Resource Efficiency
As Calidra, in Mexico; Cefas, in Argentina, owns and operates all its quarries;
however Cefas contracts the blasting operations for the raw material
extraction. The overall handling, reclamation, and safety aspects of the
quarries at Calidra’s Mexico operations are handled at corporate level through
an Integrated Quarries Management Plan, with local EHS presence at each of the
quarries. For the sound management of the quarries in its Argentinean
operations, Calidra will ensure there is proper
identification/collection/removal of any flora and fauna present, collect and
reuse the layer upper of the soil; establish procedures to prevent soil erosion
(protecting earrings, drainage vertical and horizontal and planting of grass);
manage drainages in the areas of operation and along the roads of access,
ensure proper storage and handling of explosives, noise/dust control, optimize
the exploitation approach aiming to maximize the use of its raw material, etc.
To that effect, it will assess the current approach being applied at the
quarries in Argentina to reconfirm the availability of the resource and
enhance, as appropriate, the overall exploitation scheme of these quarries.
Calidra will submit copies of the quarry optimization plans for each of the
quarries in Argentina, as indicated in the ESAP. These plans will also include
quarry closure and rehabilitation plans for all quarries, and notably those are
being shut down.
Water is of paramount importance for Calidra operations and a key input in the
hydrated lime production process, representing approximately 465 lt/ton of
calcium oxide. It is also used for cooling, washing aggregates, and cleaning
plants and equipment, including final product delivery trucks. Thus, Calidra
has developed programs and initiatives to increase water efficiency such as and
recycling, particularly at those hydrating plants located in water scare areas
by recovering the water vapor releases to the atmosphere during the hydration
process. It is also implementing rain water collection systems at several of
its plants.
For the operations in Argentina, Calidra will look to optimize the water
consumption of the hydrators. Copies of the water balance as well as water
optimization measures for each of the plants in Argentina will be submitted to
IFC as indicated in the ESAP.
Calidra also has a program in place to control and reduce the energy
consumption of its plants. For the operations in Argentina, Calidra will
develop and implement an energy consumption monitoring system and begin
implementing energy optimization measures. Calidra will submit to IFC a copy of
the energy optimization plan for each of the plants as indicated in the ESAP.
Water
At the Quilpo plant, the water is obtained from a well located at approximately
40 m from the Quilpo River for which the authorization is in process of being
obtained; once obtained, Calidra will provide a copy to IFC. The 120,000 l/d of
water obtained from the well is used for production as well as for water supply
to the nearby community located next to the plant. The plant uses bottled water
for drinking purposes. Overall, it consumes approximately 5,000 l/hr, of which
approximately one third is used in the hydration process.
The Padre Bueno plant process water is obtained from a well, located within the
course of the nearby Cienaguita creek, approximately 4 km distant from the
plant. It consumes approximately 100,000 liter/month. Cefas already conducted a
hydrological study of the area but it has yet to assess the ecological flow
conditions of this creek. As part of this project, Calidra will conduct an
ecological flow assessment of the Cienaguita Creek to determine whether there
are or there will any impacts to the hydro ecology downstream from the plant’s
water intake. Its drinking water is bought from an authorized company.
The Olavarria plant obtains water for its process from an off-premises well
located at approximately 600 m from the plant site. The plant takes 10 m3/day
for its domestic use. For its industrial use, it pumps out 100 m3/d from an
artificial lagoon about 170 m from the site. In addition, also for industrial
use, it has two concessions to take between 800 m3/d to 1,900 m3/d from the
“Don Antonio” reservoir located 500 m from the plant and between 500 m3/d and
1,200 m3/d from the “Cantera Loyola” reservoir located 1.5 km distant from the
plant. All the water used is authorized by the local environmental authorities.
The Zapala plant obtains the process and drinking water from two wells, for
which the authorization request is being submitted. Once obtained, Calidra
will provide a copy to IFC. It currently consumes 200 l/ton of product. The
well water is also used for irrigation. The water for domestic use is obtained
from the municipal system.
Energy Consumption and GHG Emissions
Lime kiln’s operations are a significant source of carbon dioxide (CO2) from
its process as well as from its fuel consumption. By optimizing its operations
by replacing obsolete technology with efficient kilns (vertical Maerz kilns),
Calidra is reducing/avoiding CO2 emissions. All Calidra current operations have
installed efficient Maerz kilns and the company measures the CO2 emissions
produced. As previously indicated, the plants in Argentina will undergo
improvements to begin the reduction on energy consumption. As part of the
proposed project, the company will install a new 400-tons natural gas/pet coke
Maerz kiln at the Padre Bueno plant. The specific energy consumption of this
kiln will be within the benchmark values established in the WBG EHS Guidelines
as it is a state of the art technology.
The operations in Argentina currently generate approximately 300,000 tons of
CO2 eq per year.
Air Emissions and Ambient Air Quality
The main air emissions generated during lime manufacturing include particulate
matter, carbon monoxide, carbon dioxide, sulphur dioxide, and nitrogen dioxide.
To control these emissions, the plants ought to maintain air pollution control
devices operating continuously in kilns, silos and solid material transfer
points. Silos and transfer areas for raw materials/intermediate and final
products ought to be also controlled to prevent the release of fugitive dust
emissions. When packaging areas are manual or semi-automatic, those typically
generate fugitive emissions which affect workplace conditions.
Cefas has in place certain air pollution controls at its plants; some stack,
transfer points, and fugitive emissions are currently controlled. As part of
this project, Calidra will conduct an assessment of the air pollution control
needs (kilns, grinders, silos, transfer points, packaging, etc.) of the plants
in Argentina, and it will install the needed air pollution control devices and
it will enhance the packaging areas of the plants to reach compliance with the
applicable local regulatory requirements and WBG EHS Guidelines. Specifically,
for the Quilpo plant, it will identify interim air pollution control actions as
this plant is anticipated to be closed down once the accumulated rejected
hydration material is fully processed. As indicated in the ESAP, Calidra will
submit to IFC reports indicating (a) the air pollution control systems to be
installed at each plant, and (b) implementation time tables to ensure
compliance with the IFC requirements.
As Calidra’s plants that currently conduct ambient air quality monitoring, the
company will also establish an ambient air quality monitoring program for the
plants in Argentina. As part of this program, it will establish the locations
of sampling points, frequencies, sampling analyses, etc., as indicated in the
ESAP.
Wastewater Treatment
The lime operations typically generate process, storm water, and domestic
wastewaters. The Quilpo plant domestic liquid effluents generated are disposed
in septic tanks and the process liquid effluents generated by the hydration
process have been released openly into a nearby area, property of the plant. As
indicated earlier, these discarded material is expected to be reclaimed as part
of this project.
The domestic liquid effluents generated from Padre Bueno plant are collected,
removed by an authorized company, and finally disposed in the municipal
treatment facility. The process liquid effluents generated are treated in an
onsite wastewater treatment plant and internally used for irrigation in the
plant green areas. The sludge generated is collected and handled as a solid
residue.
At the Olavarria plant, the wastewater is used to wash and humidify the
material, the remaining water from this operation is returned to the lagoon,
thus there are not process liquid effluents discharged. The domestic liquid
effluents are disposed in septic tanks.
The Zapala plant uses process wastewater to capture the fine particulates in
the wet filter. The filter collected material is then used in the pelletizing
process, thus there is no generation of liquid effluents or sludge. The
domestic liquid effluents generated are disposed in the municipal system.
As part of this project, Calidra will improve the wastewater treatment systems
for all Argentinean plants and provide reports indicating (a) the wastewater
treatment systems chosen to be installed at each plant to further enhance the
quality of the wastewater used for their internal purposes, and (b)
implementation time tables which will ensure compliance with the IFC
requirements as indicated in the ESAP.
Solid Waste Management
Calidra has a solid waste management system and all current plants have
residues segregation programs. The program ensures that once segregated, the
hazardous and non-hazardous wastes are properly disposed following local
requirements in authorized locations. Specifically, the hazardous wastes (i.e.
waste oils, materials contaminated with the oils, wastewater treatment plant
sludge, etc.) are properly collected, stored and send for final disposal by
authorized contractors. Calidra continues making efforts to reduce the
generation of solid wastes. Specifically, it reinjects back into its kilns the
particulates collected in the air pollution control filter from the kilns.
Calidra also records and reports total hazardous and nonhazardous waste
production volumes from operational sites.
As indicated above, the solid residue accumulated at the Quilpo plant from the
hydrator rejects will be reclaimed at the plant prior its permanent shut down,
as part of this project. In addition, the approximately 2,400 tons of rejected
lime material generated at the Decavo plant which has been accumulated on
premised will be transferred to the Padre Bueno plant, where it will be
reclaimed by mixing it with final product and selling as a road conditioning
material.
Currently, Cefas collects its solid wastes and have they disposed in authorized
landfills. The hazardous wastes are collected and stored prior being sent to
an authorized final disposal site. Calidra will extend its solid waste
management system to the plants in Argentina, for which, it will develop a
solid waste management plan including the management of rejects from the Quilpo
and Decavo plants, as well as enhance practices for storage and final disposal
for the solid and hazardous wastes generated at the Cefas plants. Copy of this
plan will be submitted to IFC as indicated in the ESAP.
Hazardous Materials
The Quilpo plant has three (one 30 m3 and two 20 m3 each) diesel aboveground
storage tanks and two underground storage tanks which are no longer in use. It
has a 1,800-tons capacity open area to store pet coke and it is authorized to
use a maximum of 11 tons of explosives. The Padre Bueno plant has two (50 m3
each) diesel aboveground storage tanks, a 500-tons capacity open area to store
pet coke and it is authorized to use a maximum of 13 tons of explosives. The
Olavarria plant has two (42 m3 and 30 m3) diesel aboveground storage tanks and
a 3000-tons capacity open area of to store pet coke. The Zapala plant has two
(1400 l combined) diesel aboveground storage tanks. All hazardous materials
have been approved for use and proper handling (i. e., secondary containment,
secure storage, etc.). The local environmental authorities conduct annual
audits related to handling/storage prior granting the authorizations.