type of FEMS,

Year of installation,

Operating Status

Technical Specifications of FEMS installed

Specification of Dust suppression system

As and when installed/modified

Locations of controlling emissions, Identity Number,

Supplier Name

Date of Commissioning,

Pump HP, flow rate in LPM

Pressure in kg/cm2 ,

Nozzles type, numbers, LPM

O&M instruction from supplier.

Specification of As and when Location of system installed, Identity




Dust Extraction cum APCD

installed/modified Number, Name of system supplier, date of commissioning, flow rate in m3/hr, Time, flow m3/hr, static pressure mm. Wc, velocity m/sec, Current Drawn by ID fan motor, operation & maintenance instruction from supplier.

Capacities of Open Storages Annually

For coal, limestone, clinker, gypsum, additives, fly ash

Dimensions, bulk density, Tons

Records Replacement of Damaged filter bags

As and when replaced

Number of Bags replaced, Date, Bag filter Identification number

Measurement of flow rate static pressure at bag filter inlet

Once a month

Bag filter Number, Date of monitoring, Time, flow m3/hr, static pressure mm Wc, velocity m/sec, Current Drawn by ID fan motor Name of the person

Stack Monitoring of all bag filters stack

Quarterly

Bag filter Number, Date of monitoring, Time, Measured Data in m3/hr and mm Wc, Name of the person, Current Drawn by ID fan motor, Dust concentration in mg/Nm3

Operational Details of Dust Suppression System

Daily

Quantity of material handled, Quantity of water sprayed, number of operational nozzles, water pressure at filter inlet and outlet, details of damaged nozzles and replacements,

Road Sweeping record Daily

Road location swept, date, length swept, dust quantity collected kg/day, watering frequency, quantity of water, Method of watering, dust disposal details

Quantity of coal in open storage Daily

Inventory of Existing storage, add on, retrieved on every day basis, Tons, Date

Quantity of Daily Inventory of Existing storage, add on,




clinker in open storage

retrieved on every day basis, Tons, Date

Corrective actions taken for improving controls

As and when Details of modifications carried out, level of reduction in SPM achieved

Source: “Assessment of Fugitive Emissions & Development of Environmental Guidelines for Control of Fugitive Emissions in Cement Manufacturing Industries” - Central Pollution Control Board. Ministry of Environment & Forests, www.cpcb.nic.in

5.5 HAZARDOUS WASTE MANAGEMENT SYSTEM

The hazardous waste generated will be stored and handle as per The

Hazardous Wastes (Management, Handling and Transboundary Movement)

Rules, 2008.

Spent/waste oil from plants & machineries will be reused as lubricant within

premises / it will be sold to MoEF approved recyclers regularly.

The solid waste (i.e. cement dust) collected in different dust collection

system will be recycled in respective sections of the plant. Therefore, no

further management of solid waste is envisaged.

Record of hazardous waste generation and disposal shall be maintained on

printed logbook.

The unit will provide an isolated area for the hazardous waste storage within

premises having pucca floor and roof cover which will be expanded as per

the requirement.

The action sheet for mitigation of Hazardous and solid wastes is given Table-5.4

Table - 5.4: Action Sheet For Mitigation of Hazardous and solid Waste

Source Plants & Machineries, Primary and Secondary sources

Mitigation Measures

1. The hazardous waste likely to be generated will be stored in covered area.

2. Dust will be collected in different dust collection system and will be recycled in respective sections of the plant.

3. Spent oil will be reuse or sell to MoEF approved scrap vendors.


4. During monsoon season extra precautionary measures will be taken to prevent runoff.

Methodology of

Implementation

1. Analysis of the solid waste will be carried out periodically. 2. A record w.r.t quantity, quality and treatment/

management of solid/hazardous waste generation will be maintained

5.6 NOISE CONTROL MANAGEMENT SYSTEM

There will be slight increase in noise level due to proposed manufacturing

activities, due to mechanical equipments for the manufacturing of product.

The precautions to be taken for abatement of noise pollution are as follows,

Adequate noise control measures will be provided whenever required.

Extensive oiling, lubrication and preventive maintenance will be carried out

for the machineries and equipments to reduce noise generation.

The transport contractor shall be informed to avoid unnecessary speeding

of vehicles inside the premises.

Noise monitoring shall be done regularly at different parts of the plant.

Personal protective devices such as ear-muffs, ear-plugs etc. will be strictly

enforced for the workers engaged in high noise areas i.e. cement mill,

crushing unit etc.

The green belt area will be developed within industrial premises and

around the periphery to prevent the noise pollution in surrounding area.

Table – 5.5: Action Sheet for Mitigation of Noise Pollution

Source Process Plant & Transportation

Mitigation Measures

1. Strict adherence for maintenance schedule of various equipments.

2. Staffs to use earplugs at places where noise level exceeds 90 dBA.

3. Inform all transport contractors to avoid unnecessary speeding of vehicles inside the premises

Methodology of

Implementation

1. Periodically noise monitoring shall be done at various places inside the factory premises.

2. Playcard shall be displayed at various locations


5.7 APPLICATION OF CLEANER PRODUCTION TECHNOLOGY

Applications of CP mainly focus on preventing or minimizing the generation of

waste and gaseous emission. The basic idea of cleaner production is to avoid a

problem altogether rather than trying to find remedial measure by adopting

proactive approach of waste management. CP is nothing but a new and creative way of thinking about products and the

processes which are used to manufacture. Cleaner Production is continuous

ongoing process. It is achieved by the continuous application of strategies to

minimize the generation of waste and emission. As far as the production

processes are concern, CP is achieved by raw material and energy

conservation, by reducing quantum of emission and waste generation. CP

should be implemented by adopting the concept of product modification,

source reduction and recycling to acquire productive results.

There will be periodic arrangement of environmental training program to

create sensitivity among plant personnel towards environment.

For the operation of the plant, standard SOP will be followed.

The water generated from the scrubber attached to kiln will be reused for

the granulation purpose.

Dust Collected from various units will be recycled or reused in the plant

premises.

The used/spent oil will be reuse for oiling / greasing of equipments.

The exact electricity requirement in the plant premises will be identified to

conserve energy.

Proper working instructions will be given to all the workers in factory.

To reduce raw material handling loss, installation of raw material conveyor

system will be provided.

All the passages, floors and stairways will be maintained in good condition.

Sufficient disposable bins will be clearly marked and will be suitably located

in the plant.


Roads/walkway within the plant will be maintained neat and clean.

Walkways will be clearly marked and free from obstructions.

5.8 APPLICATION OF CLEAN DEVELOPMENT MECHANISM

Cement is a defined chemical entity formed form predetermined ratio of

reactants at fairly precise temperature. Portland cement results from the

calcinations of lime stone and silica.

The production of 1 tone of cement produces 0.55 tone of chemical CO2 in

reaction that take place at high temperature. An addition of 0.44 tone of CO2 is

given off as a result of the burning of carbon fuel to provide the heat.

To put it simply, 1 tone of Cement produce = 1 tone of CO2 released. Without

altering the reaction chemistry of the cement the reaction component of this

CO2 can not change. The other 40 % of CO2 emission resulting from the fossil fuel

burn in the kiln could be fractionally reduced if modern operating efficiency

improvements could be made to existing kilns.

CO2 emission could be reduced by following methods:

Use of industrial by-products as raw mix component

Partially or completely calcined industrial wastes and by-products such as fly-

ash, blast furnace slag, lime sludge etc. can be effectively used in raw mix to

partially substitute limestone

Incineration of combustible wastes in kiln

Combustible wastes such as pet-coke, tyres, oil sludge, municipal wastes etc,

when co-fired as partial replacement of fossil fuel, can reduce CO2 emission.

Production of reactive belite clinker

Reduction in specific fuel consumption due to lower clinkering temperature

resulting in lower co2 emission

Increasing manufacture of blended cements

Use of energy efficient equipment/systems


Grinding systems

improved ball mill internals

high efficiency separators

vertical roller mill

roller press

Pyro-processing

low pressure cyclones

high efficiency coolers

multi-channel burners

Material handling systems

Bucket elevator in place of pneumatic conveying systems

Process control systems

Expert control system

Electrical drives/fans

High efficiency fans

Variable speed fan drives

High efficiency motors

Use of solar & wind energy

Recovery of waste heat for cogeneration of power

Up to 25-30% of Total Power Requirement can be met through Cogeneration of

Power Utilizing Waste Heat in Cement Plant


Figure-5.2: CO2 reduction methodology in Cement industry

5.9 APPLICATION OF ODS REDUCTION POTENTIAL FOR OXIDES OF NITROGEN

The only possible source of NOx emission from cement plant is Kiln. NOx emissions

should be controlled by using proper kiln design, low -NOx burners, and an

optimum level of excess air. NOx emissions from a dry kiln with preheater and

precalciners are typically 1.5 kg /ton of clinker, as against 4.5 Kg/t for the wet

Process.

In order to control NOx emission of kiln, an automatic kiln control system is

recommended to maintain constant burning conditions in kiln thereby reducing

the NOx emission. NOx will also be controlled by reducing the quantity of

emissions by lowering the excess air factor to a value, which is compatible with

oxidizing emissions of burning.

Emission Reduction of CO2

Decrease by Substitution

Decrease by reduction of

Energy Consumption

Strong Interaction

Of raw –meal Component

Of fossil fuels

Of clinker Of cement components

Of thermal energy

Of electrical energy

Recuperation


5.10 SOCIO ECONOMIC ENVIRONMENT AND SOCIAL OBLIGATIONS

Environment Management Plan is prepared to reduce the likely adverse

impacts of the project based on existing socio economic profile in the area.

Environment Management plan would help smooth functioning of the project

and uplift of the quality of life of the people within or around the area will

generate direct / indirect employment and try to increase the economic

condition of the area.

The unit is aware of the obligations towards the society and for fulfill the social

obligations they will employ semi-skilled and skilled labor form the nearby

villages for the proposed project. The unit will also try to generate maximum

indirect employment in the near by villages by appointing local contractor

during construction phase as well as during operation phase. Apart form this the

unit will give their adequate and reasonable contribution for the following

action in the nearby villages,

Plantation all along the road side in nearby villages and development of

garden/greenbelt on government barren land/common plots.

Education aids & scholarship to poor students for higher education.

Organizing medical camp for the near by villagers.

Company will also cooperate and participate in the various activities

conducted by the government for the socio-economic development and

welfare of the society such as;

Participate in the medical camp organized in the villages.

Participate and cooperate in animal husbandry camp.

Participate in the Forestry Programme of state government.

Participate and Cooperate in Education Camp of state government.

Award scholarship to students for higher education.

Participate in the national programme organized on 15th August and 26th

January.

Participate in new school admission campaign.

Participate in Cleanliness Camp of state government.


5.11 GREEN BELT DEVELOPMENT

The main objectives of green belt are to provide a barrier between the plant

and surrounding area to prevent air and noise pollution. To maintain the

ecological balance project authorities are planning to develop green belt

around the plant. Green belt recommendations around the company premises

will be evolved as per CPCB norms for noise pollution control, balancing eco-

environment, soil erosion/protection, economic sustenance and aesthetics. The

scenario of planting arrangement and size will be based on the optimum use of

available land. Based on the agro-climatic conditions of the region, location

of proposed plant and physico-bio-chemical properties of the soil strata in

addition to the nature of pollutants and their rate of dispersion, it is suggested

to develop green belt around the plant. Plants suitable to abate the pollution

have been identified to be local plants.

The plant authorities have proposed to develop a green belt on the boundary

of the land acquired and on the plot which is on other side of the canal within

the acquired land. In addition to the green-belt planted around the project,

roadside plantation will also be required within the project.

The tree plantation shall be based on the following principles:

The plant shall be fast growing and indigenous

It shall be maintain ecological, land and hydrological balance of the region.

It shall be possess extensive foliar area to provide maximum impinging

surface for continued efficient adsorption and absorption of pollutants.

It shall be tall in peripheral curtain plantation, with large, spreading canopy

in the primary and secondary attenuation zones.

It shall be able to grow and thrive on soil of areas, be evergreen in habitat

having minimum of leaf fall.

It shall be efficient in absorbing pollutants without significant effects on plant

growth.


In order to mitigate the air pollutants and to attenuate the noise generated by

the plant and also improving the ecology and aesthetics of the area, total area

provided for the green belt will be 1796 m2 which will be @ 22.19% of the total

area. Green belt is developed to avoid any kind of fugitive emission into

surrounding environmental in any case. Table 5.6(A) shows the details of plant

species development. The green belt development program (three years) for

the proposed plantation is shown in Table – 5.6(B)

Table – 5.6(A): Plantation Species

Sr. No. Botanical Name Vernacular Name No. of Plants

1. Azadirachata Limbdo 30 2. Anthocephalus Chinensis Kadamb 25 3. Babool Baval 25 4. Bouganvillea glabra Boganvila 20 5. Cassia siamea Kasod 25 6. Cassia fistula Amltas 20 7. Carica papaya Papayu 10 8. Eucalyptus sp. Nilgiri 20 9. Miscellaneous --- 25

Total 200

Table – 5.6(B): Three Year Program for Proposed Plantation Species

Proposed Plants 1st Year 2nd Year 3rd Year

200 100 60 40

In addition to the green belt development plan within the own industrial

premises, the unit propose to develop green belt on out side peripheral of the

industry premises and also develop the green belt in common plots, barren land

and along the road side in the nearby villages and contributes towards the

green belt development. Thus, the unit will contribute indirectly to develop

green belt on minimum 1000 m2 on such areas. Thus, total green belt


development by the unit will come to 2796 m2, which will be around 35 % of the

total area occupied by the unit.

5.12 ENVIRONMENTAL MANAGEMENT CELL

All the project activities will be monitored to ensure that appropriate

environmental mitigation activities are implemented and to identify areas

where environmental management plan compliance is not satisfied. Effective

monitoring will allow corrective actions to be identified and implemented in a

timely manner.

One of the principal goals of environmental monitoring is the effective

observation of site conditions and work activities to:

Verify and document compliance with environmental requirement

Identify and document potential non compliance situations and initiate

corrective or remedial actions

Regular monitoring of environmental parameter will be made to find out any

deterioration in environmental quality. The head of environmental cell will be

responsible for total environmental management. The EMS broadly includes

Establishment and maintenance of documented environmental

objectives and targets at all relevant levels starting from quality assurance

of feed/fuels, at each relevant operation/function at individual utilities,

offsite, power modules units up to policy level of the organization

Allocating responsibilities at different levels for achieving the set

objectives and targets

Assessing the performance of environmental management system.

Periodic assessment studies by an independent agency would be highly

useful.

Development of a full fledged environmental management cell with

necessary infrastructure.

Regular monitoring of environmental parameter conducted in respect of

air, effluent quality, noise level and hazardous waste.


The environmental management cell set up by the unit is given herewith in

Figure-5.3.

Figure-5.3. Organogram of Environment Management Cell

Apart from having an environment plan, it is also necessary to have a

permanent organizational set up for effective implementation of various

activities. In this effect, M/s. Satva Cement Industries will assign responsibility to

officer from various disciplines to co-ordinate the activities concerned with

management and implementation of environmental control measures. The

management of the unit will keep adequate funds aside to meet with regular

expenses for the environmental control measures. Recurring cost for

environmental management plan is shown in Table- 5.7

Table –5.7: Recurring Cost for Environmental Management Plan (EMP)

Sr. No. Description Recurring Cost

(Rs. In Lac. /Annum) 1. Air Pollution Control 2.00 2. Occupational Health 0.42 3. Green Belt 0.25 4. Community welfare 0.30 5. Environmental Monitoring 0.25 6. Statutory Compliance and Chartered Services 0.34 7. Noise Pollution 0.40

Total 3.96

Management Authority

Environment In charge

Operator and Field Assistance

Manager (Production)


5.13 POST PROJECT MONITORING All the project activities shall be monitored to ensure that appropriate

environmental mitigation activities are implemented and to identify areas

where environmental management plan compliance is not satisfied. The

cement unit will schedule periodic investigations at predetermined locations

actions for effective monitoring and corrective actions to be identified and

implemented in a timely manner. Unit shall undertake monitoring work and

keep a close vigil on any deterioration of environmental quality in the project

area. Work place environment monitoring for particulate matter and silica will

be carried out as per Gujarat factories rules.

The schedule, duration and parameters to be monitored are described below

and summarized in Table – 5.8

Table – 5.8: Monitoring schedule and parameters

Source of monitoring Parameter Frequency of monitoring

Stack Emission SO2, Particulate Matter and NOx Monthly for each stack

Ambient Air SPM, RSPM, SO2 and NOx (2 location within the premises)

Monthly for each station

Ambient Noise Noise level in dB(A) (within the premises)

Monthly

Work Place Particulate Matter & silica Quarterly

Occupation Health X-ray, Blood test, Respiratory disease

Once in a year

CHAPTER-6

RISK ASSESSMENT,

SAFETY MANAGEMENT

AND OCCUPATIONAL HEALTH

________________________________________________________________________________ Draft Rapid Environmental Impact Assessment Report M/s. Satva Cement Industries Chapter-6 Risk Assessment, Safety Management & Occupational Health Page: 1 of 9

CHAPTER -6 6.1 RISK ASSESSMENT AND MITIGATION MEASURES

Risk assessment forms an integral part of any plan. Risk assessment is not only a

legal necessity but also a social requirement. Risk analysis consists of two parts

viz. Risk identification and risk assessment. Risk identification can be as simple as

asking “what if” questions at design review stage itself. Other method in use is

preparing a checklist of the normal hazards associated with a particular

situation or a piece of equipment. Risk assessment techniques are:

• Hazard and Operability Study (HZOP)

• Safety Studies

• Safety Indices

Risk is associated with disaster and a disaster is the product of a hazard such as

earthquake, flood or windstorm, coinciding with a vulnerable situation. There

are four basic types of hazardous events, which put societies at risk:

Those based in nature

Earthquakes, droughts, floods, avalanches etc.

Those based in violence

War, armed conflict, physical assault etc.

Those based in deterioration

Declining health, education and other social services, environmental

degradation etc.

Those based in the failings of industrialized society

Technical failures, effluent (chemical) discharge, factory explosions, fires,

gas leakages, transport collisions

RISK ASSESSMENT, SAFETY MANAGEMENT AND OCCUPATIONAL HEALTH


6.1.1 RISK ASSESSMENT

On the basis of the field studies and analysis, the following major risks or

emergencies are identified associated with the proposed project:

Emergencies Type of Risk Project Execution Stage Risk Level

Accidents Human Related Construction as well as Operation Moderate

Fire Human Related Operation Low

Cyclone Natural Construction as well as Operation Low

Tsunami Natural Construction as well as Operation Low

Earthquake Natural Construction as well as Operation Low

In order to understand the variation in dust exposure and the risk of respiratory

disorders in workplaces, knowledge about the magnitude of variability in dust

exposure from day-to-day (within-worker) and between workers is important.

There are various evidences that there is a high risk for developing chronic

respiratory symptoms when working for many years in the dustiest work areas.

It was found that the majority of unacceptable risks were associated with

operation of the crusher, with the other major risks being cement inhalation and

catching of clothing or hair on rotating part. The possible sources are indicated

below;

Sr. No. Source Risk Factor Possible

Hazardous Remarks

1. Crusher Fugitive Emission

Nose, throat or lung irritation and choking., lung injury, Silicosis, eye irritation

• The dust should be controlled either by spraying water or by extracting to bag filter.

• Machinery with casing should be used to reduce the accidental risk.

• Proper maintenance should be carried out for all equipments.


2. Transfer unit Fugitive Emission

Injury to the workers

• A competent person should be designated to supervise activities that require the use of cranes.

• Cranes should not be operated near any power lines.

• All picks should be carefully planned to ensure that the crane adequately hoist the load.

• The hoisting signals should be posted on the exterior of the crane.

• PPE should be provided to workers.

4 Kiln Heat Emission Skin Burns, Eye irritation

• Proper insulation

• PPE shall be provided to the workers,

6.1.2 MITIGATION MEASURES

In order to reduce a risk, the following hierarchy of controls should be

considered. Obviously elimination of a risk is most desirable, but if that is not

possible other options can be used to mitigate the risk level

Elimination

Substitution

Engineering

Administrative

Personal Protective Equipment (PPE) The use of PPE should be considered a last resort, as that simply offers physical

protection from the risk, rather than acting against the root cause.


For risk mitigation/reduction, attempts should be made to either reduce

inventories that could get released in the event of loss of containment or failure

likelihood’s or both as feasible. Risk analysis identifies the major risk contributors,

which enables prioritization of the plant that deserve special attention in terms

of inspection and maintenance in particular and over all safety management

as a whole.

For the risk reduction, the following salient suggestions and recommendations

are made:

The dust exposure and health surveillance programme shall be carried out in

the factory to monitor risk area and to identify workers with respiratory health

problems as early as possible. More thrust shall be given to the workers

engaged in the dusty areas like crushers, packing etc. prone to the

This will involve engineering control of the work environment as well as

administrative control.

Periodically rotation of the workers among the different section of plant

shall be adopted to reduce the overall dust exposure.

On site and off site emergency response plan should be prepared and

circulated to concern persons.

Personnel at the proposed plant and public in surrounding area should be

made aware about the hazardous substance stored at the plant and risk

associated with them.

A written process safety information document should be compiled for

general use.

Personnel engaged in handling of hazardous material should be trained to

respond in an unlikely event of emergencies.

The plant should check and ensure that all instruments provided in the plant

are in good condition and documented.

Regular mock drills should be carried out once in every 3 months and

shortcomings should be recorded and rectified. Records should be


maintained for the response of Mock Drills and corrective actions should

listed and taken accordingly.

6.2 SAFETY MANAGEMENT

Safety is an integral part of sound management and the absence of adequate

safety programmer result in avoidable injuries; loss of profits and lowering of

moral. The safety management includes the implementation of preventive

methods or accident prevention methods to avoid incident or accident and

handling of emergency in case of accident. Hazard is an inherent property of a

substance, agent, source of energy or situation having potential of causing

undesirable consequences & physical situation that may cause human injury,

damage to property or to the environment.

Following precautions shall be taken to avoid foreseeable accident like spillage

and to minimize the effect of any accident and to combat the emergency at

site level in case of emergency.

1) Various emergency spots in plant area will be identified and kept in sharp

and alert watch.

2) Protective equipments will be regularly checked and will be kept easily

accessible and easily workable during emergency.

3) Safety installations like available quantity of running water will be regularly

watched.

4) Fire buckets will be provided to withstand the fire or explosion conditions.

5) Various types of fire extinguishers such as (Foam type, Water CO2 type,

CO 2 type) will be provided inside the factory premises.

6) General dilution ventilation will be provided to control dust levels below

applicable exposure limits.

7) Suggestions from the workers will always be welcomed to modify the

system as well as to make system more reliable and effective.

Following actions will be taken to train the employees for handling various safety

equipments,

1) Procedures of safe shut down and isolation.


2) Actions to be taken if emergency arise from any collapsing of structures

or equipments etc.

3) Workers will be fed with the knowledge of safety measures and controls.

4) Dust and silica levels in excess of appropriate exposure limits will be

reduced by all feasible engineering controls, including ventilation,

process enclosure, and enclosed employee work stations.

5) Rehearsals will be provided so that on-site personnel can fully train

themselves for the emergency.

6) Emergency boards will be provided at the various places in Gujarati, Hindi

and English to materialize the emergency.

7) Suitable notices / boards shall be displayed at several locations indicating

appropriate hazards warning as well as DOs and DON’Ts for ensuring

operational and personal Safety for information of workers / staff and

visitors.

8) Suitable personal protective equipments will be provided to the workers

whenever needed & details of which is given in Table – 6.1

Table -6.1 Details of Personal Protective Equipments

Sr. No. Type Of PPE Name Of PPE

1. Inhalation Protection Dust Mask

Supported hand gloves Unsupported hand gloves 2. Hand Protection

Shock proof hand gloves Helmet Helmet ring 3. Head Protection Helmet with welding face shield

4. Face Protection Face shield 5. Eye Protection Safety goggles

Ear muff 6. Ear Protection

Ear plug 7. Foot Protection Safety shoes


6.3 OCCUPATIONAL HAZARDS AND REMEDIES

Hazard is an inherent property of a substance, agent, source of energy or

situation having potential of causing undesirable consequences & physical

situation that may cause human injury, damage to property or to environment.

Health hazards associated with the occupation are called occupational

hazard. The need of safety is to protect and serve the mankind, to search and

suggest the safe ways of behavior and keeping the safe working condition on

environment, health and welfare of the humanity.

6.3.1 CLASSIFICATION OF CEMENT DUST AND OCCUPATIONAL HAZARDS

The dust generated from cement plant could be categorized as inert dust or

nuisance dust and can be defined as dust that contains less than 1% quartz.

Because of its low content of silicates, nuisance dust has a long history of having

little adverse effect on the lungs. Any reaction that may occur from such dust is

potentially reversible. However, excessive concentration of nuisance dust in the

workplace may reduce visibility, may cause unpleasant deposits in eyes, ears,

and nasal passages and may cause injury to the skin or mucous membranes by

chemical or mechanical – action.

From an occupational health point of view, dust is classified by size into three

primary categories: Respirable, Inhalable and Total. Respirable dust refers to

those dust particles that are small enough to penetrate the nose and upper

respiratory system and deep into the lungs. Particles that penetrate deep into

the respiratory system are generally beyond the body’s natural clearance

mechanisms of cilia and mucous and are more likely to be retained. The

Inhalable dust is that size fraction of dust, which enters the body, but is trapped

in the nose, throat, and upper respiratory tract. The median aerodynamic

diameter of this dust is about 10 microns. Total dust includes all airborne

particles, regardless of their size or composition.


The concept of safety has developed through three stages: Accident

Prevention, Total Loss prevention and Total Loss Control. The potential health

aspects, impacts and remedies are shown in Table 6.2

Table 6.2: Potential Health Aspects, Impact and Remedies

Potential Health Aspect

Potential Health Effect First Aid Measures Remedies

INHALATION (acute)

Breathing dust may cause nose, throat or lung irritation and choking. The described

effect depends on the degree of exposure.

INHALATION (chronic)

Prolonged or repeated exposure may cause lung injury including silicosis. This

product may contain crystalline silica. Crystalline silica has been classified by

IARC as a known human carcinogen. Some human

studies indicate potential for lung cancer from crystalline silica exposure. Risk of injury depends on duration and

level of exposure. Long term exposures which result in

silicosis may result in additional health effects.

Move person to fresh air. Seek

medical attention for

discomfort.

Under ordinary conditions no

respiratory protection is

required. Wear a NIOSH approved

respirator when exposed to dust above exposure limits.

EYE CONTACT (acute/chronic)

May cause eye irritation, severe burns and damage to

cornea.

Rinse thoroughly with water. Seek

medical attention for abrasions.

Wear glasses or safety goggles to

prevent Contact with eyes. Wearing contact lenses when using this

product under dusty

conditions is not recommended.

SKIN CONTACT (acute/chronic)

May cause dry skin, redness, discomfort, irritation or severe burns. May produce allergic

reaction potentially associated with hexavalent chromium. Thickening of the

Wash with soap and water. Use

moisturizing creams

for irritated skin. Seek medical

Wear impervious gloves, shoes

and protective clothing to

prevent skin contact


skin (scleroderma) may be associated with exposure to

high levels of Crystalline silica.

attention for burns.

INGESTION (acute/chronic)

Ingestion of large amounts may cause intestinal distress.

Do not induce vomiting, but drink plenty of

water. Seek Medical attention

for discomfort.

The following check-ups shall be carried out regularly to avoid occupational

hazard.

1) Pre-employment medical check-up at the time of employment.

2) Provision of periodic medical check up for all the employees

3) To provide necessary first aid facilities. The first aid training shall also be given

to the employees.

4) Monitoring of occupational hazards like noise, ventilation shall be carried out

at frequent intervals.

5) The unit shall become member of EIS scheme.

6.3.2 THRESHOLD LIMIT VALUES FOR FUGITIVE EMISSION

The primary objective of controlling fugitive emission is to improve the work zone

ambient air quality to an allowable extent. This allowable extent is generally

threshold limit values. For the cement manufacturing plant the following values

(presented in Table 6.3) are applicable.

Table 6.3: Permissible Dust Values Recommended by OSHA

Sr. No. Substance Type of Dust

Allowable concentration

mg/m3 Respirable Dust 5 1 Portland Cement Total Dust 10

Respirable Fraction < 5 % SiO2 2.4 2 Coal Dust Respirable Fraction > 5 % SiO2 10 Respirable Fraction 5 3 Inert/ Nuisance

Dust Total Dust 15