Page 3 of 13

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which willcause physical changes in the locality (topography, land use, changes in water bodies, etc.)

S.No. Information/Checklistconfirmation

Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of

information data

1.1 Permanent or temporarychange in land use, land coveror topography includingincrease in intensity of land use(with respect to local land useplan)

Yes Due to mining in proposed new Shyamgarhlease area; there will be development of pit dueto mining.

At the conceptual stage of mining the workedout pit will be developed as water reservoir andpart of the area of worked out pit will be backfilled depending upon the availability of thewaste.

It is proposed to develop green belt inearmarked area of lease area which willcontribute to increasing the Aesthetic beautyand reduction of pollution.

There will be no change physically for theinstallation of clinker unit as this will beinstalled within the existing premises.

1.2 Clearance of existing land,vegetation and buildings?

No No as the proposed project will be establishedin the existing cement plant premises.

No vegetation and buildings are in proposedShyamgarh lease area.

1.3 Creation of new land uses? No At the conceptual stage of mining the workedout pit will be developed as water reservoir andpart of the area of worked out pit will be backfilled depending upon the availability of thewaste.

No additional land is required as the proposedproject will be established in the existingcement plant premises.

1.4 Pre-construction investigationse.g. bore houses, soil testing?

Yes Soil testing shall be done to shows that the soilconsistency is strong enough with required loadbearing capacity.

1.5 Construction works? Yes In the Shyamgarh mining lease area a mineoffice, weighbridge workshop, store and restshelters will be constructed. It is also proposedto install a crusher within the plant area.

1.6 Demolition works? No No demolition works will be done as theproposed project will be established in theexisting cement plant premises.

Page 4 of 13

1.7 Temporary sites used forconstruction works or housingof construction workers?

No No additional temporary residential facilitieswill be required for the workers as the sameexisting facilities will be utilize to install theproposed project.

1.8 Above ground buildings,structures or earthworksincluding linear structures, cutand fill or excavations

Yes In the mining lease area a mine office, weighbridge workshop, store and rest shelters will beconstructed.

1.9 Underground works includingmining or tunneling?

No Not applicable

1.10 Reclamation works? Yes At the end of life of Shyamgarh mine, themined out pits will be partly backfilled andstabilized with plantation.

1.11 Dredging? No Not applicable

1.12 Offshore structures? No Not applicable

1.13 Production and manufacturingprocesses?

No. In the lease area, open cast, fully mechanizedmethod of mining will be adopted. The interburden will be stored at approved OB site andwill be used for back filling. Wet drilling willbe done. Limestone benches of maximum 10 mheight will be drilled and blasted withcontrolled blasting techniques. The blastedlimestone will be transported by dumpers tothe crusher site.

In the cement plant, the production andmanufacturing processes involves crushing,blending, grinding and preheating beforeentering the rotatory cement kiln for clinkermanufacturing.

Cooling the clinker and grinding it with smallquantity of gypsum to make cement.

High Efficiency ESP, Bag House and bag filterswill be installed in the proposed Cement Plantto reduce pollution dust to suspendedparticulate matter (SPM) from the gaseousemissions from the kiln.

In cement plant coal will be used and fuelhowever if available pet coke / waste materialshaving calorific value will also be used.

1.14 Facilities for storage of goodsor materials?

Yes At the initially stage the inter burden will bestored at the lease site at approved OB site.

1.15 Facilities for treatment ordisposal of solid waste orliquid effluents?

No In the lease area, there will be no waste exceptinter burden. The inter burden will be dumpedin the lease area (ear-marked temporarily fordumping). At the conceptual stage of miningthe worked out pit will be developed as water

kumarashish

Rectangle

FINAL ENVIRONMENTAL IMPACT ASSESSMENT REPORT

EXPANSION OF CEMENT PLANT CLINKER PRODUCTION : 1.6 MTPA

AT VILLAGE : ANDHERI DEORI, TEHSIL : MASUDA

DISTRICT : AJMER (RAJASTHAN) &

NEW LIMESTONE MINING PROJECT LIMESTONE PRODUCTION : 2.0 MTPA

AT VILLAGE – SHYAMGARH, TEHSIL - MASUDA

DISTRICT : AJMER (RAJASTHAN)

by

SHREE CEMENT LIMITED

Prepared by

Shree Cement Limited Beawar, Rajasthan

EMTRC Consultant Private Limited

B-16, East Arjun Nagar, Delhi &

Associate Engineers & Consultants 4/8, Malviya Nagar, Jaipur

MARCH 2010

EMTRC CONSULTANTS PRIVATE LIMITED 30

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

Note that timings mentioned are surface firing times with each hole

initiated with a constant 200 MS DTH Unit.

The Company proposes to use the latest technology in blasting

practices to minimize vibration level & fly rock. This will reduce the

vibration level & fly rock drastically. We will arrange to conduct ground

vibration studies to monitor ground vibration.

The safe vibration limits will be adopted as per threshold levels given by

Director General of Mines Safety circular DGMS (Tech) Circular No. 7

dt. 29th Sept. 1997.

2.4.8.4 Loading & Transportation

The loading of limestone is done by loader & hydraulic excavator. A

hydraulic excavator of 3.6 cubic meter bucket capacity is proposed for

excavation and loading of blasted limestone and overburden material

into 35 Tonne capacity rear dumper. In the mining leasehold area, the

limestone and waste will be transported from working faces to crusher/

waste point by. The sized material from crusher is proposed to be

transported to the Plant by conveyor belt / Tippers. The average lead

distance considered is 1.5 km one side.

2.4.8.5 Crushing of Limestone

The area is witnessed by deposit of limestone. As such, new crusher

will be installed in the southern part of lease area in proximity to current

proposal five year working. ROM will be crushed to -75 to -90 mm size

fractions. The proposed crusher is single stage rotary impact crusher

system of capacity 800 TPH (as calculated on two shifts working for 300

days in a year). The limestone will be supplied to the crushing plant and

finally the crushed limestone will be sent to the proposed cement plant

by conveyor belt / Tippers. The material will be dispatched to the stock

piles located within cement plant premises.

EMTRC CONSULTANTS PRIVATE LIMITED 41

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

Homogenisation of raw meal in a blending silo.

Clinkerisation of the raw meal in a rotary kiln with preheater and

precalcinator.

Various operations of dry process plant are detailed as follows:

2.6.2 Crushing of Limestone

Crushing of limestone is done usually in a single stage crusher to

reduce the size of ROM limestone from 1.0-1.2 m to less than 80mm

feedable to Vertical Roller Mill (VRM). This is achieved in a single rotor

impact crusher.

2.6.3 Pre-blending of Crushed Limestone

Pre-blending of limestone is done in a longitudinal stockpile where

limestone is stacked in large number of layers in a pre-determined

configuration. When reclaimed across the layers, homogenised

limestone is obtained. Longitudinal stockpile is proposed to be used due

to its flexibility of increasing the capacity simply by extending the length

of the stockpile or by slewing the stacker at a later date.

2.6.4 Drying and Grinding of Raw Material

In the dry process, the raw materials are dried and ground in close

circuit drying-cum-grinding installations. The following alternative

processes are available:

Ball mill

Vertical Roller Mill (VRM)

Roller Press (RP)

Selection of process is based on the energy saving and drying

requirements. The table below shows the comparison of energy

consumption and drying capacities in the three systems:

EMTRC CONSULTANTS PRIVATE LIMITED 43

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

travels down as the kiln rotates. The chemical reaction completes when

the material reaches the burning zone and cement clinker is formed.

2.6.7 Cooling of Clinker

The clinker is discharged from kiln at around 1000 Deg. C temp. and is

cooled in a grate cooler. The cooled clinker is then transported to

clinker storage silo by Deep Bucket Conveyor (DBC).

2.6.8 Pet Coke Grinding

Grinding of pet coke is done in vertical roller mill. Because of saving in

energy and better drying capacity VRM is proposed for use.

2.6.9 Major Equipments Capacity for proposed Expansion

- Crusher : 800 TPH

- Raw Mill : 400 TPH

- Pyroprocessing : 5500 TPD (Pre-Heater and Kiln)

- Coal Mill : 45 TPH

2.6.10 Major storage facility

- Limestone storage : 2*50000 MT

- Continuous blending Silo : 15000 MT

- Clinker stockpile/Tank : 50000 MT or 2 x 30000

- Coal storage : Existing

- Gypsum storage : Existing

- Cément Silo : Existing

- Fly Ash : Existing

EMTRC CONSULTANTS PRIVATE LIMITED 109

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

Figure 4.6 : Predicted Noise Level at Various Distances - Crusher

Figure 4.7: Predicted Noise Level at Various Distances - Blasting

EMTRC CONSULTANTS PRIVATE LIMITED 131

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

There may be some fugitive dust emissions and noise from transport

but proper mitigation measures will be taken like water sprinkling

during transport activities and green belt development by the sides of

roads to control air pollution.

6.2.3 Fugitive Emissions in Cement Plant & Mitigation Measures

1) Crushing:

The dust may also be generated due to the crushing of limestone. The

crushing of lime stone will be done by impact crusher to -75mm to -

90mm size fractions. The crushed limestone will be transported by

conveyor belt to cement plant. The crusher will be equipped with

Covered unloading hopper with atomized water spray system.

Operators and attendants will be provided with dust mask.

2) Transfer Points (Conveyor belt to Stockpiles):

At the discharge point, dust is emitted due to free fall of product and

wind carry over. To control the dust emission from dropping/transfer

points of the belt and bucket conveyors, water will be sprayed in

crusher to made the rushed limestone sufficient moist . Atomized Water

spray system will be installed with reclaimer.

3) Storage of Raw Materials

Dust may be generated here due to carryover by wind. However to

avoid this, clinker will be stored in closed clinker silo / stock pile,

gypsum will be stored in covered shed, coal/pet coke will be stored in

covered sheds and water will be sprayed on coal / pet coke. Proper

water sprinkling will be carried out for dust suppression in open yards.

4) Transportation:

Movement of heavy trucks/vehicles on the unmetalled road generates

substantial quantity of dust emission. This is due to the presence of

dust over the road, which is carried away by wind. To control the

generation of dust all the roads inside the plant premises will be

EMTRC CONSULTANTS PRIVATE LIMITED 175

Environment Impact Assessment Report Expansion of Cement Plant and New Lime Stone Mine

Village- Andheri Deori Tehsil –Masuda, District –Ajmer (RJ)

8.2.2.2 Noise Environment and Ground Vibration – At Mine Site

o All the latest machines will be purchased and due care will be taken of

generation of noise by the equipment.

o Limestone Mine will adopt: - Total Productive Maintenance (TPM). Under

the TPM concept. All types of maintenance i.e. scheduled maintenance

and preventive maintenance of all machines will be carried out. This will

help in reducing generation of noise during working of machines.

o Use of in built eco friendly system in HEMM in mining like vaporized water

injection in drilling machine & sound/ dust proof AC cabins. This will help in

reducing noise as well as dust generation during drilling.

o Controlled Blasting will be done with Shock tube detonator i.e. Non-Electric

Bottom Initiation & use of rock breaker for secondary breaking.

o Rock breaker used for breaking boulders in place of secondary blasting

helps in avoiding generation of noise due to secondary blasting.

o Plantation of dense belt of trees has been planned under green belt

development programme, which will act as an acoustic barrier, so that

public at large will be not affected.

o Dense plantation would be carried out around the crusher, on the sides of

approach roads, on both sides of belt conveyor system, around office

complex and workshop area and on the sides of working pit. This would

help in arresting noise at source due to mining activities in the area.

o In order to reduce the effect of noise pollution, earmuffs will be provided to

all operators and employees working at mining site as a safety measure.

o Periodical monitoring of noise level of mining machines and at some

locations in the surrounding area of mine working are carried out with the

help of sound level meter. The results obtained are submitted to MOEF,

SPCB & IBM as per statutory requirement.

8.2.3 Waste water Management

8.2.3.1 Wastewater Management in Cement Plant

Industrial waste water Management

"_his Mining plan ha, bt;tQ, ~,o ~Tide leyer No .s.af..t.c.,.'t).@.(J.9.~.i)j'2DOq -111 oS}")Jdt.?I.tS/.p.9. .. under MeeR. U88'1MCR,1960

P. B. No.33, Bangur Nagar,Beawar, Distt. Ajmer,

305901- Rajasthanf;ui,"(.~

MINING PLAN:ontrollerofMines (No. th)"nff')" V'"' lIn:)

Indian Bureau of MinesCLOSURE PLAN

&PROGRESSIVE MIN

of

NN SHYAMGARH & NEEMGARlITEHSIL-MASUDA, DISTRICT -AJMER (RAJASTHAN)

M.L.N0.8/99(Area - 448.5 Ha)

(Non Forest)(A Category)

SUBMITTD UNDER RULE 22 OF MCR, 1960 & RULE 23B OF MCDR, 1988AND AMENDMENT VIDE NOTIFICTION GSR 33 OFDATED 10.04.2003

*****PREPARED BY*****

M.K.GARG T.K.DHELAWATADDL.G.M.{MINES) A.G.M.{Mines)RQPIAJMI24412003IA RQPIAJMI31612009IA

****** ASSISTED BY ******Dr. Gopal Rathi

GEOLOGISTo. P. SharmaMINING ENGINEER

(a)

In the present mining plan, it is planned to start mining from Southern part of thelease. The crusher is also planned to be located near to the proposed 5 yearsworking in the mining lease. This part of the deposit has been selected for mineopening considering accessibility to the proposed plant. The advancements of themining faces (moving front) have been planned in all directions for feeding theperfect blend requirement of the plant.

As per the statutory requirement of DGMS, a safety distance of 7.5m has beenmaintained as statutory buffer from the lease boundary.

There is no top soil in mine working area & hence during current proposal there is noplanning for top soil stack space. The Inter burden will be dumped at external dumpat earmarked site in the lease area which is on foot wall side of deposit, & expectedto be barrenl non mineralized zone. The site will be proved to be barrenl nonmineralized, we propose to drill 4 no. of Core/DTH Bore hole in the area beforestarting actual waste dumping in the area.

Since there is no overburden, hence no separate benches for over burden havebeen planned. The bench horizon in limestone will be at 560, 550, 540, 530, 520,510, 500, 490, & 480 with bench height being maximum 10m. The overall strippingratio of ore to OB works out to be 1:0.45.

Limestone will be raised adopting conventional method of drilling and blastingexcavation and loading. Down the hole drilling machines in conjunction withpneumatic compressor will be deployed to drill 165mm diameter holes. The spacingand the burden will be maintained as 6-7m X 4.50- 5.50m. Holes will be blastedusing slurry explosive, ANFO and suitable delay detonators.

The area is witnessed by deposit of limestone. As such, new crusher will be installedin the southern part of lease area in proximity to current proposal five year working.ROM will be crushed to -75 to -90 mm size fractions. The proposed crusher is singlestage rotary impact crusher system of capacity 800 TPH (as calculated on two shiftsworking for 300 days in a year). The limestone will be supplied to the crushing plantand finally the crushed limestone will be sent to the proposed cement plant byconveyor belt I Tippers. The material will be dispatched to the stock piles locatedwithin cement plant premises.In order to produce 1.6 million tones of clinker every year, 2.4 million toneslimestone is required. This requirement of 2.4 Million tonnes of Limestone will be met

** Page 47 **

Secondary drilling:There will be no secondary drilling. The boulders of over size will be broker) usingsecondary rock breaker mounted on PC-300 excavator or equivalent. 1" '~<', ',.

./J ~ .<, dJ;, ,

2. Loading equi'pment ~ __:....A hydraullc excavator of 3.6 cubic meter bucket capacity is prop.osed for excavation aQA" .loading of blasted limestone and overburden material into 35 Tonne capacity rear dumRer~ ",' :The hydraulic excavator has been preferred due to its features like less cycle I e, (,\,operator's comfort, avoidance of undercuts, and flexibility in handling shallower benchheight, higher digging force and easy manoeuvrability.

<~.,..~,"':

....:.',

.../

. I

Since majority of the area has overburden, limestone benches will be operated alternativelyin such a way that the lead between these benches is not too far off. Accordingly therequirement of Hydraulic Excavator has been worked out.Excavator / Loading Machine Requirement:Th f II' t h b td d f I Iff E te 0 oWing parame ers ave een cons: ere or ca cu a Ion 0 xcava or.Bucket capacity = 3.6 m3

Out put per hour = 350 tones

Utilization = 80%

Equipment availability = 85%

Effective running hour per shift = 7x85/100x80/100 :: 4.76

Out put per shift = 4.76x350 :: 1666 tones

Total material to be excavated per shift = 5000 tones

Number of equipment required = 5000/1666= 3.00

Say 3 units + 1 Spare unit.

Bucket Make I MotiveType Nos. capacity in Model Power H.P.Cu.m.

Hydraulic 3+1 3.6 m3 Tata Hitachi Diesel 320Excavator EX600

3. Haulage and Transport EquipmentIn the mining leasehold area, the limestone and waste will be transported from workingfaces to crusher/ waste point by dumpers as proposed and mentioned above. The sizedmaterial from crusher is proposed to be transported to the Plant by conveyor belt / TippersThe average lead distance considered is 1.5 km one side.

Dumper requirement:The following parameters have been considered for calculation of Dumper.

** Page 62 **

SHREE Ci:MENT LlM.ITEP . ," ,

....

1. Cycle timeI ~J'

\\'.,_~ "a. Spotting time :: 30 seconds

~.~'~~~ -

b. Loading time :: 240 seconds (6 passes @ 40 sec. per pass).. [Pi

c. Travelling time to crusherl waste :: 270 seconds (Speed 20 km per hour) C~· '""-'-Ivyard

d. Spotting time at the loading point :: 30 seconds

e. Unloading time :: 30 seconds

f. Travelling time from crusherl = 180 seconds (Speed 30Km per hour)waste yard to face

g. Total cycle time :: 780 seconds

I

2. Trip per hour of dumpers :: 1 hr x 60 minute x 60 seconds 1 780 :: 4.6triQ_sper hour

3. Out put per hour of dumpers :: 4.6 x 30.8:: 141.68 tones per hour (Pay loadof dumper 30.8 tones)

4. Available hour per shift :: 6.5 hrs.

5. % availability :: 80%

6. % utilization :: 70%

7. Net running hours per shift :: 6.5 x 0.8 x 0.7:: 3.64 hrs per shift

8. Net out put of dumpers per shift :: 3.64 x 141.68:: 515 tones per shift

9. Total handline per shift :: 5000 tones

10. Number of dumpers required :: 5000/515:: 9.69

Say 10 numbers-

11. Additional standby capacity :: 2

12. Total requirement of dumpers :: 12

Type Nos. Size I Make Motive H.P.capacity Power

Rear Dump 10+2 35MT BH35 or Diesel 310Equivalent

** Page 63 **

<"' ..... I" -.-.~ ..... -..

., • ".<., j.} ?-:''J. ".

rfl;'L.iMITEO- =..r" ".. =. ,\", .. '• ~ I) ~

"'i) ,..-..,. I 't '/10.0 MINERAL PROCESSING f ,,-;,, / . '.";,;

I ( ':

Ne benificatien 'Oflimestone is required except sizing. The sizing is proposep by cr;msherprevisiened as described earlier. Hewever, blending will be done to gef'§uita,Q~~ raW;--1material required fer the designed cement plant. ~()~...." ,

JC(t:- •. - "', .J" 'r. #.

'" ..........__, -'.CRUSHINGAs mentioned earlier it is proposed to lead limestone by hydraulic excavator into,., .~~:::dumper and transported te the crusher. The single rotor impact Crusher will be used. Ihe ".suitable size from the mine is fed to the Crusher having a capacity 'Of800 TPH (at ~®rrfM'Opening).The crushed limestene carried 'Outby conveyor belt / Tipper to stock pile withinplant area.

BLENDING AND QUALITY CONTROLAs already stated, the cement grade composition 'Ofthe limestone mined from the area willbe such that it will be directly useable in crushed form fer the Cement manufacturingprecess. Fer quality control regular sampling 'Ofthe blasted limestone and the cutting fromthe blast holes will be carried 'Out& analyzed.

** Page 78 **

_--~-'r -...

,It I,~{ ~\ ',\1, Z7 I!!l>:\ ~ . "'f>

SHREE CEMENT L ~'!i;;f 1.1'\\ •._ ,t~,~,Ie' ",:".! .4': ..

c. Production level: ~ f '~'\/1 ' "TABLE FOR PROPOSED EXCAVATION I 6( "t' s

• 0 \. .;. J;;,"'! \. ~~'1f1q 1J-;Qe1 '/4-Over Over Sub-

~-9._re'to ..-'..(;. ,burden I burden I Saleable Mineral ~\d:O ~

Inter Inter ROM Ore Ore grade Rejects tl f I'l--.~

Year Pit Burden Burden Oreratio lIWi mrNo. •~.'ltCv••

lac lac M3 lac lac lac lac Tone/M3Tones Tones Tones Tones Tones

First 1 2.57 1.03 5 5 Nil Nil 1 : 0.21

Second 1 7.72 3.09 15 15 Nil Nil 1 : 0.21

Third 1 9.86 3.94 20 20 Nil Nil 1 : 0.20

Fourth 1 9.67 3.87 20 20 Nil Nil 1 : 0.19

Fifth 1 9.14 3.65 20 20 Nil Nil 1 : 0.18

Total 38.96 15.58 80 80 NIL NIL 1 : 0.19

12.2.4MINERAL BENEFICIATION:a. Describe in brief the mineral beneficiation practice if any:

No benification of limestone is required except sizing. The sizing is proposed bycrusher. However, blending will be done to get suitable raw material required forthe designed cement plant.

b. Indicate discharge details of any tailingsl middling and their disposailutilization practice followed:This is not applicable, as limestone mining does not involve generation andhandling of any tailing.

** Page 122 **