F. No. J-11011/616/2010-IA-II (I)

             Government of India

Ministry of Environment and Forests

(I.A. Division)

Paryavaran Bhawan

CGO Complex, Lodhi Road

New Delhi – 110 003

E-mail: ahuja.rai@nic.in

           Tele/fax: 011 – 2436 3973

                                                             Dated: 13th August, 2012      

To,

M/s Ultratech Cement Limited

504, Pragtideep Building, Laxmi Nagar District Centre,

Laxmi Nagar, Delhi- 110 092

 

Ph : 011- 22469576                Fax : 011- 22469432

E-mail : kvijender.reddy@adityabirla.com

 

  Sub:  Expansion of Existing Cement Plant, Installation of  Line 2, expansion of CTPP & New Limestone Mine- ML area 564.106 ha) at Villages Damodarpura, Kesharpura, Khor, Kanka and Nayagaon, Tehsil Jawad, District Neemuch in Madhya Pradesh by M/s Ultratech Cement Limited - regarding Environmental Clearance.

Sir,     

   This has reference to your letter no. UTCL/ENV/DEL/2012 dated 2.03.2012 along with copies of EIA/EMP and public hearing reports and subsequent communication dated 3.05.2012 seeking environmental clearance under the provisions of EIA Notification, 2006.

 

2.         The Ministry of Environment and Forests has examined your application.  It is noted M/s. UltraTech Cement Limited (UTCL) Unit: Vikram Cement Works located at Villages Damodarpura and Khor, Tehsil Jawad, District Neemuch in Madhya Pradesh has proposed for expansion in existing production capacity. Total project area after proposed expansion will be 225.142 ha  of which green belt area is under 62.957 ha of area. Land area of 12.3 ha is being acquired for green belt development. No Eco-sensitive area like National Park, Wildlife Sanctuary, and Biosphere Reserve exists within 10 km. radius of the project site except protected forests which are located at a distance of 7.75 km to 9.5 km and Reserve forest at a distance of 9.07 km. Total cost of the project is Rs. 1,950 Crores. Capital cost for Environmental Protection Measures is Rs. 110 crores and Recurring Cost is Rs. 4.0 Crores/annum.

 

3.         Details of the plant configuration along with production capacity are given below:

 

S.

No.

Description

Existing Capacity

Proposed Capacity

Total Capacity after Expansion

1.

Clinker (MTPA)

3.59

Phase I – 0.41 MTPA

(only by optimization)

Phase II – 2.2 MTPA (Installation of Line IV)

6.2 MTPA

2.

Cement (MTPA)

4.0

Phase I – 2.67 MTPA

(only by optimization)

Phase II – 3.66 MTPA (Installation of Line IV)

10.33 MTPA

3.

Captive Power Plant (MW)

46 MW

(2x 23 MW)

Phase I – 16 MW

Phase II – 50 MW

(Installation of new CPP of 2x25 MW capacity)

112 MW

4.

Waste Heat Recovery Boiler

--

10 MW

10 MW

 

4.         The cement plant is based on the dry process technology for cement manufacturing with pre-heater and pre-calciner technology. Raw materials required for the proposed expansion of cement plant are limestone, transported from the captive limestone mines (existing ML I and II, proposed ML III). Other raw materials are gypsum and fly ash, which are transported from Nagaur, Bikaner and Jaisalmer (Gypsum) and Captive CPP, Kota, Suratgarh, Chhabra power plants (Fly ash), respectively, by road. Existing power requirement is being met from 2x23 MW Coal based CPP. Power requirement for the proposed enhancement will be met from the existing as well as additional unit of CPP (i.e. 2x25 MW) & WHRB (10 MW). The company has signed MoU with SWISS SINGAPORE OVERSEAS ENTEREPRISE PVT LIMITED for supply of imported coal from South Africa / Indonesia (p. 105-110/c).

 

5.         It is noted that ESP, Bag houses and Bag filters will be installed to control the dust concentration below 50mg/Nm3. All material transfer points have been provided with bag filters to entrap the emissions at the source itself. Clinker & fly ash will be stored in silo and gypsum in covered yard. Total water requirement after proposed expansion will be 8877m3/day (existing 5,127 m3/day & additional 3,750 m3/day). Water will be sourced from the existing mine sump pit of capacity 32 lac m3. No industrial wastewater will be generated from the Cement Plant. Domestic wastewater generated from Cement Plant and Colony will be treated in the STP. The treated water will be utilized for greenbelt development. No solid waste will be generated in cement manufacturing process. Dust collected from the various pollution control equipments will be recycled back to the process. STP Sludge is/will be utilized as manure for green belt development within the plant premises.

 

6.         The Cement Plants with production capacity >1.0 MTPA are covered under Category A as per para 3(b) of the Schedule of EIA notification, 2006 and appraised by the Expert Appraisal Committee (Industry-1) in the MoEF.

 

7.         The proposal was considered by the Expert Appraisal Committee-1 (industry) in its 34th meeting held during 29th - 30th March, 2012. The Committee recommended the proposal for environmental clearance subject to stipulation of specific conditions along with other environmental conditions. Public hearing for the project was held on 1.03.2012.

 

8.         Based on the information submitted by you, presentation made by you and consultant, M/s J.M. EnviroNet (P) Ltd., Gurgaon, the Ministry of Environment and Forests hereby accords environmental clearance to the above project under the provisions of EIA Notification dated 14th September 2006 subject to strict compliance of the following Specific and General conditions:

 

A.        SPECIFIC CONDITIONS :

 

i.        Compliance to all the specific and general conditions stipulated for the existing plant by the Central/State Government shall be ensured and regular reports submitted to the Ministry’s Regional Office at Bhopal/SPCB.

 

i.        Continuous stack monitoring facilities to monitor gaseous emissions from all the stacks shall be provided.  After expansion, limit of PM shall be controlled within 50 mg/Nm3 by installing adequate air pollution control system.  Electrostatic precipitators to clinker cooler, bag house to raw mill/kiln and bag filters to coal mill and cement mill. Low NOX burners should be provided to control NOX emissions. 

 

ii.        The National Ambient Air Quality Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 shall be followed.

 

iii.        Secondary fugitive emissions shall be controlled and shall be within the prescribed limits and regularly monitored. Guidelines / Code of Practice issued by the CPCB in this regard should be followed.

 

iv.        Efforts shall be made to reduce impact of the transport of the raw materials and end products on the surrounding environment including agricultural land. All the raw materials including fly ash should be transported in the closed containers only and shall not be overloaded. The company shall have separate truck parking area. Vehicular emissions should be regularly monitored.   

 

v.        Total water requirement for the proposed expansion shall not exceed 3,750 m3/day  Efforts shall be made to further reduce water consumption by using air cooled condensers. All the treated wastewater shall be recycled and reused in the process and/or for dust suppression and green belt development and other plant related activities etc. No process wastewater shall be discharged outside the factory premises and ‘zero’ discharge should be adopted. 

 

vi.        Regular monitoring of influent and effluent surface, sub-surface and ground water should be ensured and treated wastewater should meet the norms prescribed by the State Pollution Control Board or described under the Environment (Protection) Act, 1986 whichever are more stringent. Leachate study for the effluent generated and analysis should also be regularly carried out and report submitted to the Ministry’s Regional Office at Bhopal, SPCB and CPCB.

 

vii.        All the bag filter dust, raw mill dust, coal dust, clinker dust and cement dust from pollution control devices should be recycled and reused in the process and used for cement manufacturing. Spent oil and batteries shall be sold to authorized recyclers / reprocessors only.

 

viii.        All the fly ash shall be utilized as per Fly ash Notification, 1999 subsequently amended in 2003. Efforts should be made to use fly ash maximum in making Pozollona Portland Cement (PPC).

 

ix.        Efforts shall be made to use low-grade lime, more fly ash and solid waste in the cement manufacturing.

 

x.        An effort shall be made to use of high calorific hazardous waste in the cement kiln and necessary provision should be made accordingly.

 

xi.        As proposed, green belt shall be developed in at least 33 % area in and around the cement plant as per the CPCB guidelines to mitigate the effects of air emissions in consultation with local DFO.

 

xii.        All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for the Cement plants should be implemented.

 

xiii.        The company shall adopt well laid down corporate environment policy and identified and designate responsible officers at all levels of its hierarchy for ensuring adherence to the policy and compliance with environmental clearance, environmental laws and regulations.

 

xiv.        All the commitments made to the public during the Public Hearing / Public Consultation meeting held on 1st March, 2012 shall be satisfactorily implemented and a separate budget for implementing the same shall be allocated and information submitted to the Ministry’s Regional Office at Bhopal.

 

xv.        At least 5 % of the total cost of the project shall be earmarked towards the Enterprise Social Commitment based on Public Hearing Issues and item-wise details along with time bound action plan shall be prepared and submitted to the Ministry’s Regional Office at Bhopal. Implementation of such program shall be ensured accordingly in a time bound manner.

 

xvi.        The company shall provide housing for construction labour within the site with all necessary infrastructure and facilities such as fuel for cooking, safe drinking water, medical health care, crèche etc. The housing may be in the form of temporary structures to be removed after the completion of the project.

 

xvii.        The Company shall submit within three months their policy towards Corporate Environment Responsibility which should inter-alia address (i) Standard operating process/ procedure to being into focus any infringement/deviation/violation of environmental or forest norms/conditions, (ii) Hierarchical system or Administrative order of the Company to deal with environmental issues and ensuring compliance to the environmental clearance conditions and (iii) System of reporting of non compliance/violation environmental norms to the Board of Directors of the company and/or stakeholders or shareholders.

 

B.      GENERAL CONDITIONS: 

 

i.    The project authority shall adhere to the stipulations made by Madhya Pradesh Pollution Board (MPSPCB) and State Government.

 

ii.    No further expansion or modification of the plant shall be carried out without prior approval of this Ministry.

 

iii.    At least four ambient air quality monitoring stations shall be established in the down wind direction as well as where maximum ground level concentration of PM10, SO2 and NOX are anticipated in consultation with the SPCB. Data on ambient air quality and stack emissions shall be regularly submitted to this Ministry including its Regional Office and SPCB / CPCB once in six months.

 

iv.    Industrial wastewater shall be properly collected and treated so as to conform to the standards prescribed under GSR 422 (E) dated 19th May, 1993 and 31st December, 1993 or as amended from time to time. The treated wastewater shall be utilized for plantation purpose.

 

v.      The overall noise levels in and around the plant area shall be kept well within the standards 85 dB(A) 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 Environmental (Protection) Act, 1986 Rules, 1989 viz. 75 dB(A) (day time) and 70 dB(A) (night time).

 

vi.   Proper housekeeping and adequate occupational health programmes shall be taken up. Occupational Health Surveillance programme shall be done on a regular basis and records maintained properly for at least 30-40 years. The programme shall include lung function and sputum analysis tests once in six months. Sufficient preventive measures shall be adopted to avoid direct exposure to dust etc.

 

vii.  The company shall undertake eco-development measures including community welfare measures in the project area.

 

viii. The project proponent shall also comply with all the environmental protection measures and safeguards recommended in the EIA/ EMP and public hearing reprots.

 

ix.   A separate environmental management cell with full fledged laboratory facilities to carry out various management and monitoring functions shall be set up under the control of Senior Executive.

 

x.    Adequate funds shall be allocated to implement the conditions stipulated by the Ministry of Environment and Forests as well as the State Government. Time bound implementation schedule for implementing all the conditions stipulated herein shall be submitted. The funds so provided shall not be diverted for any other purpose.

 

xi.   The Regional Office of this Ministry / CPCB / MPPCB shall monitor the stipulated conditions. The project authorities shall extend full cooperation to the officer (s) of the Regional Office by furnishing the requisite data / information / monitoring reports. A six monthly compliance report and the monitored data alongwith statistical interpretation shall be submitted to them regularly.

 

xii.  The project proponent shall also submit six monthly reports on the status of compliance of the stipulated EC conditions including results of monitored data (both on hard copies as well as by e-mail) to the respective Regional Office of MoEF, the respective Zonal Office of CPCB and the MPPCB.

 

xiii. The Project Authorities shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of commencing the land development work.

 

xiv. Measures shall be taken for control of noise levels below 85 dB(A) in the work environment. Workers engaged in operations of HEMM etc. shall be provided with ear plugs/ muffs.

 

xv.  Industrial waste water (workshop and waste water from the mine) shall be properly collected, treated so as to conform to the standards prescribed under GSR 422 (E) dated 19th May, 1993 and 31st December, 1993 or as amended from time to time. Oil and grease trap shall be installed before discharge of workshop effluents.

 

xvi. Personnel working in dusty areas shall wear protective respiratory devices and they shall also be provided with adequate training and information on safety and health aspects. Occupational health surveillance program of the workers shall be undertaken periodically to observe any contractions due to exposure to dust and take corrective measures, if needed.

 

xvii.        The project authorities shall inform to the Regional Office located regarding date of financial closures and final approval of the project by the concerned authorities and the date of start of land development work.

 

xviii.       A copy of clearance letter shall be sent by the proponent to concerned Panchayat, Zila Parishad/Municipal Corporation, Urban Local Body and the Local NGO, if any, from whom suggestions/representations if any, were received while processing the proposal. The clearance letter shall also put up on the website of the Company by the proponent.  

 

xix. The project authorities shall advertise at least in two local newspapers widely circulated, one of which shall be in the vernacular language of the locality concerned, within seven days of the issue of the clearance letter informing that the project has been accorded environmental clearance and a copy of the clearance letter is available with the Madhya Pradesh Pollution Control Board and also at web site of the Ministry of Environment and Forests at "http://envfor.nic.in and a copy of the same shall be forwarded to the Regional Office of this Ministry.

 

xx.  The environmental statement for each financial year ending 31st March in Form-V as is mandated to be submitted by the project proponent to the concerned State Pollution Control Board as prescribed under the Environment (Protection) Rules, 1986 as amended subsequently, shall also be put on the website of the Company alongwith the status of compliance of EC conditions and shall also be sent to the respective regional Office of the MoEF by e-mail.

 

9.         The Ministry may revoke or suspend the clearance, if implementation of any of the above conditions is not satisfactory.

 

10.       The Ministry reserves the right to stipulate additional conditions if found necessary. The Company in a time bound manner shall implement these conditions.

           

11.       The above conditions shall be enforced, inter-alia under the provisions of the Water (Prevention & Control of Pollution) Act, 1974, the Air (Prevention & Control of Pollution) Act, 1981, the Environment (Protection) Act, 1986, Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008 and the Public (Insurance) Liability Act, 1991 along with their amendments and rules.

 

 

 

 

 

 

 

 

 

(Dr. P.L. Ahujarai)

                                                                                                                   Scientist ‘F’

 

 

Copy to: -

 

1.    The Secretary (Environment), Govt. of Madhya Pradesh, Mantralaya, Ballabh Bhavan, Bhopal, MP.

2.    The Chairman, Central Pollution Control Board, Parivesh Bhavan, CBD-cum-Office Complex, East Arjun Nagar, New Delhi - 110032.

3.    The Chairman, Madhya Pradesh Pollution Control Board, Paryavaran Parishar , E-5, Arera Colony, Bhopal - 462016

4.    The Chief Conservator of Forests (Central), Ministry of Environment, and Forests, Western Regional Office, Kendriya Paryavaran Bhavan, Link Road No. 3, Ravi Shankar Nagar, Bhopal - 462016

5.    Monitoring Cell, Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New Delhi-110003.

6.    Guard file / Record file

 

(Dr. P.L. Ahujarai)

                                                                                                                                 Scientist ‘F’