THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
COMPLIANCE REPORT FOR THE PERIOD APRIL TO SEPTEMBER 2014
Expansion of Cement plant (clinker 0.85 to 1.32 MTPA, Cement 0.90 to 1.52 MTPA at village Muktyala Dist Krishna, AP
by M/s. The KCP Limited- Reg,
Letter No.J-11011/514/2008-IA.II (I), Dated: 28.01.2010
S. No
i
CONDITION
A. SPECIFIC CONDITIONS:
No construction work at the proposed project site
shall be started without obtaining prior clearances /
approvals for the linked mining component from
the Indian Bureau of Mines (IBM) and State Govt.
of Andhra Pradesh. A copy of mining lease
approval from the Indian Bureau of Mines (IBM)
and State Govt. of Andhra Pradesh shall be
submitted to the ministry and its Regional Office at
Bangalore before initiating any construction work
at site related to mining. The company shall
comply with the conditions stipulated in the mining
plan approval letter issued by the Indian Bureau of
Mines and mining lease accorded by the State
Government.
COMPLIANCE STATUS
Received CFE from APPCB for the expansion of the cement plant Vide letter
No 226/PCB/CFE/RO – VJA/HO/2010 dated 24.01.2011 and obtained CFO
for the expansion of the cement plant from 0.85 to 1.32 MTPA vide letter No
APPCB/VJA/226/HO/CFO/2012 - 2281 dated 24.08.2012
Received CFE from APPCB for the expansion of the mines Vide letter No
2289/PCB/CFE/RO – VJA/HO/2009 dated 02.09.2010 and obtained CFO for
the expansion of the lime stone mines from 1.50 to 2.0 MTPA vide letter No
APPCB/VJA/VJA/4/HO/CFO/2011 - 3023 dated 13.12.2011
Necessary Clearances/approvals were obtained from the concerned
departments i.e., Indian bureau of Mines, State Government, Ministry of
Environment and Forests.
Muktyala Lime Stone Mine:
MOEF:F-No.J-11011/347/2010-IA-II (I) dt:20/10/2010
IBM: Mining Plan Approval renewal Order No AP/KSN/MS/Lst-246-SZ/1259
dt14.12.2012.
Industries and Commercial Dept: Mining Lease Grant: GO. No 585 DT
3/12/2001.The copy was submitted to MOEF, Bangalore office on 03-1-2013
Page 1 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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Compliance to all the specific and general
conditions stipulated for the existing plant by the
Central/State Govt. shall be ensured and regular
reports submitted to the Ministry and its Regional
Office at Bangalore.
Continuous monitoring system to monitor gaseous
emissions shall be provided and limit of SPM shall
be controlled within 50 mg/Nm3 by installing
adequate air pollution control system and energy
efficient technology. Electrostatic precipitator
(ESP) shall be provided to clinker cooler and bag
house to kiln, raw mill, coal mill and cement mill.
Inert gases from pre-heater shall be de dusted in
twin cyclones. In the event the pollution controls
equipment not working, the respective unit (s) shall
be shut down automatically. The gaseous and
particulate matter emissions from various units
shall conform to the standards prescribed by the
A.P. Pollution Control Board. At no time,
particulate emissions from the cement plant
including kiln, coal mill, cement mill, cooler and
captive power plant (CPP) shall exceed 50
mg/Nm3.
Possibilities shall be explored for the proper and
full utilization of gases generated from the kiln in
waste heat recovery boiler (WHRB) and a
feasibility report shall be prepared and submitted
to the Ministry and its Regional Office at Bangalore
within months from the date of issue of the letter
All specific and general conditions stipulated for the existing plant by the
Central/State Govt. are being adhered and the previous half yearly
compliance reports were submitted to the Regional Office, Bangalore.
Continuous emission on line monitoring systems was provided for the four
major stacks. Cooler ESP, RABH and Coal Mill and Cement mill. All pollution
control equipment was designed to maintain dust emissions below 30
mg/Nm3. Electrostatic precipitator (ESP) for clinker cooler and bag houses
for kiln/raw mill, coal mill and cement mill were installed. The emissions from
the stacks are well below the limits prescribed by the Pollution control Board.
Please see Annexure-1
M/s. THE KCP Limited operating high energy efficient cement plant with a
capacity of 1.32 MTPA clinker designed by Humboldt wedag, Germany. The
system was designed and operating with low exit vent gas temperatures
which are just sufficient for drying both limestone and raw coal to meet the
process requirement.
In July 2011, M/s. FL Smidth, Denmark studied the feasibility of installing
WHRB for Preheater gases and reported that the project is not viable
Page 2 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
v
The National Ambient Air Quality Emission
Standards issued by the Ministry vide G.S.R. No.
826(E) dated 16`h November, 2009 shall be
followed.
vi
Ambient air quality including ambient noise levels
shall not exceed the standard stipulated under
EPA or by the State authorities
vii
The Company shall install low NOx burner with
Kiln/Calciner for control of NOx emissions below
400 mg/Nm3.
The company shall install adequate dust
collection, extraction /dust suppression system to
control fugitive dust emissions at various transfer
points, raw mill handling (unloading, conveying,
transporting, stacking), vehicular movement,
bagging any packing areas etc. to minimize air
pollution. Bag filters shall be provided to kiln
feeding system, crusher and other transfer points
viii
because of high efficiency of the process design.
Presently, 2 CAAQM stations were installed. One station located between
Lime stone crusher and colony and the second one installed at factory main
gate and both the CAAQM stations were connected to PCB web site. And also
Monthly once Ambient Air Quality tests at three locations in and around the
plant premises and all the stacks emissions are being monitored by the third
party and the test reports are being submitting to APPCB, Regional Office,
Vijayawada regularly.
Project authorities propose to install one more CAAQ by January 2015.
All the values of AAQ & Noise levels are well within the stipulated limits.
Cement plant AAQ & Noise levels are being monitored monthly once by the
third party. Noise levels are measuring at the locations, Near packing plant,
Near main gate entrance, Near coal mill & Near guest house. Near packing
plant and coal mill the noise levels are around 60 dB (A). Ambient Air Quality
at lime stone mines area , tests are being conducted in Core zone as well as
in Buffer zone four times in a year Pre monsoon (April/May), Monsoon
(August), Post Monsoon (November) and Winter (January) Seasons and data
was submitted to Regional Office, Bangalore once in Six Months earlier.
Please see the Annexure-2
M/s. KCP has installed low NOx pyro jet burner for Kiln to control the NOx
emissions. The emissions are below 400 mg/Nm3.
To control fugitive emissions dust collectors were installed along with the roof
sheet for all materials handling systems like gypsum, clinker, lime stone and
coal feeding. A part from the above Spraying of water on roads and at all
material transfer points including at lime stone crusher and their haulage
roads. Apart from the above all the raw materials like Gypsum, coal, fly ash,
laterite, refractory materials and clinker are stored in closed
silos/domes/sheds of October 2013.
Page 3 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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to control the fugitive dust. All conveyers shall be
covered with GI sheets. Covered sheds for storage
of raw, materials and fully covered conveyers for
transportation of materials shall be provided
besides coal, cement, fly ash and clinker shall be
stored in silos. Pneumatic system shall be used for
fly ash handling. Dust suppression system shall be
provided to the coal stock pile. Regular water
sprinkling shall be carried out it critical areas prone
to air pollution and having high levels of SPM and
RPM particularly in mine area and other vulnerable
areas.
Gaseous emission levels including secondary
fugitive emissions from all the sources shall be
controlled within the latest permissible limits
issued by the Ministry and regularly monitored.
Guidelines / Code of Practice issued by the CPCB
shall be followed. New standards for the sponge
iron plant issued by the Ministry vide G.S.R. 414
(E) dated 30" May, 2008 shall be followed.
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 shall
be transported in the closed containers only and
should not be overloaded. Vehicular emissions
shall be kept under control and regularly
monitored. Measures shall be taker, for
maintenance of vehicles used in mining operations
and in transportation of mineral. The vehicles shall
Please see the Photographs as Annexure-3
Received CPCB guide lines copy and adhered to the stipulated conditions.
Fugitive emissions are well controlled by spraying water on roads and one
road sweeping machine was purchased and it is under use to avoid the dust
settling on the roads.
Action has been initiated to lay railway line for transporting/ procuring coal
gypsum and laterite by 2016 March. The road leading to National High way
from project site is totally blacktopped and widened. Covering the trucks with
Tarpaulin is made mandatory and is strictly followed. The trucks are not over
loaded.
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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be covered with a tarpaulin and shall not be over
loaded.
Asphalting/concreting of roads and water spray all
around the critical areas prone to air pollution and
having high levels of SPM and RPM shall be
ensured.
Total water requirement shall not exceed 870
m3/day from bore wells/ River Krishna and the
conditions stipulated in the permission letter
obtained from the Central Ground Water
Authority/State Ground Water Board complied with
and shall be submitted to Ministry's Regional
Office at Bangalore. The treated waste water from
sewage water treatment plant (STP) and utilities
shall be reutilized for green belt development and
other plant related activities i.e. cooling and dust
suppression in raw material handling area etc.
after necessary treatment. 'Zero' discharge shall
be strictly adopted and no effluent from the
process, shall be discharged. outside the
premises.
'Permission' for the drawl of 870 m3/day water
from bore wells / Krishna River shall be obtained
from the CGWA / SGWB / concerned department.
The water stored n the artificial reservoir made in
the mine pit shall be used maximum to reduce
ground water consumption. No effluent shall be
discharged from the mine to any water body or
nearby river.
M/s. KCP has developed paved roads inside and outside the plant (15000
square meters) including residential area (30000 square meters). To control
fugitive dust emissions further, water spraying on concrete roads is adopted.
The STP is under operation and the treated water is being used for the green
belt development. Though M/s KCP got permission to use 870m3/day, but
due to installation of Reverse air Bag house in place of ESP huge quantity of
water has been conserved. Accordingly APPCB amended water use quantity
from 870 to 694 m3/day for the both limestone mine and cement plant
together..
All the domestic sewage routed to STP and the treated water is being used
for the green belt development at CPP and Colony. No waste water is being
discharged or generated.
As per the CFO Order APPCB/VJA/VJA/226/HO/CFO/2011 – 2308 dated
29.10.2011 for the cement plant; the water consumption quantity is 770 KLD.
And
for
the
limestone
mines
as
per
the
CFO
order
APPCB/VJA/VJA/226/HO/CFO/2011 – 3023 dated 13.12.2011 the water
consumption quantity is 100 KLD. During the cement plant CFO renewal for
three years order no APPCB/VJA/VJA/226/HO/CFO/2012 – 2281 dated
24.08.2012 the water use quantity amended/reduced from 770 to 594 KLD.
Hence the total water permission from the both plant and mines is 694 KLD
only (The conservation of water is due to installation of RABH in place of ESP
Page 5 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
and installation air cooled compressors in place of water cooled
compressors). There are 5 bore wells in the industry premises and 2 in the
colony. M/s.KCP obtained permission for drawing water from State Ground
Water Board. To conserve ground water, when ever water oozes in mine pit
is being collected and pumped to cement plant for process cooling/ make up
water.
A natural sloped pond of 300 meters x 300 meters x 2.5 meters depth,
located in front of the main gate was excavated to store 3.0 lakh KLD water
which in turn augmented/retain ground water levels in and around the plant.
xiv
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The project proponent shall ensure that no natural
water course shall be obstructed due to any
mining operations. The company shall make the
plan for protection of the natural water course
passing through the plant and mine area premises
and subject to the ministry's Regional Office at
Bangalore.
Detailed hydrological study shall be carried out
and implementation of recommendations of the
detailed hydrological study shall be ensured.
Rainwater harvesting measures shall be adopted
for the augmentation of ground water at cement
plant, colony and mine site. Besides, company
must also harvest the rainwater from the rooftops
and storm water drains to recharge the ground
water. The company must also collect rain water in
the mined out pits of captive lime store mine and
There is no natural water course passing through the plant area or mine area.
Hydrological study was carried out and the recommendations are under
implementation. As recommended by hydro geologist 30 x 30 meters x 2.5
meters depth pit was made to store the oozed water from the mine and the
same is being pumped to the cement plant for the process use. Two bore
well points are been dedicated to monitor water table levels. And also it is
proposed to install piezo meters/ on line electronic equipment to monitor
ground water levels regularly.
Roof top rainwater harvesting provision has been made to recharge the
ground water. A pond was established in front of the factory main gate, which
can store three lakhs cubic meters of rain water. Rain water harvesting into
mine pit is in vogue and this water is being used in the plant for various
purposes. Rain water harvesting and ground water recharge structures were
made available on consultation with Gram Panchayat leaders to enhance the
ground water table in the vicinity. Photos were already submitted to Ministry.
Page 6 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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xix
use the same water for the various activities of the
project to conserve fresh water and reduce the
water requirement pressure from the river. The
Company shall construct the rain water harvesting
and groundwater recharge structures outside the
plant premises also in consultation with local Gram
Panchayat and Village Heads to augment the
ground water level. An action plan shall be
submitted to Ministry's Regional Office at
Bangalore within 3 months from date of issue of
this letter.
Efforts shall be made to make use of rain water
harvested. If needed, capacity of the reservoir
shall be enhanced to meet the maximum water
requirement. Only balance water requirement shall
be met from other sources.
Catch drains and siltation ponds of appropriate
size shall be constructed for the working pit, inter
burden and mineral dumps to arrest flow of silt and
sediment. The water so collected shall be utilized
for watering the mine area, roads, green belt
development etc. The drains shall be regularly
desalted, particularly after monsoon, and
maintained properly.
Garland drain of appropriate size, gradient and
length shall be constructed for both mine pit and
inter burden dumps and sump capacity shall be
designed keeping 50%(safety margin over and
above peak sudden rainfall (based on 50 years
data) and maximum discharge in the area
Please see photographs as Annexure - 4
Rain water harvested is used to the maximum possible extent.
No overburden / soil dumps were seen. No mineral is stacked in mine as
dump. However, with the garland drain of 1.50 x 1.00 m size and 850m of
length, the natural drainage water is directed away from the mine pit.
The sump capacity is designed, keeping in the view of sudden peak rainfall,
to give maximum retention time to completely settle the sediments.
Sedimentation pits with de-siltation facilities were provided.
Page 7 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
adjoining the mine site. Sump capacity shall also;
provide adequate retention period to allow proper
settling of silt material. Sedimentation pits shall be
constructed at the corners of the garland drains
and desalted at regular intervals.
xx
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xxii
Regular monitoring of ground water level and
quality shall be carried out establishing a network
of existing wells and constructing new piezometers
at suitable locations by the project proponent in
and around project area in consultation with
Regional Director, Central Ground Water Board.
The frequency of monitoring shall be four times a
yearpre-monsoon
(April/May),
monsoon
(August), post-monsoon (November), and winter
(January). Data thus collected shall be sent at
regular intervals to Ministry of Environment and
Forests and its Regional Office Bangalore, Central
Ground Water Authority and State Ground Water
Board.
Suitable conservation measures to augment
ground water resources in the area shall be
planned and implemented in consultation with
Regional Director, Central Ground Water Board.
The monitoring of ground water and establishing piezometers is yet to be
undertaken. However periodical monitoring of ground water level
measurements are being carried out regularly at dedicated sampling bore
well test points. .
A letter wrote to Central Ground Water Board on 08.04.2013 and soon we
Will request the department for further immediate actions to be taken for
Ground water augment and conservation.
Please see the Annexure-5
Dimension of the retaining wall at the toe of inter There are no dumps in the mine area as it is a captive mine for the cement
burden dumps and inter burden benches within the plant. There is no OB. The small quantities of OB along with the mineral is
mine to check run-off and siltation shall be based being ground in vertical roller mill and then fed into the kiln.
on the rain fall data
Page 8 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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All the bag filter dust, raw meal dust, coal dust,
clinker dust and cement dust from pollution control
devices shall be 100% recycled and reused in the
process and used for cement manufacturing. Solid
waste from Sewage Treatment Plant (STP) shall
be used as manure. No solid waste shall be
disposed off from the cement plant. Over burden
from mines shall also be used for afforestation
purposes in plant and mine. Spent oil, grease and
grinding media shall be disposed to licensed
vendors.
An effort shall be made to use of high calorific
hazardous waste in the cement kiln and necessary
provision shall be made accordingly. The company
shall keen the record of the waste utilized and
shall submit the details to ministry's Regional
Office at Bangalore, CPCB and APPCB.
The company shall carry out the analysis of the
trace metals like mercury, chromium, lead,
arsenic, uranium etc. in the all the raw materials
like lime stone, gypsum, fly ash, slag coal etc. and
the analysis reports shall be submitted Ministry's
Regional Office at Bangalore, CPCB and APPCB.
Efforts shall be made to use low grade lime, more
fly ash and solid waste in the cement
manufacturing
Dust collected through various bag filters is being recycled into the
manufacturing process and the segregated mine over burden suitable for
plantation is being used at colony and cement plant inside for the
development of green belt. The suitable over burden is being used for the
road construction inside and outside the plant premises. The waste lubricants
collected in both mines and the plant is using during kiln light up.
The kiln was designed for firing of high calorific value Hazardous wastes.
M/s.KCP is maintaining the record of waste utilization and submitting the
same to the RO, APPCB.
The spent carbon received (66.0 tons) from Hindustan Coca Cola Beverages
private Limited and Carbon block(60.0) received from Tushar Enterprises is
being fired in the kiln so far for the year 2013 - 14..
Reportedly, there are no heavy metals, trace metals like, mercury, chromium,
lead, arsenic and uranium in the raw materials.
Low grade lime stone is being mixed with high grade lime stone along with
overburden because of the usage of 100 % imported coal in the
manufacturing of clinker. Fly Ash is being used for manufacturing PPC. About
36% of the cement produced constituted PPC in 2011 – 2012 and fly ash
consumption maintaining from 35 to 40% in the current year.
Page 9 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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All the fly ash shall be utilized as per Fly Ash
Notification, 1999 subsequently amended in 2003.
Efforts shall be made to use fly ash maximum in
making Pozollona Portland Cement (PPC).
There is no in-house fly ash generation as the CPP is yet to be
commissioned. The project authorities are importing fly ash and using it to the
maximum possible extent by making PPC to the tune of 30-32 % of total
production. Fly ash storage bins 2 x 600 metric tons capacity with adequate
transport system was installed and operating.
Wet drilling blasting method and provision for the Wet drilling method is followed to suppress the dust generated.
control air emissions during blasting using dust
collectors etc. shall be used.
Blasting operation shall be carried out only during
the daytime. Controlled blasting shall be practiced.
The mitigate measures for control of ground
vibrations and arrest fly rocks and boulders shall
be implemented.
Bench height, width and slope for individual bench
shall be properly assessed and implemented.
Adequate measures shall be adopted to stabilize
the slope before abandonment. The fencing
around the reservoir shall be provided to prevent
accidents
The project proponent shall modify the mine plan
of the project at the time of seeking approval for
the next mining scheme from the Indian Bureau of
Mines so as to reduce the area for external over
burden dump by suitably increasing the height of
the dumps with proper terracing. It shall be
ensured that the overall slope of the dump does
not exceed 28°.
Blasting is done only during daytime and in accordance with the
recommendations of IBM. Ground vibrations and fly rock are controlled by
using non-el. bottom initiation detonators.
Reporting, the height, width and slope of the benches are as per the norms.
Fencing of reservoir is yet to be completed. Project authorities have agreed
to complete the works on priority basis.
The condition is not applicable, as there is no dump proposed.
Page 10 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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Top soil, if any, shall be stacked with proper slope
at earmarked site(s) only with adequate measures
and shall be used for reclamation and
rehabilitation of mined out areas.
Action plan for the mining, management of over
burden (removal, storage, dispose; etc.),
reclamation of the mined out area and mine
closure shall be submitted to the Ministry and its
Regional Office at Bangalore. Final mine closure
plan along with details of Corpus Fund shall be
submitted to the Ministry 5 years in advance of fine
mine closure, for approval.
The inter burden and other waste generated shall
be stacked at earmarked dump site(s) only and
shall not be kept active for long period. The total
height of the dumps shall not exceed 30m in three
terraces of 10m each and the overall slope of the
dump shall be maintained to 28°. The inter burden
dumps shall be scientifically vegetated with
suitable native species to prevent erosion and
surface run off. Monitoring and management of
rehabilitated areas shall continue until the
vegetation becomes self-sustaining. Compliance
status shall be submitted to the Ministry of
Environment& Forests and its Regional Office,
Bangalore on six monthly basis.
There is no top soil at present. Whatever was generated earlier was
reportedly used in the colony.
As there is no overburden generation, dumps are not proposed. Hence the
reclamation of the same does not arise. Final mine closure plan along with
details of Corpus Fund 5 years in advance with Bank Guarantee no. 0528
IGFIN006012, for an amount of Rs.11, 51,500 /- Guarantee Period from
18.09.2012 to 31.03.2017 for implementation of other related reclamation
works was submitted to IBM.
Limestone outcrop is exposed and there is neither topsoil nor waste soil
available / generated / removed. However small quantity of inertial soil is
removed and the same is being used for plantation.
The void left unfilled in the mining area shall be Agreed to comply. As cement plant commissioned in the year 2011 and due
converted into water body. The higher benches of to poor marketing of cement, the operation of the cement plant as well as
excavated void/mining pit shall be terraced and mines utilization capacity is only 60 %. As soon as the excavated mine area
Page 11 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
plantation done to stabilize the slopes. The slope
of higher benches shall be made gentler for easy
accessibility by local people to use the water body.
Peripheral fencing shall be carried out along the
excavated area.
xxxvi A Risk and Disaster Management Plan along with
the mitigation measures shall be prepared and a
copy submitted to the Ministry's Regional Office at
Bangalore, APPCB and CPCB within 3 months of
issue of environment clearance letter.
xxxvii All the safety norms stipulated by the Director
General, Mine & Safety (DGMS) shall be
implemented.
xxxviii Digital processing of the entire lease area using
remote sensing technique shall be done regularly
once in three years for monitoring land use pattern
and report submitted to Ministry of Environment
and Forests and its Regional Office, Bangalore.
xxxix As proposed, green belt shall be developed in at
least in 35 acres (35 %) out of total/100 acres all
around the cement plant. In the limestone mine
area, afforestation shall be carried out in 156.96
ha. Out of total 368.40 ha all the mined out area
except used for reservoir as per the CPCB
guidelines.
reaches certain level the stipulated conditions will be implemented.
A detailed safety audit conducted by a reputed external agency Chinmaya
safety Management Consultancy , Hyderabad on April 2014 in which
disaster, emergency preparedness as well as mitigation plan were submitted
and the same is being fallowing.
Complied.
A copy of digital processing remote sensing picture related to The KCP unit–
II has been obtained .As the plant was commissioned recently and also the
mine development is under initial stage, now action has been initiated to get
detailed satellite picture of plant and mines soon.
Greenbelt along the boundary of the cement plant and in the open areas is
being strengthened. In about 3.5 ha area green belt was developed in 2010–
2011. About 2.5 ha in 2011–2012 was brought under green belt.1.5 ha area
was planted in 2012 -2013. Greenbelt area is being developed in phased
manner. Suitable species were selected to make greenbelt programme a
success in spite of the area being generally rocky and un productive. During
2013-14 project authorities developed green belt (1.5 HA) around the mine
office and north side of lime stone mine In 2014 – 15 ( Upto Sep) about 0.5
HA green belt developed in Mines and about 16 HA green belt developed
between CPP & Colony
Please see photographs - 6
Page 12 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
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xll
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xliv
Permission' and `Recommendations' of the State
Forest Department regarding impact of cement
plant and mining activities on the surrounding
reserve forests Jaggayyapeta RF(1km), Budavada
RF(2km) and BalusupaduRF(9km) Chintapalem
RF
(7.6km),Venkatayapalem
RF(5.0km),
Ginjupalle RF(4.7km) Kuntimaddi RF(3.1km) shall
be
obtained
and
implemented.
Further,
Conservative Plan for the conservation of wild
fauna in consultation with the State Forests
Department shall be prepared and implemented.
Rehabilitation and Resettlement Plan for the
project affected population including tribal’s, if
applicable, shall be implemented as per the policy
of the State Govt. consultation with the State Govt.
of Andhra Pradesh shall be implementer
Compensation paid in any case shall not be less
than the norms prescribed undo the National
Resettlement and Rehabilitation Policy, 2007.
All the recommendations made in the Charter on
Corporate
Responsibility
for
Environment
Protection (CREP) for the Steel plants shall be
implemented.
The company shall comply with the commitments
made during public hearing held on 25th August,
2009 and a separate budget for implementing the
same shall be allocated and information submitted
to the Ministry's Regional Office at Bangalore.
No Objection Certificate was obtained from State Forest Department for
setting up of the cement plant and mines. M/s The KCP Limited implementing
conservation plan as per the Forest Department suggestion.
M/s The KCP established the cement plant in the private patta lands owned
by the Organization.
Compliance for CREP attached
Please see Annexure -7
All these commitments were met. However, the continuous beneficiary works
carried out by the company are reflected in their CSR activity.
Please see photographs and Annexure - 8 for the period April – September
2014
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
xlv
At least, Rs.7.00Crores (2% of the total cost of the
project) shall be earmarked towards the corporate
social responsibility and item-wise details along
with time bound action plan shall be prepared and
submitted to the Ministry's Regional Office at
Bangalore. Implementation of such program shall
be ensured accordingly in a time bound manner.
xlvi
Provision shall be made for the housing of
construction labour within the site with all
necessary infrastructure and facilities such as fuel
for cooking, mobile toilets, mobile STP, 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
Section B
GENERAL CONDITIONS
i
The project authority shall adhere to the
stipulations made by Andhra pradesh State
Pollution Control Board (APPCB) and State
Government.
ii
No further expansion or modification of the plant
shall be carried out without prior approval of this
Ministry.
iii
Project authorities have earmarked Rs. 7 Crores towards CSR activities.
Some of the activities taken up and the cost are given in
Annexure- 9
Temporary housing facility was provided for workers during construction, with
all necessary infrastructure and facilities such as fuel for cooking, mobile
toilets, mobile STP, Safe drinking water, medical health care, crèche. Etc.
100 houses were reportedly constructed for work men with facilities.
Project authorities are adhering to the stipulations made by the APPCB from
time to time.
Received EC F.NO.J -11011/347/2010 1A –II (I) dated 26 .08.2014.for the
expansion of the cement plant and for the installation of 2 x 18 MW CPP at
the existing plant site and the proposal for the expansion of the mine is with
the Ministry.
No change in mining technology and scope of Agreed to comply. No deviation against the specified rules and regulations.
working shall be made without prior approval of
the Ministry of Environment & Forests. No change
in the calendar plan including excavation, quantum
of limestone and waste shall be made.
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
iv
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 SPM, SO2 and NOx are
anticipated in consultation with the APPCB. Data
on ambient air quality and stack emissions shall be
regularly submitted to this Ministry including its
Regional Office and APPCB/CPCB once in six
months.
Presently, 2 CAAQ monitoring stations with online monitoring facility were
installed. Project authorities propose to install one more by January 2015.
And the balance fourth CAAQM will be installed in January 2016.
Please see Annexure as photographs - 10
v
Industrial waste water (workshop and waste water Sewage is the only waste water generated from the plant for which, sewage
from the mine) shall be properly collected, treated treatment plant is commissioned in the 1st week of October 2013, and the
so as to conform to the standards prescribed treated sewage water is being used for greenbelt development.
under GSR 422 (E) dated 19th May, 1993 and
31st December, 1993 or as amended from time to
time. Or and grease trap shall be installed before
discharge of workshop effluents. The treated
wastewater shall be utilized for plantation purpose.
vi
The over-all noise levels in and around the plant
area shall be kept well within the standards (85
dBA) 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 dBA (day
time) and 70 dBA (night time). Measures shall be
taken for control of noise levels below 85 dBA in
the work environment. Workers engaged in
The noise levels are being monitored and efforts are being made to reduce
the noise levels further. All the values of noise are well within the stipulated
limits. Noise is monitored monthly, at four points. Near packing plant, near
main entrance gate, near coal mill & near guest house. Near packing plant
and coal mill the noise levels are around 50 - 60 dB(A). In order to reduce
noise levels in the plant , silencers were installed for 11 process fans and to
reduce the noise level at Coal mill area, Coal mill circulating air fan flow
control changed from damper control to fan speed control(VFD) which has
resulted both power saving as well as reduced noise levels. In addition, all
major fans are provided with enclosures to minimize sound levels. Third party
M/s Sri Durga Enviro Consultans, Vijayawada was engaged for conducting
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
operations of HEMM etc. shall be provided with tests monthly once to monitor ambient air quality at three locations, noise
ear plugs/muffs.
levels and stack emissions. And the test results are being sending to APPCB,
RO, Vijayawada regularly.
vii
viii
ix
x
Please see the Annexure - 2
Proper housekeeping and adequate occupational As a part of good housekeeping, Road sweeping machine purchased and
health programmes shall be taken up. extra man power engaged to clean interiors/corners of the work places
Occupational Health Surveillance programme shall further.
be done on regular basis and records maintained
properly for at least 30-40 years. The programme And also it was planned to improve plant inside beautification by plantation
shall include lung function and sputum analysis and confined road routes for material transportation as well as civil pass
tests once in six months. Sufficient preventive ways.
measures shall be adopted to avoid direct
Please see the Annexure- 11
exposure to dust etc.
The company shall undertake eco-development The company has so far spent nearly Rs 45 lacs on social welfare activity.
measures including community welfare measures
in the project area. Rs.20.00 Lakhs shall be
earmarked towards social welfare activities.
The project proponent shall also comply with all All the environmental protection measures and safeguards recommended in
the environmental protection measures and the EIA/ EMP are being implemented.
safeguards recommended in the EIA/ EMP.
A separate environmental management cell with Environmental Management Cell is established and working actively.
full fledged laboratory facilities to carry out various Environmental cell structure is given below. All the Environmental team
management and monitoring functions shall be set members reportedly assemble every Saturday at 4.00 PM and discuss the
up under the control of Senior Executive.
Pollution control equipment performance, maintenance, water sprinkling,
roads cleaning, wastages and implementing immediate corrective action, if
any lagging
Executive President CPU-II (Chairman)
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
DGM (Process) (Convener)
Senior Engineer (1) /Engineer(1)
Environmental committee members:
1) Safety Officer
2) Manager (Process)
3) Officer (Horticulture).
xi
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.
Personnel working in dusty areas are being provided with protective devices.
Occupational Health Checkup programme (including lung function and
sputum analysis tests) are being conducted on regular basis. Records of the
all the Occupational Health Surveillance programmes are being maintained
properly.
xii
As proposed, Rs.35.00 Crores and Rs.7.00 Crores
shall be earmarked towards recurring cost/annum
toward environmental pollution control measures
end 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.
Project authorities have earmarked the funds as per the condition.
Environmental pollution control equipment and maintenance cost so far is as
follows :
Bag filters
-Rs. 24.78 Crores.
Maintenance
-Rs. 4.1 Crores.
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
xiii
The project proponent shall also submit six M/s. KCP has extended co-operation to the visiting officers of Regional Office
monthly reports on the status of compliance of the and furnished required data.
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,
they/ respective Zonal Office of CPCB and the
APPCB. The Regional Office of Ministry / CPCB /
APPCB shall monitor the stipulated conditions.
The project authorities shall extend full
cooperation to the officer (s) of the Regional Office
furnishing the requisite data / information /
monitoring reports.
xiv
The Project Authorities shall inform the Regional
Office as well as the Ministry, date of financial
closure and final approval of the project by, the
concerned authorities and the date of commencing
the land development work.
A copy of clearance letter shall be marked to
concerned Panchayat / local/NGO if any, from
whom suggestion/representation, if any, was
received while processing proposal.
A copy of clearance letter shall be sent by the
proponent to concerned Panchayat, ZillaParishad
/Municipal Corporation, Urban Local Body and the
Local NGO, if art from whom suggestions /
representations if any, were received while
processing proposal. The clearance letter shall
also put up on the website of the Company the
proponent.
xv
xvi
The work was commenced in May 2009 and completed in May 2011. The
funding was from internal sources. Hence, the clause on financial closure is
not applicable.
Complied. No suggestions and representations were reportedly received from
the villagers.
Complied. The hard copies were circulated to all the said governing bodies.
Page 18 of 20
THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
xvii
xviii
xix
The proponent shall upload the status of
compliance of the stipulated EC condition
including monitored data on their website and shall
update the same periodically shall simultaneously
be sent to the Regional Office of MoEF, the
respective Zonal Office of CPCB and the APPCB.
The criteria pollutant namely; SPM, RSPM, SOx,
NOx (Ambient levels as well as stack emissions)
or critical sectoral parameters indicated for the
project shall be monitored and displayed at the
convenient location near the main gate of the
Company in the public domain.
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 7 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 A.P.
Pollution Control Board and also at web site of the
Ministry of Environment and Forests at "Error!
Hyperlink reference not valid. and a copy of the
same shall be forwarded to RO of the Ministry.
The environmental statement for each financial
year ending 31st March in Form-V is mandated' to
be submitted by the project proponent to the
concerned State Pollution Control Board as
prescribed under the Environment (Protection)
Rule-1986 as amended subsequently, shall also
be put on the website of the Company along with
The data on AAQ and stack emissions is being uploaded on APPCB website
http://pcbsite.nic.in regularly. And the same will be linked to KCP company's
website.
Advertisements were given in news papers Deccan Chronicle and Eenadu on
01.06.2012.
Form–V is submitted to RO for the financial year 2012–2013. And also Form
– V and compliance report kept in KCP website on 13.02.2013.
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THE KCP LIMITED, CEMENT UNIT-II, RAMAKRISHNA PURAM, MUKTYALA VILLAGE,
JAGGAYYAPETA MANDAL, KRISHNA DIST, ANDHRA PRADESH
xx
xxi
xxii
the status of compliance of EC conditions and
shall also be sent to respective regional Office of
the MoEF by e-mail.
The ministry of any other competent authority may Agreed to comply.
stipulate any further condition(s) on receiving
reports from the project authorities. The above
conditions shall be monitored by the Regional
Office of this Ministry.
The Ministry may revoke or suspend the clearance Agreed to comply.
if implementation of any other above conditions is
not satisfactory.
Any other conditions or alteration in the above Agreed to comply.
conditions shall have to be implemented by the
project authorities in a time bound manner.
Page 20 of 20