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_______________________________________________________________________________________ EC Compliance report (4.0 MTPA Cement Plant & 46 MW Thermal Power Plant) of 22


COMPLIANCE REPORT

Name of Project : M/s UltraTech Cement Ltd; Unit – Kotputli

Cement Works (Formerly know as M/s Grasim Industries Ltd), Located at/near Village - Mohanpura, Tehsil - Kotputli, Distt - Jaipur (Rajasthan). The Scheme of Amalgamation with UltraTech Cement Ltd. has been submitted by our letter dated 26/07/2010 in MoEF, New Delhi.

Environment Clearance Letter No. : J-11011/971/2007 IA (II), dated 27/02/2008. For Cement Plant (4.0 MMTPA Clinker & 4.0 MMTPA Cement production) and Captive Thermal Power Plant (46.0 MW Power Generation)

Period of Compliance Report : April, 2013 to September, 2013

A ) SPECIFIC CONDITIONS :

S.N. CONDITIONS COMPLIANCES STATUS

(i) The project authority shall obtain all other necessary statutory clearance from the concerned departments including ‘No Objection Certificate’ from the Rajasthan State Pollution Control Board (Rajasthan SPCB) prior to commencement of construction.

Complied with.

The consent to establish obtained from Rajasthan State Pollution Control Board for Cement Plant (4.0 MMTPA Clinker & 4.0 MMTPA Cement production) & Captive Thermal Power Plant (46.0 MW Power generations) vide letter no. F (Tech)/Jaipur (Kotputli) /4(1)/2008-2009/1889 dated 04/03/2009 under Air Act & vide letter no. F (Tech)/Jaipur (Kotputli) /4(1)/2008-2009/1893 dated 04/03/2009 under Water Act. We also obtained consent to establish for D.G. Sets (2x2825 KVA) vide letter no. F (Tech)/Jaipur (Kotputli) /4(1)/2008-2009/5785-5787 dated 22/11/2011.

Obtained consent to operate from RSPCB for Cement Plant (4.0 MMTPA Clinker & 4.0 MMTPA Cement production); Captive Thermal Power Plant (46.0 MW Power generation) & D.G. Sets (2x2825 KVA) vide File No: F (Tech)/Jaipur (Kotputli) /4(1)/2008-2009/4143-4147 & Order No. 2012-2013/ CPM/1499, dated 21/08/2012.

(ii) The project authorities shall adhere to the stipulations made by the Ministry in its earlier environmental clearance issued vide F.No.J-11011/301/2005-IA-II (I) dated 18th November,2005 and subsequently no objection was granted vide even no. dated 17th August,2007 for 46 MW capacity power plant.

Complying with the conditions stipulated in the earlier environmental clearances by MoEF.

(iii) All the recommendations mentioned in the CREP guidelines for cement and power plant shall be followed and complied.

We are complying with all the applicable conditions of charter of corporate responsibility for Environmental Protection specified for Cement Plants and Thermal Power Plants which are as follows:

� Compliance of Cement Plant CREP:

1. The stack emission level within 50 mg/Nm3 as limits prescribed RSPCB.

2. The plant is neither located in critically polluted area nor in urban area.

3. Bag house is provided at raw mill & kiln stack to control stack emission.


4. Fugitive dust emission controlled by providing closed

storage silo for clinker, Fly ash, cement and covered shed provided for coal & raw materials (additives). Closed conveyor belts and dust collectors provided at all the raw material transfer points. Water sprays arrangements at raw material storage area & coal shed. The bulckers are being used for transportation of fly ash and unloading is being done by the pneumatic system directly into the fly ash silo.

5. 60-70% Petcoke is being used in cement kiln as fuel in place of natural coal (fossil fuels)

6. Opacity monitors installed at all the major stacks of cement plant for continuous monitoring of particulate matter. Continuous monitoring system provided for monitoring of flue gases i.e. SO2 & NOx in Raw mil/ Kiln bag house stack (Under observation)

7. Fly ash generated from our Captive Power Plant is being consumed in our existing Cement Plant for the manufacturing of PPC cement.

8. The necessary provisions for the utilization of hazardous/non hazardous waste are under planning. Presently only the non-hazardous waste i.e. carbon black is being used & for that necessary infrastructures facility for feeding has been provided.

9. The waste heat recovery is not feasible at our plant due to insufficient available heat generation from plant as required for WHR, because we required heat for VRM operation/pre-heating of raw material to save energy (fossil fuel) consumption. Although we are exploring the possibility for the same.

� Compliance of Power Plant CREP:

1. The ESP,s are installed at power plant boilers (1&2) stack & the stack emission level within 100 mg/Nm3 as limits prescribed RSPCB. The ambient air quality is within the prescribed limits. Waste water generating from captive power plant is reutilizing for ash quenching & dust suppression related activities after neutralization. There is no discharge of effluent inside / outside the plant premise.

2. Provided 80 meters height of Power plant stack which is more then the required for better dispersion of pollutants.

3. Opacity meter installed at power plant stack for continuous monitoring of particulate matter.

4. The CFBC Boilers are installed at power plant for complete combustion of coal. Our captive power plant is not pit head power plant.

5. Fly ash generated from our Captive Power Plant is being used in our existing Cement Plant for the manufacturing of PPC cement.

6. Power plant is based on cleaner technology & registered availing CDM benefits.

For other conditions, whenever the standards will be formulated, we will follow the same as per guideline.

(iv) The stack emissions from various sources shall not exceed 50 mg/Nm3.

We are complying with the standards prescribed by RSPCB for stack emission level as particulate matter 50 mg/Nm3 for Cement Plant and 100 mg/Nm3 for Captive Thermal Power Plant.


The stack emission level monitoring data for the pe riod from April, 2013 to September, 2013 are as giv en below :

Remarks: The D.G. sets only for emergency purpose for domestic supply & to start up the auxiliaries of existing power plant in case of blackout / non availability of power from Grid.

ULTRATECH CEMENT LTD.(UNIT:KOTPUTLI CEMENT WORKS)STACK EMISSION LEVEL

22.2 26.1 24.1

7.4 12.7 9.521.6 26.9 24.2

14.7 17.7 16.129.7 34.2 31.4

50.0

100.0

0102030405060708090

100

Min

.

Max

.

Avg

.

Min

.

Max

.

Avg

.

Min

.

Max

.

Avg

.

Min

.

Max

.

Avg

.

Min

.

Max

.

Avg

.

Cem

ent

Pla

nt

Pow

erP

lant

Raw Mill & Kiln Coal Mill Clinker Cooler Cement Mill(1&2)

Boiler (1 & 2) PrescribedLimit from

Location of Stack

Par

ticul

ate

Mat

ter

Em

ssio

n (m

g/N

m3)

PM (mg/Nm 3) S. No. Location of Stack Min. Max. Avg.

A) Cement Plant :

1. Raw mill & Kiln Bag House Stack 22.2 26.1 24.1

2. Coal mill Bag House Stack 7.4 12.7 9.5

3. Clinker Cooler ESP Stack 21.6 26.9 24.2

4. Cement mill (I& II) Bag House Stack 14.7 17.7 16.1

Prescribed limits by RSPCB for Cement Plant Stacks: 50 mg/Nm3 B) Captive Thermal Power Plant:

5. Boiler (I& II) ESP Stack 29.7 34.2 31.4

Prescribed limits for TPP Stacks by RSPCB : 100 mg/Nm3

C) D.G. Sets:

S.No. Parameters Monitored ( During D.G. Sets performance test) D.G. Set-1 D.G. Set-2

1. NOx

2. NMHC 3. Particulate Matter 4. CO

D.G. Sets was not operated

Prescribed limits for D.G. Sets Stacks by RSPCB are : Parameters Prescribed limits

NOx 710 mg/Nm3 NMHC 100 mg/Nm3

Particulate Matter 75 mg/Nm3 CO 150 mg/Nm3


The fugitive emissions during loading and unloading shall be suitably controlled. Bag house/filters shall be provided to control particulate emissions. The project authorities shall store all the raw materials except limestone in the covered sheds to control fugitive emissions.

We have provided following measures to control fugitive dust emissions at our pant:

• We have installed 100 nos. bag filters at the various material transfer points, loading/unloading & storage to control the fugitive emission.

• Covered conveyors belts provided for raw materials transportation to control fugitive emission.

• Bag house & water sprinkling arrangements provided at limestone crusher to control dust emission.

• Bag house installed with Raw Mill & Kiln stack, Coal Mill stack, Cement Mill and ESP’s installed with Clinker Cooler stack and Power Plant Boiler stack. Acoustic enclosure, stack attached with D.G. Sets

• The dust collected from the pollution control equipments is being recycled back into the process.

• Covered dump hopper for unloading of raw materials along with bag filters arrangements.

• Silos provided for storage of raw meal (Capacity: 35000 MT), clinker (Capacity: 1, 50000 MT), cement (Capacity 2×15000) & fly ash Capacity: 5000 MT).

• Covered sheds provided for storage of raw materials (additives) in an area of 10482.55 m2.

• Covered shed provided for entire coal storage (96mx300m) & automated system provided for coal handling and stacking due to which chances of fugitive is negligible.

• The boundary wall around raw material storage is under progress.

• The construction of covered shed for gypsum is under progress.

(v)

Glimpses of measures provided to control emissions

Covered conveyor belts for raw material transportat ion Bag filters at material transfer point s


Bag House for Crusher Stack and Sprinkl ing system with covered dump hopper at crusher

Bag House for Raw Mill & Kiln Stack Bag House for Coal Mill Stack

ESP for Clinker Cooler Stack Bag House’s (02 nos.) for Stack of Cement Mill (1 & 2)

ESP’s (02 nos.) for Stack of TPP Boiler’s (1&2) Acoustic enclosures & stack for D.G. s ets (1 &2)


Covered dump hopper for raw materials unloading

Silo for storage of Raw Meal Silo for s torage of clinker

Silo for storage of Fly as h Silo’s for storage of Cement


Covered storage sheds for Coal and Raw Material (ad ditives)

Water sprinkling system in coal shed

Gypsum storage shed (Construction under progress)


The location of the ambient air quality monitoring stations shall be set up as per statutory requirement in consultation with the Rajasthan State Pollution Control Board and additional stations shall be installed, if required, in the downwind direction as well as where maximum ground level concentration are anticipated.

Four ambient air quality-monitoring stations has been established at our plant premises along with plant boundary wall in respect of cross wind / down wind / up wind directions as suggested by the Regional Office of RSPCB.

The Ambient Air Quality monitoring data for the period from April, 2013 to September,2013 are as given below :

At Plant Boundary

Location Near Main Gate

Near TPP Near Colony Near Shopping Complex

Parameters All Values are in µg/m3

Min. 32.4 34.2 22.5 23.2 Max. 77.6 87.0 77.6 81.2 PM10 Avg. 54.3 57.0 42.4 44.0 Min. 19.8 21.2 7.8 9.2 Max. 46.6 49.3 40.3 43.6 PM2.5 Avg. 32.8 34.1 25.1 26.7 Min. 7.4 8.1 4.2 4.8 Max. 13.5 15.2 8.1 8.2 SO2 Avg. 9.7 11.4 6.3 6.6 Min. 10.6 11.5 8.1 9.2 Max. 22.2 23.5 15.8 16.2 NO2 Avg. 16.3 17.3 11.7 12.4

(vi)

Ambient air quality-monitoring stations at plant pr emises

ULTRATECH CEMENT LTD.(UNIT:KOTPUTLI CEMENT WORKS)AMBIENT AIR QUALITY AT PLANT BOUNDARY

32.4

77.6

54.3

34.2

87.0

57.0

22.5

77.6

42.4

23.2

81.2

44.046.6

32.8

21.2

49.3

34.1

7.8

40.3

25.1

9.2

43.6

26.7

7.4

13.59.7

8.1

15.2

11.4

4.28.1

6.3 4.88.2 6.6

10.6

22.2

16.3

11.5

23.5

17.3

8.1

15.8

11.79.2

16.212.4

19.8

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

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

Near Main Gate Near TPP Near Colony Near Shopping Complex

Locations of Monitoring

Air Polluta

nts Le

vel (µg

/m3)

PM10 PM2.5 SO2 NO2


(vii) Rain water harvesting shall be done within the premises. The structure designed for this shall be such that full monsoon rainwater can be harvested.

We have developed 16 nos. of Artificial recharge measures/system inside plant, colony mines and nearby area for harvesting of full monsoon rain water & augmentation of ground water resources.

The summaries details of existing rain water harvesting structures/measures are as under :

• Plant premises: Constructed three injection wells including one recharging reservoir, and three dug well along with de-silting & filter pits. These structures are connected with rooftop of entire building, paved area roads etc. through storm water drains.

• Colony premises: Constructed three recharging dug wells and two recharging injection wells along with de-silting & filter pits. These structures are connected with roof top entire colony buildings, paved areas, roads etc. through storm water drains.

• Limestone mine & near by area: Developed five recharging reservoirs/ponds (one at the mine foot hill, 02 at south-west direction of mine, 01 is near village Kujota & 01 is near village Mohanpura). The rain water of entire mine area & near by area are channelized through natural slop/ catch drains/diversion channels/ garland drains in all developed rain water harvesting reservoir/pond

Periodic monitoring of ground water level (Quarterly) and quality (Twice in a year) are being carried out in & around the area as per prescribed schedule by establishing a network of piezometers. We have established 08 piezometers for monitoring of ground water level of area at our Plant, Colony, Mines & nearby villages (02 piezometers in each area). The reports of findings are being yearly submitted to the concern authorities. The water level monitored in year 2012-13 is around 25.95m to 31.20m in pre monsoon and 22.16m to 29.89m in post monsoon season in the area; which is showing the effectiveness of recharge measures adopted at our site. The compliance report along with the monitored data of ground water level & quality (for the period from Pre-monsoon;2012 to Pre-Monsoon;2013) has been submitted to the CGWA-New Delhi, CGWB-Jaipur & MoEF-New Delhi, MoEF- Lucknow & SPCB-Jaipur vide our letter no. UTCL/KCW/ENV/CGWA/2013-14/30 dated 31/07/2013. We are committed for continual implementation of artificial recharge measures/ rain water harvesting measures for augmenting the ground water resources of the area.

(viii) Ground water recharge structures shall be installed around the plant area in consultation with local authorities to contain the ground water table.

We have developed 02 nos. recharge pond, one near the Kujota village (approx. capacity of 100000 m3) & second near the village Mohanpura (Approx capacity 50000 m3). The runoff from nearby area & mines area channelized through natural slope to the reservoir/recharge pond.

We are committed to augment the resources of the near by area and we are in regular in touch with local authorities regarding any proposal in this context.


Glimpses of Rain Water Harvesting Structures

(ix) Out of total 400 Acres land, green belt shall be

developed in 100 Acres as per the guidelines of Central Pollution Control Board to mitigate the effect of fugitive emission.

Green belt development and tree plantation is our ongoing process. Every year we are planting new plantation for the increase of density in existing area.

Our Plant & Colony area is approx. 162 hect and out of which till date we have developed 54.77 hect area under plantation and achieved 33.81% greenery by planting 40751 nos. of fast growing suitable/native plant & shrubs species; out of total planted plantation 37867 nos. of plantation is survived with survival rate of 93% till September, 2013.

Out of which in current year 2013-14 (from April-13 to September,2013) we have planted 5329 nos. of plant in our existing area of plant & colony; out of this 5177 nos. of plants are survived with survival rate of 97% till September, 2013.


GLIMPSES OF GREEN BELT DEVELOPMENT AT PLANT & COLNY

Plantation around Plant Boundary Plantation in Colony

Plant View with Green Belt Development

Plantation view from Mine side Plantation both side of roa ds


(x) The project authorities shall make all out efforts to use high calorific value hazardous waste in the kiln and accordingly, necessary provision in the kiln shall be made.

Yes, As per CPCB Guidelines on Co-processing in Cement/Power/Steel Industry and The Hazardous Waste (Management, Handling & Trans-boundary Movement) Rules, 2008; we have obtained regular permission from CPCB vide letter no. B-33014/7/2006/PCI-II/3438 dated 27.07.2011 & renewed authorization from RSPCB vide letter no. vide no. RPCB/HWM/ 2013-14/SWMC/HSW/116 dated 12/09/2013 for the co-processing of hazardous waste i.e. 100 TPD Phosphate sludge (cat.-12.5); 100 TPD process waste, residues & sludge (cat.-21.1); 100 TPD spent organic solvents (cat.-28.5) and 100 TPD Chemical sludge from waste water treatment (cat.-34.3) in cement kiln .

We have also obtained permission to use non hazardous waste i.e. Agro waste; Plastic waste, Municipal Solid Waste/RDF vide letter no. F.16 (432) RPCB/SWMC/HAZ/4618 dated 29/03/2012 as co-fuel in cement plant. The carbon

At present we are only using carbon black which is a non hazardous waste (a product of tyre pyrolysis plant) as co-fuel in our cement kiln. The closed bulckers are being used for transportation of carbon black and unloading is being done by the pneumatic system directly into the coal hopper for feeding in kiln after mixing & grinding with caol. We complying with condition mentioned in permission obtained for use of carbon black vide letter no. F.16 (482) RPCB/HWMR/ 49 dated 02/04/2013. For other hazardous/non hazardous waste necessary provisions for storage & feeding are under planning. After implementation of the same we will use the permitted waste in our plant.

(xi) The project authorities shall earmarked adequate funds towards pollution control equipments, online monitoring equipments and green belt development and the funds so provided shall not be diverted for any other purpose. The company shall also earmark annual budget for the implement the conditions stipulated by the Ministry of Environment & Forest as well as the State Government along with the implementation schedule for all the conditions stipulated therein.

We have installed and implemented all the pollution control measures such as Bag house, Bag filters, ESP and online dust monitors (opacity meters)/CEMS/CAAQMS and green belt development. We are taking care for the over all environmental management/protection measures. The construction of Gypsum shed and boundary wall around raw material yard is under progress.

In year 2012-13 we have spent Rs. 1992 Lacs towards environment management & protection measures.

The annual budget for the year 2013-14 is 68 Lacs towards green belt development. All other Environment management activities will be done as per schedule/approved budgets.

(xii) The project authorities shall install full fledge sewage treatment plant for treatment of domestic sewage and treated sewage shall be utilized for the green belt development. No discharge from the premises shall be allowed.

Complied with. There is no waste water/effluent generation from Cement Plant. The Domestic waste water is being treated in Sewage Treatment Plant (STP of 500 KLD Capacity) and treated waste water is being re-utilized for plantation/horticulture related activities. The waste water generating from Captive Power Plant is being re-utilized for ash quenching, mine haul road dust suppression & crusher dump hopper spraying related activities after neutralization.

The quantity of waste water (Domestic & TPP process) generated in year 2013-14 (From April-13 to Sept-13) is 236 m3/day & it is been 100 % reutilized. The quality of effluent water is under permissible limits given by RSPCB & being reported quarterly to the board. We are maintaining zero discharge of effluent inside/out side our plant premises.


SEWAGE TREATMENT PLANT

FOR DOMESTIC WATER TREATMENT

NEUTRALIZATION PIT FOR POWER PLANT WASTE WATER

TREATMENT

(xiii) The fly ash generated form the power plant shall be handled pneumatically and 100% fly ash shall be utilized with in the plant for cement manufacturing. The provision of fly ash notification 2003 amended up-to-date shall be complied with.

Complying with. Fly ash generated from our Captive Power Plant is being consumed 100 % in our existing Cement Plant for the manufacturing of PPC cement. We have provided silo for storage of fly ash. The closed bulckers are being used for transportation of fly ash and unloading is being done by the pneumatic system directly into the fly ash silo.

The annual compliance report with respect to fly ash notification dated 14.09.1999; for the year 2012-13 of our 46 MW Captive Thermal Power Plant has been submitted to RPCB, RO-RPCB, CPCB & MoEF vide our office letter no. UTCL/KCW/ENV/FLY-ASH/2013-14/02 dated 13/04/2013.

(xiv) The project authorities shall provide a health centre with all emergency medicines and ambulance along with full time doctor. Occupational health surveillance of workers shall be carried out on a regular basis and record shall be maintained as per the Factories Act.

We have provided the health care centre at our plant site having the full time one MBBS doctor & 04 nos. qualified/trained nursing staff with all the emergency medicines and 02 nos. round the clock ambulance facility.

Occupational health surveillance of the workers/employees is being carried out on yearly basis & records of the same are maintained as per the Factory Act. As per the reports, no occupation ailment has been observed.


B ) GENERAL CONDITIONS :

S.N. CONDITIONS COMPLIANCES STATUS

(i) All the recommendations mentioned in the CREP guidelines shall be followed and implemented.

All the recommendations mentioned in the CREP guidelines are being followed and implemented. Detail given as compliance of specific condition (iii).

(ii) The project authorities shall strictly adhere to the stipulations of the SPCB/State Govt. or any statutory body.

We are complying with all the stipulation made by the RSPCB/State Govt. and other statutory body.

(iii) No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment & Forest. In case of deviations or alterations in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any.

Agreed and we shall comply accordingly, if any expansion or modification carried out.

(iv) At no time, the emission shall exceed the prescribed limits. In the event of failure of any pollution control system adopted by the unit, the unit shall be immediately put out of operation and shall not be restarted until the desired efficiency has been achieved.

Complying with. The emission level form all the sources are under permissible limits. Regular checking/ maintenance of pollution control equipments are being done for their efficient working.

(v) The gaseous emissions (SO2, NOx,) and particulate matter levels from various process units shall conform to the standards prescribed by the concerned authorities from time to time.

We are complying with the emission standards prescribed by RSPCB for particulate matter from stacks i.e. 50 mg/Nm3 for Cement Plant & 100 mg/Nm3 for Power Plant. However we have provided low NOx burners at cement kiln and limestone dosing system provided for power plant boiler furnace for the control of SO2 emission. CFBC boilers have been provided at power plant for complete combustion of fuel.

We have also installed the online continuous emission monitoring system (CEMS) for SO2 & NOx at main stack (Ram Mill& Kiln bag house stack) of cement plant; which is under observation.

(vi) The company shall undertake following waste minimization measures: � Reuse of by-products from the process as raw

materials or as raw materials substitutes in other processes.

� Use of “Closed pneumatic” system for transport of fine material.

� All venting systems shall be connected with dust arresting equipments.

� Dust collected in pollution control equipments shall be reused.

We have provided the following waste minimization measures as under:

� Fly ash generated from our captive power plant is being used in PPC cement manufacturing.

� Closed bulckers are being used for the transportation of fly ash. Loading/ unloading of fly ash is being carried out through pneumatic system directly into fly ash silo.

� Bag houses attached with raw mill/kiln (01 nos.), coal mill (01 nos.), cement mills (02 nos.) and ESP’s attached with cooler (01 nos.) and boilers (02 nos.) for the control of stack emission.

� Closed conveyors belts are provided for the transportation of materials. 100 nos. Bag filters provided at all the raw material transfer points to control fugitive dust.

� Dust collected from the air pollution control equipments is being recycled back into the process.

� Covered hopper with de-dusting arrangement provided for raw materials (coal, additives and limestone).

� Covered dump hopper for unloading of raw materials along with bag filters arrangements.


Covered hopper for raw materials Covered dump hopper for unloading of raw materials Fugitive emissions in the work zone environment, product, and raw materials storage area shall be regularly monitored. The emissions shall conform to the limits imposed by the State Pollution Control Boards/Central Pollution Control Board.

Fugitive dust emission inside the plant premise is being is monitored monthly. The emission level is well within the limits imposed by RSPCB/CPCB.

We have provided 100 nos. Bag filters at all loading/ unloading points, material transfer points along with covered conveyors belts for material transportation. Water spraying arrangements provided for dust suppression in raw material yard, coal shed, crusher dump hopper etc.

The paved roads/concreted floor provided in plant area as well as raw material storage yard are to control of fugitive dust emission due to vehicular movement. The sweeping of roads is being done by vacuum sweeping machines (03 no. sweeping machines & 1 vacuum cleaner machine). The vehicle speed in raw material storage area is limited upto 10 km/hr.

All the efforts are being done to control fugitive dust & to comply with the fugitive dust guideline provided by CPCB.

(vii)

Cemented Roads/Area Photographs of the Inside Plan t


Vacuum sweeping arrangements Speed limit display

The overall noise levels in and around the plant area shall be kept well within the standards by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels shall conform to the standards prescribed under Environment (Protection) Act, 1986 Rules, 1989 viz. 75 dBA (day time) and 70 dBA (night time).

Noise control measures has been provided including acoustically treated room for compressor house; covered cabinet for turbine generators; Acoustic silencer in cooler fans; Acoustic enclosure for D.G. sets etc. Regular maintenance of machineries & green belt development in or around the plant area are being done to control noise generation from/at the source.

The work zone noise monitoring is being done on monthly basis & are maintained as per the standards prescribed in Factory act i.e. < 90 dB (A). All the personal protective equipments i.e. earplug/ear muffs etc. have been provided to the workers/employees working in the noisy area.

(viii)

Ambient noise level is well within the standards prescribed. The Ambient Noise Level monitoring data for the period from April, 2013 to September, 2013 are as given below :

Noise Level results (dB (A) Leq)

Day Time Night Time

S.N. Monitoring Locations At Plant Boundary

Min Max Avg Min Max Avg

1 Near Main Gate 67.2 68.9 68.3 58.4 60.8 59.5 2 Near TPP 68.6 70.2 69.4 60.2 61.4 60.7 3 Near Colony 57.2 58.4 57.7 46.6 47.6 47.1

4 Near Shopping Complex 61.2 62.1 61.7 47.6 49.2 48.4

D.G. sets Noise Level Monitoring results: Monitoring location D.G. Sets -1 D.G. Sets -2 Noise Level (dB (A) Leq) D.G. Sets was not operated

ULTRATECH CEMENT LTD.(UNIT:KOTPUTLI CEMENT WORKS)

NOISE LEVEL AT PLANT BOUNDARY

67.2 68.9 68.3 68.6 70.2 69.4

57.2 58.4 57.761.2 62.1 61.7

75

61.4

47.6 47.1 47.6 49.2 48.4

70

46.6

60.759.5 60.258.4 60.8

05

1015202530354045505560657075

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

Near Main Gate Near TPP Near Colony Near Shopping Com plex PrescribedLimit

Locations of Monitoring

Noi

se L

evel

dB

(A) L

eq

Day Time (6.00 AM to 10.00 PM) Night Time (10.00 PM to 6.00 AM)


Acoustically treated room for Compressors Covered cabinet for Turbine generator

Acoustic enclosure for D.G. sets Green belt de velopment around D.G.

(ix) The project authorities shall strictly comply with the rules and guidelines under manufacture, storage and import of hazardous chemicals rules, 1989 as amended and Hazardous Waste (Management and Handling) Rules, 1989, as amended from time to time. Authorization from the SPCB shall be obtained for collection, treatment, storage, and disposal of hazardous waste.

We are complying with rules & guideline given for hazardous chemicals and hazardous waste. We are complying with the provisions made in Manufacture, Storage and import of Hazardous Chemicals rules, 1989. The quantities of hazardous chemicals are under the threshold limits prescribed in hazardous chemicals rules. The chemicals are stored according to provisions of rules with safety. The display boards & MSDS provided for the safe handling of chemicals. We have obtained the authorization under the Hazardous Waste (Management, Handling & Trans-boundary Movement) Rules, 2008. vide no. RPCB/HWM/ 2013-14/SWMC/HSW/116 dated 12/09/2013, which is valid up to 30/11/2016. The authorization is granted for the collection, Disposal, Generation, Reception, Storage, Treatment of Hazardous waste i.e. oil/spent oil (cat.-5.1) & Waste oil/residue containing oil (cat. 5.2) from our cement plant, power plant & limestone mine as well for co-processing of hazardous waste i.e. 100 TPD Phosphate sludge (cat.-12.5); 100 TPD process waste, residues & sludge (cat.-21.1); 100 TPD spent organic solvents (cat.-28.5) and 100 TPD Chemical sludge from waste water treatment (cat.-34.3) in cement kiln. The used/spent oil generated from Cement Plant, Power Plant, D.G. Sets & Mines machinery etc. is being stored in M.S. drums on concreted floor inside the covered roof shed and being reused for lubrication in plant or sold out to


authorized recycles from RSPCB/CPCB. Annual returns for the year 2012-13 in Form-4 under Hazardous waste Rules submitted to RSPCB vide our office letter no.UTCL/KCW/ENV/HAZ/2013-14/20 dated 22/06/2013. The manifest in Form no. 13 regarding information of movement of hazardous waste is being submitted to RSPCB as & when used oil sold. The record of used oil generation & disposal is being maintained in Form no. 3. The marking of hazardous waste container & transport emergency (TREM) card Is being maintained as per prescribed form-11 & form-12.

(x) The company shall undertake eco-developmental measures including community welfare measures in the project area for the overall improvement the environment. The eco-development plan should be submitted to the SPCB within three months of receipt of this letter for approval.

We are regularly working for community welfare including eco-developmental measures in the nearby villages under of CSR activities.

In F.Y. 2012-13, we have spent 77.79 Lacs on CSR activities including eco-developmental measures i.e. World Environment Day Celebration & Sapling Distribution Programme for surrounding villages, Sanitation Campaign, water facilities to villagers etc.

In year 2013-14 upto September-2013, following activities has been done under eco-development programme:

• Environment programme conducted on awareness of general environment issues i.e. Air pollution, Water pollution, Noise pollution, land pollution, water conservation, rain water harvesting for school children of nearby villages.

• Sanitation Campaign is conducted in 02 villages namely Kansli & Jodhpura.

• Farmers Club is formed in 03 villages. • 06 Cattle immunization camp is conducted in 04

villages. • To promote social forestry, & Environment

conservation, Sapling Distribution Programme was organized. 4000 saplings of 18 types has been distributed.

The eco-development measures shall be done on continual basis including community welfare measures in the nearby village area for overall improvement of the environment & community.

Plantation distribution to nearby area people Environment Awareness in village schools

Farmers club meeting Cattle vaccination camp


(xi) A separate Environmental Management Cell equipped with full fledge laboratory facilities shall be set up to carry out the Environmental Management and Monitoring functions.

Environmental management cell has been established under the control of senior executives; having suitable qualified personnels & all the facilities to carry our over all environmental monitoring/measurement activities and to look after the implementation of various environment protection & conservation measures. We also have certification of ISO: 14001 for Environment management system.

(xii) The implementation of the project vis-à-vis environmental action plan shall be monitored by the concerned Regional Office of the Ministry/SPCB/CPCB. A six monthly compliance status report shall be submitted to monitoring agencies and shall be posted on the website of the company.

We are complying with all the stipulated conditions in environment clearance and regularly submitting the six monthly compliance reports to the MoEF and its Regional Office at Lucknow/ RSPCB/CPCB.

Previous six monthly compliance report (for the period of October’12 to March’13) has been submitted to Regional office MoEF-Lucknow, Head office MoEF-New Delhi, Zonal office CPCB-Bhopal, Head office & Regional office RSPCB-Jaipur vide our office letter no. UTCL/KCW/ENV(Plant)/ MoEF/2013-14/14 dated 29/05/2013 and sent by e-mail on 31/05/2013.

(xiii) The project proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the SPCB and may also be seen at website of the Ministry at http://envfor.nic.in. This shall be advertised within 7 days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and copy of the same shall be forwarded to the concerned Regional Office of the Ministry.

We had informed the public about the environmental clearance by the advertisement given in two local news papers “Rajasthan Patrika” dated 08/03/2008 and “Mahka Bharat” dated 08/03/2008 and a copy of the news papers advertisement has been already submitted to MoEF with the environment Clearance compliance report vide our office letter no. GIL/GCK/MoEF/2009-10/1507 dated 30.05.2009.


(xiv) The project authorities shall inform the Regional Office as well as the Ministry, the date of financial closure and financial approval of the project by the concerned authorities and the date of start of the project.

The date of commissioning of plants is as given below: 1. Cement Plant:

• Clinkerization : 29th March, 2009 • Cement grinding : 06th January, 2010 •

2. Captive Power Plant:

• Boiler & Turbine # II : 27th March, 2009 • Boiler & Turbine # I : 01st May, 2009

3. D.G Sets (2x2825 KVA) installation & commissioning:

• D.G. Sets installation : 20, June, 2012 • D.G. Sets commissioning : 06, November, 2012

Remark : D.G Sets commissioning/trial run has been done after obtaining of consent to operate.

C ) ADDITIONAL CONDITIONS : S.N. CONDITIONS COMPLIANCES STATUS

(i) Continuous monitoring of stack emissions as well as ambient air quality (as per notified standards) shall be carried out and continuous records maintained. Based on the monitored data, necessary corrective measures as may be required from time to time shall be taken to ensure that the levels are permissible limits. The results of monitoring shall also be submitted to the respective Regional Office of MoEF regularly. Besides, the results of monitoring will also be put on the website of the company in the public domain.

The opacity monitor has been provided at all the major stacks of our cement plant & power plant for the continuous monitoring of Particulate Matter (PM).

The stacks emission & Ambient Air Quality monitoring are being carried on regular basis as per prescribed schedule by the board. The emission & Ambient Air quality levels are well within the prescribed permissible limits.

We have installed & commissioned the Continuous Ambient Air Quality Monitoring System (CAAQMS) at our plant site for the online monitoring of ambient air quality i.e. for PM10, PM2.5, NO2, NO, NOx & SO2 along with meteorological data.

The installation & commissioning of Continuous Emission Monitoring System (CEMS) have been completed at Raw mill/ Kiln stack for online monitoring of flue gases (SO2 & NOx).

The CAAQMS & CEMS are under observation before transmission of data to CPCB

We are regularly submitting the monitored data to respective offices of MoEF & CPCB & SPCB along with EC compliance report. Beside this we are also putting the same on the website of the company in the public domain.

(ii) The six monthly monitoring report as well as the monitored data on various parameters as stipulated in the environment clearance conditions shall be put on the website of the company and also regularly updated. The monitored data shall also be submitted to respective State Pollution Control Borad/ UTPCCs and the Regional Office of MoEF.

We are regularly submitting the six monthly EC compliance report along with monitored data to MoEF/CPCB/SPCB offices and beside this, we are also putting the same on the website of the company & updated regularly.

Previous six monthly compliance report (for the period of October’12 to March’13) has been submitted to Regional office MoEF-Lucknow, Head office MoEF-New Delhi, Zonal office CPCB-Bhopal, Head office & Regional office RSPCB-Jaipur vide our office letter no. UTCL/KCW/ENV(Plant)/ MoEF/2013-14/14 dated 29/05/2013 and sent by e-mail on 31/05/2013.


Screen shot of Company website showing uploaded com pliances & data

(iii) The ambient air quality data as well as the stack emission data will also be displayed in the public domain at some prominent place near the main gate of the company and updated in real time.

We have provided the online digital display for the CEMS & CAAQMS monitoring data at our company main gate in the public domain with real time updates. We have also provided a display board for displaying monthly Environmental parameters results at our company main gate.

Glimpses of Online Continuous Monitoring Systems

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CAAQMS (For Ambient Air PM 2.5, PM10 SO2 , NOX

& Weather data monitoring)

CEMS (For Stack SOx , NOx Monitoring)

OPACITY METER (For Stack Particulate Matter emission

Monitoring)

Digital Display board at Main gate for Environment Parameters

ec compliance report (4.0 mtpa cement plant & 46 mw ... · pdf filethermal power plant...

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