Proposed Expansion of Vizag Cement Grinding Unit (from 0.95 MTPA to 2.00 MTPA-PPC/OPC/PSC) Application/Form-1 Feasibility Report

Transcription

1 Proposed Expansion of Vizag Cement Grinding Unit (from 0.95 MTPA to 2.00 MTPA-PPC/OPC/PSC) (Stand Alone Grinding Unit since 2014) Gobburupalem & Gobburu Villages, Kasimkota Tehsil, Visakhapatnam District, Andhra Pradesh Environmental Clearance under EIA Notification 2006 Schedule Sl. No. 3(b) - Category B Application/Form-1 Feasibility Report January 2018 EIA Consultant Environmental System Consultants & Ambiente Lab Solutions Private Limited (Accreditated for Sectors 1, 4, 9, 31, 33 - Category A & 38-Category B By QCI- NABET; Sl. No. 54 of List-A dated ) Old 7, New 14, Shanmuga Naicker Street, K K Nagar, Chennai Phone : ; Fax ensyscon@gmail.com

2 The Ramco Cements Limited Expansion of Ramco Vizag Cement Grinding Unit (0.95 MTPA to 2.00 MTPA) (Stand Alone) Gobburupalem & Gobburu Villages, Kasimkota Mandal, Visakhapatnam District, AP Project Feasibility Report 1.0 Executive Summary M/s. The Ramco Cements Limited (RCL), are one of the reputed Cement Companies in India. The cement production of RCL is about million tons per annum (MTPA) from their cement plants in South India : Ramasamy Raja Nagar near Virudhunagar, Tamil Nadu (established in 1959) : 2.0 MTPA (2 Lines). Kumarasamy Raja Nagar, Jayantipuram near Vijayawada, Andhra Pradesh (1986) : 3.65 MTPA (2 Lines). Alathiyur near Viridhachalam, Tamil Nadu (1997) : 3.0 MTPA (2 Lines). Mathodu near Chithradurga, Karnataka : 0.3 MTPA (since 2000). Govindapuram near Ariyalur, Tamil Nadu :5.5 MTPA (established in 2009)(2 Lines). RCL is also operating Cement Grinding Units at : Kolaghat (0.95 MTPA; being expanded to 2.0 MTPA) in West Bengal. Kattuputtur (0.75 MTPA) near Chennai, Tamil Nadu. Valapadi (2.0 MTPA) near Salem, Tamil Nadu. Vizag (0.95 MTPA) near Anakapalli, Andhra Pradesh. It is operating a Packing Plant at Nagercoil. RCL is producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) and Slag Cement (PSC). The cement produced by RCL is marketed in the brand name of RAMCO. The brand name RAMCO SUPER GRADE is very popular PPC and RAMCO SUPER STEEL is the slag cement brand. The market centers are mainly in Tamil Nadu, Andhra Pradesh, Kerala, Karnataka, Odisha and West Bengal States. RCL, which has always been striving for Total Quality, possesses International Certificate ISO:9001, ISO:14001,ISO:18001and IS/ISO: The company has achieved various awards for 'Best Performance 'in the Cement Industry. RCL is marketing about MTPA cement in the Eastern Districts of Andhra Pradesh from its Jayanthipuram Cement Plant located in Krishna District. NTPC has commissioned its Simhadri Super Thermal Power Station near Visakhapatnam which is a potential Fly Ash Source in the Region. Thus, in tune with the Govt. of India Policy of encouraging Cement Units near the raw material sources and

3 marketing centers, RCL has proposed and established the Vizag Cement Grinding Unit with a capacity of 0.95 MTPA (@3000 Tons per day, TPD) with a Project Cost of Rs crores. Main raw material for manufacturing these Cement products are Clinker, Gypsum, Fly Ash and Slag. Clinker is being brought to the Unit by rail / road from Jayanthipuram Plant (near Jaggayyapet; 310 kmaerial distance). Gypsum is procured from Coromandel Fertilizers, Visakhapatnam. Fly Ash is received from NTPC Simhadri Super Thermal Power Station, Parawada (@ 20 km in the east). For PSC manufacture, granulated blast furnace slag from Vizag Steel Plant is used. Initially, the Grinding Unit was established in an extent of Ha in own Patta Lands and additional land of Ha is added mainly for Approach Roads from the National Highway, Truck Parking, etc. Thus, the Grinding Unit is located in an extent of Ha ( Acres) in Gobburupalem & Gobburu Villages, Kasimkota Mandal, Visakhapatnam District of Andhra Pradesh State. The Unit is located bear the National Highway (NH) 16 (earlier NH-5) inbetween Tuni-Anakapalli Towns. It is about 13.5 km from Anakapalli (in north-northeast), 9 km from Kasimkota (in NE; Mandal Head Quarters) and 35 km from Visakhapatnam (District Head Quarters) in northeast. Tallapalem (@ 1.2 km in north), Gobburupalem/AS Peta (@ 0.5 km in east) and Narsingapalli (@ 1.3 km in southwest) are the nearest villages. The Cement Grinding Unit is located inbetween 17 o o N Latitude & 82 o o E Longitude (Survey of India Topo Sheet No. 65 K/14). There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Elephant Corridor, Archaeological/Historical Monuments, Heritage sites, etc. within 10 km from the proposed Plant boundary. Kondakarla Bird Sanctuary/Ava is at a distance of 10.3 km in the East. Also, there are 9 Reserved Forests (RFs) within 10 km radius of the Plant Area viz. Gobburu RF (1.26 km), Bayyavaram RF (1.6 km), Panduru RF (4.70 km), Gokieda RF (6.31 km), Panchadaria RF(6.91 km), Mallam RF (7.41 km), Pangidi RF (7.90 km), Paddapalli RF (9.20 km) and Theeda RF (9.80 km). The Principal Chief Conservator of Forests, Hyderabad has issued the NOC for establishment of the Unit in the Area vide Letter Rc. No /2012- F3 dated The minimum and maximum elevation of the area is 21 m and 30 m AMSL respectively. River Sarada drains the region and flows north to south in the east of the Plant at a distance of 1.3 km from the Plant. Seasonal Mamidivakka Gedda/Nalla flows north of the Plant at a distance of m and joins River Sarada. RCL had obtained the Environmental Clearance (EC) for Vizag Cement Grinding Unit (0.95 MTPA) from the State Level EIA Authority-AP (SEIAA-AP) vide Order Letter No. SEIAA/AP/VSP-86/2013/661 dated The combined Consents for Establishment (CFE) was obtained from Andhra Pradesh Pollution Control Board (APPCB) vide Order No. 312/PCB/CFE/RO-VSP/HO/ dated The combined Consents for Operation (CFO) under Air & Water Acts was obtained from APPCB vide Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated The CFO is being renewed by the Board periodically and the recent CFO Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated is valid upto

4 The Plant is in Operation from March The maximum production of Cement (PPC) achieved is 0.65 MTPA in the Year and there is no violation in the Production Quantity. There is no litigation against the Project. The Unit has not received any Notice under Section 5 of the Environment (Protection) Act, 1986 or Show Cause Notices from APPCB under Air and Water Acts. The Plant operations are in full compliance with the EC Conditions stipulated by SEIAA-AP and CFE Conditions stipulated by the APPCB. Periodical EC Compliance Reports are submitted to the MoEF&CC Monitoring Cell, Southern Region, Chennai.. The recent Certified Compliance Status to EC Conditions has been issued by the MoEF&CC, Chennai vide its Letter No. EP/12.1/ /SEIAA/151/AP/058 dated The Cement Grinding is a Dry Process. Thus, the Raw Water is required for Equipment Cooling (60 cu.m/day), Dust Control Measures (1 cu.m/day), Green Belt (20 cu.m/day) and for Domestic Use (15 cu.m/day). The total Water Demand of 96 cu.m/day is met from permitted 2 Nos. Borewells within the Plant under the Andhra Pradesh Ground Water & Water Audit Department, Visakhapatnam vide Letter No. 207/Tech/ dated There is no trade effluent generation from the Unit. Domestic sewage to the tune of 12 cu.m/day is generated now which is biologically treated in the Septic Tanks (about 7 Nos.) followed by a Dispersion Trenches. The entire Dust from Bag Filters is being fully utilized in the Cement grinding. Used Lubricating Oil (Cat. 5.1) of 600 Lits./year is stored and sold to CPCB Authorised Recyclers for recovery and use. An effective Green Belt is developed and maintained over an extent of Ha (28.95% coverage) with about 15, trees/ha (Survival Rate : 85-90%). Also, 2 Nos. Recharge Pits are constructed and maintained for Rain Water Harvesting. A fully equipped Occupational Health Centre is established and an Onsite Emergency Preparedness Plan are in place in the Unit. The Project Cost of the existing Plant is Rs crores. An EMP Budget of Rs.5.00 crores has been spent as Capital Cost for Environmental Management Plan (EMP)/Pollution Control Measures and Rs.5.00 lakhs per annum towards EMP Operating Cost. In order to meet the increasing Cement Demand in the Region, RCL is, now proposing to increase the Cement Grinding capacity of Vizag Cement Grinding Unit from existing 0.95 MTPA (Line I) to 2.00 MTPA by introduction of Line II (of 1.95 MTPA) with the following Components : Vertical Roller Mill - VRM (Mill 2) for a capacity of 130 TPH. One Hot air Generator (HAG - 2) of 12 MKcal/hr for driving out the moisture in the raw materials. One concrete Silo (Silo 2) for storing clinker of Capacity MT Two concrete Silos (Silo 3 and 4) for storing Cement of capacity 8000 MT each. In addition to this, Two steel silos (Silo 5 and Silo 6) of 500 MT capacity is also considered for storing cement. One steel silo (Silo 2) of capacity 1000 MT for storing dry Flyash Covered storage yard for storing chemical Gypsum and Wet slag of capacity 3000 MT and 5000 MT respectively. One number of electronic rotary packer (Packer 3) of capacity 180 TPH with double discharge will be shifted from our Jayanthipuram plant and will be installed. Two nos of double discharge Electronic rotary packers (Packer 4 and 5) of capacity 240 TPH respectively.

5 8 nos of Truck loading machines for loading packed cement bags in trucks / trailers. Additionally, 4 nos of Wagon loading machine is also proposed to reduce the loading time. 2 nos of Bulk loading facility to despatch cement through closed bowsers. One weigh bridge for weighing raw materials and finished goods of capacity 100 Tonnes. Bag Filters are proposed at new stacks and all material transfer points to control PM emission <30 mg/nm 3. The dust collected from the various Air Pollution Control Measures like Bag Filters, etc. will be totally recycled in the process for cement manufacturing. The additional Water Demand for Equipment Cooling (30 cu.m/day) and for Domestic Use (4 cu.m/day) will also met from the existing Permitted source only. There is no wastewater generation from the Process. Domestic sewage to the tune of 3.5 cu.m/day will be generated which will be biologically treated in a Septic Tanks of adequate size followed by a Dispersion Trench. Existing Infrastructures are adequate for the proposed Expansion activities. The Project Cost for the Expansion activities is Rs crores with the following breakup: Land Cost : Nil (proposed within the existing Industrial Premises) Buildings & Structurals : Rs crores Plant & Machineries : Rs crores Others & Contingencies : Rs crores Total : Rs crores A budgetary allotment of Rs.5.00 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 2.5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs lakhs per annum. The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. In addition to the environmental benefits waste materials like utilization of Fly Ash, Gypsum, etc., there will be a huge positive impact due to the proposal, by way of employment, better socioeconomic conditions, improved local and regional economy, etc. As per Environmental Impact Assessment Notification 2006, all Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category B for prior Environmental Clearance from the State Level Environmental Impact Assessment Authority (SEIAA) with applicability of General Conditions. The proposed Expansion of Vizag Cement Grinding Unit (Stand Alone) requires prior EC from SEIAA-AP. Accordingly, Application/Form-1 and Project Feasibility Report are submitted herewith for your kind perusal in awarding TOR for the EIA Study. As the Expansion is proposed within the existing Industrial premises with the combined water demand, sewage/effluent treatment & disposal, solid wastes disposal, etc., the Spatial Impacts due to the Proposal is negligible/insignificant. Accordingly, the proposal may be considered by the Authority with Public Hearing Exemption under Clause 7(ii) of EIA Notification 2006, as amended, for according the environmental clearance. ***

6 2.0 Introduction of the Project 2.1 Project Proponent Ramco Group is one of the leading, highly reputed and Second Largest Industrial Group in South India. It is well diversified in the fields of Cement, Ready Mix Concrete, Cement Fibre Products, Cotton and Synthetic Yarn, Software Systems, Wind Farms, Research & Development, Dry Mortar Plants, Cotton Textiles and Surgical. The total employees are about 8,500 and the Turnover of the Group is Rs.6,200 crores. The main companies of RAMCO Group are : M/s. The Ramco Cements Limited (formerly M/s. Madras Cements Limited). M/s. Rajapalyam Mills Limited. M/s. Ramco Industries Limited. M/s. Ramco Systems Limited. M/s.The Ramco Cements Limited (RCL) are one of the reputed Cement Companies in India. The cement production of RCL is about million tons per annum (MTPA) from their cement plants in South India: Ramasamy Raja Nagar near Virudhunagar, Tamil Nadu (established in 1959) : 2.0 MTPA (2 Lines). Kumarasamy Raja Nagar, Jayantipuram near Vijayawada, Andhra Pradesh (1986) : 3.65 MTPA (2 Lines). Alathiyur near Viridhachalam, Tamil Nadu (1997) : 3.0 MTPA (2 Lines). Mathodu near Chithradurga, Karnataka : 0.3 MTPA (since 2000). Govindapuram near Ariyalur, Tamil Nadu :5.5 MTPA (established in 2009)(2 Lines). RCL is also operating Cement Grinding Units at : Kolaghat (0.95 MTPA; being expanded to 2.0 MTPA) in West Bengal. Kattuputtur (0.75 MTPA) near Chennai, Tamil Nadu. Valapadi (2.0 MTPA) near Salem, Tamil Nadu. Vizag (0.95 MTPA) near Anakapalli, Andhra Pradesh. It is operating a Packing Plant at Nagercoil. RCL is producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) and Slag Cement (PSC). The cement produced by RCL is marketed in the brand name of RAMCO. The brand name RAMCO SUPER GRADE is very popular PPC and RAMCO SUPER STEEL is the slag cement brand. The market centres are mainly in Tamil Nadu, Andhra Pradesh, Kerala, Karnataka, Odisha and West Bengal States. RCL, which has always been striving for Total Quality, possesses International Certificate ISO:9001, ISO:14001,ISO:18001and IS/ISO: The company has achieved various awards for 'Best Performance 'in the Cement Industry and also Green Rating Project Awards 4 Leaves from Centre for Science and Environment for the Year 2005.

7 The Ramco Cements Limited is managed by a Board of Directors comprising of eminent personalities as its members. Under the dynamic leadership of Late Shri.P.R.Ramasubrahmaneya Rajha, the company has grown into a massive organization. Shri.P.R.Venketarama Raja is the Chairman & Managing Director of the Board. Shri.A.V.Dharmakrishnan, Chief Executive Officer (CEO) is heading the Cement Division and dealing with the environmental issues and EC compliances. Any non-compliance/violations of environmental norms and the corrective actions taken will be reported by the Unit Heads to CEO and by CEO to the Chairman, the Board and the Shareholders. RCL has the well laid down Safety, Health and Environmental Policy approved by its Board of Directors. Each Unit of RCL is having the Unit Head under whom the Environmental Management Plan (EMP) Cell and Corporate Social Responsibility (CSR) Committee are functioning. The Units are having their Integrated Management System (IMS) Policy. The Contact information of the Corporate Office is : The President (Mfg.), The Ramco Cements Ltd. 5 th Floor, Auras Corporate Centre, No. 98A, Dr.Radhakrishnan Road, Mylapore, Chennai Tel. No. : / / Fax No. : ms@ramcocements.co.in 2.2 Identification of the Project Vizag Grinding Unit RCL is marketing about MTPA cement in the Eastern Districts of Andhra Pradesh from its Jayanthipuram Cement Plant located in Krishna District. NTPC has commissioned its Simhadri Super Thermal Power Station near Visakhapatnam which is a potential Fly Ash Source in the Region. Thus, in tune with the Govt. of India Policy of encouraging Cement Units near the raw material sources and marketing centers, RCL has proposed and established the Vizag Cement Grinding Unit with a capacity of 0.95 MTPA (@3000 Tons per day, TPD) with a Project Cost of Rs crores. RCL has identified a suitable site and established the Vizag Cement Grinding Unit over an extent of Ha at Gobburupalem village (near Anakapalli), Kasimkota Mandal in Visakhapatnam District. The Cement Grinding Unit is designed to manufacture Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC) and Ordinary Portland Cement (OPC). Main raw material for manufacturing these Cement products are Clinker, Gypsum, Fly Ash and Slag. Clinker is being brought to the Unit by rail / road from Jayanthipuram Plant (near Jaggayyapet; 310 km-aerial distance). Gypsum is procured from Coromandel Fertilizers, Visakhapatnam. Fly Ash is received from NTPC Simhadri Super Thermal Power Station, Parawada (@ 20 km in the east). For PSC manufacture, granulated blast furnace slag from Vizag Steel Plant is used. Clinker, Fly Ash and Cement are stored in RCC Silos. Gypsum and Slag are stored in covered sheds. All silos are provided with suitable bag filters to control the fugitive emissions Plant Site Initially, the Grinding Unit was established in an extent of Ha in own Patta Lands and additional land of Ha is added mainly for Approach Roads from the National Highway, Truck Parking, etc.

8 Thus, the Grinding Unit is located in an extent of Ha ( Acres) in Gobburupalem & Gobburu Villages, Kasimkota Mandal, Visakhapatnam District of Andhra Pradesh State (Fig. 1.1). The Unit is located bear the National Highway (NH) 16 (earlier NH-5) inbetween Tuni-Anakapalli Towns. It is about 13.5 km from Anakapalli (in north-northeast), 9 km from Kasimkota (in NE; Mandal Head Quarters) and 35 km from Visakhapatnam (District Head Quarters) in northeast. Tallapalem (@ 1.2 km in north), Gobburupalem/AS Peta (@ 0.5 km in east) and Narsingapalli (@ 1.3 km in southwest) are the nearest villages Statutory Clearances & their Compliances RCL had obtained the Environmental Clearance (EC) for Vizag Cement Grinding Unit (0.95 MTPA) from the State Level EIA Authority-AP (SEIAA-AP) vide Order Letter No. SEIAA/AP/VSP-86/2013/661 dated The combined Consents for Establishment (CFE) was obtained from Andhra Pradesh Pollution Control Board (APPCB) vide Order No. 312/PCB/CFE/RO-VSP/HO/ dated The combined Consents for Operation (CFO) under Air & Water Acts was obtained from APPCB vide Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated The CFO is being renewed by the Board periodically and the recent CFO Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated is valid upto The Plant is in Operation from March The maximum production of Cement (PPC) achieved is 0.65 MTPA in the Year (Table 1.1) and there is no violation in the Production Quantity. There is no litigation against the Project. The Unit has not received any Notice under Section 5 of the Environment (Protection) Act, 1986 or Show Cause Notices from APPCB under Air and Water Acts. The Plant operations are in full compliance with the EC Conditions stipulated by SEIAA-AP and CFE Conditions stipulated by the APPCB. Periodical EC Compliance Reports are submitted to the MoEF&CC Monitoring Cell, Southern Region, Chennai.. The recent Certified Compliance Status to EC Conditions has been issued by the MoEF&CC, Chennai vide its Letter No. EP/12.1/ /SEIAA/151/AP/058 dated Online Stack Monitoring Systems (2 Nos.) (Forbes Marshall Model DECM 2100) are installed for Cement Mill Stack & Bag House and established the connectivity to APPCB. Two Continuous Ambient Air Quality Monitoring Stations (Metone USA) are also installed in the Premises and connected to Central Pollution Control Board (CPCB). APPCB is also periodically monitoring the Ambient Air Quality, Stack Emissions, Noise Levels etc. at the Unit. CREP Compliance : A series of industry specific guidelines are formulated in the Charter on Corporate Responsibility for Environmental Protection (CREP) and action points are also enlisted for the Cement Industry. RCL Plant activities are in compliance with the CREP Guidelines (Table 1.2).

9 Table : 1.1 Production Details of Vizag Grinding Unit Month PPC Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar PSC Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total : Not included/produced.

10 Table : 1.2 Compliance to CREP Guidelines No. Action Points in CREP Compliance Status 1 Implementation of standards in noncomplying units. The Plant operations are in compliance with the latest notified norms. 2 Plants in critically polluted or urban area RCL is operating the Unit for PM emissions <30 mg/nm 3. (5 km distance outside urban boundary) will meet 100 mg/nm 3 SPM emission and continue working to reduce the emission of particulate matter to 50 mg/ Nm 3. 3 The new cement kilns to be accorded RCL is operating the Unit for PM emissions <30 mg/nm 3. NOC/EC for complying 50 mg/nm 3 emission limit. 4 CPCB will evolve load based standards by June MoEF&CC has evolved the Load Based Emission Norm of kg/tonne of Clinker for the Rotary Kiln Cement Plants with Co-processing & without Co-processing and 0.5 kg/tonne of Clinker for the Vertical Shift Kiln Cement Plants. This is a Cement Grinding Unit and no Clinker is manufactured. However, the emission levels were well within the Norms stipulated by SPCB and MoEF&CC. 5 CPCB and NCBM will evolve SO 2 and NOx emission standards by June Control fugitive emissions from all the raw material and products storage and transfer points by December The feasibility for the control of fugitive emissions from limestone and coal storage areas will be decided by the NTF. The NTF shall submit its recommendations within three months. 7 CPCB, NCBM, BIS and oil refineries will jointly prepare the policy on use of pet coke as fuel by July NTF will decide feasible unit operations/ sections for installation of continuous monitoring equipment. The industry will install the continuous monitoring systems (CMS) by December Tripping in Kiln ESP to be minimized by July Industries will submit the target date to enhance utilization of waste materials. 11 NCBM will carryout a study on hazardous waste utilization in cement kiln by December Cement industry will carry out feasibility study and submit target date to CPCB for cogeneration of power by July As per MoEF&CC Notification dt , the standard for all the parameters i.e. Sulphur Dioxide (SO 2), Oxides of Nitrogen (NOx) and Particulate Matter (PM), with respect to Rotary Kiln without Co-processing are notified. The Plant operations are in compliance with the latest notified norms. Clinker Storage : Clinker Silo. Gypsum Storage: Covered Shed Fly Ash : Concrete Silo Slag Storage: Covered Shed Cement Storage : Cement Silos. Jet Pulse Bag Filters are installed in the Cement Mill and Packing Plants Stacks to control the PM emission <30 mg/nm 3. All point sources and material transfer points are provided with Bag Filters to control Fugitive emission. Plant roads are also concretised and Mechanical Sweeping Machines (2 Nos.) are used to clean the Plant roads periodically. Noted. Online Stack Monitoring Systems (2 Nos.) (Forbes Marshall Model DECM 2100) are installed for Cement Mill Stack & Bag House and established the connectivity to APPCB. Two Continuous Ambient Air Quality Monitoring Stations (Metone USA) are also installed in the Premises and connected to Central Pollution Control Board (CPCB). Not applicable. RCL has already using waste material like fly ash, Gypsum, Slag, etc. in the Plant. Not applicable. Not applicable.

11 2.2.4 Existing Project Profile Main raw material for manufacturing these Cement products are Clinker, Gypsum, Fly Ash and Slag. Clinker is being brought to the Unit by rail / road from Jayanthipuram Plant (near Jaggayyapet; 310 kmaerial distance). Gypsum is procured from Coromandel Fertilizers, Visakhapatnam. Fly Ash is received from NTPC Simhadri Super Thermal Power Station, Parawada (@ 20 km in the east). For PSC manufacture, granulated blast furnace slag from Vizag Steel Plant is used. The Cement Grinding is a Dry Process. Thus, the Raw Water is required for Equipment Cooling (60 cu.m/day), Dust Control Measures (1 cu.m/day), Green Belt (20 cu.m/day) and for Domestic Use (15 cu.m/day). The total Water Demand of 96 cu.m/day is met from permitted 2 Nos. Borewells within the Plant under the Andhra Pradesh Ground Water & Water Audit Department, Visakhapatnam vide Letter No. 207/Tech/ dated There is no trade effluent generation from the Unit. Domestic sewage to the tune of 12 cu.m/day is generated now which is biologically treated in the Septic Tanks (about 7 Nos.) followed by a Dispersion Trenches. The entire Dust from Bag Filters is being fully utilized in the Cement grinding. Used Lubricating Oil (Cat. 5.1) of 600 Lits./year is stored and sold to CPCB Authorised Recyclers for recovery and use. An effective Green Belt is developed and maintained over an extent of Ha (28.95% coverage) with about 15, trees/ha (Survival Rate : 85-90%). Also, 2 Nos. Recharge Pits are constructed and maintained for Rain Water Harvesting. A fully equipped Occupational Health Centre is established and an Onsite Emergency Preparedness Plan are in place in the Unit. The Project Cost of the existing Plant is Rs crores. An EMP Budget of Rs.5.00 crores has been spent as Capital Cost for Environmental Management Plan (EMP)/Pollution Control Measures and Rs.5.00 lakhs per annum towards EMP Operating Cost. The Plant location is shown in the Regional Map (Plate I) and in the High Resolution Satellite Imagery (Plate II). The Plant and its Environs are shown in Plate III and the Green Belt Development in the Plant in Plate IV. 2.3 Need for the Expansion In order to meet the increasing Cement Demand in the Region, RCL is, now proposing to increase the Cement Grinding capacity of Vizag Cement Grinding Unit from existing 0.95 MTPA (Line I) to 2.00 MTPA by introduction of Line II (of 1.95 MTPA). 2.4 The Proposal The Proposal is with the following Components : Vertical Roller Mill - VRM (Mill 2) for a capacity of 130 TPH. One Hot air Generator (HAG - 2) of 12 MKcal/hr for driving out the moisture in the raw materials. One concrete Silo (Silo 2) for storing clinker of Capacity MT

12 Two concrete Silos (Silo 3 and 4) for storing Cement of capacity 8000 MT each. In addition to this, Two steel silos (Silo 5 and Silo 6) of 500 MT capacity is also considered for storing cement. One steel silo (Silo 2) of capacity 1000 MT for storing dry Flyash Covered storage yard for storing chemical Gypsum and Wet slag of capacity 3000 MT and 5000 MT respectively. One number of electronic rotary packer (Packer 3) of capacity 180 TPH with double discharge will be shifted from our Jayanthipuram plant and will be installed. Two nos of double discharge Electronic rotary packers (Packer 4 and 5) of capacity 240 TPH respectively. 8 nos of Truck loading machines for loading packed cement bags in trucks / trailers. Additionally, 4 nos of Wagon loading machine is also proposed to reduce the loading time. 2 nos of Bulk loading facility to despatch cement through closed bowsers. One weigh bridge for weighing raw materials and finished goods of capacity 100 Tonnes. Grinding Unit Expansion (Line-II) is proposed within the existing Premises with : no additional land. no additional infrastructures. no significant change to the existing Layout. no change in Zero Effluent Discharge practice. As the Expansion is proposed within the existing Industrial premises with the combined water demand, sewage/effluent treatment & disposal, solid wastes disposal, etc., the Spatial Impacts due to the Proposal is negligible/insignificant. Accordingly, the proposal may be considered by the Authority with Public Hearing Exemption under Clause 7(ii) of EIA Notification 2006, as amended, for according the environmental clearance. 2.5 Project Cost The Project Cost for the Expansion activities is Rs crores with the following breakup: Land Cost : Nil (proposed within the existing Industrial Premises) Buildings & Structurals : Rs crores Plant & Machineries : Rs crores Others & Contingencies : Rs crores Total : Rs crores A budgetary allotment of Rs.5.00 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 2.5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs lakhs per annum. Project will be completed in about 12 months on approval of statutory clearances.

13 2.6 Project Benefits The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. In addition to the environmental benefits waste materials like utilization of Fly Ash, Gypsum, etc., there will be a huge positive impact due to the proposal, by way of employment, better socioeconomic conditions, improved local and regional economy, etc. 3.0 Project Description 3.1 Type of Project As per Environmental Impact Assessment Notification 2006, all Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category B for prior Environmental Clearance from the State Level Environmental Impact Assessment Authority (SEIAA) with applicability of General Conditions. The proposed Expansion of Vizag Cement Grinding Unit (Stand Alone) requires prior EC from SEIAA-AP. Accordingly, Application/Form-1 and Project Feasibility Report are submitted herewith for your kind perusal in awarding TOR for the EIA Study. As the Expansion is proposed within the existing Industrial premises with the combined water demand, sewage/effluent treatment & disposal, solid wastes disposal, etc., the Spatial Impacts due to the Proposal is negligible/insignificant. Accordingly, the proposal may be considered by the Authority with Public Hearing Exemption under Clause 7(ii) of EIA Notification 2006, as amended, for according the environmental clearance. MoEF&CC has accorded the EC with Public Hearing Exemption for our Salem Grinding Unit Expansion (from 1.0 MTPA to 2.0 MTPA) and also SEIAA-West Benagal for our Koalaght Grinding Unit Expansion (from 0.95 MTPA to 2.0 MTPA) Proposal recently. No Rehabilitation/Resettlement is envisaged due to the proposal. There is no litigation/pending case against the proposal. 3.2 Location/Site & Its Environmental Setting The Cement Grinding Unit is located inbetween 17 o o N Latitude & 82 o o E Longitude (Survey of India Topo Sheet No. 65 K/14; Fig. 1.2). There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Elephant Corridor, Archaeological/Historical Monuments, Heritage sites, etc. within 10 km from the proposed Plant boundary. Kondakarla Bird Sanctuary/Ava is at a distance of 10.3 km in the East. Also, there are 9 Reserved Forests (RFs) within 10 km radius of the Plant Area viz. Gobburu RF (1.26 km), Bayyavaram RF (1.6 km), Panduru RF (4.70 km), Gokieda RF (6.31 km), Panchadaria RF(6.91 km), Mallam RF (7.41 km), Pangidi RF (7.90 km), Paddapalli RF (9.20 km) and Theeda RF (9.80 km). The Principal Chief Conservator of Forests, Hyderabad has issued the NOC for establishment of the Unit in the Area vide Letter Rc. No /2012-F3 dated

14 The minimum and maximum elevation of the area is 21 m and 30 m AMSL respectively. River Sarada drains the region and flows north to south in the east of the Plant at a distance of 1.3 km from the Plant. Seasonal Mamidivakka Gedda/Nalla flows north of the Plant at a distance of m and joins River Sarada. The site is located bear the National Highway (NH) 16 (earlier NH-5) inbetween Tuni-Anakapalli Towns. It is about 13.5 km from Anakapalli (in north-northeast), 9 km from Kasimkota (Mandal Head Quarters) and 35 km from Visakhapatnam (District Head Quarters) in northeast. Tallapalem (@ 1.2 km in north), Gobburupalem/AS Peta (@ 0.5 km in east) and Narsingapalli (@ 1.3 km in southwest) are the nearest villages. South Central Railway Line Vijayawada-Visakhapatnam Section runs at southern boundary of the Plant. The Unit s Railway sidings are from the nearby Narasingapalli Railway Station. Physiography : The elevation of the study area is in the range 10 - <500 m above mean sea level (amsl) (Fig. 3.2). There are hillocks in the southeast and northwest to southwest (part of Eastern Ghats; Amdalavakka Gonda, Gondivaka Konda, Dama Konda, etc.) & southeast (Ramagiri) parts of the study area. The site is located in the elevation range of m amsl. Drainage Pattern : Sarada River drains the region (Fig. 3.3). The seasonal river flows at a distance of 1.3 km in the east. There are first order streams near the site (in southern parts) and there is no nallah crossing at the site. There is an irrigational canal flows in the northern parts of the Plant. 3.3 Alternative Sites The Expansion Activity is proposed within the existing Industry premises near to the Fly Ash source and therefore, no alternate site has been considered. 3.4 Size/Magnitude of Operation Additional Cement Grinding Line-II of 1.05 MTPA production capacity will be added to the existing Cement Grinding Line-I of 0.95 MTPA production capacity. The total Cement Grinding/Production capacity will be 2.00 MTPA. The Plant Layout is given as Fig Additional 25,500 sq.m area will be under Building Area to the existing 36,540 sq.m area. An effective Green Belt is developed and maintained over an extent of Ha (34.00% coverage). Existing Railway siding is adequate for the Expansion activity also. On Expansion, in total area of Ha, the Land Use at the Plant Site will be : Total Building Area : 6.20 Ha Green Belt Area : Ha (34.00% coverage) Roads & Parking Area : 6.05 Ha Railway Track : 3.98 Ha Guest House : 0.09 Ha Bachelor Quarters : 0.03 Ha Outside Parking, etc. : Ha Vacant Area : 8.90 Ha

15 3.5 Process Main raw material for manufacturing these Cement products are Clinker, Gypsum, Fly Ash and Slag. Main process of manufacturing PPC involves inter-grinding clinker, dry fly ash and gypsum in the ratio of about 60:35:5. Manufacturing PSC involves inter-grinding clinker, Slag and gypsum in the ratio of about 25:70:5. Manufacturing OPC involves inter-grinding clinker and gypsum in the ratio of about 95:5. Clinker is being brought to the Unit by rail / road from Jayanthipuram Plant (near Jaggayyapet; 310 kmaerial distance). Gypsum is procured from Coromandel Fertilizers, Visakhapatnam. Fly Ash is received from NTPC Simhadri Super Thermal Power Station, Parawada (@ 20 km in the east). For PSC manufacture, granulated blast furnace slag from Vizag Steel Plant is used. A Ball Mill of size 4.6 m dia and m length with capacity of 150 TPH is being used for grinding the raw materials and to produce the Cement. The Cement is despatched to various Market Centers in the Districts of AP and nearby Odisha State. Existing Machineries :- Ball Mill (1 No.) : 150 TPH Hot Air Generator (1 No.) : 12 MKcal/hr. Electronic Rotary Packers (2 Nos.) : 240 TPH each Truck Loading M/Cs. : 8 Nos. Wagon Loading M/Cs : 8 Nos. Weigh Bridge : 1 No. To control the fugitive emissions, Clinker (1x15,000 Tonnes), Fly Ash (1x4,500 Tonnes) and Cement (2x8,000 Tonnes) are stored in RCC Silos. Gypsum (1x3,000 Tonnes), Imported Coal (1x3,000 Tonnes) and Slag (1x5,000 Tonnes) are stored in covered sheds. In order to meet the increasing Cement Demand in the Region, RCL is, now proposing to increase the Cement Grinding capacity of Vizag Cement Grinding Unit from existing 0.95 MTPA (Line I) to 2.00 MTPA by introduction of Line II (of 1.05 MTPA) with the following Components : Vertical Roller Mill - VRM (Mill 2) for a capacity of 130 TPH. One Hot air Generator (HAG - 2) of 12 MKcal/hr for driving out the moisture in the raw materials. One concrete Silo (Silo 2) for storing clinker of Capacity MT Two concrete Silos (Silo 3 and 4) for storing Cement of capacity 8000 MT each. In addition to this, Two steel silos (Silo 5 and Silo 6) of 500 MT capacity is also considered for storing cement. One steel silo (Silo 2) of capacity 1000 MT for storing dry Fly ash Covered storage yard for storing chemical Gypsum and Wet slag of capacity 3000 MT and 5000 MT respectively. One number of electronic rotary packer (Packer 3) of capacity 180 TPH with double discharge will be shifted from our Jayanthipuram plant and will be installed. Two nos. of double discharge Electronic rotary packers (Packer 4 and 5) of capacity 240 TPH respectively.

16 8 nos of Truck loading machines for loading packed cement bags in trucks / trailers. Additionally, 4 nos of Wagon loading machine is also proposed to reduce the loading time. 2 nos. of Bulk loading facility to despatch cement through closed bowsers. One weigh bridge for weighing raw materials and finished goods of capacity 100 Tonnes. On Expansion, a highly energy efficient Vertical Roller Mill (VRM) will be installed to produce OPC, PPC and PSC. VRM has in-built Classifier for adjusting the product fineness. Clinker, gypsum and wet slag from storage will be transported to respective feed hoppers with the help of belt conveyors. Measured quantities of clinker, gypsum, Fly ash and Slag in desired proportions for the respective product will be fed to VRM. Weigh feeders will be installed under each feed hopper to ensure accurate measurement of input quantities of materials to the mill. While producing PPC, Fly ash of desired dosage will be extracted from fly ash silo and fed through a solid flow meter to the mill. Cement stored in silos will be packed in 50 kg bags using electronic packers. Apart from the facility to pack cement in bags, there will be facility to load cement in bulker so that it can be despatched in bulk. Wet Slag receipt from steel plant will have a average moisture of 15% and requires hot gas for evaporating the moisture while grinding. It is proposed to install a Fluidised bed coal based Hot Air Generator (HAG) of capacity 12 Million Kcal/hr to drive out the moisture in wet Slag. Indigenous Coal / Imported coal / Petcoke will be used as a fuel in Hot air Generator. All transport equipment, transfer points, silos, hoppers, loading equipments, packers, etc. are provided with proper venting system and also dedusted using bag filters of suitable size at each location to ensure that the emission (PM) level is kept <30 mg/nm EMP Measures Air : The main pollutant expected from the Cement Grinding Unit is Particulate Matter, PM. The identified sources of dust/spm are : Wagon & Truck unloading (Tipplers), Clinker hopper, Clinker storage silo, Weigh feeders for Clinker, Gypsum and solid flow meter for Fly Ash, Fly Ash storage silo, Clinker Grinding Mill, Cement Silos and Packing Machines. Emissions from these sources, other than Cement Mill & Packing Plants, would be fugitive in nature. Pulse Jet Bag Filters are proposed to control PM emission <30 mg/nm 3. All the transfer points in material handling will also be fitted with bag filters with proper capacity to ensure that the dust emission is kept well below 30 mg/nm³. All the conveyors for material handling will be completely covered. To minimise the fugitive emission, it is proposed to provide completely closed storage for all materials. Proposed Stack details are given in Table 3.1. Table : 3.1 Proposed Stack Data Stack Attached to Stack Height (from GL), m Stack Dia., m Stack Temperature, o C Exit Velocity, m/sec Discharge, Nm 3 /hr. SPM, mg/nm 3 Cement Mill ,000 <30 Packer ,000 <30 Packer ,000 <30 Packer ,000 <30

17 Water : Presently, Raw Water is required for Equipment Cooling (60 cu.m/day), Dust Control Measures (1 cu.m/day), Green Belt (20 cu.m/day) and for Domestic Use (15 cu.m/day). The total Water Demand of 96 cu.m/day is met from permitted 2 Nos. Borewells within the Plant under the Andhra Pradesh Ground Water & Water Audit Department, Visakhapatnam vide Letter No. 207/Tech/ dated The additional Water Demand, on Expansion, for Equipment Cooling (30 cu.m/day) and for Domestic Use (4 cu.m/day) will also met from the existing Permitted source only. There is no trade effluent generation from the Unit. : Domestic sewage to the tune of 4 cu.m/day from the Plant and 8 cu.m/day from Guest House & Bachelor Qtrs. are generated and the Domestic Sewage is biologically treated in about 7 Nos. individual Septic Tanks followed by a Dispersion Trench. On Expansion, additional Domestic sewage to the tune of 3.5 cu.m/day will be generated which will also be biologically treated in a Septic Tanks of adequate size followed by a Dispersion Trench. Thus, Zero Effluent Discharge will be adopted/practiced. The Water Demand & Wastewater Generation (Water Balance) details are given in Table 3.2. Table : 3.2 Water Demand & Wastewater Generation Sl. No. Description Existing Plant, cu.m/day Additional on Expansion, cu.m/day Total, cu.m/day 1 Water for Equipment Cooling Water for Green Belt Water for Domestic Use Dust Control Measures 1-1 Total Water Demand Trade Effluent Generation Domestic Sewage Generation Total Solid Wastes (Lines I & II) : The dust collected from the various Air Pollution Control Measures like Bag Filters, etc. is totally recycled in the process for cement manufacturing. Thus, no solid waste is envisaged from the process. On Expansion, the total quantity of Spent/waste Oil (Cat. 5.1) will be about 1,500 Lits./year which will be stored and sold to CPCB Authorised Recyclers for recovery and further use. Filter Bags Scrap (500 kg/year) will also be generated which will be sold to Vendors. Spent 5 Nos./year will be disposed to the Dealer on Buyback System. Noise Levels : Cement Grinding Mill be the main source of noise. The noise level within the plant building at a distance of one meter from the source shall be maintained at less than 85 db(a). Noise level at the nearest plant boundary will be <75 db(a) during day times and <70 db(a) during night times i.e. will be well within the permissible MoEF&CC Norms for Industrial areas. Green Belt : An effective Green Belt is developed and maintained over an extent of Ha (34.00% coverage).@ 1,000 trees/ha (Survival Rate : 85-90%).

18 Rain Water Harvesting : RWH Ponds of 20,000 cu.m capacity within the premises and 10,000 cu.m capacity outside the premises in own land have been made and used. Harvested Rain Water is being used for Green Belt development. Occupational Health : All efforts is being taken and followed by RCL to avoid the accidents and have a good Occupational Environment. A fully equipped Occupational Health Centre is established and an Onsite Emergency Preparedness Plan are in place in the Unit. Entry Level and Periodical Medical Examinations of the Employees is being undertaken by the Unit. The Medical Reports are reviewed and evaluated for Occupational Health related problems. 3.7 Power Demand & Source Existing Plant requires about 12 MW power which is sourced from About 5.5 MVA of power would be required for the new grinding facility and for the additional material handling equipments and Packers. The same is proposed to be availed from the grid of Andhrapradesh Eastern Power Distribution Company /APTRANSCO. There is also 2x6.25 MW Standby DG Sets in the Unit. About 5.5 MVA of power would be required for the new grinding facility and for the additional material handling equipments and Packers. The same is proposed to be availed from the grid of Andhrapradesh Eastern Power Distribution Company /APTRANSCO. 4.0 Site Setting & Analysis 4.1 Connectivity The site is located bear the National Highway (NH) 16 (earlier NH-5) inbetween Tuni-Anakapalli Towns. It is about 13.5 km from Anakapalli (in north-northeast), 9 km from Kasimkota (Mandal Head Quarters) and 35 km from Visakhapatnam (District Head Quarters) in northeast. Tallapalem (@ 1.2 km in north), Gobburupalem/AS Peta (@ 0.5 km in east) and Narsingapalli (@ 1.3 km in southwest) are the nearest villages. South Central Railway Line Vijayawada-Visakhapatnam Section runs at southern boundary of the Plant. The Unit s Railway sidings are from the nearby Narasingapalli Railway Station. 4.2 Land Use Pattern In the study area, predominantly Plantation Land covers 58.8% followed by the Barren Land 11.67% of total area. Builtup land covers only 0.47% of the total area. Landuse Percentage, % Built-up Land - Rural 0.47 Barren Land Crop Land 9.48 Forest Plantation 1.29 Plantation Ravinous Land 3.89 Scrub forest 9.72 Semi evergreen forest 3.81 Water Body 0.88 Total

19 4.3 Existing Infrastructures/Industries The strip of the land along the coast and the interior called the plains division and hilly area of the Eastern Ghats flanking it on the North and West called the Agency Division. The Agency Division consists of the hilly regions covered by the Eastern Ghats with an altitutde of about 900 m dotted by several peaks exceeding 1200 m. The other is the Plains Division with altitude not exceeding 75 m and drained by Sarada, Varaha and Thandava Rivers. Since no major Irrigation system exists significant sub regional agronomic variations exist in this division. Thus, Polavaram Project is being implemented by the State Government. There is no Major Industry within 10 km radius area. 4.4 Soil Classification Red Loamy soils predominate with coverage of 69.9% of the villages of the District. The Soils are poor textured and easily drained. Sandy loamy soils come next with coverage of 19.2% villages, largely confined to the coastal areas. The soil texture was silty loam in nature. There was no heavy metals intrusion/leaching into the ground strata. In general, the soil in the study area would support vegetation, if modified suitably. 4.6 Climatic Data from Secondary Source The district has differing climatic conditions in different parts of it. Near coast the air is moist but gets warmer towards the interior and cools down in the hilly areas on account of elevation and vegetation. April to June is warmest months. The Temperature (Visakhapatnam Airport is the nearest IMD Station) gets down with the onset of South West Monsoon and tumbles to a mean minimum of 18.8 o C by December after which there is reversal trend till the temperature reaches mean maximum of 37.4 o C by the end of May. It receives annual normal rainfall of 1202 mm of which southwest monsoon accounts for 53.9% while Northeast monsoon contributes 24.8% of the normal rainfall. 5.0 Planning Brief 5.1 Planning Concept & Amenities/Facilities The Expansion of Cement Grinding Unit is proposed within the existing Industry Premises. 5.2 Land Use Planning Additional 25,500 sq.m area will be under Building Area to the existing 36,540 sq.m area. On Expansion, in total area of Ha, an effective Green Belt is developed and maintained over an extent of Ha (34.00% coverage). Existing Railway siding is adequate for the Expansion activity also. 6.0 Proposed Infrastructure 6.1 Industrial Area RCL Vizag Grinding Unit is located Ha in Gobburupalem & Gobburu villages, Kasikota Mandal, Visakhapatnam District of Andhra Pradesh.

20 6.2 Residential Area As such, a small Guest House and Bachelor Quarters for temporary stay of employees are already provided. 6.3 Green Belt Green Belt, with 33% coverage of the total area, will be maintained and with native tree species predominantly. 6.4 Social Infrastructure The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. About 2.5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs lakhs per annum. 7.0 Rehabilitation & Resettlement (R&R) Plan The Project does not involve any R&R and thus no R&R Plan is envisaged. 8.0 Project Schedule & EMP Budget 8.1 Project Schedule Project will be completed in about 12 months on approval of statutory clearances. 8.2 Project Cost The Project Cost for the Expansion activities is Rs crores. 9.0 Analysis of Proposal 9.1 Financial & Social Benefits The Expansion of Cement Grinding Unit is proposed within the existing Industry Premises for effective utilization of Fly Ash generated nearby. It does not require financial viability analysis/assessment. Adequate budgetary provisions are made for the Project establishment. ***