Annex 3

Case StudiesEnvironmental Aspects of Brick Factory

Intermittent kilns

• Clamp Kilns or Thado Bhatta

Continuous kilns

• Chimeny Bhatta or Bull Trench Kiln, and Chinese Bhatta or Hoffman Kilns

• About 125 brick kilns operated in the Valley

• Production capacity of 40 thousand to 45 million pieces per year

• BTK constitute about 90 per cent of the total brick kilns and they share about 87 per cent of the total brick production in Kathmandu Valley.

1,20027,798162Labour Employment in

2001

Good qualityAbout 60% best quality, 20

and 15 % second and low

grade and 5% waste

Uneven qualityBrick quality

Fixed chimneyMovable or fixed chimneyMovableType

Decreasing by 4.31

per cent

Decreasing by 0.66 per

cent

Only 0.34 million

pieces produced in

CK in 2001

Production Trend

between 1993 & 2001

31139Number in the Valley

Agricultural land, 2 in

Lalitpur and 1 in

Bhaktapur

About 509 ha of

agricultural land rented in

2001, 55, 49 and 9 in

Bhaktapur, Lalitpur and

Kathmandu

Agricultural landLocation

CommercialCommercialPersonal or

commercial

Brick Use

Hoffmann KilnsBull's Trench KilnsClamp Kilns

Types of Brick and Tile Industries in Kathmandu ValleyConsiderations

3500-40004900-56006800-7200Calorific value

WoodJahria coalAssam coalQuality of fuels

Steam,

coal and

fuelwood

Steam and Assam coal,

saw dust, fuelwood, rice-

husk and agriculture

residues

Crushed coal,

rice-husks and

cow-dung

Fuel Consumption

High

capital

cost

No permanent roof and

use of ash, low chimney

height, massive

emission

Very slow

burning process,

more non-uniform

(over-burnt or

under-burnt)

bricks

Disadvantages of

production process

Smoke and

particulate

emission due to

improper

feeding, firing

and operating

practices of fuel

Stack

emission

reduced

Stack emission

massive

InsignificantAir pollution

Environmental Issues

• Loss of top fertile soil

• Depletion of water retention capacity

• Loss of paddy production – 2413 mt/yr

• Chemical contamination – biomagnification

• Solid wastes (17.23 million pieces of bricks/yr and wastes from workers)

• Gaseous emission

• Dust

• Health problem etc.

End of Case 1

Environmental Aspects of Godavari

Marble Industry• Marble extraction started in 1934

• Present management since 1976

• Leased area 1.5 sq. miles (3.88 sq.km)

• Marble deposit/reserve - 0.625 million m3 (246,400 m3

white marble, 130,200 m3 brown marble and 248,400

m3 pink marble)

• License to industry - 2,000 m3 of marble block, 0.4

million square ff of marble slabs and tiles, and 40,000

square ft of crazy marbles, and other products such as

by-products not quantified

• Main by-products aggregates

• Marble deposit geologically faulted, jointed, weathered

and crushed resulting in very poor recovery of blocks

Godavari Industry …

• Marble located in the steep topography and difficult in quarrying, road construction and bench formation

• Marble production increased from 2,50,000 square

feet/year in 1992/93 to 9,00,000 square feet/year by

the end of 1997/98

• In 2004, 6,00.000 square feet marble production

• Employment - about 500 (325 direct and 180 persons

indirect)

• Turn over for 2002/03 - about 75 million rupees

• Industry implemented Quality Circle Systme in

1996/97 and environmental management system

(EMS) with ESPS Support

In-situ marble

Clearing around the block

manually

Block extractionWaste removalTop soil

Drilling by Jack

Hammer

Blasting

Secondary Breaking

Manually

Loading boulder to

truck manually

Crushing plant

Loading by H/E

to dumper

Filling/gravelling

to dump yard

Loading of soil mixed

aggregates to

dumper

Screening

plant

Crushing plant

Cleaning of block manually

Drilling 3 holes at right

angle to each other by LD4

Cutting by Diamond

wire sawDislodging by hydraulic

jack

Sizing/dressing by drilling

or wire sawing

Factory block yard

Mining Process

Marble blocks

Block dressing by dressing machines, handicraft decorative

stones

Slabbing (Gang Saws)

Reinforcing and resining

Marble sizing

Gauging and polishing

Sorting, inspection, packing and dispatch

Crane unloading of blocks

Production Process

Environmental Issues

• Removal of plants and top soil to extract marble,

landscape change and land degradation

• Noise and dust from drilling activities

• Soil erosion and mines mud during the rainy season

• Noise, possible accident and vibration from the use of

explosives and operation of heavy equipment

• Dust generation in the quarry, during transportation

activities, and in the crushing plant

• Factory sludge – generated during marble cutting

• Haphazard disposal of by-products etc.

Several Committees Formed

Factory’s Environmental Activities

From 1990 onwards• Air pollution management – water spraying, and use

of cyclone dust collectors, and bag filters in crusher and chips machines

• Noise level – use of noise enclosures in stationary equipment, blasting charge reduced to 25kg

• Water pollution management – drainage and sedimentation pond constructed , sludge ponds operated, river training and gabion check dams

• Forest conservation – afforestation in quarry 4, plantation of 3 laks saplings, nursery operation, grass and shrubs for nitrogen fixation/erosion control, salary to forest guard

• Waste management – waste reused, planned dumping by mechanical compaction, land reclamation

Factory’s Environmental Activities

From 2001 onwards

• Joined pilot EMS of HMG/ESPS

• Environmental policy (Effective from 2059/5/20)

• Receipt of ISO 14001 certificate on 1 February 2003

• Commitments of industry for reduction of energy

consumption, waste minimisation by reusing, and

reduction in natural resource utilisation

• Provided personal protective devices to ensure safety

and health of workers, medical check from time-to-time,

training to workers on OHS

• One crore revenue to HMG annually

• Financial and material support to locals

• Support to students for field study of the industry

Only 5 ha of leased area used now

Factory would like this after

completion of operation

End of Case 2

Stone Quarry and Environmental

Impacts

� Conversion of prime agriculture land to settlements in

Kathmandu Valley

� Increased demand for construction materials such as

stones, aggregates and sands for the construction of

buildings and roads

� Establishment of Purna Aggregate Industry in 1962 to

supply construction materials

� Stone reserve 1.047 million m3, and would be

sufficient for 93 years if extracted at the rate of 45

m3/day

� About 50 people employed and factory site sale price

NRs. 350/m3

Excavation Process

� Drilling, and making small pieces of stones as

blasting difficult to insurgency

� Machines such as drilling, pick, shovel, hammer,

crowbar, chisel etc. used to excavate stones from

the hill

� Benching method used and bench height 1.5m and

width 4m maintained, fertile soil stored for future

rehabilitation of degraded lands

� Produced stones sent to destination by workers

� About 20 % pf excavated materials unused or

overburden e.g., soil, gravel etc.

State of Biodiversity

� Pine and mixed forests with alder, juglansrhododendrons, strawberry etc (in local names, sallo, red siris, uttis, tanki, koiralo, katus, lankuri, lapsi, okhar, champ, kafal, seti kath, kaulo, amala, sallo, painyu, khirro, angeri, simali etc.)

� Lapsi and champ endangered and species of orchids listed in CITES appendices

� About 45 ha of forest on the southern side of the stone quarry are managed by community users (242 houses involved)

� Community forests handed over to users in 1999 for the management and sustainable use

� Users have conserved species

State of Biodiversity …� Community forests managed with five blocks, and number 2 block is joined with stone quarry

� Based on survey, average growth of forest – 25.42 m3/ha, 592 poles/ha, and 2391 saplings/ha based on survey

� Bajrabarahi religious forest located at ChapagaonVillage Development Committee (political and administrative unit at the grass root level) at about 2 km from mining area

� Community forests provide habitat for spiny babler(bird) – an endemic species

� Community forests also provide habitat for barking deer, purcupine, jungle cat, rats, malsapro, hare, leopard, patridge, bhadrai, dove, owl, snakes etc.

� Stream has some fish species such as asala, hile, buduna

Environmental Impacts

� Alternative – although no alternative but consider

sensitive area, endangered and endemic species,

excavation technology, timing etc.

� Beneficial impacts - employment opportunities

provided, income increases

Adverse impacts

� Possible landslides, loss of top fertile soil, and stream

and river sedimentation

� Land use change, air and water pollution, increase in

noise level

� Loss of species and their habitats

� Possible decline in agricultural products

� Possible impacts on fish species due to mud flow etc.

Settlement on the hill slope and soil loss

Forests and vegetation in the mining site

Stone quarry operated in forests

Stone excavation technique

Drilling to make the block small

Block Stones

Stones loading

Workers to make stone pieces

Soil loss

Possible effect on agricultural land

Vehicular pollution in settlements

At the end,� Regular supply of stones, employment generation and

stable price of stones

� Revenue generation and increase in income source of local people

� Possible loss of biodiversity and habitat of spiny bablerbird while extracting stones southwards

� Necessary to operate quarry based on its technical scheme, environmental impacts to be assessed, approach for avoiding and mitigating impacts

� Possibility to make stone quarry environment-friendly etc.

� Any questions ?? If not, be ready for field visit