New Cement Questionnaire

Central Pollution Control Board, Zonal Office (Central)
3rd Floor, Sahkar Bhawan, North T.T. Nagar, Bhopal - 03
Format for inspection and monitoring of Mini Cement Plants in Central Zone
1.0 1.1 General information Name of the Cement Plant & Address
1.2
Name of contact person with phone numbers. Name: Designation: Tel. No. (with STD Code): Mobile No.: Fax: E-mail: Category / Year of commissioning Date of Inspection & name of officials inspected Total area of the factory site (in Sq.M.) Production details Manufacturing process description Technology (CRI-MVSK, RRLVSK, Saboo-VSK, Rotary Kiln) and raw materials used Raw material used / tonne of product Products manufactured Bye-Product ( If Any)
CPCB-ZO-Bhopal Page 1
1.3 1.4 1.5 2.0 2.1

2.2
2.3 2.4 2.5
2.6
Capacity in TPD / TPA Location of the industry: Industrial/Sensitive/Residential, Rural & Other area (Attach a map showing land use pattern within 10 km radius from the industry. Also attach a site layout plan) Distance of the plant from the nearest habitation & its population: Is plant located in critically polluted area (list enclosed)? : Yes / No If yes, name of critically polluted area: Is plant located in urban area with population of one lakh & above (including 5 km distance outside urban boundary)? : Yes / No If yes, name of urban area: Total capital investment (as per latest balance sheet): Capital investment on pollution control measures: (Break up may be given in a separate sheet) Annual turn over: Annual expenditure on operation & maintenance of pollution control measures No. of Personnel working in the factory: No. of Personnel engaged in pollution control activity: Average working days of the plant per annum:
3.0 3.1
3.2
3.3
3.4
4.0 4.1 4.2
4.3
5.0 5.1 5.2
5.3
CPCB-ZO-Bhopal
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6.0
In case of grinding unit, give the name of the plant from where clinker is taken : Details of kilns Total no. of kilns Kiln no. Type of process of each kiln (i.e. Dry/ Wet/Semi-Dry) Date of commissioning of each kiln Clinker production of each kiln in Million Tonnes/ Annum Installed Actual capacity production (For the year 201011) Capacity utilization factor (for the year 2010-11)
7.0
Total 8.0 8.1
Total
Type and details of Cement Mill Details of Cement packing section Variety-wise cement production S. No. Variety of the cement Installed cement Actual cement production in produced production capacity in Million Tonnes / Annum (for (OPC/PPC/PBFS/Other) Million Tonnes / Annum the year 2010-11)
8.1
9.0
CPCB-ZO-Bhopal
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10.0
(Attach a note on cement manufacturing process in a separate sheet) Raw material & fuel requirement / tonne of clinker production S. Name of the raw Quantity of raw material Quantity of raw material & No. materials & fuels & fuels required in fuel consumed in Million tonne / tonne of clinker Tonnes for the Year 2010-11 production
11.0
12.0
Blending material / additives / set retarder consumption for cement production S. Name Name of the Quantity of blending Quantity of blending No. of the blending material/ material / additives / set material / additives / set cement additives / set retarder required in retarder consumed in retarder tonne / tonne of cement Million Tonnes for the production year 2010-11 1. O.P.C. 1. Gypsum/phosp ho-gypsum 2. 2. P.P.C. 1. Flyash 2. Clay 3. Gypsum/phosp ho-gypsum 4. 3. P.B.F.S 1.Blast furnace slag 2.Gypsum/ phospho - gypsum 3. 4. Others Details of raw material, blending material & fuel sources/ linkages S.No. Name of raw material / Source / linkage of Distance of Mode of blending material / fuel etc. raw material / source/ transport blending material / linkage to fuel etc. cement plant
13.0
Details of fuel quality S. Fuel No.
Average ash Average content sulphur content
Average nitrogen content
Average calorific value (Kcal/Kg)
CPCB-ZO-Bhopal
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(Also attach a separate sheet for chemical composition of each fuel) 14.0 14.1 14.2 15.0 15.1 15.2 Energy requirement Electrical energy in kwh / tonne of cement: Thermal energy in kcal/kg of clinker: Waste heat utilization Co-generation of Power (MW), if any: Attach a note on waste heat utilization being practiced in the plant Provide process flow chart showing material and gas flow with air pollution control equipment (in a separate sheet) Details of control measures taken for fugitive emission generated from transfer points; raw material, flyash, fuel and clinker storage area (Please provide information in a separate sheet) Solid waste management Solid waste / sludge generation & management: S. Sources State Quantity generated No. ( Dry / (tonnes/day) on dry Sludge) basis
16.0
17.0
18.0 18.1
Composition
Method of collection, treatment, storage & disposal
18.2
Details of solid waste / sludge recycling, if any: Hazardous waste (e.g. oil sludge) management
CPCB-ZO-Bhopal Page 5
19.0
19.1
Hazardous waste generation & management: S. Sources State Quantity No. (Dry / generated Sludge) (tonnes/day) on dry basis
Method of storage transportation & disposal
Whether Hazardous Waste (Management & Handling) Rules, 2003 being complied
19.2 20.0 20.1

20.2 20.3 20.4 20.5 21.0 21.1 21.2
Details of hazardous recycling, if any: Water pollution control Water Consumption (in KLD)
waste
Waste Water Generation (in KLD) Treatment facility provided Effluent Disposal Detail Wastewater monitoring details Air pollution control Type of Fuel and Quantity Name of the pollution control devices installed No. of Stacks and Height Ash quantity & disposal AAQ, stack monitoring details Details of the Green Belt Development Plant Status of Rain Water Harvesting Status of Consents and Authorization (Validity) Air Consent Water Consent Authorization
21.3 21.4 21.5 22.0 23.0 24.0 24.1
24.2
24.3
CPCB-ZO-Bhopal
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25.0
Observation:
26.0
Recommendation:
CPCB-ZO-Bhopal
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CPCB-ZO-Bhopal
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Central Pollution Control Board, Zonal Office (Central)

3rd Floor, Sahkar Bhawan, North T.T. Nagar, Bhopal - 03

1.3 1.4 1.5 2.0 2.1

2.3 2.4 2.5

4.0 4.1 4.2

5.0 5.1 5.2

Total 8.0 8.1

Details of fuel quality S. Fuel No.

Average ash Average content sulphur content

Average nitrogen content

Average calorific value (Kcal/Kg)

Method of collection, treatment, storage & disposal

Method of storage transportation & disposal

19.2 20.0 20.1

21.3 21.4 21.5 22.0 23.0 24.0 24.1

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