Final Ambuja Cements Pali Ex Summary English 31 05

Integrated Cement Project – Expansion of Clinker Capacity (2.4 MTPA to 2.9 MTPA), Captive Power Plant Capacity (33

MW to 53 MW) along with New Limestone Mine Ras-I (ML Area: 183.5 Ha, 0.279 MTPA Limestone production)

At Rabriyawas, Tehsil: Jaitaran, Distt: Pali (Raj.)

Executive Summary

of Draft EIA/EMP

Report

Ambuja Cements Ltd. 1

EXECUTIVE SUMMARY

1.0 INTRODUCTION

Ambuja Cements Ltd. (ACL), popularly known as “AMBUJA CEMENT” a leading Cement

Manufacturing Company in India Operates 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.and with a total cement production of 25.0

million tonnes per annum (MTPA).

ACL first plant was established at Ambujanagar, located adjacent to Vadnagar village in

Kodinar Taluka of Junagadh district, Gujarat. The company enjoys recognition for high

productivity, energy efficiency, best pollution control and environmental management

practices.

Presently, the Rabriyawas plant located in Rajasthan, is having Clinker production

Capacity of 2.4 MTPA, Cement Production capacity of 3.6 MTPA, along with RAS-II

limestone mine (ML area: 803 ha; producing 3.6 MTPA of limestone)& 2 units of Captive

Power Plant (i.e. 15 MW & 18 MW) and 6 MW DG Set.

Now, ACL has proposed to enhance Clinker production capacity from 2.4 MTPA to 2.9

MTPA, Captive Power Plant (33 MW to 53 MW) & new limestone mine i.e. RAS - I (ML

area: 183.5 ha) to produce 0.279 MTPA of limestone at Rabriyawas, Tehsil: Jaitaran,

Distt.: Pali, (Raj.).

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

ToR approval on 24th June, 2010. The Terms of References (ToR) letter has been

issued by MoEF, New Delhi for preparation of the Draft EIA / EMP Report vide File No.

J-11011/154/2010- IA-II-(I), dated 14th July, 2010.

As per EIA Notification dated 14th September 2006, as amended on 01.12.2009, this

Integrated Cement Project falls in Category ‘A’ and therefore this project requires

Environmental Clearance from MoEF, New Delhi.

1.1 DETAILS OF THE PROJECT

TABLE - 1

S.No. Particulars Details

1. Location

Village Rabriyawas

Tehsil Jaitaran

District Pali

State Rajasthan

2. Latitude & Longitude Cement Plant:

26o17’56’’ N & 74o07’40’’ E




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Report


Limestone Mine (Ras I):

26o23’14’’ N to 26o24’16’’N

74o13’34’’ E to 74o14’39’’ E

3. Topo Sheet Number 45 J/3 (1:50000 scale)

Area Details

4. Total Plant Area (Cement Plant, CPP, Colony)

354.74 ha

(Cement Plant: 132.34 ha, & Colony: 222.39 ha)

Proposed expansion will be within the existing plant premises, therefore no additional land is required

5.

Green Belt Development 91.0 Ha ( as on 30.04.2011), out of 354.74 ha developed as green belt/plantation

6. Ras - I Mining Lease area 183.5 ha

Cost Detail

7. Total Cost of the Project Rs. 250 Crores

8. Cost of Environmental Protection Measures (Rs)

o Capital Cost : Rs. 20 Crores

o Recurring Cost: Rs. 50 Lakhs / Annum

Climatology

(Post Monsoon Season: October to December, 2010)

9. Temperature 6.6 oC to 37.0 oC

Relative Humidity

At 8:30 hrs.

At 17:30 hrs.

34% to 48%

19% to 31%

10. Dominant Wind Direction From NE

Details of Environmental Settings

11. Nearest National Highway NH-8 (55km)

12. Nearest Railway Station Beawar, about 40 km from the plant site in SE

13. Nearest Air port Jodhpur at a distance of about 150 km from the Cement Plant in WSW.

14. National Parks, Wildlife Sanctuaries, Biosphere Reserves

None within 10 km radius

15. Reserves / Protected Forests within 15 km

5 Nos protected forests

16. Nearest River Three seasonal rivers Lilri (12 km), Luni (13 Km) & Sukari (from the mining lease boundary)

17. Nearest villages From Plant: Rabriyawas, Ballupura, Ballada, Kherpura & Patan

From Mine: Sewariya, Kotariya, Bhaktawarpura and Dhaneriya

18. Seismic Zone Zone – II

Source: Pre-feasibility Report




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FIGURE 1.1: LOCATION MAP OF THE PROJECT SITE




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Report


1.2 MAJOR REQUIREMENTS FOR DIFFERENT UNITS OF THE INTEGRATED PROJECT

1.2.1 Water Requirement

The existing water requirement for the project is 2000 m3/day. After enhancement of

production capacity the water requirement will be about 2400 m3/day, for which ACL has

already obtained permission from Central Ground Water Board for drawl of 2400 m3/day

of ground water.

TABLE - 2

WATER BREAKUP DETAILS

S. No. Particulars Quantity (M3/Day) (For Existing

Capacity)

Quantity (M3/Day) (After Proposed Enhancement)

1. Industrial Activity (Plant + CPP)

1600 1859

2. Domestic Use (Colony) 250 290

3. Limestone Mines (Ras - I & Ras- II)

80 110

4 Others (Environmental Maintenace & ACF activities)

70 141

4. Grant Total 2000 2400

Source: Pre-Feasibility Report

1.2.2 Power Requirement

Existing power requirement for the project is 33 MW, which is being met from 2 units of

CPP (i.e. 15 MW & 18 MW) and one DG Set of 6 MW (only for back up). Power

requirement for the proposed enhancement will be 53 MW.

1.2.3 Manpower Requirement

TABLE – 3

MANPOWER REQUIREMENT

Project Existing

Requirement

Proposed

Requirement

Staff 276 281

Workmen 253 273

Total 529 554

Source: Pre-Feasibility Report

ACL has provided employment to the local populace and in future also labour of

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




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2.0 PROJECT DESCRIPTION

2.1 Mining Details

TABLE – 4

S. No. Details Explanation

1. ML area 183.50 ha

2. Mineable Reserve 54.62 million tones

3. Life of the Mine 196 years

4. Method of mining Opencast fully mechanized

5. Drilling 100 millimeter – 115 millimeter diameters drill

6. Blasting Deep hole blasting

7. Extent of mechanization DTH Drills, Exploders, Crawl Mounted hydraulic

excavators, Highway rear Tippers, Dozer, Water

sprinkler etc.

8. Bench Height (H) 8 m (except one of 6m)

9. Bench Width 18 m (advance side)

10. General Ground Level About 400 mRL

11. Ultimate working depth 4 m mbgl (396 mRL)

12. Ground Water Table 45 m bgl (355 mRL) during Post Monsoon season

13. Bench Slope 60o

14. Number of Working Days in

a year

300 days

15. Number of shifts per day 2 (8 hrs per day)

Source: Mining Plan

2.2 Cement Plant, Captive Power Plant and RAS-I Limestone Mine

2.2.1 Raw Material and Fuel Requirements

TABLE - 5

S. No. Raw Material Existing Total requirement

After enhancement

Source Mode of

transportation

1. Limestone

(MTPA)

3.6 3.879

Captive mines

(Ras II & Ras I)

Conveyor belt &

by road

respectively.

2. Gypsum (MTPA) 0.124 0.124 nearby areas By Road

3. Fly ash (MTPA) 0.55 0.55 Own CPP

Suratgarh TPP

Closed circuit

system

4. Coal / Petcoke /

Lignite (mixed

fuel)

0.274 0.389 From Coal India

Ltd. Rajnagar &

Badgaon and

Transportation

by Road from 2

railway sidings




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(Cement Plant)

(MTPA)

existing identified

source

(approx. 80 km

away from the

plant)

5. Red ochre / Iron

scale, China clay

(MTPA)

0.0462 0.0520 Near by market By Road

6. Furnace Oil

(D.G. Set)

0235

g/kwh

(1692

kg/year)

0235 g/kwh (1692

kg/year)

Local Source By tankers

Source: Prefeasibility Report

2.2.2 Cement Manufacturing Process

The cement plant is based on 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. Limestone excavation and crushing

2. Raw material preparation, grinding and blending operations

3. Pyro processing in the kiln circuit

4. Clinker cooling and stocking

5. Cement grinding and packing

Increase in clinker capacity will be done by modification in existing system &

Optimization of resources. The Optimization of process to increase clinker production:

1. Coal Mill # 1 separator drive upgradation,

2. Two new Coriolis feeders,

3. Pet Coke Ash usage system for Coal Mill #1,

4. Kiln Inlet modification,

5. Cooler modification,

6. Segmented dip - tube cycle 6 ILC & Others,

7. Installation of VVVFD for RFT fan,

8. SPRS for cooler vent fan, MV SWBD at MIS

9. Modification of Bag House Plenum, additional module of Bag house,

10. Engineering of Bag filters,

11. Quality control equipments

2.2.3 Captive Power Plant




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ACL has 2 unit of captive power plant of 15 MW & 18 MW and one DG Set of 6 MW

(only for back up), existing power requirement is being met from these two units. Power

requirement for the proposed enhancement will be 53 MW.

ACL intends to install a coal / lignite / petcoke/ AFR (Alternative Fuel) multifuel based

thermal power plant having capacity of 20 MW. The generating unit will consist of one

Air Fluidized Bed Combustion (AFBC) boiler firing coal as primary fuel, one condensing

steam turbine and generator, one air cooled condenser and other necessary auxiliary

equipment.

3.0 DESCRIPTION OF ENVIRONMENT

Baseline study of the study area was conducted during Post-Monsoon Season (October

to December, 2010).

The concentration for all the 10 AAQM stations for PM10 ranges between 40.62 µg/m3 to

85.04 µg/m3, PM2.5 ranges between 16.37 µg/m3 to 43.67 µg/m3, SO2 ranges between

5.4 µg/m3 to 10.04 µg/m3 and NO2 ranges between 21.38 µg/m3 to 89.6 µg/m3

The ground water analysis for all the 8 sampling stations shows that pH varies from 7.22

to 7.94, total hardness varies from 159.08 mg/l to 399.36 mg/l & total dissolved solids

varies from 345.00 mg/l to 901.00 mg/l.

The analysis results for all 8 soil samples shows that soil is neutral in nature as pH value

ranges from 7.58 to 8.15 & is sandy loam in texture. The concentration of Nitrogen,

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

3.1 Socio-Economic Environment

The population as per 2001 Census records is 66292 (for 10 km radius buffer zone).

Scheduled Caste fraction of the population of the study area (10 km radius) is 19.51%

and Scheduled Tribe is 3.71%. Literacy rate is 30.49% and that of workers those are

actually engaged in occupation is 45.39% which includes, 31.91% of Main workers &

13.47% of marginal workers. Rest 54.61% of the total population, are considered as

non-workers.

4.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES




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4.1 Impact on Soil

Open cast mining activities may alter the landscape of the lease area and shall not have

any effect on the surface features of the surrounding areas.

Total area excavated for mineral rising at end of life of mine will be about 95.91 ha, out

of which about 88.52 ha will be developed as a water reservoir through rain water

harvesting and about 7.39 ha will be covered by plantation. Additionally, green belt

plantation will be done over 16.50 ha on waste dump and 40.11 ha near office, haul road

etc. A total of about 64 ha will be afforested at the end of life of mine.

4.2 Impact on Air Quality

� The generation of dust will be anticipated from various mining activities i.e. dozing,

drilling, blasting, loading, haulage and other transport activities related to mining.

These will increase particulate matter in the area if no mitigative measures are

taken. Controlled drilling and blasting technique will be used to avoid dust

generation.

� Gaseous emission will be generated from HEMM and their transportation vehicles.

By proper mitigation measures viz regular water sprinkling on haul roads & loading

points, better maintenance and efficient operation of equipments & vehicles and

green belt development will keep the gaseous emission under control.

� The key emissions from the cement manufacturing process & CPP are emissions

of particulate matter, oxides of nitrogen (NOx) and sulphur dioxide (SO2).But use of

pollution control equipments like ESP, Bag houses and Bag filters will maintain the

dust concentration at its outlet well within the prescribed CPCB Norms. 76 Bag

Filters, 1 Bag House, and 5 ESPs are currently installed at the plant to control

emissions. Continuous Emission Monitoring System (CEMS) has also been

installed at kiln stack for continuous online monitoring of various parameters.

4.3 Impact on Water Quality

� Mining in the area will be done well above the water table therefore impact on

water regime is not anticipated. There will be no discharge of mine water. Mineral

reject as well as overburden is non – toxic in nature.

� There is no perennial water body within 10 km radius study area to have any

adverse impact due to the project activities.

� No waste water will be generated from the Plant/CPP; thus no adverse impact is

envisaged on the same due to the project activity.




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4.4 Impact on Noise Level

Major noise generating sources of the project activity will be drilling & blasting in the

mining area, transportation of material, operation of plant machinery etc. The instant

noise level from blasting is high for some instance but it will be within the prescribed

limits due to application of improved technology and will be confined to working zones.

The general noise level generated from equipment in the proposed project would usually

be below 85 Leq dB (A) in the working area and below 70 Leq dB (A) around periphery.

These noise levels are temporary in nature and its transient insignificant due to the large

distances. The plantation will also check propagation of noise in the surrounding areas.

5.0 ENVIRONMENTAL MONITORING PROGRAMME

TABLE - 6

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-11011/154/2010- IA-II-(I), dated 14th July, 2010 are Biological Study,

Hydro-geological Study & Rain water Harvesting Plan and 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 has been

already been 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, health

awareness programmes & surgical camps, supplementing resettlement efforts in areas

affected by natural calamities, assisting social forestry programmes in the area, are

some of the highlights of the CSR activities which are operating presently & will continue

for the life of the plant.




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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 form 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

� Use of sharp drill bits for drilling holes, wet drilling and Controlled blasting will be

practiced & used.

� Water sprinkling on haul roads will be done to avoid dust generation during

transportation.

� All material transfer points are being/will be provided with bag filters to entrap the

emissions at the source itself.

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

� Fly ash is/ will be stored in silos.

� Open storage with water spray for pet coke / coal.

� Better maintenance and installation of proper pollution control equipment like Bag

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

� CPCB guidelines for fugitive emissions are being/will be followed.

� Green belt has been developed along the roads and around the plant premises as

dust preventive barrier. The same practice will be continued in the future also.

� Atomized water sprinkling system is/will be provided at limestone and coal

unloading hopper and handling area.

� Concreted roads with vacuum sweeping

� Covered unloading hoppers with water sprinkling arrangement for unloading of

limestone and Fly Ash.

� Water sprinkling arrangement in limestone crusher and reclaimer.

8.2 Water Management

� No waste water will be generated from mining operation.

� Domestic waste water generated from mine office will be disposed off in soak pits

via septic tank.

� No industrial waste water is being/will be generated during cement manufacturing

process.




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� Domestic waste water generated from the office toilets and township is being/will

be treated in the STP and treated water is being/will be used for green belt

development.

� Rain water harvesting is being/will be practiced at plant, colony and mines area.

� Waste water will be generated from power plant only and will be used for ash

quenching. No waste water will be disposed off on ground out side the plant

premises.

� Water reservoir will be developed over 88.52 ha of the excavated area at the end

of mine life.

8.3 Noise Environment

� Controlled (NONEL) blasting will be practiced.

� Wet Drilling will be done with sharp drill bits.

� Properly insulated enclosures will be equipped for noise producing equipments to

minimize high noise.

� PPE like earplugs and earmuffs is being/will be provided to the workers exposed to

high noise level.

� Sufficient green belt is being/will be maintained around the cement plant, colony

and mine areas.

� Regular monitoring of noise level is being/will be carried out and corrective

measures in concerned machinery are being/will be adopted.

8.4 Solid Waste Management

� In the mines, there will be no waste except inter burden. The inter burden will be

dumped at ear-marked site.

� No solid waste is being/will be generated from the cement manufacturing process,

hence zero solid waste generation from the Cement Plant.

� Dust collected from air pollution control equipment is being/will be totally recycled

back in the process.

� Sludge from Sewage Treatment Plant (STP) is being/will be used as manure for

green belt development.

� Solid waste generated from CPP is in the form of ash, which will be utilized in

cement manufacturing process.

8.5 Green Belt Development

� Out of the total plant area (354.74 ha), 91.0 ha (as on 30.04.2011) i.e. (25.65 % of

the total area) has been developed under green belt/plantation.




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� The species planted so far are Ajadirachta indica (Neem), Cassia fistula (Amaltas),

Dalbergia sissoo (Sissoo), Albizzia app. (Siris), Ficus spp. (Pipal, Bargad, Gular),

Jatropha curcas (Ratanjot), Prosopis cinereria (Khejri) etc.

� A thick green belt all along the roads, colony and plant is being developed under

afforestation program.

� In the limestone mine (Ras-I), 64 ha of the total area will be covered under green

belt plantation at the end of life of mine.

� The plant species will be selected as per CPCB guidelines.

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 development around 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 Plant.

Final Ambuja Cements Pali Ex Summary English 31 05

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