Manikgarh Cement- Environment

Environmental Management System

Right from inception, great emphasis has been laid at Manikgarh Cement on maintaining ecological balance and environmental preservation so as to provide green, healthy and pollution free environment. Continuous monitoring of various Pollution Control equipments are done round the clock to maintain emission levels much below the norms specified by State Pollution Control Board.

Landscaping inside the Plant

Environment Policy

We at Manikgarh Cement are fully conscious of the envionmental impacts of our activities. We also realise the need for minimising the impacts, towards preservation of environment in keeping with the image of BK Birla Group of companies as a socially responsibile organisation.

We, therefore, commit ourselves to:

Prevention of pollution incidental to Plant operations
Adopting clean technology and eco-friendly processes in the Plant
Compliance with all applicable legal and statutory requirements
Conservation of natural resources
Reduction in waste generation.
Awareness amongst employees and business associates.
Continual improvement in environmental performance by effective implementation

The plant has been accredited with IS / ISO 14001:1996 Environmental Management System Certification.

Totally Dust-free Chimneys

Measures Taken Towards a Cleaner Environment

Installation of highly efficient Pollution Control Equipments viz., ESPs, Bag Houses and Pulse Jet Dust Collectors at every dust generating point in the Plant.
Regular monitoring of all stacks and ambient air quality.
Proper treatment of domestic affluent generated from residential colony in Oxidation Ponds and use of treated water for plantation purposes.
Massive efforts for plantation of various species of trees for ecological up-gradation.

To control fugitive emission, following additional steps have been taken:

Covering of Conveyor belts transporting various process materials
All raw materials are stored in covered gantry.
Water sprinklers have been provided on the roads to check fugitive emission generated due to movement of vehicles
Concretisation of roads and floors inside the Plant
The Fly Ash generated from Thermal Power Plant is used as an additive for manufacture of PPC.

The Plant maintains perfect harmony with environment through effective pollution control measures in respect of air, water, land and noise level. All efforts are made to curb pollution at grass root level.

Garden developed on Mine Waste Dump

TREES ARE TREATED OUR BEST FRIEND

Every year tree plantation is undertaken in a planned manner on a massive scale. As a result the barren land acquired by the Company looks like green land today with different varieties of trees, gardens, lawns, fountains, flora and fauna. The plant presents a wonderful balance between concrete and ecology with smokeless chimneys and lush greenery all around. Number of Trees surviving as on date is 316000.

Clean Development Mechanism

Cement Industry is highly energy intensive and leads to generation of CO2 during clinkerisation process due to calcination of limestone and combustion of fossil fuel inside the Kiln. CO2 is a Green House Gas (GHG) which leads to global warming and depletion of ozone layer above earth's atomosphere causing health hazard for all living beings. Manikgarh Cement is actively engaged in reduction of GHG emissions and has undertaken CDM projects. The project activities consist of an increase in % addition of flyash in Portland Pozzolana Cement (PPC) as well as an increase in the proportion of PPC in the over all product mix. This leads to reduction in usage of clinker in cement production which in turn contributes to reduction in GHG emissions.

At Manikgarh Cement, proportion of Blended Cement has been gradually enhanced over the last few years. The project activity contributes to sustainable development at Regional, National and Global levels in the following ways.

Reduction of GHG emissions - by way of reduction in clinker usage in cement production as explained above;
Industrial Waste Utilisation - Fly Ash Handling and disposal not only involves extra cost for Thermal Power Plant (TPP) but also leads to land and air pollution as well as water contamination at fly ash ponds / land fills. Hence the project indirectly helps TPP in cost reduction and pollution abatement. It also leads to reduction in specific energy consumption for cement manufacture and positively contributes to conservation of coal which is a valuable renewable natural resource.

Reduced usage of clinker in cement manufacture also means reduction in mining / extraction of limestone and its associated fugitive dust emission, loss of bio-diversity etc.Therefore the CDM project related activity has excellent environmental benefits in terms of reduction of carbon emissions, conservation of natural resources like limestone and coal, decreased environmental degradation and enhanced waste utilisation.

Energy Conservation

All out efforts are made at every level to achieve the highest level of efficiency in managing and conserving energy resources. This includes involvement of both financial and human resources coupled with technological upgradation.Following measures have been taken at Manikgarh Cement for conservation of electrical and thermal energy:

Upgradation of Kilns by installation of LP cyclones and upgradation of preheater section and CIS MFR system on Clinker Grate Cooler;
Close circuiting of Raw Mills and Cement Mills by installation of High efficiency Classifiers;
Installation of pregrinder in conjunction with close circuit Cement Mills for capacity upgradation and reduction of specific power consumption;
Replacement of pneumatic conveying system of Raw meal and cement by Mechanical handling system
Incorporation of VVVF drives;
Replacement of low efficiency fan impellers by high efficiency Impellers;
Optimisation of Raw Mills and Cement Mills by upgradation of internals and grinding media charge;
Dry Fly Ash storage and handling system has been installed at Cement Mill.
Installation of high efficiency dyamic seperators for Coal Mills in place of static Grit seperators for power saving and better residue control
Process automation with DCS and Fuzzy logic control