Preparation of environment management plan for 3 MTPA integrated cement plant and comparative analysis of Ordinary Portland Cement and Portland Pozzolana Cement
Student name: Mr Sushant Figueiredo
Guide: Dr Nandini Kumar
Year of completion: 2011
Host Organisation: Ramky Enviro Engineers Ltd.
Supervisor (Host Organisation): Mrs Sabita Kaushal
Abstract: Environment Impact Assessment has evolved as a highly effective tool in identifying and mitigating
harmful impacts of development projects not only those on the environment but also on the society
and economy thereby playing its part in sustainable development.
The proposed plant in Karauli has a production capacity of 3 million metric tonnes per annum which
means a daily production of 9000 tonnes of clinker. It also includes a captive power plant and a staff
colony. The major problem associated with a cement plant is the release of SPM and gaseous
pollutants including carbon dioxide, oxides of nitrogen and sulphur dioxide. The significant source of
the above mentioned pollutants is the kiln section including the pre-calciner/pre-heater and the kiln
or clinker burning section. Particulate matter is released during the entire process, mostly as fugitive
emissions and requires efficient pollutant control devices for their reduction.
The impacts were predicted based on the visit to the project site, process of production, inputs used,
outputs and waste generated and existing socio economic conditions of the village
The aim was to prepare an environment management plan (EMP) so as to make the project as
sustainable as possible with respect to use of water, land, and energy, clearing of vegetation and also
generation of wastes. This included use of best available practices for cement manufacture, efficient
use of natural resources and least possible disturbance of the surrounding environment.
In doing so the process of EIA was brought under the scanner and the loopholes and possible
recommendations for improving the process were suggested
Further in a comparison of ordinary Portland cement and fly ash cement it was found that fly ash
cement is far more feasible not just by virtue of it costing about 100 Rs/tonne less but also in terms of
emissions of the four major pollutants including SPM, NOx, SO2 and CO2. The reasons for the same
boils down to the fact that 25% of the clinker in OPC is substituted by fly ash thereby resulting in
drastic declines in raw materials required for cement production.
Keywords: EIA, Cement kiln, EMP, OPC & PPC, Sustainable
