WELCOME
THE QUALITY CIRCLE FORUM OF INDIA, HYDERABAD CHAPTER
PRESENTATION ON
“ENVIRONMENT EXCELLENCE AWARD”
National Awards and Sustainability-2030 Vision & Excellence
Conclave of Indian Cement Industry
On Dated: 15 & 16 Oct-2018
FOR: HEIDELBERGCEMENT INDIA LTD.
NARSINGARH, DAMOH, M.P.
HeidelbergCement Group :
In around 60 countries across the world, HeidelbergCement stands for competence and quality. For 145 years sinceits founding in 1873, HeidelbergCement has grown from a regional cement manufacturer, with one plant inHeidelberg, to one of the world’s leading building materials groups. With the takeover of Italcementi,
HeidelbergCement has become the number 1 in aggregates production, number 2 in cement, and number 3 inready-mixed concreteworldwide.
HC India:HeidelbergCement entered India in 2006 and is currently one of the top ten Cement Players. The Group acquired
majority stakes in Mysore Cements and Cochin Cements as well as the Indorama Cement (joint-venture), which wasconverted to a full acquisition in 2008. Following the merger with Indorama Cement, Mysore Cements was renamed
as HeidelbergCement India Ltd. (HCIL) in 2009. HCIL expanded its capacity by way of a brownfield project in CentralIndia from 2 million tonnes to 5 million tonnes in early 2013.
With the acquisition of Italcementi in 2016, HeidelbergCement further strengthened its presence in India. Italcementihad entered the Indian market in 2001, through acquisition of Zuari Cement (joint-venture), which had an integrated
cement plant in Andhra Pradesh and subsequently acquired Sri Vishnu situated in Telangana. Italcementi acquired fullcontrol of Zuari Cement in 2006 and expanded its capacity in Andhra Pradesh by way of a brownfield project in early2010.
Currently, HeidelbergCement India has production facilities at: Damoh (Madhya Pradesh), Jhansi (Uttar Pradesh),
Solapur (Maharashtra), Sitapuram (Telangana), Yerraguntla (Andhra Pradesh), Ammasandra (Karnataka), Chennai(Tamil Nadu) and Cochin (Kerala).
HeidelbergCement markets its products across 12 States and 2 Union Territories under the brand names “Mycem”and “Zuari”.
ABOUT THE GROUP/COMPANY
Name and address DIAMOND CEMENTS- CLINKERISATION UNIT (PROP: HEIDELBERGCEMENT INDIA LIMITED), NARSINGARH, DAMOH, M.P.
Production Capacity 3.1 Million Ton/Annum Clinker
Year of establishment Line – I 1982-83, Line – II 1988-89Line – III 2013WHRPP 2015
IMS POLICY
OPERATIONS OF CLINKERISATION UNITS
Following activities are involved in operation of Clinkerisation units.
➢ The limestone requirement for producing clinker is met from Patharia Lime stone mines.
➢ The limestone is received at Narsingarh plant by Covered Over Land Belt Conveyor
(OLBC).
➢ The lime stone received is further sized in crusher and transported through covered
conveyor belt equipped with dust collectors & water sprinklers to a longitudinal stock pile
in the plant from where, it is reclaimed for finer grinding.
➢ Lime stone & Laterite/Bauxide mix in raw mill make raw mix, store in Raw mill silo.
➢ Raw mix enters the kiln from the Pre-heater. Clinkerisation reaction occurred at high
Temperature between 350 to 1450 degree Celsius in Kiln and finally Raw mix converted
into Clinker.
➢ Clinker cool in Cooler and stock in Clinker silo.
➢ Clinker transported to Grinding unit by rope way/road for cement production.
➢ Clinker, Gypsum and Fly ash are ground in Cement mill and cement is produced which is
being transported by truck and Railway to the end user.
AIR POLLUTION CONTROL DEVICES (APCD)
S. No. Air Pollution Control Device Remark
1 Hybrid Filter (ESP+ Bag House) Installed with Kiln No. -1 and 2
2 Reverse Air Bag House (RABH) Installed with Kiln No.-3
3 Electro Static Precipitator (ESP) Installed with Cooler No.-1, 2 and 3
4 Bag house Installed with Coal Mill No.- 1, 2 and 3
5 Dust Collectors Installed at all loading, unloading and material transfer point
6 Telescopic Chute Installed with Clinker Silo No.-3
7 Covered Material Sheds For Bauxite, Laterite, Petcoke and Coal
8 Covered conveyor belts For transportation of all kind of Raw material & Product.
9 Water Sprinkler Installed at various locations like material handling area, green belt
area, between Lime stone stock piles etc.
10 Rope Way (Safe Way of materialtransportation)
For Clinker transportation from Clinkerisation unit, Narsingarh to
Grinding unit, Imlai.
11 Covered Over Land Belt Conveyor For Lime stone transportation from Patharia Lime Stone Mines to
Clinkerisation unit, Narsingarh.
12 Waste Heat Recovery Power Plant Waste Heat Recovery Power Plant has been installed for 15 MW
Power generation by Waste Heat generated during Plant process.
PHOTOGRAPHS OF APCD
Reverse Air Bag House (RABH) at
Kiln/Raw Mill-3
Hybrid ESP (ESP + Bag House) at
Kiln/Raw Mill-1
Hybrid ESP (ESP + Bag House) at
Kiln/Raw Mill -2
ESP at
Clinker Cooler No-3
Bag House at
Coal Mill- 3
Dust Collectors at
different material transfer points
Covered Over Land belt Conveyor (OLBC) (22 km.)
between Lime Stone Mines, Patharia & Clinkerisation Unit, Narsingarh
Rope way (13 km.) between Clinkerisation Unit, Narsingarh
& Grinding Unit, Imlai
PHOTOGRAPHS OF APCD
Covered Material Storage Yard and covered conveyor Belt Waste Heat Recovery Power Plant (15 MW)
Telescopic Chute at clinker silo Covered conveyor Belt
PHOTOGRAPHS OF APCD
ONLINE MONITORING SYSTEM
CAAQMS
CEMS
• CEMS has been installed with each stacks for Particulate Matter and SO2 & NOx analyser for each Kiln stacks. Online data of
CEMS is being punched in MPPCB & CPCB server.
• Online remote calibration facility have installed for SO2 & NOx analyser for all Kilns and its demonstration has been
completed at MPPCB & CPCB.
SEWAGE TREATMENT PLANT (600 KLD)
Month STP water treated (KL)
Apr-17 2575
May-17 2829
Jun-17 2773
Jul-17 4485
Aug-17 4450
Sep-17 3688
Oct-17 3880
Nov-17 3329
Dec-17 3604
Jan-18 4514
Feb-18 4016
Mar-18 3587
Total 43730
No effluent water is being generated during plant process only domestic waste water
is being generated from plant and colonies which is being utilised in dust
suppression & Greenbelt development after treatment in STP.
HCIL / ZCL - SGU
SPRINKLER/DRIP IRRIGATION SYSTEM
RAIN WATER HARVESTING
Plantation by Director TechnicalPlantation by Managing Director
Mass Plantation
PLANTATION • Total area of Clinkerisation Unit: 191.77 Ha
• Total area of Green Belt Development: 74.635 Ha• % of green belt development: 38.92%• Plantation during 2017-18: 5505 Nos.
• Total plant planted from 1983 to 2017: 969983 Nos.
GREEN BELT
BIO-DIVERSITY
Waste Collection Bin at site
HOUSE KEEPING
Scrap Storage YardHazardous Waste Storage Yard
Road Sweeping by Machine
Door to door collection Shredder & ComposterSegregation of waste
Curing system Domestic Waste Processing Facility
DOMESTIC WASTE MANAGEMENT SYSTEM
WORLD ENVIRONMENT DAY 2018
INTERNATIONAL OZONE LAYER PRESERVATION DAY
Environment Training, Mock drill & Sustainability Goal
Training by CII for GreenCo rating Training by Manager Environment
Mock drill by Environment Dept.Sustainability commitment 2030
Installation of solar energy plant at Kasturba girls hostel, Narsingarh
CSR
Renovation of Diamond Park-Damoh Construction of Check Dam - Satpara
CAAQMS- Collectorate Campus Damoh installed by HCIL for Local Public under direction of MPPCB
CSR Activities by HCIL - Damoh
Slide 31
School and Hostel Facililty at Damoh
CSR Activities by HCIL
Slide 32
Construction of library hall at girls hostel
Road at Village
Construction of Toilet at Narsingarh Village
Incineration of Narcotic (Ganja) in Kiln by Police Department of Madhya Pradesh
Incineration of Plastic waste in Kiln by Madhya Pradesh Pollution Control Board
INCINERATION
Water Positive Certificate from TUV SUD
in 2018
National Energy Conservation Award 2014 received
from BEE through Honourable Energy (Cabinet)
Minister
ACHIEVEMENTS
Green Manufacturing Excellence Award 2013 from
Frost & Sullivan
“Golden Peacock Occupational Health
& Safety Award” 2018
Controller General,IBM Facilitating Mines team with the
5 star recognition award during MEMC final day
function-2018
ACHIEVEMENTS • Green School Program Award through
Honourable HRD (Cabinet) Minister
Green School Programme -2017
All India Rank -4
Green School Programme -2018
All India Rank -1 (Water sub Category)
• Green School Program Award by Dr.
Bhure Lal, Head- Environment Pollution
Control Authority (EPCA)
Hierarchy of hazard control
The hazard controls in the hierarchy are, in order of
Decreasing effectiveness.
Elimination: - Physically removing the hazard, the most
effective hazard control
Substitution: - Replacing something that produces a
Hazard (similar to elimination) with something that doesnot produce a hazard
Engineering Control: - These do not eliminate hazards, but rather isolate people
from hazards.
Administrative Control: - Changes to the way people work.
Personal Protective Equipment (PPE): - The least effective means of controlling
hazards, a 2nd line of defence.
Our aim ZERO harm
Control measures
Gate pass System:-
Manpower screening, Document verification, incl. Medical Check up, Safety
Induction for all, PPE provision & Compliance
Permits & Procedures:-❑ Risk Assessment (HIRA), control measures following to Hierarchy
of Hazard Control
❑ Safe Operating Procedures for routine, non-routine & critical activities
❑ Work Permits (LOTO, Hot Work, Work at height, Excavation, Scaffolding work,
❑ Commissioning / Equipment trial run job, Local mode operation, Pocking job &Safe work)
❑ Work Instructions, checklist & Tool box Talk
❑ Certified tools & tackles
❑ Accident/ Incident/ Near miss Reporting and Investigation
❑ Award & Penalty system
Safety Inspection:-
❑ Lifting tools & tackles, pressure vessel by the Competent person
❑ All critical process equipment, portable machines, power tools and lifting tools
& Tackles
Our aim ZERO harm
❑ Fire & Safety Equipment
❑ General facility of the plant
❑ Vehicle inspection (Driver Passport, Vehicle Gate pass)
❑ Plant Area Safety inspection by Safety Dept. as well as HODs and Line
Managers ❑ Round-the-clock plant safety surveillance by Safety Patrollers/Supervisors and
Traffic Marshal (Pointsman)
Way of Communication:-
❑ Gate meetings (sharing incident/ accident/ observation of the previous day, good practices, inviting speakers every day)
❑ Spot Safety Meetings
❑ Shop floor (Short duration) tool box talk
❑ Posters, Slogans, Notices on H&S aspects
❑ Safety Booklet❑ Practical Training
❑ Observance of National/State/Group Safety day/week
Control measures
Monitoring & Measurement:-
❑ Safety KPI (No. of Accidents, FR & SR)
❑ Weightage in Annual PMS
Safety Audits:-❑ Internal audit by Safety Dept. and Safety Head
❑ Internal / Interdepartmental audit by Other Dept.
❑ Interplant audit by Plant Safety Managers
❑ Third Party Audit
❑ Corporate / Group audit❑ External audit
Review:-
❑ Safety Committee meetings
❑ Safety Update during MRM with Leadership Team❑ Review during Management Review Meeting (IMS)
-
Control measures
Our aim ZERO harm
Our aim ZERO harm
HCIL / ZCL - SGU
Awareness program through Demonstration
HCIL / ZCL - SGU
Sharing Accident Alert Sharing Accident Alert
One to one touch with villagers One to one touch with villagers
Our aim ZERO harm
“Run For Safety” for villagers
Safety training to children, Teachers & villagers
Our aim ZERO harm
Safety Practices
• Safety Induction for all
• Safety Guide for Co. & Cont. emp and Visitors
Our aim ZERO harm
SAFETY MOCK DRILL
Safety is our foremost priority
Cement Plant Process Flow Chart
ACHIEVEMENTS
• Swachh Vidyalaya Puraskar -2017
• District Level Awards
• Behaviour Change and Capacity Building for Swachh Vidyalaya – Score – 93.33 %
• Handwashing with Soap – Score- 90 %
• Water conservation – Score – 100 %
• Overall Score – 92 % with overall rating of 5 Star
• Swachh Vidyalaya Puraskar -2018
• Letter Writing Competition
• Two students – Ms Sunidhi Thakur (Class-7th ) & Ms. Samiksha (Class-8th ) are
nominated by MP state for National award for writing letter to Hon’ble Prime
Minister India for Swachha Bharat.
