Journal of Environmental Research And Development

J. Environ. Res. Develop. Vol. 7 No. 2, October-December 2012

ENVIRONMENTAL IMPACT ANALYSIS : A CASE STUDY OF ACC CEMENT PLANT

1. 2. Tiwari Jeetendra Kumar*1 and Rawani A. M.2 Department of Mechanical Engineering, SSGI, Bhilai (INDIA) Department of Mechanical Engineering, NIT, Raipur (INDIA)

Received July 10, 2012

Accepted November 10, 2012

ABSTRACT
Cement is an extensively used material. The demand of cement is high both in building and infrastructure development. However, the environmental impact of cement production process starting from pre production stage to end stage is significant. This study scrutinizes the environmental impact due to cement production process in ACC cement plant of Chhattisgarh state, India. The plant production adopted the dry processes which include simply of raw materials, clinker burning and grinding process from which dust is emitted due to the kiln feed, crushers, grinding clinker cookers and material handling equipments. A case study of ACC cement plant is developed, focusing on crusher unit for evaluating the significant environmental impact. The study shows that how one can generate aspects from activities and can analyze that which aspects are significant or insignificant. The case study suggests that the aspects like fugitive dust emission and noise need to be emphasized and require more attention and to be managed. Key Words : Environmental Impact Assessment (EIA), Environmental Management, Cement plant, Significant aspect, Sustainability

INTRODUCTION
The use of cement has long been the basis of the development of the society and for the welfare of the people for generations. Concrete, which is made from the cement, has been the ultimate material for construction. Cement manufacturing process is technology intensive. Raw material extraction causes serious environmental problems by damaging the landscape and most of these raw materials become scarce. The cement industry recognizes its responsibility to manage the environmental impact associated with the manufacturing of its product from first to last stage. Cement industry is considered as one of the most pollution hazardous industry. Crusher plays an important role in cement making process but it is also a major source of pollution. Hence, the author decides to conduct a case study on crusher unit for impact analysis.
*Author for correspondence

Environmental impact assessment process Environmental Impact Assessment is a systematic process to identify, evaluate and predict the potential impacts of a proposed development project. EIA is a decision making tool for the proposed developmental activities which scales the project based on its environmental consequences. The tool is used before making any major decisions and commitments. The environment here, in a broader perspective, includes biophysical, social, cultural and health impacts. By considering the environmental effects of the project and their mitigation early in the project planning cycle as part of environmental assessment has many benefits, such as protection of environment, optimum utilization of resources and saving of time and cost of the project. Properly conducted EIA also lessons conflicts by promoting community participation, informing decision makers and helping lay the base for environmentally sound projects. EIA provides a procedure for the full consideration

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of all possible adverse environmental impacts of policies, programs activities and projects before any decision is taken to proceed. This is an opportunity to present recommendations to the decision maker on the suitability of the policy, programme activity or project, on environmental grounds. There is an opportu-

nity to incorporate conditions of consent for mitigating adverse environmental effects. Conditions of approval may ensure monitoring by the proponent, post-project analysis and independent auditing. Thus, Environmental Impact Assessment helps in harmonizing the developmental activities with the environmental concerns.1-3 (Fig. 1)

Start

Site Selection

Conduct EIA

Apply for NOC

SPCB arranges public nearing

Project proponement apply for the environmental clearance, submitting required documents (EIA reports. NOC from SPCB, etc)

Review by Environmental Appraisal Committee

Change suggested

Accepted

Rejected

Fig 1 : EIA Process requirements in India The EIA process includes the following : Determination and investigate feasible alternatives for the proposed development. Identify the environmental status in terms of the baseline information that has been obtained. Identify the potential environmental impacts of the proposed development. Access the potential environmental impacts in terms of the following extent Duration Frequency Probability Significance of the impact Make recommendations regarding suitable migration measures to reduce the significance of the identified impacts. Conduct the specialist studies and integrate the findings into the final report. (Fig. 2) Characteristics of the impacts Typical characteristics to be taken into account in impact prediction and decision making includes.4-8 Nature(positive/negative/direct/indirect/ cumulative) Magnitude (severe/moderate/low)

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J. Environ. Res. Develop. Vol. 7 No. 2, October-December 2012

Proposal Identification

Screening Initial Environmental Examinations Scoping Public Involvement

EIA Required

No EIA

Impact Analysis Mitigation and Impact Management Public involvement typically occurs at this point . It may also occur at any other stage of the EIA process

EIA Report

Resubmit

Review

Public Involvement

Redesign

Decision Making Information from this process contribution to effective future EIA

Not Approved

Approve

Implementation and Follow Up

Fig 2 : EIA process as suggested by UNEP Extent/location (area/volume covered/distribution i.e. local, regional and global) Timing (during construction/operation/ decommissioning/immediate/delayed/rate of change) Duration (short term/long term/intermittent/continuous) Reversibility/Irreversibility Like hood (probability/uncertainty or confidence in the prediction) Significant/Insignificant (Fig. 3) Methods of impact identification Overtime a number of EIA methodologies and tools have been developed for use in impact identification. In practice, relatively simple methodologies and tools are applied to impact identification. The most common formal methods used for impact identification and analyses of significance of impacts are9-13 Checklist Matrices Networks Overlays and Geographic Information System (GIS) Expert systems Professional judgement The conditions for significant impact if present are : Extensive over space and time Intensive in concentration Exceed environmental standards. Do not comply with policies Affect sensitive areas Affect social values

AIMS AND OBJECTIVES

The case study of ACC cement plant is developed with following objectives focussing on crusher unit which are : To understand various activities on crusher unit. To identify key environmental aspects associated with the selected activities.

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To identify actual and potential, positive and negative environmental impacts associated with each identified aspects. To meet the above objectives, we develop a case study for which we have visited a

cement plant and conducted unstructured interviews with the relevant key personnel. Raw data were also collected from secondary sources i.e. published magazine and manuals.

Fig 3 : Generic classification of impacts

Raw materials 1. Limestone 2. Clay/shale Quarrying process Crushing process Crushed limestone + Clay/shale are mixed and ground together Mixture is heated in a kiln Clinker Gypsum is added and the mixture is ground to a provider resulting in Portland cement

Fig 4 : Production of Portland cement

METHODOLOGY
Case study of plant ACC cement plant is situated in Nandini, Bhilai, Chhattisgarh state, India, industrial area. It is providing quality product and excellent service. It has ISO 14000 certification too and ISO 9002 quality system. It continues to promote various environmental performance initiatives in its own facilities viz.

reduce dust emission, create a healthy environment, plantation and also reduce electricity consumption. It also recognizes the importance of social responsibility as a part of its overall commitment to sustainable development. (Fig. 4) Therein, perform the following activities : maintain a mini hospital to provide medical services, donations, education and development. The ACC plant

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consists of several units from limestone crushers to packing plants. Crusher unit comes under the main processing unit.

RESULTS AND DISSCUSSION

Table 1 shows various activities of crusher unit, aspects and associated impacts. Determination of significance of identified aspects After finding various activities, aspects and impacts, the next step is the identification of the significant aspects. For this again, unstructured talk with the people we came to know that it is essential to determine what factors will be considered in determining significant aspect and secondly to establish a rating scheme for the factors of significance. It

entirely depends on the management of the system or industry to give scaling factor. Table 2 shows six factors naming as A to F (top row) and column 1 to 6 shows rating scheme with minimum as 1 and maximum marks as 10 depending upon their severity. Procedure of significance evaluation For evaluation process the various activities of Table 1 is rated on the basis of parameters and score criteria given in Table 2 and a benchmark of 75 units is taken as a deciding factor. If the total unit of any particular aspect for an activity comes out to be more than 75, then the aspect can be considered as significant otherwise insignificant. (Table 3)

Table 1 : Aspect/impact analysis form for crusher unit Activity 1.Receipt of limestone Aspect Fugitive dust emission Noise Lose of resource Fugitive dust emission Stack emission Noise Oil leakage 3. Conveying of crushed limestone after primary crushing 4.Secondary crushing Use of water for cooling Fugitive dust emission Noise Oil leakage Fugitive dust emission Stack emission Noise Oil spillage Fugitive dust emission Noise 6.Conveying of crushed limestone from secondary crusher Fugitive dust emission Noise Oil leakage Impact Health effects Hearing impairment Wastage of resources Health effects Air pollution Hearing impairment Land contamination Leakage of recirculation water Health effect Hearing impairment Land contamination Health effects Air pollution Hearing impairment Land contamination Health effects Hearing impairment Health effects Hearing impairment Land contamination Resource consumption

2. Primary crushing

5.Screening

7. Replacement of gear box of Leakage of lube oil during belt conveyors transfer

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Table 2 : Parameters and score criteria

A-Quantity 1-5
5-High

B-Occurrence 1-6
6-Contineous

C-Impact 1-6
6-Fatal to human life 5-Health effects 4-Affects flora and fauna 3-Resource consumption

D-Detection 1-5
5-More than 24 hours 4-Within 24 hours 3-Within 8 hours 2-Within 1 hour

E-Controls 1-5
5-Absence or no effective controls 4-Mechanism in place but not reliable 3-Control needs human intervention 2-Has in-built secondary control 1-Available and effective at source. ---

F-Legislation 1and10
10-Not meeting legislation/ control limits 1-In Compliance

3-Moderate

5-Several times a day 4-Once a day

1-Low

---

3-Once a week ---

---

-----

2-Once a month or less frequent 1-Very Rare

2-Discomfort ,Acid rain, nuisance 1-Negligible visual impacts.

1-Immediately

-----

---

Table 3 : Completed aspect/impact analysis form for crusher unit

Total A*B*C*D*E* F Remarks SIG/INSIG Condition/A/ N Legislation, F Detection, D Occurrence, B Impact, C Quantity, A Control, E

Receipt of limestone

Activity

Fugitive dust emission Noise Lose of resource Fugitive dust emission Stack emission Noise Oil leakage Use of water for cooling

N Health effects N N N N N A N

Impact

Aspect

225 60 45 90 150 150 18 54 30 36 9 30 20 30 9 120

SIG INSIG INSIG SIG SIG SIG INSIG INSIG INSIG INSIG INSIG INSIG INSIG INSIG INSIG SIG INSIG INSIG INSIG INSIG INSIG

Primary crushing

Conveying of crushed Fugitive dust emission limestone after primary Noise crushing Oil leakage Secondary crushing Fugitive dust emission Stack emission Niose Oil spillage Screening Conveying of crushed limestone from secondary crusher Replacement of gear box of belt conveyors Fugitive dust emission Noise Fugitive dust emission Noise Oil leakage Leakage of lube oil during transfer

Hearing impairment 3 5 2 1 2 1 Wastage of resources 1 5 3 1 3 1 Health effects 3 5 2 1 3 1 Air pollution 3 5 5 1 2 1 Hearing impairment 3 5 5 1 2 1 Land contamination 1 1 3 2 3 1 Leakage of 1 6 3 1 3 1 recirculation water N Health effect 1 5 2 1 3 1 N Hearing impairment A Land contamination N Health effects N Air pollution N Hearing impairment A Land contamination N Health effects N N N A Hearing impairment Health effects Hearing impairment Land contamination 1 1 3 1 1 3 6 1 5 5 5 4 2 1 3 1 1 4 2 5 1 1 1 1 3 3 2 1 3 3 2 1 1 1 1 1 1 1

1 1 1 6 1 5 1 6 1 1 1 2

3 1

2 1 3 1 36 2 1 3 1 30 2 1 3 1 36 3 1 3 1 9 3 1 3 1 18

N Resource consumption

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CONCLUSION
Cement production is one of the main pollution contributors due to its extensive energy consumption and gas emission. Dust emission sources are kiln, crusher, grinders, clinker cookers and material handling equipments. Crusher department is one of the major sources of environmental pollution. Fugitive dust emission, stack emission and noise have been identified as significant aspects during activities like receipt of limestone, primary crushing, screening. These significant aspects are imparting very much impact on the human health like respiratory disorderness, hearing impairment, etc. Thus there arises a need for developing a strategy for reducing the impacts and this require more attention to be emphasized on the aspects.

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