Previous Environmental clearance - Welcome to...

ANNEXURE-II

Previous

Environmental clearance

Issued by SEIAA, Odisha

(Vide Letter No 624/SEIAA, Dated 17.11.2011)

ANNEXURE-III

Consent to establish

Issued by SPCB, Odisha

(Vide Letter No 3228/Ind-II-NOC-5395, Dated 23.02.2012)

ANNEXURE-IV

Brief summary

On

Amendment

OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha

Page 1

PROPOSED AMENDMENT IN EXISTING ENVIRONMENTAL CLEARANCE

1.0 INTRODUCTION

M/s Kapilas Cement Manufacturing Works, a Unit of OCL India Limited under the Dalmia

Bharat Group (here-in-after termed as KCMW) is operating a Cement Grinding Unit having

installed capacity of 1.35 MTPA at village Biswali, P.O. Barunia, Tehsil -Tangi, Dist. Cuttack,

Odisha since year 2008. The Unit has been granted all required statutory clearances like

Environmental Clearance by MoEF and Consent to Establish by Odisha State Pollution Control

Board for 2 x 1.35 MTPA Cement and 1 x 27 MW Coal based Captive Power Plant as well as

Consent to Operate for 1 x 1.35 MTPA Cement manufacturing.

KCMW has so far established and operating 1 x 1.35 MTPA Cement manufacturing and

2.5 MW Solar PV Captive Power Plant in Phase-I within the said premises. Now with

technological advancement, KCMW has envisaged up-gradation of the existing Cement Mill

capacity from 1.35 MTPA to 1.7 MTPA with an investment outlay of INR 400 Lakhs, without

making any alterations in the existing Cement Vertical Roller Mill (CVRM). This can be

achieved by replacing the existing LSKS Classifier with a dynamic LSVS Classifier with

increased Mill availability hours by debottlenecking process.

In Phase-II, KCMW will go for expansion of the existing Plant capacity by adding another Unit

of 1 MTPA at the Blaine size between 3500 to 4000 cm2/gm, thereby limiting its total original

planned and approved capacity of 2.7 MTPA.

KCMW will continue to meet its Raw material requirement by sourcing Clinker from its parent

Unit at Rajgangpur, Odisha, BF Granulated Slag from nearby Steel Plants in Kalinga Nagar and

Dhenknal- Angul belt and Gypsum from IFFCO, Paradeep and imported sources.

2.0 PROJECT BRIEF

Phase-I

Already operating a Cement Vertical Roller Mill (CVRM) of 1.35 MTPA Cement

producing capacity at the Blaine size between 3500 to 4000 cm2/gm, meeting the

requirement of BIS 455 -1989 and BIS 1489 (part 1) -1991.


Page 2

Without undertaking any alteration/ modification in the existing CVRM, KCMW envisages

upgrading its Mill capacity to 1.7 MTPA at the same Blaine size between 3500 to 4000

cm2/gm, by the following process:

By replacing existing Separator, i.e. LSKS Classifier with new dynamic LSVS

Classifier to be supplied by its OEM, Loesche, Germany.

Increasing Mill Availability hours by debottlenecking process

Developing and managing the enhanced capacity in an environment friendly manner

according to the regulatory requirements and best industrial practices, whilst ensuring

economic viability;

Maximizing operational flexibility and adhere to Total Quality Control Concept in

Operation, Maintenance and Management;

Phase-II

Installing one more Cement Vertical Roller Mill/ Roller Press Finishof 1 X 1.0 MTPA

capacity at the Blaine size between 3500 to 4000 cm2/gm which will meet the requirement

of BIS 455 -1989 and BIS 1489 (part 1) -1991 and 27 MW Captive Power Plant.

Thus, the total originally planned and approved capacity (both Phase-I & II) will remain at

2.7 MTPA.

Table 1.0 Project outline

Phase Description Existing

Capacity

Proposed

Capacity Method

I Cement Manufacturing with existing Cement Vertical Roller Mill (CVRM)

1.35 MTPA 1.70 MTPA

Up-gradation by

replacing

existing LSKS

with a dynamic

LSVS Classifier

and

debottlenecking

process

II Cement Manufacturing with new CVRM/ Roller Press Finish mode

Nil 1.0 MTPA

New Mill

alongwith all

associated


Page 3

facilities

Coal based Captive Power Plant

Nil 1 X 27 MW With CFBC

(With 335days of Annual Operation)

3.0 LAND REQIREMENT

Table 2.0 Land Use of Both Phase-I & Phase-II

4.0 RAW MATERIAL REQUIREMENT

Sl. No. Descriptions Land in Acres

EXISTING (PHASE-I)

1 Cement plant and associated facilities 30.00

2 Raw Material storage- Open Yard + Shed 12.50

3 Water storage & Treatment Plant including Rain Water Harvesting System

5.80

4 Railway siding (inside Plant boundary) 18.00

5 Railway siding (Outside Plant boundary) 54.00 6 Internal roads 18.50

7 Truck parking Area 3.70

8 Self-sustained Industrial colony with Dispensary, Multi-Purpose Hall, Club, School, Shopping Complex, Bank, etc.

28.50

9 Solar PV Captive Power Plant- 2.5 MW 12.00 10 Wildlife Management Plan (dedicated) Implementation 8.00 11 Green Belt/ Plantation 112.00

PROPOSED (IN PHASE-II)

a 2nd Cement Mill (CVRM/ Roller Press Finish) 12.00

b CPP (1x27 MW) 20.00

c Future Wagon Loading Area for Finished Goods 8.00 d Miscellaneous Usage 5.00

Total 348.00


Page 4

Table 3.0 Raw material requirement for both phase-I & Phase-II

Sl. No.

Raw material

Existing (1.35 MTPA)

Phase-I After proposed up gradation ( 1.7 MTPA)

Phase-II Additional 1.0 MTPA and 27 MW CPP

Source Mode of Transportation

Lac TPA 1 Clinker 4.72 6.00 4.10 Own Clinker

Unit at rajgangpur

Rail

2 Gypsum 0.40 0.51 0.32 Existing sources Paradeep/

Road/Rail

3 Slag 8.40 10.50 4.90 Bhushan Steel Ltd., NINL etc.

Road/Rail

4 Coal 0.202 0.255 0.150 MCL Road 5 Pet Coke 0.101 0.128 0.075 Imported Road 6 CPP Coal Nil Nil 0.19 Imported Road Auxiliary Fuel KL/Annum 7 HFO 47 59 35 Local Road

5.0 WATER REQUIREMENT

Table 4.0 Water Requirement for both Phase-I & Phase-II

Sl.

No

Description Water Requirement

(m3/day)


After Proposed

Up gradation

(1.7 MTPA)-A

Phase-II –

Additional

1.0 MTPA & 27

MW CPP-B

Total

requirement-

A+B

1 Equipment

Cooling

90 110 100 210

2 Raw Water

Treatment,

backwash

15 15 0 15


Page 5

3 Dust suppression/

Green Belt/Fire

fighting

35 35 0 35

5 Domestic 140 240 0 240

Total 280 400 100 500

6 27 MW CPP 0 0 1200 1200

Grand Total 280 400 1300 1700

Source

Being a Grinding Unit, water requirement for process is very low and basically water is required

for cooling. Total make-up water requirement for the proposed enhanced cement production for

Phase-I will be 400 m³/day. Water requirement for (Phase-I) process and cooling will be met

from existing rain water harvesting system for 10-11 months and for balance 1-2 months and

domestic requirement, water will be sourced from Ground Water. NOC from CGWA shall be

obtained.

For Phase-II, 1300 m³/day (1200 m³/day for CPP and 100 m³/day for 1.0 MTPA CGU) water

will be source from Birupariver as per the original proposal.

6.0 WASTE WATER GENERATION AND ITS MANAGEMENT PLAN

Sl. No.

Process Waste Water Management

1 Auxiliary Cooling Blow Down Reused for Dust Suppression 2 Waste water from Domestic usage

routed to STP Will be treated in STP and reused for Green Belt Development

3 Backwash of Raw Water Treatment Plant

Reused for Dust Suppression

7.0 SOLID WASTE GENERATION AND ITS MANAGEMENT PLAN

Sl.No Type of Waste Source Disposal

1 Sludge Raw water

Treatment Plant

Shall be used for land filling.

ETP Shall be disposed off as hazardous waste.


Page 6

STP Shall be used for plantation as manure.

Common Basin Shall be used for land filling.

2 Used Oil / Used

Lubricants

Plant Activities Will be sold to authorized repressors.

3 Resin WTP Resins will be subjected to regeneration and

further reused in DM Plant & Rejected Resin

to be put in impervious pit.

4 Fly ash CPP To be used for cement manufacturing.

8.0 POWER REQUIREMENT

Table 5.0 Power requirement for both Phase-I & Phase-II

Sl. No

Description Power Requirement

Existing ( 1.35

MTPA)

After Proposed Upgradation (1.7 MTPA)

Phase-II – Additional 1.0 MTPA

Total

1 Power Requirement (MVA)

9-10 MVA Existing Power is sufficient

9 MVA (will be met from

CPP)

19 MVA

9.0 MANPOWER REQUIREMENT

Table 6.0 Man Power requirement for both phase-I & Phase-II

Sl. No.

Plant Man Power

1 Existing (1.35 MTPA Cement) 659

2 After up gradation to 1.70 MTPA Cement (Ph-I) 659 3 Additional for Proposed Expansion of Cement Grinding

Unit to 1.0 MTPA 15

4 CPP -Proposed 21

Total 695

10.0 PROJECT COST

Phase-I (up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70

MTPA by replacing existing LSKS Classifier with a dynamic LSVS Classifier)

Rs. 4.0 Crore


Page 7

Phase-II (expansion by adding1.0 MTPA and 27MW CPP in Phase-II)

Rs. 300.00 Crore

Detailed report

On

Amendment

ANNEXURE-V

DETAILED TECHNICAL REPORT

Page 1

NOTE ON PROPSED CHANGES IN MILL CONFIGURATION 1.0 INTRODUCTION 1.1 PREAMBLE

M/s Kapilas Cement Manufacturing Works, a Unit of OCL India Limited under the Dalmia

Bharat Group (here-in-after termed as KCMW) is operating a Cement Grinding Unit having

installed capacity of 1.35 MTPA at village Biswali, P.O. Barunia, Tehsil -Tangi, Dist. Cuttack,

Odisha since year 2008. The Unit has been granted all required statutory clearances like

Environmental Clearance by MoEF and Consent to Establish by Odisha State Pollution Control

Board for 2 x 1.35 MTPA Cement and 1 x 27 MW Coal based Captive Power Plant as well as

Consent to Operate for 1 x 1.35 MTPA Cement manufacturing.

KCMW has so far established and operating 1 x 1.35 MTPA Cement manufacturing and 2.5 MW

Solar PV Captive Power Plant in Phase-I within the said premises. Now with technological

advancement, KCMW has envisaged up-gradation of the existing Cement Mill capacity from

1.35 MTPA to 1.7 MTPA with an investment outlay of INR 400 Lakhs, without making any

alterations in the existing Cement Vertical Roller Mill (CVRM). This can be achieved by

replacing the existing LSKS Classifier with a dynamic LSVS Classifier with increased Mill

availability hours by debottlenecking process.

In Phase-II, KCMW will go for expansion of the existing Plant capacity by adding another Unit

of 1 MTPA at the Blaine size between 3500 to 4000 cm2/gm, thereby limiting its total original

planned and approved capacity of 2.7 MTPA.

KCMW will continue to meet its Raw material requirement by sourcing Clinker from its parent

Unit at Rajgangpur, Odisha, BF Granulated Slag from nearby Steel Plants in Kalinga Nagar and

Dhenknal- Angul belt and Gypsum from IFFCO, Paradeep and imported sources.

1.2 LOCATION AND ACCESSIBILITY

Latitude : 200 37’ 26” to 200 37’ 53” N Longitude : 850 59' 45” to 860 00’ 23” E Site Elevation : 50 meter above MSL Toposheet No. : 73 H/14, 73 L/2 (on 1:50000 scale) Village : Biswali Tehsil : Tangi District : Cuttack

Accessibility to the site is as per details given below:

Road

The Plant is located at about 10 km from NH-5. The nearest major town is Cuttack at a distance

of 30 km from the plant site.


Page 2

Rail

The major Railway station is at Cuttack, which is 30 km from the existing Plant site. KCMW is

having its own private Railway siding within the Plant premises which is connected to Byree

railway station located at a distance of about 5 km from the existing plant. The railway line

connecting to the Byree railway station and the Plant site falls under Byree, Amiyajhari and

Baymba villages of Jajpur District and is sufficient to take care of the enhanced plant

requirement including Phase-II.

Air

The nearest airport is at Bhubaneswar, which is about 60 kms from the Plant site.

1.2.1 METEOROLOGICAL DATA

Elevation of site : 210 m above mean sea level.

Temperature : Daily max. 410C, min 130C.

Rainfall : Average 1501 mm annually

Seismic Zone : Seismic Zone of III.

Relative Humidity : Max. 79% and Min. 65%.

Wind Speed : Average 8 km / hr.

1.3 PROMOTER’S BACKGROUND

OCL INDIA LIMITED, formerly "Orissa Cement Limited" and popularly known as "OCL", was

established in the year 1949, started producing Cementthrough Wet Process technology under

the brand name of "Konark". Keeping a steady progress with time and technology it has

modernized to a fully automated Dry Process Plant in 1988. OCL commands the position of

market leadership in the state of Odisha since its inception and today it’s premier lead brand.

‘Konark' cement enjoys brand advantage in the region. It is a name cemented to Quality.

OCL diversified from Cement to the field of Refractoryin 1954. Over the years, it has become

one of the largest and well-equipped state of the art Refractory plant in India covering a wide

range of products for use in the Ferrous & the non-ferrous Industries. Its customer base spreads

from iron and steel to cement, aluminum, glass, copper, chemicals and hydrocarbon industries.

Today, OCL enjoys a huge market share in India and overseas extending to five continents

across the globe. OCL is a globally focused organization with presence in key areas of

infrastructure development. With its range of product and strong R & D orientation it enjoys a

strong customer and brand loyalty.

Now it is a part of the reputed Dalmia Bharat Group having an Installed Cement capacity of 24

MTPA in the country.


Page 3

1.4. PROJECT BRIEF

1.4.1 Production and Operational

Phase-I:

Already operating a Cement Vertical Roller Mill (CVRM) of 1.35 MTPA Cement producing

capacity at the Blaine size between 3500 to 4000 cm2/gm, meeting the requirement of BIS

455 -1989 and BIS 1489 (part 1) -1991.

Without undertaking any alteration/ modification in the existing CVRM, KCMW envisages

upgrading its Mill capacity to 1.7 MTPA at the same Blaine size between 3500 to 4000

cm2/gm, by the following process:

By replacing existing Separator, i.e. LSKS Classifier with new dynamic LSVS Classifier to

be supplied by its OEM, Loesche, Germany

Increasing Mill Availability hours by debottlenecking process

Developing and managing the enhanced capacity in an environment friendly manner

according to the regulatory requirements and best industrial practices, whilst ensuring

economic viability;

Maximizing operational flexibility and adhere to Total Quality Control Concept in Operation,

Maintenance and Management;

Phase II:

Installing one more Cement Vertical Roller Mill/ Roller Press Finishof 1.0 MTPA capacity

at the Blaine size between 3500 to 4000 cm2/gm which will meet the requirement of BIS 455

-1989 and BIS 1489 (part 1) -1991.

Thus, the total originally planned and approved capacity (both Phase-I & II) will remain at

2.7 MTPA.

1.4.2 Environmental

Phase-I:

Presently the Unit is well equipped with the required Pollution Control Equipment and well

meeting the environmental standards stipulated by SPCB, CPCB and MoEF.

Already connected its 3 Ambient Air Monitoring Stations and main CVRM Stack monitoring

station to SPCB and CPCB servers by on-line real time data transmission.


Page 4

The existing Air Pollution Control Equipment, viz. Main Bag Filters and Auxiliary Bag

Filters will be adequate to meet the upgraded plant capacity for Phase-I.

Protecting the surrounding environment during operation of proposed expanded plant with

appropriate environmental safeguards to meet community expectations in terms of

environmental outcomes and cost;

Ensuring that ecological balance of the area is not adversely affected by Air, Water & noise

emissions and solid wastes; and

Protecting native flora and fauna, quality of local surface and groundwater and minimize

public health risks.

1.4.3 Socio-economic

Improvement in indirect means of livelihood;

Improvement in the living standard of local habitants; and

Establish monitoring program and provide procedures for resolution of community concerns,

if any.

2.0 PROJECT DESCRIPTION

Preamble

KCMW is already operating a Cement manufacturing (Grinding) unit of 1.35 MTPA

capacity at Village-Biswali, P.O- Barunia, Tehsil- Tangi, District- Cuttack, Odisha. The main

raw materials used for manufacturing Cement are Clinker, Gypsum, BF Granulated Slag and

Fly Ash. Clinker, the main raw material is being sourced from its parent Unit at Rajgangpur

by Rail or from other Clinkering plants, in case of shortfall. Chemical Gypsum, a by-product

of the Fertilizer Industry is received from the fertilizer plants at Paradeep, Coramandal by

rail or truck and Mineral Gypsum is being imported through Paradeep port. Coal is used as

fuel in Hot Air Generator for drying purpose in Mill. BF Granulated Slag, a waste product of

the Steel plants is procured by rail/road from various nearby steel plants like NINL,

BHUSAN, MESCO, etc.

In Phase-I, with technological advancement, KCMW has now envisaged up-gradation of the

existing Cement Mill capacity from 1.35 MTPA to 1.7 MTPA with an investment outlay of

INR 400 Lakhs, without making any alterations in the existing Cement Vertical Roller Mill


Page 5

(CVRM). This can be achieved by replacing the existing LSKS Classifier with a dynamic

LSVS Classifier with increased Mill availability hours by debottlenecking process.

In Phase-II, KCMW envisages to set-up another Cement Mill of 1 MTPA capacity (CVRM/

Roller Press Finish mode) alongwith a Captive Power Plant (Coal based) of 1 x 27 MW with

an capital outlay of Rs.300 Crs.with all associated facilities.

Outline of the proposed project is given in the following Table 2.0below.

2.1 : Project outline

Phase Description Existing

Capacity

Proposed

Capacity Method

I Cement Manufacturing with

existing Cement Vertical

Roller Mill (CVRM)

1.35 MTPA 1.70 MTPA

By Up-gradation of

Classifier and

debottlenecking

process

II Cement Manufacturing with

new CVRM/ Roller Press

Finish mode

Nil 1.0 MTPA New Mill alongwith

all associated facilities

Coal based Captive Power

Plant

NIL 1 x 27 MW With CFBC Boiler

(With 335 days of Annual Operation)


Existing Classifier

The Raw materials required from Cement manufacturing, i.e. Clinker, Gypsum, BF

Granulated Slag will continue to be procured from the existing sources as mentioned above.

The proposed installations

Railway siding, situated

Biswali&Badapokharivillages of Cuttack district and Byree and Amiyajhari of Jajpur district,

Odisha. Hence no alternate sites

2.3Land Utilization Pattern

Land Utilization pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7

MTPA (Phase-I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase

of 348 Acres of acquired land


Existing Classifier Modified Classifier


continue to be procured from the existing sources as mentioned above.

s will be made inside the existing Plant premises

Railway siding, situated over an area of 348 Acres

villages of Cuttack district and Byree and Amiyajhari of Jajpur district,

o alternate sites are envisaged.

Pattern

pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7

I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase

of acquired land is givenin following Table 2.3.


Page 6

Modified Classifier


continue to be procured from the existing sources as mentioned above.

lant premises and with existing

48 Acres in Mania and

villages of Cuttack district and Byree and Amiyajhari of Jajpur district,

pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7

I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase-II over an area


Page 7

Table 2.3: Land Utilization Pattern (Phase-I & Phase-II)

2.4:Plant Details& Capacity

Cement Plant

The revised Plant Configuration are given hereunder.

Sl. No. Descriptions Land in Acres

EXISTING (PHASE-I)

1 Cement plant and associated facilities 30.00

2 Raw Material storage- Open Yard + Shed 12.50

3 Water storage & Treatment Plant including Rain Water Harvesting System

5.80

4 Railway siding (inside Plant boundary) 18.00

5 Railway siding (Outside Plant boundary) 54.00 6 Internal roads 18.50

7 Truck parking Area 3.70

8 Self-sustained Industrial colony with Dispensary, Multi-Purpose Hall, Club, School, Shopping Complex, Bank, etc.

28.50

9 Solar PV Captive Power Plant- 2.5 MW 12.00 10 Wildlife Management Plan (dedicated) Implementation 8.00 11 Green Belt/ Plantation 112.00

PROPOSED (IN PHASE-II)

a 2nd Cement Mill (CVRM/ Roller Press Finish) 12.00

b CPP (1x27 MW) 20.00

c Future Wagon Loading Area for Finished Goods 8.00 d Miscellaneous Usage 5.00

Total 348.00


Page 8

Table 2.4: Existing & Proposed Plant Capacity

Sl No.

Existing CVRM- 1.35 MTPA Proposed Enhancement 1.35 to 1.70 MTPA (after

Up gradation)

CVRM/ Roller Press Finish - 1.0 MTPA

1 Vertical Roller Mill – (Existing Mill) Performance Parameter: Clinker Grinding

• 210- 220 TPH (Blaine 3600 cm2/g)

Slag Grinding

• 200-210 TPH (Blaine 3700 cm2/g)

Blaine for finished product3700 +-100 cm2/g Running hours per annum 6500-7000 hrs.

Vertical Roller Mill (Existing Mill) Performance Parameter: Clinker Grinding

• 230-240 TPH (Blaine 3600 cm2/g)

Slag Grinding • 220-230 TPH

(Blaine 3700 cm2/g) Blaine for finished product3700 +-100 cm2/g Running hours per annum 7300-7600 hrs.

Vertical Roller Mill / Roller Press Finish. Performance Parameter Clinker Grinding

• 190 TPH (Blaine 3600 cm2/g)

Slag Grinding • 175 TPH (Blaine

3700 cm2/g) Blaine for finished product3700 +-100 cm2/g Running hours per annum 5500-6000 hrs.

2 Coal Mill (Ball race mill)- 1 no Capacity: 15

Existing coal mill is sufficient

Existing Coal mill is sufficient for fulfill the expansion plant requirement

3

Coal crusher – 1 no Capacity- 150 TPH

Existing coal crusher is sufficient

Existing Coal crusher is sufficient for fulfill the expansion plant requirement

4

Hot Air Generator – 2 sets Capacity: 15 MKCal/hr each

Existing Hot Air Generator is sufficient.

Hot Air Generator – Additional 1 sets for expansion plant Capacity: 25 MKCal/hr each

5

Rot packer (16 spout) – 2 sets Capacity: 180 TPH each Loading Machines: 8 nos. Truck/ Trailer loaders

Existing Roto Packers aresufficient.

Rot packer (16 spout) – 1 sets Capacity: 180 TPH each Loading Machines: 4 nos. Truck/ Trailer loaders


Page 9

6

Material handling system such as stacker, reclaimer, conveyers, feed system, storages etc.

Existing material handling system is sufficient.

Material handling system such as stacker, reclaimer, slag , gypsum storages system etc. are common for new mill & additional Mill feed conveyors , Mill hopper with clinker storage system to be installed for new mill.

Table 2.5: Fuel for Cement Grinding:

Particulars Existing

(1.35

MTPA)

After

Proposed

Upgradatio

n

(1.7

MTPA)

Phase-II –

Additional

1.0 MTPA

Source Distance

from

Plant

Mode of

Transporta

tion

Lac TPA

Coal 0.202 0.255 0.150 MCL Within 100

Km

Road

Pet Coke 0.101 0.128 0.075 Imported/

Paradeep

Port

Within 100

Km

Road

CPP Coal NIL NIL 0.19 --do--- ---do--- ---do--

Auxiliary Fuel : Auxiliary Fuel Existing (1.35

MTPA)

After Proposed

Upgradation

(1.7 MTPA)

Phase-II –

Additional

1.0 MTPA

Source/ Mode of

Transportation

KL/Annum

HFO 47 59 35 Domestic/ Road

Fuel for CPP 1 x 27 MW: As per original Plan (No change)

2.6: Raw Material

The main raw materials required for manufacturing cement BIS 455 -1989 and BIS 1489 (part

1) -1991.are Clinker, Slag , Gypsum and Fly Ash.

Details of raw material required to produce Cement is given in Table 2.6.


Page 10

Table 2.6: Details of Raw Material Requirement (dry basis) &its Source

2.7: Equipment and Storage Capacities

The storage capacities for various materials required for enhanced capacity including existing is

given in the following Table 2.7

Table 2.7: Details of Storage Capacities for Grinding Unit

Description Existing ( 1.35 MTPA)



Storage Capacity

Materials Stock Days Stock Days Stock Days Ton

Clinker silo 10 Existing

5 2 X 25000 ( 1 Existing +1 Proposed)

Gypsum stock pile (covered)

20 Existing Existing

2 X 2,500---Existing

Cement Silos 4 Existing Existing 4 X 7,500 ---Existing

Slag Stock pile 10 Existing Existing (2 X 50000-Existng

Coal Stock pile 15 Existing Existing 1 X 5000

Fly Ash (MC Silo) 7 Existing 7 1 Nos Proposed silo

Sl. No

Raw Material

Existing ( 1.35

MTPA)

After

Proposed

Upgradatio

n

(1.7 MTPA)

Phase-II –

Additional

1.0 MTPA

Source

Distance from plant

(Km)

Mode of Transportatio

n

Lac TPA

1 Clinker 4.720 6.000 4.100 Existing source (Our RGP Unit)

400 Rail

2 Gypsum 0.400 0.510 0.320 Existing sources

Paradeep / Imported

100 Road/Rail

3 Slag 8.400 10.500 4.900 Bhushan,NINLetc .

75 Rail/Road

4 Fly Ash 0.270 0.340 0.680 MCL/ Others NIL


Page 11

2.8: Manufacturing Process (Cement)

Clinker, Slag and Gypsum are the raw materials are used in the manufacture of Portland Slag

Cement (PSC). In case of Pozzolana Cement (PPC), Fly Ash replaces Slag.

Requisite quantity of clinker will be supplied from our own Integrated Cement Plant at

Rajgangpur to the factory site by railway wagons. Clinker received by rail shall be stored in

suitable clinker storage silo. Slag, which is a waste material generated in the process of steel

making will be received by rail/road and stored and is stored at designated place. Fly Ash, a

waste product of Power Plants will be transported by covered trucks and stored in MC (Multi-

compartment) Silo. Gypsum which is a by-product of the fertilizer industry will be received from

the fertilizer plants at Paradeep or Imported Mineral Gypsum from Paradeep Port by road and

stored in a covered storage shed.

For cement grinding, appropriate imported Cement Vertical Roller Mill (CVRM) has been

installed. Clinker is fed into Cement Vertical Roller Mill along with requisite quantity of

gypsum, where it is ground to a fine powder to produce Ordinary Portland Cement (OPC).

Portland Slag Cement (PSC) is normally manufactured by grinding clinker with gypsum at

suitable proportion and grinding granulated slag separately and thereafter mixing them together

intimately in a paddle mixer. Alternatively, all the above raw material i.e clinker, gypsum and

slag can be ground together. The mill has been provided with a dynamic classifier internally

which allows only the fine particle of requisite Blaine to pass to the bag filter where the fine

particles is settled and collected in the hopper in the bag filter. The collected cement in the

hopper is transported by enclosed air slide to the elevator and is stored in the Reinforced Cement

Concrete silo called cement silo. In case of separate grinding the material is stored in the multi

compartment silo from where the ground clinker and slag is extracted, blended in proper

proportion in a mixer and then send to cement storage silo. In case of inter grinding of clinker,

gypsum and slag together the material from bag filter hopper is directly sent to cement storage

silo. In case of manufacture of PPC, clinker, fly ash (extracted from the Fly ash storage

compartment) and gypsum are inter-ground and stored in the identified cement silo.

Cement extracted from silos is conveyed to the automatic electronic packers (2X180 TPH, 16

spout electronic roto-packers with twin discharge) where it is packed in 50 kg HDPE bags and

dispatched in trucks. Manufacturing Process Flow is presented in following Fig. No.- 2.8.


Fig No. 2.8: Manufacturing

2.9Water

2.9.1 Break Up of Water Requirement (Cement Grinding Unit)


: Manufacturing Process Flow Diagram (Cement Grinding)

Break Up of Water Requirement (Cement Grinding Unit)


Page 12

Process Flow Diagram (Cement Grinding)


Page 13

The water requirement for the existing as well as the proposed expansion is given in Table

below.

Table 2.9.1: Water requirement

Sl.

No

Description Water Requirement

(m3/day)


After Proposed

Up gradation

(1.7 MTPA)-A

Phase-II –

Additional

1.0 MTPA & 27

MW CPP-B

Total

requirement-A+B

1 Equipment Cooling 90 110 100 210

2 Raw Water

Treatment, backwash

15 15 0 15

3 Dust suppression/

Green Belt/Fire

fighting

35 35 0 35

5 Domestic 140 240 0 240

Total 280 400 100 500

6 27 MW CPP 0 0 1200 1200

Grand Total 280 400 1300 1700

2.9.2 Source of water

Being a Grinding Unit, water requirement for process is very low and basically water is required

for cooling. Total make-up water requirement for the proposed enhanced cement production for

Phase-I will be 400 m³/day. Water requirement for (Phase-I) process and cooling will be met

from existing rain water harvesting system for 10-11 months and for balance 1-2 months and

domestic requirement, water will be sourced from Ground Water. NOC from CGWA shall be

obtained.

For Phase-II, 1300 m³/day (1200 m³/day for CPP and 100 m³/day for 1.0 MTPA CGU) water

will be source from Birupariver as per the original proposal.

Rain Water Harvesting System:

Presently we have the following system for Rain Water Harvesting:

Two Reservoirs of 5000 m3 capacity each i.e. total 10000 m3 for storage of rain waterafter collection from drain, ponds and is used for plant operation.


Page 14

Kachha drains of 2m x 2.5m x 2000 m in which check dam has been made to retain storm water up to 2m height. Thus about 10,000 m3 water remains in drain in rainy season and after rainy season also.

Throughout rainy season, we are able to operate the plant by pumping this rain water to the reservoir and from reservoir to the plant by pumping after treatment. The roof top water is directed to the main rain water drains as mentioned above through sub- drains and pipes and utilized for plant as mentioned above.

We have already initiated required action for upgrading the existing Rainwater Harvesting System to increase the storage s as follows, which will be sufficient to meet the requirement of expanded capacity.

Table 2.9.2- Rain Water Harvesting System

S.NO Location Earlier capacity in

KL After Up-gradation

capacity in KL 1 Reservoir 2nos ,RCC at WTP 10,000 10,000

2 Drain from garage to WTP & substation to WTP

10,016 14,758

3 Drain from guest house to Rail way line near rail way gate .

4,800 6,400

4 Drain truck tippler to slag yard (1.2mtr x 150mtr)

679 679

5 Drain at railway yard.(500x1x0.60)m

300 300

6 New Pond Near Colony 0 3,305

7 Drain at combo tower, hume pipe (dia 1.2mtr x length 100mtr)

0 452

Total 25,795 35,894

Bore Wells: 9 nos Bore Wells (for drinking & sanitation and one/ two months’ plant requirement in Summer)

Treated Domestic waste water of STP is reused for green belt development& Sanitation. The

Backwash of the raw water treatment plant are treated in the settling tank and the treated water is

utilized for dust suppression on roads.

3.0 Power

The present contract demand from CESU is 10 MVA andExisting power consumption for plant

operation is 8-9 MVA. So there will be no additional requirement of power for capacity

enhancement from 1.35 MTPA to 1.70 MTPA.


Page 15

The specific power consumption also reduces due to following reasons.

Optimization of Mill with desired blaine& increase in Mill TPH results in lower Specific

Power consumption.

Mill auxiliary power will remain same irrespective of output, so with the higher output,

auxiliary power (KWH/MT) will also reduce by minimize the idle run hours of equipment.

Fan power will reduce by replace the new GRR & Removal of venture.

Plant auxiliaries Unit – Auxiliaries are less load by increasing the mill performance.

Packing Plant –With optimization of the packer output& increased the fan efficiency.

Table 3.0: Power requirement

Sl. No

Description Power Requirement

Existing ( 1.35

MTPA)



Total

1 Power Requirement (MVA)

9-10 MVA Existing Power is sufficient

9 MVA 19 MVA

Table 3.1: Power Requirement for Capacity Expansion (Ph-II)

Required Power Break-up for Expanded Capacity (Based on technical Offer of KHD): HAC CODE KW DRIVES FOR 1 SET OF ROLLER PRESS: 531FN1 7.5 531BC1 3.7 531FN2 15 531FN3 9.3 531BC2 3.7 531BC3 30 531BC4 3.7 531FN4 7.5 531FN5 7.5 541BE1 250 BUCKET ELECATOR 541BC1 15 541BC2 22 541BC3 3.7 541FN2/DA1 7.5 541RP1 3200 MAIN DRIVE MOTOR 541FN1/LD5 45 581SR1 215 SEPARATOR/CLASSIFIER 581FN2 9.3 581FN1/LD1 720 BAG HOUSE FAN 591 FA1-2 5.5


Page 16

591FA3 7.5 591FN1 7.5 CONNECTED LOAD 4596 For one RP Circuit 2SET OF SAME 9192 For two RP Circuit PACKING PLANT OTHER AUX 1000 One Packer with 2 loaders TOTAL CONNECTED LOAD 10192 CONSIDERING 90% LOADING 9173 CONNECTED LOAD IN KVA 10295

WITH 80% OF LOADING LOAD IN KVA 8236 Required 8 MVA Our existing Contract demand is of 10MVA & our operating range is 9 to 9.5 MVA. We

have to enhance our Contract Demand from 10 MVA to 18 MVA. The existing Grid and Power status are conducive for the enhanced load.

4.0Environmental Management (Cement Grinding Unit)

The proposed expansion is being designed taking cognizance of prevalent environmental laws

and the importance attached to maintaining environmental standards.

4.1 Air Pollution

The dust is the crucial parameter among the main pollutants. Efficient tapping of dust generating

sources, their de-dusting with efficient filters and recycling the dust to the process is the prime

objective. Primary dust sources of the manufacturing process are raw material, coal, cement

grinding, cement packing and transfer points. All other dust sources are considered as secondary

sources since these are not process implied. These dust sources may occur wherever relatively

dry or dusty material is handled, conveyed, pumped or extracted. To achieve stipulated emission

levels, bag filters have been considered at all dust generating points including transfer towers.

Besides arresting emission of dust, appropriate steps have been considered to arrest dust

generation e.g. water spray controlled dust suppression system at unloading hoppers, discharge

gate at extraction of silos and totally enclosed operations for all belt conveyors, storages, etc.

KCMW proposes to adopt the dust emission level from each bag filter within 30 mg/Nm3 as per

CREP (Chapter on Corporate Responsibility for Environment Protection) guidelines.

Existing plant is well equipped with adequate pollution control equipment’s as shown in the

following table.

4.2AirPollution Control Measures (Existing & Proposed)

Existing (Phase-I):

Existing plant is well equipped with pollution control devices. Details of pollution control

equipment are given in the Table 4.2.Pollution Control Equipment as existing for 1.35 MTPA &

After upgradation to 1.70 MTPA will remain the same, as the same are adequate.


Page 17

Table 4.2.1: Air Pollution Control Equipment- Existing

Sl. No.

Pollution Control

Equipment

Pollution Control

Equipment attached to

Quantity of Pollution Control

Equipment’s in Nos.

Designed Gas Handling

Capacity of Pollution Control

Equipment in m3/hr

Quantity of

emission m3/hr

Efficiency in %

1 Bag house Cement Vertical Roller Mill (CVRM

1)

1 7,50,000 (Before recirculation)

4,72,221* 99.99

2 Bag filter Coal mill 1 50,000 50,000 99.80

3 Bag filter Packing

Machine-1

1 50,000 50,000 99.89


Machine-2

1 50,000 50,000 99.89

5 Bag filter Wagon

Tippler

1 1,70,000 1,70,000 99.90

Expansion (Phase-II):

The proposed expansion of the plant shall be well equipped with adequate pollution control

devices.The details are mentioned below.

Table 4.2.2: Pollution Control Equipment- Proposed

Sl.

No

.

Proposed

Pollution

Control

Equipment

Pollution

Control

Equipment

attached to

Quantity of

Pollution

Control

Equipment in

Nos.

Designed Gas

Handling

Capacity of

Pollution Control

Equipment in

m3/hr

Quantity

of

emission

m3/hr

Efficienc

y in %

1 Bag house CVRM/RP 1 6,00,000 3,77,599 99.99


Machine

1 50,000 50,000 99.89

3 ESP CPP 1 2,60,000 2,55,000 99.96

Note: Existing Coal Mill & Wagon Tippler is capable of handling the proposed enhancement,

hence no additional Pollution Control Equipment is proposed.

Low sulphur coal is being/ shall be used in the Hot Air Generator to the maximum possible

extent. The heights of stacks are also being considered as per CPCB guidelines for proper

dispersion of SO2. In the Hot Air Generator, generation of NOx gases depends to a great extent


Page 18

on the combustion temperature and percentage excess air. Installation of a well-designed burner

system using low quantity of primary air, therefore, shall limit the core flame temperature to

ensure a reasonably low value of NOx. Generation of Carbon Monoxide (CO) emission shall be

negligible in view of the firing technique of keeping a positive oxygen balance.

However, regular monitoring and continuous auto regulation of fuel and air by automatic

combustion control system is an indispensable part of all large Cement Plants now a days.

4.3 Fugitive Emission Management

Adequate pollution control measures are being taken to suppress the fugitive dust generated near

various sources with water spray and provision of auxiliary bag filters. Also fugitive dust

monitoring is being carried out regularly in the existing plant, which will be practiced during the

post expansion phase also.

Table 4.3: Source & Measure- Ambient Air Pollution control

Sl. Source of Pollution pollutants APC Measures

TRANSPORTATION OF RAW MATERIALS

1 Transportation of Raw

Materials

Fugitive Dust Transportation through covered

trucks

RAW MATERIAL HANDLING

1 Raw Material Unloading,

Stock Piling

Fugitive Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

• Reclaimed Materials is being

transported to the raw material

hoppers through covered belt

conveyors.

• Bag Filter has been installedat

Raw Mill feed bin.

• Vents of storage silo has been

connected to bag filter.

• Stock Piles has been located in

covered sheds.

The above will be followed for

Phase-II (1.0 MTPA) expansion.

COAL GRINDIND IN VRM

1. Coal Grinding Dust Coal Mill Vent Gas has been


Page 19

connected to bag filter.

MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT)

1 Transfer Points Fugitive Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

All transfer points has been fully

enclosed with provision for access

doors. Spillages is being

periodically removed. Air borne

dust at all transfer points is being

extracted through dust extraction

system to the bag filters.



2. Air Slides Dust All the air slides are closed type

and has been connected to dust

extraction system i.e bag Filter.

3. Belt Conveyers Fugitive Dust All the belt conveyers are covered

and it has been connected to Bag

Filter.

4. Weigh feeder discharge Fugitive Dust The weigh feeder vents has been

connected to bag filters.

5. Raw materials hoppers (receiving Hopper, Granulated Slag hopper, gypsum hopper, clinker hopper)

Fugitive Dust The vents of the hoppers has already been connected to dust extraction system i.e bag filter.

HOT AIR GENERATOR

1. Operation of Hot Air

Generator

Dust, SO2 • Bag House

CLINKER STORAGE & TRANSPORT

1. Clinker Storage & Transport

Dust • Silo vent has been connected to Bag filter.

• Dust generated from the transfer points has


Page 20

beenconnected to Bag filter.

GYPSUM TRANSPORT

1 Transportation of Chemical gypsum.

Fugitive Dust Chemical gypsum is being transported through covered trucks, which already contains 16% moisture, hence gypsum dust generation will be insignificant.

2 Gypsum unloading section

Fugitive Dust

Existing & up gradation (1.35

MTPA to 1.70 MTPA)

From trucks, gypsum is beingunloaded at Truck Tippler and it is being transported by coveredbelt conveyor to gypsum storage yard under a covered shed.

The above will be followed for Phase-II (1.0 MTPA) expansion.

SLAG TRANSPORT

1 Transportation of slag

Fugitive Dust

Existing & up gradation (1.35

MTPA to 1.70 MTPA)

Reclaimed Slagis being transported to the raw material hoppers through covered belt conveyorsfor Cement Grinding.

The above will be followed for Phase-II (1.0 MTPA) expansion.

2 Slag unloading section

Fugitive Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

From trucks, Slagis beingunloaded at Truck Tippler and it is being transported by covered belt conveyor to Stack yard.




Page 21

SLAG DRIER

1 Slag Drier Fugitive Dust Bag Filter.

BLENDING & STORAGE SILO

1 Blending & Storage Silo Dust The silo vent has been provided

with a bag filter type system to

vent out the air borne fines.

CEMENT GRINDING

1. Cement Grinding Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

• Gas from the cement mill outlet

is being de-dusted in the Bag

filter .

• The reject circuit is also being

de-dusted by means of bag filter.



CEMENT STORAGE & HANDLING

1. Cement Storage &

Handling

Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

• Cement from the cement

grinding section is being

transported to the storage silo by

a system of Air Slides and

Bucket Elevator.

• Vents of Silo has been connected

to bag filter.

• The air slides and bucket elevator

is closed type andhas been

connected to Bag Filter.




Page 22

CEMENT PACKING & DISPATCH SECTION

1. Packer Dust Existing & up gradation (1.35

MTPA to 1.70 MTPA)

• The packing machine has been

equipped with dust extraction

arrangement such that the

packing operation is performed

under negative pressure. The

dust will be captured in bag

filters.

• Adequate ventilation for the

packing hall has been provided

for venting out suspended

particulates thereby ensuring

dust free work environment.

• The spilled cement from the

packing machine is being

collected properly and sent for

recycling.

• The spilled cement on the shop

floor is being swept by vacuum

sweeping machines

periodically.

• Proper engineering controls has

been provided to prevent the

fugitive emission. This will

include arrangements like

guiding plate, scrapper brush

for removing adhered dust on

cement bags etc.

• The vibratory screen provided

for screening / recycling spilled

cement has been provided with

a dust extraction arrangement

to prevent fugitive emission

from that section.


Page 23



2. Loading to trucks Dust From Packing Section finished

product is being taken through

enclosed belt conveyor. From belt

conveyor through truck loader, it is

being loaded in trucks.

ROADS

1. Internal Roads Fugitive Dust • The internal roads has been

Concreted.

• Mechanical sweeping is

being carried out regularly

followed by water

sprinkling.

2. Vehicular Movement Fugitive Dust The speed of the heavy vehicles is

limited to 10 Km/hr in the plant

premises to prevent the road dust

emission.

The following measures are being practiced in the existing cement plant and also envisaged for

the proposed expansion project (Ph-II) which shall be in line with the measures adopted for

operation of existing plant:

Pulse jet bag filters at all dry material conveying and transfer points.

Dust extraction system having pulse jet type bag filter at dump hopper of

coal/Slag/Gypsum/Clinker

Regular dust suppression with water sprinkler on the haul roads

Plant roads & approach roads shall be made of concrete

Areas between various sections and truck parking areas shall be made of concrete/ brickwork

Open areas within the plant premises and along with boundaries of the plant premises

are/shall be covered under green belt

Raw Materials/ Cement shall be fully covered during transportation to/ from the site by road/

rail.


Page 24

The air pollution load will be as per the previous EIA because the total capacity will remain

the same as per the approved EIA.

4.4 Water Pollution

As this is a dry grinding unit, no effluent is/shall be generated from the process. Water is being

used for cooling of machineries, domestic, green belt development & firefighting purposes.

Cooling water is/ shall be recycled with generation of waste water as cooling blow down.

Domestic effluent is/shall be generated, which is/shall be treated in the existing STP complying

the suitable norms of CPCB. Detail of waste water generation from various sources is given in

the Table 4.4.

Table 4.4: Quantity of Waste Water generated

Sl. No.

Process Waste Water Management

1 Auxiliary Cooling Blow Down Reused for Dust Suppression

2 Waste water from Domestic usage routed to STP

Treated in STP and reused for Green Belt Development

3 Backwash of Raw Water Treatment Plant

Reused for Dust Suppression

No waste water will be discharged to outside. The plant is/shall be developed with zero discharge

concept.

4.5 Solid Waste

This project is based on dry process of cement production and there is very little chance of

generation of solid waste. With the bag filter and other effective pollution control measures, the

dust generated is re-used in the process in different stages. The solid waste generated from the

Sewage Treatment Plant is being used for green belt development.

Table 4.5 Generation & Management of Ancillary Solid Wastes

Sl.No Type of Waste Source Disposal

1 Sludge Raw water Treatment Plant

Used for land filling and manure for plantation.

ETP (Phase-II) Shall be disposed off as hazardous waste. STP Shall be used for plantation as manure. Common Basin Shall be used for land filling.

2 Used Oil / Used Lubricants

Plant Activities Is being sold to authorized re-processor.


Page 25

3 Resin WTP Resins will be subjected to regeneration and further reused in WTP& Rejected Resin to be put in impervious pit.

4 Fly ash CPP To be used for cement manufacturing.

Note: Handling & disposal of hazardous wastes shall be carried out as per the Hazardous Waste

(Management, Handling &Trans boundary Movement) Rules’ 2008 and subsequent amendments

thereafter.

4.6 Noise Pollution Noise pollution from turbine, fans, centrifugal pumps, electric motors etc, shall be kept below the

permissible level of 85 dB (A) at 1m away from the source by proper design.

Noise from safety valves, startup vents, steam jet ejectors of condenser etc. are reduced by

providing silencers at the outlet of down steam piping.

5.0 Fire Fighting System

A complete firefighting system is already provided comprising of following.

A suitable high pressure system of fire hydrants consisting 19 nos. of fire hydrants points.

A complete separate firefighting water piping network for feeding the hydrants connected

with a 40000 liter capacity overhead tank.

42 nos. of dry chemical powder (DCP) type and one heavy duty ABC powder type fire

extinguishers are hung at particularly important electrical equipment areas.

22 nos of portable CO2 extinguishers and 15 nos of mechanical foam type fire extinguisher

are provided throughout the plant.

Automatic fire extinguishing system using water shall be provided for empty bags store in

the packing plant in due course.

A team of around 21 nos security personnel have been trained on fire fighting and first-aid

and in each shift six nos. are available in side the plant .This team of six trained security

personnel is helped by plant operative personnel for various jobs whenever required during

fire.

The company is in touch with the Govt. fire brigade authorities of Chandikhol and Cuttack

for necessary service which are in a distance of approximately 25 Km and 30 km far from the

plant site respectively.

The emergency contact nos. has been displayed at various important locations of the plant

along with our internal emergency no 3471 for an immediate help.

An emergency siren has been installed at the security gate, in order to make alert to others as

and when the emergency situation arises.


Page 26

6.0 Laboratory

KCMW iswell equipped with most modern and up-to-date laboratory with a proper combination

of a qualified group of personnel and a high-tech infrastructure. The primary task of laboratory is

to carry out the testing of samples round the clock for controlling the quality of all input and

output materials to provide a consistent quality of products conforming to the applicable BIS

norms and to satisfy the needs and expectations of the customers. The laboratory is also equipped

with X-ray analyzer for testing of cement and its raw materials. The existing laboratory shall be

further upgraded as per the requirement of proposed expansion.

7.0 Man power

Total manpower requirement in the post expansion phase will be 695 nos. Break of the

manpower is given in the Table 7.0.

Table 7.0: Break Up of the Man Power (Total Plant after proposed expansion)

Sl. No.

Plant Man Power

1 Existing (1.35 MTPA Cement) 659 2 After upgradation to 1.70 MTPA Cement (Ph-I) 659 3 Additional for Proposed Expansion of Cement Grinding

Unit to 1.0 MTPA 15

4 CPP -Proposed 21

Total 695

8.0 ENVIRONMENTAL SETTING

The details of environment settings of the study area covering an area equivalent to 10 km radius

surrounding KapilashCement manufacturing works of M/s. OCL is same as mentioned in the

approved EIA.

9.0 OCCUPATIONAL HEALTH AND SAFETY

In compliance with national and international standards on health and safety, a unit has been

created to see to the implementation of all safety measures.

A well-equipped Fire Fighting System is in place to see to all fire outbreaks and fire prevention.

In addition, hydrants and fire extinguisher are positioned at vantage points to be used when

necessary.


Page 27

Electrical safety precautions has been provided in the design e.g. circuit breakers etc. have been

placed at vantage points to strip off and protect the personnel and installation from danger.

Earthing grid for proper system operation as required by I.E.C standards has been designed for

the safety of personnel and equipment. An efficient illumination system for plant buildings and

roads has been considered and provided.

Other facilities that have been provided for ensuring safety in the plant operation are as follows.

a) Suitable DCS and programmable logic control system;

b) Automatic closed loop circuit control system with necessary instrumentation;

c) Mimic diagrams/graphic display with fault monitoring system.

The personnel protective devices considered for the proposed thermal power plant is shown in

the Table- 9.0

Table 9.0 :Personnel Protective devices provided

Protection

Area Equipment Protection Against

HEAD

a) Fiber Helmet. Fall of objects/hitting against

objects during construction,

maintenance etc.

b) Welder's leather cap. Falling of molten slag, splashing of

liquid etc.

EYE

a) Panorama goggles with

clear plastic vision.

Oil and paint splashes, dust and

chips.

b) Leather mask goggles. Foreign bodies entering the eyes and

smoke.

c) Spectacle type goggles

with plain spatter proof

lens.

Foreign bodies entering the eyes

and reflected arc rays.

d) Spectacle type goggles

with blue lens.

High temperature flame during

furnace work.

e) Panorama goggles with

green plastic visor.

Reflected arc rays during arc welding

jobs.

FACE

a) Plastic face shield. Liquid chemicals, dust particles.

b) Welding helmet and

shield.

Welding fumes, sparks and' UV rays.


Page 28

c) Asbestos hood. Heat radiation during furnace work.

BODY

a) Leather apron. Falling of hot chips, slags etc.

b) Asbestos apron. Heat radiation.

c) PVC apron. Splashing of chemicals.

d) Safety belt. Falling of persons from height.

EAR a) Ear plugs or muffs. High noise level.

NOSE

a) Dust respirators. Fine dust particles.

b) Light fume mask. Acid fumes and vapours (0.1%).

c) Heavy fume mask. Toxic gases (0.1%).

d) Canister gas mask. Acid fumes, vapours and gases

(2.0%).

HAND

a) Leather gloves. . Cuts due to handling.

b) Asbestos gloves. Heat radiation.

c) Acid & Alkali proof

rubber gloves.

Burns due to chemical handling.

d) Electrical resistance

gloves.

Electric shock.

e) Canvas gloves. Contact with oil, grease etc.

f) Hand sleeves. Falling of hot slag.

LEG

a) Leg-guards. Welding sparks.

b) Leather safety boots. Striking by objects, fall of objects and

stepping on sharp or hot objects.

c) Asbestos safety boots. Heat radiation, stepping on hot or

sharp objects, striking by stationary

or moving objects.

d) Gum boots. Liquid splashing.

10.0 ANTICIPATED ENVRIONMENT IMPACTS AND MITIGATION MEASURES

It will be as per the approved EIA.


Page 29

11.0CONCLUSION

KCMW management is circumspect on the continuous menace posed by pollution to the society

and is committed to use congenial environment management practices at planning & design

stage and during construction and operation phase. The mitigation measures have been designed

within the framework of various Central/ State legislative and regulatory requirements on

environmental and socio-economic aspects and discussed in detail in the preceding chapters as

well as in approved EIA Report.

In brief, we can conclude that the proposed change in Project/ Plant configuration will definitely

be beneficial to the industry with no additional burden on environment, maximise revenue for the

industry, improve socio-economic conditions in the periphery and shall definitely alleviate the

gap between peak demand and supply of electricity.

Date post:	11-May-2018
Category:	Documents
Upload:	phungthien
View:	217 times
Download:	1 times

Previous Environmental clearance - Welcome to...

Documents