1 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

Original Article

Environmental Impact Assessment (EIA) studies of existing of Lime stone industries

D.Gopla Krishna*, M.Anji Reddy and T.Vijaya Lakshmi

Centre for environment, Institute of Science & Technology (IST)

Jawaharlal Nehru Technological University (JNTUH)

Kukatpally, Hyderabad-500072, Andhra Pradesh, India.

E-mail*: gkmtech@gmail.com

Received 21 September 2011; accepted 03 October 2011

Abstract

The present report is a case study of Environmental Impact Assessment and Auditing of existing and expansion of limekiln

industries in and around piduguralla area. The base line studies on air environment, ambient air quality levels of suspended

particulate matter (SPM) Sulphur dioxide, oxides of nitrogen and meteorological data during summer. In order to access the

likely the arising impact from limekiln industries. EIA studies have been carried out, as a part of EIA studies base line

environment monitoring have been carried out during summer to know the existing air quality and predictions have been

carried out using meteorological data collected at the site during the summer season to estimate the incremental rise of ground

level over the base line values. EMP has been formulated for the proposed activity which has been thoroughly discussed.

© 2011 Universal Research Publications. All rights reserved

Key words: Environmental Impact Assessment (EIA), Environmental management plan (EMP), Environmental management system (EMS), Environmental Impact Statement (EIS), Lime stone, Calcium carbonate, Calcium oxide, Calcium sulfite, SOX,

NOX.

Introduction: EIA is a planning tool that is now generally

accepted as an integral component of sound decision-making.

The objective of EIA is to foresee and address potential

environmental problems/concerns at an early stage of project

planning and design. EIA/EMP should assist planners and

government authorities in the decision making process by

identifying the key impacts/issues and formulating mitigation measures.

Environmental Impact Assessment (EIA) methods

consists five analytical functions “Identification, Prediction,

Evaluation, Mitigation and Documentation”.

Andhra Pradesh contains 44% of limestone reserves of the

country with estimated reserves around 30,400 million tons of different

grades, produces 1.5 million tons and contributes 15 % of the total

production of the country. State is one of the largest producer of cement

(18-20%) with 18 major and 29: mini cement plants.

Materials and methods: Lime and lime stone are one of the basic

materials without which life would be greatly diminished and modern

commerce and industry could not exist. .Literally any object in man's home

and his office has acquired these ancient, prosaic, unglamorous, low cost

materials in some form of its manufacture-directly or indirectly. In fact,

the basic essentiality of Lime and Limestone has 'been linked to one leg of

a six-legged stool on which industry revolves. The other essential legs

being iron ore, salt, sulphur, petroleum and coal among these, Lime Stone

is the greatest in physical volume. The small-scale limekiln sector in India is

significant because of its important contribution to the country's economic development and rural employment.

Manufacturing Process of Lime – Kiln: Lime, in the form of

quick lime or hydrated lime, consists of CaO and MgO in various

proportions. High-calcium quicklime contains 0-5% MgO and is the

most common type of lime produced. Magnesium quicklime contains

5-35% MgO and dolomitic quicklime (also referred to as dolime)

contains 35-45% MgO.

Hydrated lime (calcium hydroxide, Ca (OH)2, also known as

slaked lime, is a dry powder manufactured by adding water

to quicklime, converting the oxide to hydroxide. The production

of quick lime involves crushing/chipping of limestone and

burning in a kiln at temperatures ranging from 890°C to

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2 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

Table.1: Lab equipment for air and micrometeorological parameters.

S.No Pollutants to be analyzed Laboratory equipment Nos available

1 SPM Portable air sampler 2

2 SO2 High volume sampler 10

3 NOX Oven 1

Table 2: Facilities envisaged in limekiln industry

Name of the product Existing facilities in tones Expansion plan in tons

Calcium carbonate & coal 1500 2000

Calcium oxide 937.5 1250

Solid waste 562.5 750

Calcium sulfite 375 500

Air emissions 187.5 250

Sources of Wastes at limekiln industry area:

Table 3: During Construction Phase

Feed Operation Pollutants Pathways Form of pollutant

All types of

construction

materials

Civil & structural

steel work

Dusts

Noise Air Air pollution

Plant &

machineries

Mechanical /

electrical erection Slurry water

Construction debris

Open drain

Land

Water pollution

Land pollution

Table 4: During Operation Phase

Operation

phase

Pollutants Pathways Form of pollutants

Combustion

Heat, Dust, SO2, NO2, noise Air Air pollution & work zone pollution

Ash

Existing ash, Ponding

ash, Dry disposal Land pollution

3 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

Table 5: Suspended Particulate Matter (SPM)

Sampling

Location #

Minimum

Observation

Percentiles Maximum

Observation Average

10 25 50 80 95

1 282 317 335 349 371 386 426 354

2 273 312 324 327 349 375 386 329.5

3 265 286 316 332 339 343 363 314

4 262 298 339 355 363 379 411 336.5

Table 6: Sulphur dioxide (SO2)

Sampling

Location #

Minimum

Observation

Percentiles Maximum

Observation Average

10 25 50 80 95

1 62.3 65.2 69.4 72.7 74.9 77.5 81.6 71.9

2 29.5 32.8 34.1 37.9 41.5 44.3 47.8 38.6

3 27.5 29.4 33.4 37.7 41.1 44.7 49.9 38.7

4 31.4 33.8 35.8 39.4 42.7 45.7 51.9 44.9

Table 7: Nitrogen dioxide (NO2)

Sampling

Location #

Minimum

Observation

Percentiles Maximum

Observation Average

10 25 50 80 95

1 35.6 36.2 37.6 40.9 46.3 48.4 50.0 42.8

2 68.6 71.8 74.7 78.1 81.3 83.4 85.6 77.1

3 19.6 20.8 22.0 24.9 30.3 32.4 34.0 26.8

4 51.1 53.8 55.0 56.9 59.3 60.4 63.7 57.4

Note: Units are expressed in µg per cum

1340°C. A dissociation reaction (calcination) takes place when the

limestone is broken down, releasing CO2 and producing CaO or

CaO.MgO (quicklime).

CaCO3 + heat = CaO + CO2

The Calcination temperature depends upon several

factors. At the atmospheric pressure and with CO2 concentration of

25 %, the dissociation starts at about 810°C. Some components in fact

(e.g. NaHCO3 or KHCO3) dissociate at lower temperatures (200-

300°C) already in the preheating zone; some other like NaCO3 or K2CO3

dissociate at 800-900°C in the calcining zone, this forming Na2O and K2O which sublime to Na and K vapours at approx. 1200°C.

Limekiln Industry in India:

The small-scale limekiln sector in India is significant because of its important

contribution to the country's economic development and rural

employment. There are an estimated 6,000 operational limekilns in

India. Most of the kilns exist in clusters near limestone deposits. The

major clusters are spread across the western region (Gujarat,

Rajasthan-Maharashtra), northern region (Uttaranchal, Uttar

Pradesh, and Himachal Pradesh), southern region (Andhra Pradesh,

Karnataka, and Tamil Nadu), central region (Madhya Pradesh), and

eastern region (Jharkhand, Meghalaya). The sector faces numerous

challenges such as excessive fuel consumption, low yield, inconsistent

product quality, environmental concerns, and safety and health of

workers. Most of the kilns employ outdated technologies with very low

energy efficiency, low yield, and poor environmental performance.

Considering the challenges faced by the sector and its impact on the

livelihoods of hundreds of thousands of people, the issues of resource efficiency and productivity must be addressed

immediately.

Results and Discussion: The turnover of the calcium oxide

is 937.5 tons per day for 150 limekilns. Each kiln provides

6.25 tons of calcium oxide. 562.5 tons per day of waste is

generated from 150 lime kilns. From those 375 tones of

calcium sulfite is liberated. Remaining (187.5 tones) of the

waste is emitted as fly ash.

4 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

Table 8: Water quality around the project site-Physical and Inorganic parameters

Parameter Sampling Location #

1 2 3 4 5 6

pH 7.8 7.1 7.1 7.3 7.8 7.7

Total Suspended Solids 47 49 61 63 185 80

Total dissolved solids 174 182 215 223 1715 297

Total Alkalinity as CaCO3 107 98 79 81 563 94

Total hardness as CaCO3 60 65 240 248 580 520

Calcium hardness 32 33 157 160 342 315

Magnesium hardness 28 34 83 88 238 205

Chlorides as Cl 12 14 14 15 --- 17

Sulfates as SO4 31 25 9 8 --- 10

Nitrate as NO3 5 4.5 7.5 7.4 --- 7.0

Cyanide as CN BDL BDL BDL BDL BDL BDL

Fluoride as F 0.4 0.4 0.4 0.5 ---- 0.8

Table 9: Soil Quality Data

Parameters

Location #

1 2 3 4 5

PH 5.3 6.1 8.1 7.6 7.9

Electrical Conductivity (ms) 0.142 0.146 0. 27 0.29 0.11

Organic carbon (%) 0.95 0.34 0.78 0.79 1.54

Nitrogen (mg/Kg ) 211 215 201 210 223

Phosphorous as P2O5 (mg/Kg) 10 08 11 17 10

Potash as K2O (mg/Kg) 284 279 341 327 302

5 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

Table 10: Stack emissions

S.

No Stack attached to

Dia

(m)

Height

(m)

Temp. of

flue gas

(0C)

Velocity

of flue gas

(m/sec)

SPM

(g/s)

SO2

(g/s)

NOX

(g/s)

1. Pelletisation plant stack attached to Grate 1.5 37 100 14.1 0.3 --- ---

2. EAF & LRF (common Stack) 0.80 30 100 16.0 0.86 --- ---

3 Reheating Furnace 1.10 30 180 15.0 0.52 1.96 2.30

4. FBC Boiler 1.85 75 150 20.0 2.38 74.1 3.6

5. WHRB 2.62 40 150 20.0 7.2 3.05 1.4

6. DG Set (750 KVA) 0.25 6 90 2.5 0.01 2.10 1.80

Wind rose diagrams

Conclusion and EMP:

The air emissions from the proposed activity include

mainly dust (SPM), SO2 and NOX. Therefore limekiln

industry has been proposed to maintain the Green belt around

the 500m of the industrial area.

The one and only source of solid waste from the limekiln

industry is calcium sulfite from combustion of coal and

calcium carbonate. Calcium sulfite is being collected in a separate pond so to arrest the nuisance. Thus collected and

stored calcium sulfite is been utilized to a smaller for the

brick manufacturing and other construction activities in

conjunction with cement for laying roads and buildings.

Limekiln industry has been suggested to take up studies for

the efficient utilization of calcium sulfite and proper disposal

methods. The other methods should also to be taken care such as process changes, raw materials change (usage of low ash

6 International Journal of Green Chemistry and Bioprocess 2011, 1 (1) 1-6

content coals in the process) and operating conditions so as to

reduce the solid wastes with a war footing effort.

To reduce the noise levels it has been suggested to use

noise-absorbing materials for construction of floors, walls

and roofs. Noise enclosures are also been suggested for the

generators. Whereas, for the personal protection from noise and dust, Nose masks and ear muffs / plugs to be provided at

work place.

Acknowledgements: Authors thank to Jawaharlal Nehru

Technological University Hyderabad for providing research

facilities to the research scholar.

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Source of support: Nil; Conflict of interest: None declared