Rajasthan State Pollution Control Board

Sector Specific Guidance Manual for Stone CrushersPrepared by

Zero Draft

Administrative Staff College of IndiaHyderabad

======================================================================

SECTOR SPECIFIC GUIDANCE MANUAL FOR STONE CRUSHERS======================================================================

ContentsChapter No. Title Foreword Acknowledgements Project Team List of Tables List of Annexures About the Manual Chapter 1 Introduction 1.0 About Rajasthan State Pollution Control Board 1.1 About the Industrial Activity 1.2 Typical Sizes of Stone Crushers 1.3 Unit Operations and Technologies 1.4 District Wise Number of Stone Crushers in Rajasthan 1.5 Important Definitions of the Environmental Acts 1.6 Classification of Stone Crushers by RSPCB Environmental Acts and Legal Requirements 2.0 Requirements Under the Provisions of the Water (P & CP) Act 1974 as Amended 2.1 Requirements Under the Provisions of the Air (P & CP) Act 1981 as Amended 2.2 Requirements of Ground Water Extraction 2.3 Requirements Under the Provisions of the Hazardous Waste (MH &TM) Rules 2008 2.4 Restriction of Certain Activities in Specified Area of Aravalli Range 2.5 Mount Abu Eco-Sensitive Zone Siting Guidelines for Establishment of Stone Crushers 3.0 Siting Guidelines Statutory Clearance Process 4.0 Consent To Establish (CTE) 4.1 Consent To Operate (CTO) 4.2 Hazardous Waste Authorization 4.3 Water Cess Assessment Environmental Aspects and Guidance 5.0 Sources of Emissions 5.1 Typical Emission Factors 5.2 Pollution Control Measures 5.3 Environmental Norms Page No. (To be given later) (To be given later) vi vii viii ix 1 2 3 3 4 5 7 8 8 8 9 10 11 15 18 25 27 27 28 29 29 32

Chapter 2

Chapter 3 Chapter 4

Chapter 5

STONE CRUSHERS

ii

Chapter 6

Checklist 6.0 Environmental Checklist Annexures

33 35-80

iii

STONE CRUSHERS

Foreword (To be given by RSPCB)

STONE CRUSHERS

iv

Acknowledgements (To be given by ASCI)

v

STONE CRUSHERS

Project TeamProject Coordination Dr. Deep Narayan Pandey Rajasthan State Pollution Control Member Secretary Board Mr. A.K. Puri Senior Environmental Engineer Core Committee - RSPCB Mr. A.K.Puri, Sr.E.E Mr. V.K. Singhal, Sr.E.E Mr. R.K.Gaur, Supdt.S.O Mr. Pradeep Agarwal, In charge Mines, Mr. Manoj Agarwal, L.O Mr. Mahesh Rastogi, E.E

Project Team Prof. V.S. Chary ASCI Director, Centre for Energy, Environment Urban Governance, and Infrastructure Development, Mr. V.R. Mahesh Consultant Shri. G. Bala Subramanyam Advisor, Environment Area Project Leader

STONE CRUSHERS

vi

TablesTables No. Table No. 1.4 Table No. 5.1 Table No. 5.2 Title District wise stone crushers Emission sources Typical emission factors Page No.

vii

STONE CRUSHERS

AnnexuresAnnexure No. Annexure No. 1 AnnexureNo. 2 Annexure No.3 Annexure No.4 Annexure No.5 Annexure No.6 Annexure No.7 Annexure No.8 Annexure No.9 Annexure No.10 Annexure No.11 Annexure No.12 Annexure No.13 Annexure No.14 Annexure No.15 Annexure No.16 Annexure No.17 Annexure No.18 Annexure No.19 Annexure No.20 Annexure No.21 Annexure No.22 Title Model Verification Format to be given by the Revenue Department Format for Verification by Assistant Engineer of Water Resource Department (Irrigation) Plantation/Greenbelt Development Guidelines Application for Consent To Establish (Air) Proforma of Affidavit for CTE/CTO Affidavit Consent Fee Under the Provisions of Air Act Areas as Identified by CGWA as- Safe Areas, Semi-Critical Areas, Critical Areas & Over Exploited Areas National Ambient Air Quality Standards Application for Consent To Operate (Air) Application for Obtaining Authorization for Collection/ Reception/Treatment/Transport/Storage/Disposal of HW E (P) Act Norms for Stone Crushers Noise Ambient Air Quality Standards Noise Limits for Generator Sets run with Diesel Application for Consent To Establish (Water) Application for Consent To Operate (Water) Consent Fee Under the Provisions of Water Act Format for Environmental Statement Format for Filing Annual Returns by the Occupier or Operator Facility Wind Breaking Walls Arrangement for Partially Enclosing Stockpiles to Reduce Wind Blowing of Dust Model Scheme for Developing Greenbelt TNPCB Location and Requirement of Water Spray Nozzles Results of Trails Conducted for Optimization of Water Consumption in Dust Suppression Page No. 36 37 38 40 44 46 47 50 52 57 59 60 61 63 67 71 72 75 76 77 79 80

STONE CRUSHERS

viii

About the ManualThe purpose of developing sector specific guidance manual for stone crushers is to provide clear and concise information to all the stakeholders i.e. project proponent, environmental consultant, Rajasthan State Pollution Control Board officials and the public to have a better understanding on the relevant environmental aspects in the initial stage itself. This manual covers the legal requirements, clearance process, environmental standards and maintenance of statutory records. The manual will also covers the environmental aspects due the stone crushers. The project proponent may use this manual to ensure that all the aspects of the environment due to the project are addressed and adequate mitigation measures are planned in the environmental management plan and he will be fully aware of the environmental process and requirements. The consultants will have similar understanding of the sector and the procedures involved, so that the quality EMP reports will be improved. The reviewers across the board may have same understanding about the sector and helps them in the process of review and appraisal. Public who are concerned about stone crushers, will have information about the environmental aspects, standards, regulatory requirements etc., and have a better understanding about the stone crusher industry. The preparation of sector specific guidance manual by Rajasthan State Pollution Control Board is in line with National Environmental Policy 2006, which emphasizes on: Formulate and periodically update, codes of good practices for environment for different category of industries Ensure faster decision making with greater transparency and access to information, together with necessary capacity building

The manual is meant to serve as a guidance purpose. In case of interpretation of any question related to law, the provisions of the original law and the rules made thereunder with various government directions/resolutions will have to be read and followed. In case of amendment to the original Act/Rules/Notifications made thereunder, the provisions as amended from time to time shall be applicable.

ix

STONE CRUSHERS

CHAPTER 1 Introduction1.0 About Rajasthan State Pollution Control BoardThe Rajasthan State Pollution Control Board (RSPCB) is a statutory authority entrusted to implement environmental laws & rules within the jurisdiction of the State of Rajasthan. The Board ensures proper implementation of the statues, judicial and legislative pronouncements related to environmental protection within the state. The Board was established in the year 1975 under the provisions of Water (Prevention &Control of Pollution) Act 1974. Over the years, RSPCB was entrusted with various responsibilities under different enactments made. Currently RSPCB is responsible completely or partially for the implementation of following Acts and rules: The Water (Prevention & Control of Pollution) Act, 1974 and Rules made there off The Air (Prevention & Control of Pollution) Act, 1981 and Rules made there off The Water (Prevention & Control of Pollution) Cess Act 1976 and Rules made there off The Public Liability Insurance Act, 1991 and Rules made there off The Environmental Protection Act, 1986 and Rules made there off Hazardous Wastes (Management, Handling & Transboundary Movement) Rules 2008 Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 as amended Municipal Solid Waste (Management and Handling) Rules, 2000 Bio Medical Waste (Management and Handling) Rules, 1998 as amended Ozone Depleting Substances (Regulation) Rules, 2000 The Batteries (Management and Handling) Rules, 2001 Fly Ash Notification as amended S.0. 2804(E) dated 3rd November 2009 Environmental Impact Assessment Notification, 2006 as amended The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996 The Recycled plastic (Manufacture and Usage) Rules, 1999 as amended The Manufacture, Use, Import, Export and Storage of Hazardous Micro Organisms, Genetically Engineered Organism or Cells Rules, 1989 Notification No. S.O. 319 (E) dated 7th May 1992 (Restricting certain activities in special specified area of Aravalli Range) Notification No. S.O. 1545 (E) dated 25th June 2009 declaring Mount Abu Eco Sensitive Zone The Noise Pollution (Regulation and Control) Rules, 2000 The EIA Notification S.O. 1533 dated 14th September 2006 as amended 1st December 2009

STONE CRUSHERS

1

1.1 About the Industrial ActivityStone Crushing activity is a significant industrial sector across the country involved in production for crushed stone of various sizes depending upon the requirement and catering requirement of raw material for various construction activities such as construction of Roads, Railway tracks, Highways, Bridges, Buildings, Canals etc. The existing number of stone crushing units is expected to grow rapidly further in view the growing demand for development of infrastructure such as roads, canals and buildings. The process involved in crushing large size stone boulders into different size of crushed stones depending upon the requirements in the demand sectors. The important stages involved in stone crushing activity are primary crushing, screening, secondary/ tertiary crusher, screening, conveyance, storage of raw boulders and crushed stone and transportation of both ROM & crushed stones. The raw material i.e. raw stone boulders are obtained from mining of the stone from quarries and hand picking etc. Typical process of stone crusher is briefed as below: Mined Stone

Transportation to crusher site Raw Material hopper Primary crusher

Tertiary crusher

Primary vibratory screen Secondary vibratory screen Products to stockpiles

Secondary Crusher Products to stockpiles Transportation to user end

STONE CRUSHERS

2

Various types of crushers are used in the stone crushing industry such as Jaw Crushers, Roller Crushers, Cone Crushers, Impactor, Rotopoctor etc. Generally, only Jaw crushers are used as Primary crushers. For secondary and tertiary crushing application either of Jaw, cone, roller, Impactor or Rotopoctor type crushers are used.

1.2 Typical Sizes of Stone CrushersThere are large variations in the types of stone crusher setup across the country depending on geographical locations, type of demand for crushed products, closeness to urban areas, type of raw material, availability of plant and machinery locally etc. Primarily the stone crusher industry sector could be divided in three categories small, medium & large. The typical characteristics of each category of stone crushers are briefly discussed below Small size crushers stone Typically the stone crushers with a production capacity ranging from 3 to 25 TPH. This category crusher have only one Jaw type crusher used as primary or secondary crusher along with one or maximum two screens Medium size stone Typically the crushers having more than one crusher i.e. one primary crushers and one secondary or one/two primary and two secondary crushers along with one or more vibratory screens are categorized as medium size crushers. Medium size stone crushers will have a production capacity in the range of 25 - 100 TPH Large stone crushers Typically having two or more numbers each of primary, secondary and tertiary type crushers with at least two or more vibratory screens with mechanized loading, unloading conveying operations and producing more than 100 TPH crushed stones.

1.3 Unit Operations and TechnologiesThe different unit operations and technologies are briefly described in the following table: Crushing technologies Various types of crushers are used in the stone crushing industry such as Jaw crushers, Roller crushers, Cone crushers, Impactor, Rotopoctor etc. Generally, only Jaw crushers are used as primary crushers. For secondary and tertiary crushing application either of Jaw, cone, roller, Impactor or Rotopoctor type crushers are used. Screening Screening is generally classified into two types (i) Coarse screening, technologies which is achieved through Grizzlies, Vibratory screens, Revolving screens or Shaking screens and (ii) Fine screening which is achieved through vibrating screens, shaking screens. Material handling Various types of material handling technologies are used in the stone technologies crushing industry for the purpose of moving the stones from one equipment to other, right from the point of raw material unloading up to stockpiles of products. Primarily, feeders and conveyors are used in almost all crushers.

3

STONE CRUSHERS

1.4 District Wise Number of Stone Crushers in RajasthanS. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. Name of the district Number of stone crushers in operation

Ajmer Alwar Banswara Baran Barmer Bharatpur Bhilwara Bikaner Bundi Chittorgarh Churu Dausa Dholpur Dungarpur Hanumangarh Jaipur Jaisalmer Jalore Jhalawar Jhunjhunu Jodhpur Karauli Kota Nagaur Pali Pratapgarh Rajasamand Sawai Madhopur Sikar Sirohi Sri Ganganagar Tonk Udaipur Table 1.4 District wise stone crushers

Requested for inputs from RSPCB

STONE CRUSHERS

4

1.5 Important Definitions of the Environmental ActsSection Section 2 (d) The Water (Prevention & Control of Pollution) Act, 1974 Key word Definition Occupier In relation to any factory or premises, means the person who has control over the affairs of the factory or the premises, and includes, in relation to any substance, the person in possession of the substance Outlet Any conduit pipe or channel, open or closed, carrying sewage or trade effluent or any other holding arrangement which causes or is likely to cause pollution Pollution Contamination of water or such alteration of the physical, chemical or biological properties of water or such discharge of any sewage or trade effluent or of any other liquid, gaseous or solid substance into water (whether directly or indirectly) as may, or is likely to, create a nuisance or render such water harmful or injurious to public health or safety, or to domestic, commercial, industrial, agricultural or other legitimate uses, or to the life and health of animals or plants or of aquatic organisms Sewage effluent Effluent from any sewerage system or sewage disposal works and includes sullage from open drains Sewer Any conduit pipe or channel, open or closed, carrying sewage or trade effluent Stream Includes river, water course (whether flowing or for the time being dry), inland water (whether natural or artificial), sub-terranean waters, sea or tidal waters to such extent or, as the case may be, to such point as the state government may, by notification in the official gazette specify in this behalf Trade effluent Includes any liquid, gaseous or solid substance, which is discharged from any premises used for carrying on any industry, operation or process, or treatment and disposal system, other than domestic sewage Company Any body corporate, and includes a firm or other association of individuals Director In relation to a firm means a partner in the firm The Air (Prevention & Control of Pollution) Act, 1981 Air pollutant Any solid, liquid or gaseous substance (including noise) present in the atmosphere in such concentration as may be or tend to be injurious to human beings or other living creatures or plants or property or environment Air pollution The presence in the atmosphere of any air pollutant Approved Any equipment or gadget used for the bringing of any

Section 2 (dd)

Section 2 (e)

Section 2 (g) Section 2 (gg) Section 2 (j)

Section 2 (k)

Section 47 (2) (a) Section 47 (2) (b) Section 2 (a)

Section 2 (b) Section 2 (c)

5

STONE CRUSHERS

combustible material or for generating or consuming any fume, gas of any particulate matter and approved by the State Board Section 2 (d) Approved fuel Any fuel approved by the State Board for the purpose of the Act Section 2 (h) Chimney Includes any structure with an opening or outlet from or through which any air pollutant may be emitted Section 2 (i) Control Any apparatus, device, equipment or system to control equipment the quality and manner of emission of any air pollutant and includes any device used for securing the efficient operation of any industrial plant Section 2 (k) Industrial plant Any plant used for any industrial or trade purposes and emitting any air pollutant into the atmosphere Section 2 (j) Emission Any solid or liquid or gaseous substance coming out of any chimney, duct or flue or any other outlet Section 2 (m) Occupier The person who has control over the affairs of the factory or the premises, and includes, in relation to any substance, the person in possession of the substance Section 40 (2) (a) Company Any body corporate, and includes a firm or other association of individuals Section 40 (2) (b) Director In relation to a firm means a partner in the firm The Water (Prevention & Control of Pollution) Cess Act, 1977 Section 2 (a) Local Authority Municipal corporation or a municipal council (by whatever name called) or a cantonment board or any other body, entrusted with the duty of supplying the water under the law by or under which it is constituted Section 2 (c) Industry Any operation or process, or treatment and disposal system, which consumes water or gives rise to sewage effluent or trade effluent, but does not include any hydel power unit Section 15 (2) (a) Company Any body corporate, and includes a firm or other association of individuals Section 15 (2) (b) Director In relation to a firm means a partner in the firm The Hazardous Waste (Management, Handling & Transboundary Movement) Rules, 2008 Rule 3 (l) Hazardous Any waste which by reason of any of its physical, waste chemical, reactive, toxic, flammable, explosive or corrosive characteristics causes danger or is likely to cause danger to health or environment, whether alone or when in contact with other wastes or substances, and shall include Waste specified under column (3) of Schedule-I Wastes having constituents specified in ScheduleII if their concentration is equal to or more than the limit indicated in the said Schedule, and Wastes specified in Part A or Part B of the Schedule-III in respect of import or export of such

appliances

STONE CRUSHERS

6

wastes in accordance with rules 12,13 and 14 or the wastes other than those specified in Part A or Part B if they possess any of the hazardous characteristics specified in Part C of that Schedule

1.6 Classification of Stone Crushers by RSPCBProject Description Red Category S.No. 33 of Red Category Stone crushers having capacity more than 600 TPD or having Jaw crusher size more than 15/30 inches Orange Category S.No 6 of Orange Category Stone crusher other than covered under Red Category Reference: RSPCB office order dated 03.04.2008 Expansion: Any expansion of the orange category industry either equal to or more than 600 TPD of crushing capacity by its overall capacity / up gradation of the crusher size more than 15/30 inches will be treated as Red category No

7

STONE CRUSHERS

CHAPTER 2 Environmental Acts and Legal Requirements2.0 Requirements Under the Provisions of the Water (Prevention & Control of Pollution) Act 1974 as AmendedSection 25 (1) Subject to the provisions of this section, no person shall, without the previous consent of the State Board:

Restrictions on new outlets and a. Establish or take any steps to establish any industry, operation or discharges process, or any treatment and disposal system or an extension or addition thereto, which is likely to discharge sewage or trade effluent into a stream or well or sewer or on land (such discharge being hereafter in this section referred to as discharge of sewage); or b. Bring into use any new or altered outlets for the discharge of sewage; or c. Begin to make any new discharge of sewage Whoever contravenes the provision of section 25 shall be punishable with imprisonment for a term which shall not be less than two years but which may extend to six years and with fine

Section 44 Penalty of contravention of section 25

2.1 Requirements Under the Provisions of the Air Pollution) Act 1981 as AmendedSection 21 (1)

(Prevention & Control of

Subject to the provisions of this section, no person shall, without the previous consent of the State Board, establish or operate any Restrictions on industrial plant in an air pollution control area use of certain industrial plants Section 37 (1) Whoever fails to comply with the provisions of section 21, be punishable with imprisonment for a term which shall not be less than Penalty of one year and six months but which may extend to six years and with contravention of fine Section 21

2.2 Requirements for Ground Water ExtractionKeeping in view of the requirements stated in the Policy guidelines for clearance of ground water abstraction for various uses issued by the Central Ground Water Authority, Ministry of Water Resources, GoI vide their letter dated 14.10.2009, the following guidelines regarding the requirement of NOC from CGWA for abstraction of ground water by any industry/ infrastructure project/ mine (proposed/existing) are being followed:

STONE CRUSHERS

8

Guidelines NOC from CGWA shall not be required for abstraction of ground water in the following cases: In case of over-exploited areas abstraction