Ex Summary English

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Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5MTPA) & Captive Power Plant (2 x 25 MW)At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

ExecutiveSummary ofEIA Report

Ambuja Cements Ltd. 1

EXECUTIVE SUMMARY

1.0 INTRODUCTION

Ambuja Cements Limited (ACL) is a leading manufacturer of various types of cements

in India, part of the Holcim group, worlds largest cement manufacturer. AmbujaCement has an excellent track record with respect to productivity, energy

conservation, quality control and environmental pollution control.

ACL is operating 5 cement plants at Ambujanagar Gujarat, Darlaghat Himachal

Pradesh, Chandrapur Maharashtra, Bhatapara Chattisgarh and Rabriyawas

Rajasthan. Besides, the company has One Clinkerisation Plant at Rauri Himachal

Pradesh and 8 Clinker Grinding Plants at Ropar and Bhatinda in Punjab, Sankrail and

Farakka in West Bengal, Surat in Gujarat, Roorkee in Uttarachal, Dadri in U.P and

Nalagarh in Himachal Pradesh.

ACL proposes for Integrated Cement Project i.e. Clinker (3.0 MTPA), Cement (4.5

MTPA), Captive Power Plant (2x25 MW) & Waste Heat Recovery Boiler (5.0 MW) at

Villages: Marwar Mundwa, Tehsil & District: Nagaur (Rajasthan).

The project was considered in front of Expert Appraisal Committee (EAC) (Industry-1)

for ToR approval on 28th August, 2010. The Terms of References (ToR) have been

issued by MoEF, New Delhi for preparation of the Draft EIA / EMP Report vide letter

No. -11011/394/2010-IA-II (I) dated 16th Sep, 2010.

As per the New EIA Notification dated 14.09.2006, this project falls in category A.

1.1 DETAILS OF THE PROJECT

Table No. : 1.1

S.No. Particulars Details

1. Location

Villages Marwar - Mundwa

Tehsil & District Nagaur

State Rajasthan

2. Latitude 27 04 9.09 N - 27 05 6 N

3. Longitude 73 48 30.3 E- 73 49 21.71 E

Project Detail

4. Cost of the project Rs 1500 Crores

5. Cost for Environmental Protection Rs. 120 Crores

6. Recurring cost per annum for

environmental pollution control

measures

Rs.100 lakhs/annum

7. Total Area (Including Green Belt) 285.10 ha

8. Green belt Area 85.10 ha


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S.No. Particulars Details

Climatology

(Summer Season: March to May, 2010)

9. A. Temperature 20.8 C 48.3 C

B. Relative Humidity

At 8:30 hrs.

At 17:30 hrs.

32% to 55%

26% to 35%

10. Dominant Wind Direction From SW

Project Site Vicinity Details

11. Nearest Village Mundwa 2.0 km in South

Khain 1.5 km in North

12. Nearest Railway Station Marwar-Mundwa (0.2km in

South) Merta Road Junction (40 km)

13. Nearest National Highway NH 89 (Near boundary in East)

NH - 65 (20 km in West)

14. Nearest State Highway SH- 02 (21 km in West)

Connecting ----&----via---

---city

15. Nearest Airport Jodhpur (165 km in West)

Jaipur (250 km)

16. Nearest town/city Nagaur (20 km in West) Mundwa

(2.0 km.)

17. Nearest River None within 10 km radius

18. Nearest Water Body Pond (4.0 km in West)

19. Ecological Sensitive Areas No National Park, Biosphere Reserve,

Wild Life Sanctuary, Reserve Forest,

Protected Forest within 10 km radius

the study area.

20. Industries/Mines falling in 10 km

radius of the area

Hanuman Cement Factory

(Near Plant Boundary in West)21. Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]


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FIGURE 1.1: LOCATION MAP OF THE PROJECT SITE


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1.2 MAJOR REQUIREMENTS FOR DIFFERENT UNITS OF THE

INTEGRATED PROJECT

1.2.1 Water Requirement

TABLE 1.2.1Total Water Requirement

S. No. Utility Water Requirement (in KLPD)

1. Cement Plant 1100

2. Captive Power Plant

including WHRB

500

3. Colony 250

4. Green belt development 150

5. Total 2000

Source:Pre-feasibility Report

Source: Water requirement of the project including Cement plant, CPP and colony is 2000

KLPD. Permission for 2000m3 /day Ground Water abstraction obtained from CGWA

vide letter No. 21-4 (16)/WR/CGWA/05-1491dated Dec.02, 2005.

1.2.2 Power Requirement

The Power required at Cement Plant is worked out based on the various loads for

3.0 MTPA clinker production 4.50 MTPA cement, 2 x 25 MW CPP and 5 MW WHRB

TABLE 1.2.2

POWER REQUIREMENT DETAILS

S. No. ParticularsPower

Requirement

1. Average Power Demand of Clinkerisation 32 MW

2. Average Power requirement of Grinding 11 MW

3.Auxiliary power consumption of 50 MW CPP

including (5.0 MW WHRB)6 MW

4. Total power required to generate 49 MW

Source:Pre-Feasibility Report

Hence, it is proposed to Install 2x25 MW Thermal Power Plant within the plant

premises.

Excess power generated from both 2x25 MW CPP and Waste Heat Recovery

Systems of 5.0 MW (after considering present requirement of Cement Plant net load

of 43 MW and CPP Auxiliary Consumption of 6 MW) will be used for Peak load

demand & future requirements.


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1.2.3 Manpower Requirement

During construction phase the peak manpower requirement shall be around 2000-2500 people and during operation phase it shall be as under:

TABLE 1.2.3

DETAILS OF MAN POWER

S. No. Type Of Manpower Mode Of Employment Persons

1 Skilled Manpower Company Owned 391

2 Semi-Skilled Manpower Contractor 125

3 Un-Skilled Manpower Contractor 375

Source:Pre-feasibility Report

ACL will provide employment to the local populace and also labour of unskilled and

semi-skilled categories will be taken from the nearby villages and towns.

2.0 PROJECT DESCRIPTION

2.1 Raw Material Requirement

Table No. : 2.1

RAW MATERIAL REQUIREMENT, SOURCE & TRANSPORTATION

S.

No.

Raw

Material/Fuel

Quantity Required

(MTPA)Source Mode of transportation

1. Limestone 4.50Captive mines (ML I & ML

II)

Overland Conveyor belt

(at a distance of approx.

1.5 km from plant site)

2. Gypsum 0.32Rajasthan State Mines &

Minerals Ltd.Road

3. Fly Ash 1.35 Captive power Plant

via closed circuit

system

4. Fuel -Kiln

0.46

considering Mix of

coal (40%)/

pet coke (27%)/

lignite (33%)

Coal Badgaon Mines,

imported

Lignite Matasukh

Mines

Pet coke-IOCL/Reliance

Coal-Rail

Lignite Road

Petcoke Road/Rail


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5. Fuel- CPP0.23 considering

coal as fuel

Coal Badgaon Mines,

SECL CollieriesRoad

6. China Clay 0.31In close vicinity of plant-

Bhadana QuarryRoad

7. Silica 0.04 Merta Road

Source:Prefeasibility Report

2.2 PROCESS DETAILS

2.2.1 Cement Manufacturing Process

The cement plant will adopt Dry Process Technology for Cement manufacturing with

Pre Heating and Pre Calciner Technology.

The major steps in the manufacture of cement are given hereunder.

1. Raw Material Transport and Storage2. Raw material preparation, grinding and blending operations

3. Calcinations in the kiln

4. Clinker cooling and stocking

5. Cement grinding and packing

2.2.2 Captive Power Plant

ACL has also proposed to install Captive Power Plant (2X25 MW considering coal

as fuel) within the cement plant premises. The required coal as fuel for the CPP would

be sourced from Badgaon mines and SECL Colliers. The Indian coal would be

transported from the source to plant site by road.

3.0 DESCRIPTION OF ENVIRONMENT

Baseline study of the study area (i.e. 10 km radius from the project boundary) was

conducted during Summer Season (March to May, 2010). Monitoring for ambient air

quality (as per CPCB standards), ambient noise levels, water quality, soil quality was

conducted at respective sampling locations. The study for land use pattern using

satellite imagery, study for hydro- geology, demography and flora & fauna has also

been conducted.

The concentration for all the 8 AAQM stations for PM10 ranges between 28.52 g/m3

to 68.31 g/m3, PM2.5 ranges between 12.62 g/m3 to 32.12 g/m3, SO2 ranges

between 6.8g/m3 to 14.3 g/m3 and NO2 ranges between 8.7 g/m3 to 16.4 g/m3.

The ground water analysis for all the 8 sampling stations shows that pH varies from

7.67 to 8.19, total hardness varies from 126.72 mg/l to 330.24 mg/l & total dissolved

solids varies from 1270 mg/l to 1982 mg/l.

The analysis results for soil shows that soil is neutral in nature as pH value ranges

from 7.20 to 8.38 & is sandy loam in texture. The concentration of Nitrogen,

Phosphorus & Potassium has been found to be in good amount in the soil samples.


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3.1 SOCIO-ECONOMIC ENVIRONMENT

The population as per 2001 Census records is 41316 (for 10 km radius buffer zone).

Scheduled Caste fraction of the population of the study area (10 km) is 20.73 %% and

Scheduled Tribe is 0.0004 %. Literacy rate is 40.79 %. Total no. of households are

6514.

4.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

The key emissions generated from Plant process are particulate matter, Oxides of

Nitrogen (NO2) and Sulphur dioxide (SO2). High efficiency ESP/bag house will be

installed with boilers, cooler, Raw Mill, kiln, coal mill and cement mill to meet the

PM (Particulate Matter) emission level of less than the prescribed limit. Fugitive

emission shall be controlled by proper covered storage facilities for raw material &

product. Installation of bag filters and proper water sprinkling shall be carried out at

the material transfer points. No industrial waste water will be generated from cement manufacturing process.

Industrial waste water will be generated from power plant only and will be used for

cooling, Plantation & ash quenching after proper treatment. Domestic effluent will

be generated mainly from office toilets and township, which will be treated in the

STP and treated effluent will be recycled for green belt development and the STP

sludge will be used as manure for green belt development within the plant

premises. Hence, the Integrated Project will be a Zero Discharge Unit.

Solid waste generated from Cement Plant / CPP in the form of sludge (from

Sewage Treatment Plant) & Fly ash (from CPP) will be used as manure for green

belt development & for manufacturing of PPC, respectively.

During operational phase noise will be generated from turbine, compressors,

motors, grinding mills in the cement plant and CPP. Ear plugs will be provided to

persons working in high noise zone.

The study area (10 km radius from the project site) is not having any National Park,Wild Life Sanctuary or Biosphere Reserve etc.

Flora found in the study area includes Acacia arabica (Babool), Acacia senegal(Kumat), Calotropis procera (Aak), Ailanthus excelsa (Ardu), Azadirachta indica

(Neem), Ziziphus mauritiana(Ber), Prosopis juliflora(Khejri) etc.

Fauna observed in the area areBlue bull (Boselaphus tragocamelus), Hare (Lepus

nigricollis), Pigeon (Columba livia), Common Myna (Acridotheres tristicus), Fivestripped squirrel (Funambulus pennanti), House crow (Corvus splendens), camel

(Camelus Dromedarius), Weaver bird (Ploceus philippinus), Rat (R. rattus) etc.


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5.0 ENVIRONMENTAL MONITORING PROGRAMME

Table No. : 5.0

S. No. DESCRIPTION FREQUENCY OF MONITORING

1. Meteorological Data Daily

2. Ambient Air Quality at project site Twice a week

3. Stack Emissions Weekly

4. Water Quality Quarterly

5. Noise Level Monitoring Quarterly

6. Soil Quality Quarterly

7. Health Check-up As per the Factory Act.

6.0 ADDITIONAL STUDIES

The Additional Studies conducted as per the additional Terms of References vide

MoEF letter no.- F. No. J-11011/394/2010-IA-II (I) dated 16th Sep, 2010 are

Biological Study, Hydro-geological Study & Rain water Harvesting Plan, Disaster

Management Plan.

7.0 PROJECT BENEFITS

The proposed project activity will help in combating the growing demand of cement in

the market & hence will help in the economic growth of the country. ACL will be

actively involved in the CSR activities in the nearby villages of the project site.

Infrastructure development in the nearby villages, creating educational facilities,

empowering women through self help groups, gainful employment for rural, healthawareness programmes & surgical camps, supplementing resettlement efforts in

areas affected by natural calamities, assisting social forestry programmes in the

area, is some of the highlights of the CSR activities which will be operated by the

plant.

8.0 ENVIRONMENT MANAGEMENT PLAN

The major sources of pollution in a cement plant are stack (Particulate Matter). Air

pollution is the major concern to be looked upon for the project activity. No major

water, noise & soil pollution is envisaged from the project activity. Various mitigation

measures have been proposed to take care of the environment in respect of air,

water, noise, soil & the green cover of the project site & nearby villages.

8.1 AIR ENVIRONMENT

All major sources of air pollution (Raw Mill Kiln, Clinker Cooler, Coal Mill, Cement

Mill) of proposed new kiln will be provided with ESP, Bag filters to maintain limits of

50 mg/Nm3 for the PM emissions.

All material transfer points will be provided with bag filters to entrap the

emissions at the source itself.


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Clinker will be stored in silos /covered stock piles and gypsum in covered shed.

Fly ash will be stored in silos and closed shed.

CPP Boiler will be provided with ESP.

Better maintenance and installation of proper pollution control equipment like Bag

Houses, Bag filters and ESP will help in reducing such emissions.

CPCB guidelines for fugitive emissions will be followed.

Green belt will be developed along the roads and around the plant premises as

dust preventive barrier.

Automized Water sprinkling system will be provided at limestone and coal

unloading hopper and handling area.

8.2 WATER ENVIRONMENT

No industrial waste water will be generated during cement manufacturing process.

Waste water generated from CPP will be recycled back to the process after

proper neutralization. Domestic waste water generated from the project will be treated in STP and used

for green belt development / horticulture activities & for dust suppression.

Rain water harvesting will be practiced at plant and colony area.

8.3 NOISE ENVIRONMENT

Silencers will be provided in the machineries generating high noise.

Properly insulated enclosures will be equipped for noise producing equipments

to minimize high noise.

PPE like earplugs and earmuffs will be provided to the workers exposed to high

noise level.

Sufficient green belt will be maintained around the cement plant.

Regular monitoring of noise level will be carried out and corrective measures in

concerned machinery will be adopted.

8.4 SOLID WASTE MANAGEMENT

No solid waste will be generated from the cement manufacturing process.

Dust collected from air pollution control equipment will be 100% recycled in

process.

Sludge from Sewage Treatment Plant (STP) will be used as manure for green

belt development.

Fly ash generated from Captive Power Plant will be utilized in the manufacturingof Cement.

8.5 GREENBELT DEVELOPMENT

Out of total project area i.e. 285.10 ha, about 85.10 ha area will be developed

under green belt / plantation.

A thick green belt all along the roads, colony and plant will be developed under

afforestation program.

Local species will be planted as per guidelines.


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9.0 CONCLUSION

As discussed, it is safe to say that the project is not likely to cause any significant

impact on the ecology of the area, as adequate preventive measures will be adopted

to contain the various pollutants within permissible limits. Green belt developmentaround the area would also be taken up as an effective pollution mitigative

technique, as well as to control the pollutants released from the premises of ACL.

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