Environmental & Social Review Summary
Project Number
8642
Company Name
Devnya Cement A.D.
Date ESRS Disclosed
Feb 5, 2010
Country
Bulgaria
Region
Europe
Last Updated Date
Dec 31, 2016
Environmental Category
B - Limited
Status
Completed
Previous Events
Approved : May 29, 1998
Signed : Sep 14, 1998
Invested : Sep 23, 1999
Sector
Cement
Industry
Manufacturing
Department
Regional Industry MAS LAC & EUR
Project Description
3
April 9, 1998 1
Project Name BULGARIA: Devnya Cement
Region Europe
Sector Cement
Project No. 008642
1. This US$ 227 million project involves the renovation and modernization of Devnya’s existing 1.8 million tpa cement plant close to Varna, Bulgaria, including: (i) renovation, upgrading and modernization of kilns 5 and 6, including environmental improvements; (ii) opening three terminals in Europe, one each in Portugal, Spain and France; (iii) converting kiln firing from oil firing to coal firing; and (iv) expanding the plant’s production by adding a new line with a capacity of one mtpa clinker using dry process technology.
2. The project is located in Devnya’s Cement current plant located in the industrial zone of the city of Devnya. The main factory is about 1,000 m from the nearest city district, Izvorite. The limestone quarry is 11 km from the factory site, and the limestone is transported to the plant by conveyor belt.
3. Devnya’s existing operation consist of six production lines using wet process including: kilns 1 and 2 each with 180,000 tpa clinker capacity, kilns 3 and 4 each with a 200,000 tpa capacity and kilns 5 and 6, each with a capacity of 520,000 tpa clinker. Only kilns 5 and 6 are currently in operation. In addition, there are four silos used for bulk cement in railroads and road transport trucks, four more silos used for cement bagging and ten additional silos with building construction defects.
4. This is a category B project according to IFC’s environmental review procedure because specific impacts may result which can be avoided or mitigated by adhering to generally recognized performance standards, guidelines or design criteria. The review of this project consisted of appraising technical and environmental information submitted by the project sponsor and the technical appraisal. The following potential environmental, health and safety impacts of the project were analyzed:
· air emissions;
· liquid effluents;
· solid wastes;
· quarry reclamation;
· fire prevention and emergency response;
· employee health safety and training; and
· employee protection from noise and dust.
The sponsor has presented plans to address these issues and demonstrate the proposed project will comply with applicable governmental and World Bank requirements. The information provided about how these potential impacts are addressed in the development of the project is summarized in the paragraphs that follow.
5. The belt conveyor transporting raw material from the quarry to the plant is covered to control dust emissions to the atmosphere. The sponsor indicates that the air emissions from kilns 5 and 6 are less than 50 mg/Nm3 thereby complying with World Bank regulations. The sponsor will install dust collector in the clinker transport areas in kilns 5 and 6, and will upgrade the existing dust collectors in cement mills A, B to ensure compliance with World Bank guidelines. In addition, the sponsor will install baghouses in the silos 11, 14, 15 and 18 as well as in the loading installations. The new clinker production line will have an electrostatic precipitator to control the particulate emissions released to the atmosphere. With the upgrading and installation of additional dust collectors, the project will be in compliance with the 50 mg/Nm3 particulate emission World Bank guideline.
6. A coal mill will be installed, as the kiln firing will be changed from oil firing to coal firing. Dust collectors will be installed to ensure particulate emissions of 50 mg/Nm3. All needed safety factors will be considered in the coal mill design, construction and operation. The steam boilers are operated and controlled to comply with the applicable World Bank guidelines.
7. The company gets its water supply from it’s own pumping station from borehole wells.
8. All industrial liquid effluents generated in the process including plant clean up and truck washing are treated before being used for equipment cooling. Therefore, there are no process liquid effluents released to the environment. Sanitary sewage is disposed in septic tanks and an authorized contractor collects and appropriately disposes these wastes.
9. The dust collected in all air pollution control devices is recirculated into the process. The domestic residues are collected and properly disposed following local requirements.
10. Devnya commits to inform IFC of any acquisition of raw material sources such as quarries and to present the proposed quarry reclamation program as well as the budget allocated for the implementation of the program.
11. The sponsor will develop and implement a safety and evacuation and fire prevention program ensuring that the environmental, health and safety measures are up to date and that the employees are properly trained. The sponsor has an emergency response plan in place, has installed fire prevention signals, and will ensure that high-pressure fire-fighting hydrants, extinguishers and smoke detectors are installed throughout the plant. The sponsor will perform periodic fire drills. The sponsor is committed to comply with the applicable health and safety World Bank guidelines.
12. Personal protective equipment are provided to and required to be used by the employees. Hard hats are provided for all personnel, and dust masks and hearing protection are provided for personnel working in areas with high dust and noise levels, respectively. The company’s moving machinery is well protected by shield guards and guard railings. Devnya will ensure that qualified personnel will implement health and safety programs. Devnya will continue training the employees in occupational health and industrial safety issues and implementing occupational health and industrial safety programs to comply with World Bank guidelines.
13. The three ports will be built according to European environmental, health and safety requirements. At this stage, the location of the ports has not been identified. The sponsor will inform IFC of the specific locations and will demonstrate and ensure his ability to comply with World Bank environmental, health and safety policies and guidelines. The sponsor will need to submit an evaluation of impacts and proposed mitigation actions six months prior the beginning of construction of each of the ports.
14. Based on its review of available information regarding potential environmental impacts and proposed mitigation measures, IFC concludes that the proposed project is being designed to meet Government of Bulgaria requirements, and World Bank policies, and environmental, health and safety guidelines.
15. IFC will also monitor Devnya’s ongoing compliance with World Bank policies and guidelines during the life of the project by evaluating environmental performance reports submitted annually to IFC by the sponsor and by conducting periodic site reviews during project supervision.
L:\wpeu\JOSEFINA\BULGARIA\devnya-ers.doc
April 9, 1998 10:22 AM
April 9, 1998
Environmental Review Summary (ERS)
Project Name BULGARIA: Devnya Cement
Region Europe
Sector Cement
Project No. 008642
1. This US$ 227 million project involves the renovation and modernization of Devnya’s existing 1.8 million tpa cement plant close to Varna, Bulgaria, including: (i) renovation, upgrading and modernization of kilns 5 and 6, including environmental improvements; (ii) opening three terminals in Europe, one each in Portugal, Spain and France; (iii) converting kiln firing from oil firing to coal firing; and (iv) expanding the plant’s production by adding a new line with a capacity of one mtpa clinker using dry process technology.
2. The project is located in Devnya’s Cement current plant located in the industrial zone of the city of Devnya. The main factory is about 1,000 m from the nearest city district, Izvorite. The limestone quarry is 11 km from the factory site, and the limestone is transported to the plant by conveyor belt.
3. Devnya’s existing operation consist of six production lines using wet process including: kilns 1 and 2 each with 180,000 tpa clinker capacity, kilns 3 and 4 each with a 200,000 tpa capacity and kilns 5 and 6, each with a capacity of 520,000 tpa clinker. Only kilns 5 and 6 are currently in operation. In addition, there are four silos used for bulk cement in railroads and road transport trucks, four more silos used for cement bagging and ten additional silos with building construction defects.
4. This is a category B project according to IFC’s environmental review procedure because specific impacts may result which can be avoided or mitigated by adhering to generally recognized performance standards, guidelines or design criteria. The review of this project consisted of appraising technical and environmental information submitted by the project sponsor and the technical appraisal. The following potential environmental, health and safety impacts of the project were analyzed:
· air emissions;
· liquid effluents;
· solid wastes;
· quarry reclamation;
· fire prevention and emergency response;
· employee health safety and training; and
· employee protection from noise and dust.
The sponsor has presented plans to address these issues and demonstrate the proposed project will comply with applicable governmental and World Bank requirements. The information provided about how these potential impacts are addressed in the development of the project is summarized in the paragraphs that follow.
5. The belt conveyor transporting raw material from the quarry to the plant is covered to control dust emissions to the atmosphere. The sponsor indicates that the air emissions from kilns 5 and 6 are less than 50 mg/Nm3 thereby complying with World Bank regulations. The sponsor will install dust collector in the clinker transport areas in kilns 5 and 6, and will upgrade the existing dust collectors in cement mills A, B to ensure compliance with World Bank guidelines. In addition, the sponsor will install baghouses in the silos 11, 14, 15 and 18 as well as in the loading installations. The new clinker production line will have an electrostatic precipitator to control the particulate emissions released to the atmosphere. With the upgrading and installation of additional dust collectors, the project will be in compliance with the 50 mg/Nm3 particulate emission World Bank guideline.
6. A coal mill will be installed, as the kiln firing will be changed from oil firing to coal firing. Dust collectors will be installed to ensure particulate emissions of 50 mg/Nm3. All needed safety factors will be considered in the coal mill design, construction and operation. The steam boilers are operated and controlled to comply with the applicable World Bank guidelines.
7. The company gets its water supply from it’s own pumping station from borehole wells.
8. All industrial liquid effluents generated in the process including plant clean up and truck washing are treated before being used for equipment cooling. Therefore, there are no process liquid effluents released to the environment. Sanitary sewage is disposed in septic tanks and an authorized contractor collects and appropriately disposes these wastes.
9. The dust collected in all air pollution control devices is recirculated into the process. The domestic residues are collected and properly disposed following local requirements.
10. Devnya commits to inform IFC of any acquisition of raw material sources such as quarries and to present the proposed quarry reclamation program as well as the budget allocated for the implementation of the program.
11. The sponsor will develop and implement a safety and evacuation and fire prevention program ensuring that the environmental, health and safety measures are up to date and that the employees are properly trained. The sponsor has an emergency response plan in place, has installed fire prevention signals, and will ensure that high-pressure fire-fighting hydrants, extinguishers and smoke detectors are installed throughout the plant. The sponsor will perform periodic fire drills. The sponsor is committed to comply with the applicable health and safety World Bank guidelines.
12. Personal protective equipment are provided to and required to be used by the employees. Hard hats are provided for all personnel, and dust masks and hearing protection are provided for personnel working in areas with high dust and noise levels, respectively. The company’s moving machinery is well protected by shield guards and guard railings. Devnya will ensure that qualified personnel will implement health and safety programs. Devnya will continue training the employees in occupational health and industrial safety issues and implementing occupational health and industrial safety programs to comply with World Bank guidelines.
13. The three ports will be built according to European environmental, health and safety requirements. At this stage, the location of the ports has not been identified. The sponsor will inform IFC of the specific locations and will demonstrate and ensure his ability to comply with World Bank environmental, health and safety policies and guidelines. The sponsor will need to submit an evaluation of impacts and proposed mitigation actions six months prior the beginning of construction of each of the ports.
14. Based on its review of available information regarding potential environmental impacts and proposed mitigation measures, IFC concludes that the proposed project is being designed to meet Government of Bulgaria requirements, and World Bank policies, and environmental, health and safety guidelines.
15. IFC will also monitor Devnya’s ongoing compliance with World Bank policies and guidelines during the life of the project by evaluating environmental performance reports submitted annually to IFC by the sponsor and by conducting periodic site reviews during project supervision.
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April 9, 1998 10:22 AM
Environmental and Social Mitigation Measures
Broad Community Support
Related SII
