1.0 PROJECT DESCRIPTION 1.1 INTRODUCTION EXECUTIVE SUMMARY Revati Cements Private Limited (RCPL) is a private limited company with its registered office at Indore (M.P.). RCPL is promoted by Ruchi Group of Indore, Madhya Pradesh. The Group has well established manufacturing and trading facilities for Soyabean products, Agri-business, oils and fats, Flat Steel, Galvanized Steel and Cold Rolled Steel etc. To keep pace with the rapidly changing industrial scenario, the group plans to diversify its activities into new areas. RCPL, therefore, proposes to set up its greenfield Integrated Cement Project comprising of Cement Plant (Clinker 2.5 MTPA, Cement 3.0 MTPA), Captive Power Plant (45 MW) and two limestone mines (Lease area 766.22 Ha & 140.618 Ha) at Tehsil Raghuraj Nagar, District - Satna (M.P.). As per new EIA Notification dated 14 th September 2006, this project falls under Category A. 1.2 DETAILS OF THE PROJECT Table No. : 1 S. No. Particulars Details A. Project Area details Project activity Area Cement Plant & CPP 50.59 ha (125 acre) Colony Total Mining Lease Area (Mine I) 10.0 Ha. 60.59 ha 766.22 ha Mining Lease Area (Mine II) 140.618 Green belt Area 19.80 ha. B. Capacity details Unit Proposed Capacity Clinker Capacity Cement CPP Limestone mine (Lease area 766.22 ha.) 2.5 MTPA 3.0 MTPA 45 MW 3.5 MTPA of Limestone Production B Project Location Limestone mine (Lease area 140.618 ha.) 0.5 MTPA of Limestone Production 1. Villages Bharjuna Khurd, Saha, Shivpurwa, Umari, M/s Revati Cements Pvt. Ltd. 1
2. Tehsil Raghurajnagar 3. District Satna 4. State Madhya Pradesh 5. Toposheet No. 63 D/14 Bharjuna Kala, Tikuri Kala, Tikuri Kothar 6. Latitude & Longitude Plant site : 24 o 39 54.43 N to 24 o 40 5.02 N 80 o 50 14.14 E to 80 o 50 30.05 E Mine site : 24 o 38 4.70 N to 24 o 40 1.82 N 80 o 49 58.07 E to 80 o 52 55.89 E C Cost Details 1. Total cost of the project Rs. 1337/- Crores 2. Cost for Environmental Protection Measures D Environmental Setting Capital Cost - Rs. 20/- Crores Recurring cost per annum - Rs. 150 lakhs 1. Nearest Railway Station Sagma railway station (~1.0 km from the mine site) 2. Nearest Town Satna (7.5 km from the mine site) 3. Nearest Airport Khajuraho airport (~90 km from the Plant site) 4. Nearest River Simrawal Nadi (5.0 km) River Tamas (9.3 km) River Satna (9.5 km) 5. National Park, Biosphere Reserve, Wildlife Sanctuary, Tiger/Elephant Reserves, Migratory Routes for birds, Reserved / Protected Forest No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger /Elephant Reserve exist within 10 km radius of proposed site. Following Reserve Forest exists within the area: Forests Jamori Reserve Forest Direction Distance from Mine from Mine site site (km) 9.8 km ESE Reserve Forest 8.5 km SE Reserve Forest 8.7 km ESE 6. Seismic Zone Zone II as per IS: 1893 (Part-I) : 2002 M/s Revati Cements Pvt. Ltd. 2
1.3 MINING DETAILS Table - 2 S. No. Details Mining Lease I Mining Lease II 1. ML area 766.22 ha 140.618 ha 2. Limestone Production capacity 3. Topography 3.5 MTPA 0.5 MTPA Flat plain with minor undulating surfaces Flat plain with minor undulating surfaces 4. Elevation range 308 m AMSL to 332 m AMSL 308 m AMSL to 322 m AMSL 5. General Ground Level 320 AMSL 320 AMSL 6. Mineable Reserves 163.56 Million Tonnes 26.21 Million Tonnes 7. Life of Mine 49 years @ 3.5 MTPA production capacity 55 years @ 0.5 MTPA production capacity 8. Method of mining Fully Mechanized opencast Fully Mechanized opencast 9. Bench Height & Width Bench Height 8 m Width 20 m Bench Height 8 m Width 20 m 10. Ground Water 28 m to 34 m bgl (292 mrl to 28 m to 34 m bgl (292 mrl to Table 286 mrl) 286 mrl) 11. Ultimate working depth 20 m bgl (300 mrl) 20 m bgl (300 mrl) 12. Overall pit Slope 45 0 45 0 13. Number of Working Days 300 days 300 days 14. Number shifts per day Two Two 1.3.1 Drilling & Blasting Removal of over burden will be done by loader cum excavator. Drilling in hard strata will be done by DTH drills of hole dia. 115 to 150 mm. For blasting, explosives such as Booster Primax, Powergel, Ordinary Detonator, Electrical Detonator OR Nonel detonator, and ANFO will be used for heaving effect and fragmentation to the Mine 1.3.2 Hauling and Transport Blasted lime stone will be loaded in to the dumpers by loaders and will be transported to the destination crushing pant. The over burden will be loaded by loaders and transported to the dumping yard/ backfilling site by dumpers. M/s Revati Cements Pvt. Ltd. 3
1.3.3 Equipment Details The following equipments are proposed for Limestone mining: Table - 3 S. No. Equipment Capacity Mining equipments 1. Hydraulic Excavator 4.6 m 3 2. Dumpers 60 T 3. Crawler mounted drills 115 150 mm dia 4. Dozer wth ripper 63 cum 5. Rock breaker 1.9 cum Service Equipments 6. Payloader 6-7 m 3 7. Mobile service van - 8. Water tanker with water 5 KLD sprinkler 9. Maintenance van - 10. Crane 5 T 11. Diesel tanker 12000 L 12. Dewatering pumps 37 litre/sec. 13. Explosive van 10 t 14. Ambulance - 15. Jeep - Source: Mining Plan & Progressive Mine Closure Plan 1.4 MAJOR REQUIREMENTS FOR DIFFERENT UNITS OF THE INTEGRATED PROJECT 1.4.1 Raw Material Requirement Table - 4 S. No. Material Quantity (MTPA) Source locality 1 Limestone 4.0 Proposed Captive Limestone Mine at Bharjuna, Shivpurwa 2 Clay 0.208 Bharjuna, Shivpurwa Approx. Distance from plant (Km) 1 3 Iron Ore 0.104 Agaria, Sehora 170 4 Gypsum 0.15 Lunkaransar, 1200 Bikaner 5 Fly ash 0.36 CPP & Vindhiyachal Thermal Power Station Sidhi (250 km) <300 6 Coal Cement Plant 0.471 Power Plant 0.27 Chirimiri, Shahdol collieries of SECL 1 ~350 M/s Revati Cements Pvt. Ltd. 4
1.4.2 Other requirements Table - 5 S. Particulars Requirement No. 1. Land S. No. Unit Area in ha. 2. Water 1. Cement plant & CPP 50.69 ha. 2. Township 10.0 ha. 3. Limestone Mine I 766.22 ha 4. Limestone Mine II 140.618 Total 967.428 ha. S. No. Unit Water Requirement (in KLD) 1. Cement Plant 2000 KLD 2. CPP 500 3. Mines 100 4. Colony 400 Total 3000 Source of Water: The water requirement will be met from Satna River. Permission for drawl of water has been obtained from Office of the Engineer, Water Resources Division Satna. 3. Power 45 MW (Source : Captive Power Plant) 4. Manpower During construction phase: 157 persons During operation phase: 557 persons. 1.5 PROCESS DESCRIPTION 1.5.1 Limestone Mining Limestone mining will be carried out by Mechanized Opencast method of mining. Mining will include the following activities: - Removal of Over Burden - Drilling & Blasting - Crushing of Limestone - Loading - Transportation to the cement plant via conveyor belts 1.5.2 Cement Manufacturing Process The cement plant will manufacture PPC (1.2 MTPA) and OPC (1.8 MTPA). Proposed procedure for cement manufacturing is dry process, which essentially consists of the following unit operation steps: - Crushing of limestone. - Pre-blending of crushed limestone. - Drying cum-grinding of raw materials. - Homogenization of raw meal in a blending silo. - Clinkerisation of the raw meal in a rotary kiln with multistage preheater and precalcinator. M/s Revati Cements Pvt. Ltd. 5
- Grinding, storage and packing. 1.5.3 Description of the Captive Power Plant - Burning of coal in the Boiler - Air Cooled system - Steam formation - Power generation in Turbine - Condensation of super heated steam for recirculation in boiler - Pre heating of feed water & air - Dust pollution Control 2.0 DESCRIPTION OF ENVIRONMENT 2.1 Climatic condition The different seasons in the area as considered by Meteorological Department are Winter (Dec-Feb), Summer (March-May), Monsoon (June-September) and Post Monsoon (October-November). The area under study experiences semi arid to moderate climate. On an average the maximum temperature of the area goes up to 42 C in summer and goes down to 12 C in winter. The humidity in summer season varies from 30 to 90%. Climatology (During study period: March to May;2010) i) Maximum Temperature : 43.7 C ii) Minimum Temperature. : 16.8 C iii) Relative Humidity (%) At 08.30 Hrs. : 23 % - 56 % At 17.30 Hrs. : 15% - 32 % Average Annual Rainfall : 1007 mm 2.2 Other Baseline Details During the study period, ambient air quality and noise level monitoring was done at 11 locations whereas water sampling was done at 8 locations and soil sampling was done at 8 locations. Table - 6 S. No. Particulars Details A. Ambient air quality 1. PM 10 30.6 to 68.5 µg/m 3 2. PM 2.5 16.7 to 30.2 µg/m 3 3. SO 2 5.3 to 12.9 µg/m 3 4. NO 2 8.2 to 16.3 µg/m 3 B. Noise level 5. Day time 46 to 53 Leq db (A) 6. Night time 40 43 Leq db (A) C. Water quality 7. ph 7.1 to 7.7 8. TDS 363 mg/l to 488 mg/l 9. Fluorides 0.17 to 0.42 mg/l 10. Nitrates 12.2 to 21.2 mg/l D. Soil quality 11. Texture Silty Loam 12. ph 7.4 to 7.9 13. Organic matter 0.81 to 1.13 % M/s Revati Cements Pvt. Ltd. 6
2.3 Biological environment Flora: Tree species which are most commonly found in the area are Azadirachta indica (Neem), Acacia nilotica (Babul), Acacia catechu (Khair), Emblica officinalis (Amla), Dalbergia sissoo (Shishum), Eucalyptus tereticornis (Eucalyptus), Ficus bengalensis (Bargad), Butea monosperma (Palas) etc. Fauna: Commonly found animal in the study area are Hare (Lepus nigricollis), Rat (R.rattus), Brahminy Starling (Sturnus pagodarum), Koel (Eudyanamus spp.), House crow (Corvus splendens), Squirrel (Funambulus palmarum), Common garden lizard (Calotes vesicolor) etc. 2.4 Socio-economic environment As of 2001 India census, population of the study area is 75934. The Schedule caste is 24.51 % and scheduled tribe is 7.64% of the total population. Average literacy rate is 64.59%. The total number of households is 13640. The total working population is 28880. 75.10% are main workers and marginal workers are 24.89%. 3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES The key emissions generated from Plant process & Limestone mining (i.e. drilling, blasting, loading, haulage and other transport activities during mine operation) are particulate matter, Oxides of Nitrogen (NO X ) and Sulphur dioxide (SO 2 ). High efficiency ESP/bag house will be installed with boilers, cooler, 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. Proper water sprinkling shall be carried out at the mine site & material transfer points. Impact of mining on ground water table: - Water table in the area varies from 28 to 34 m below ground level. The working is expected to be done upto 20 m below ground level i.e. 300 m RL. Therefore, mining will not intersect the ground water table. Industrial waste water will be generated from power plant only and will be used for ash quenching. 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. In the lease area, noise and vibrations will occur due to blasting. But these will be minimized by controlled blasting. The study area (10 km radius from the project site) is not having any National Park, Wild Life Sanctuary or Biosphere Reserve etc. M/s Revati Cements Pvt. Ltd. 7
4.0 POST PROJECT MONITORING PROGRAMME Table No. : 7 S. No. DESCRIPTION FREQUENCY OF MONITORING 1. Meteorological Data Daily 2. Ambient Air Quality at project site Quarterly 3. Stack Emissions Weekly 4. Water Quality Quarterly 5. Noise Level Monitoring Quarterly 6. Soil Quality Quarterly 5.0 ADDITIONAL STUDIES The Additional Studies conducted as per the additional Terms of References vide MoEF letter no.- J-11011/554/2007-IA-II (I) dated 16 th Aug., 2010 are Biological Study, Hydro-geological Study & Rain water Harvesting Plan, Disaster Management Plan. 6.0 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. RC will get 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, assistance in social forestry programmes in the area, are some of the activities to be undertaken in CSR plan for development of the society. 7.0 ENVIRONMENT MANAGEMENT PLAN 7.1 Air Environment 7.1.1 Limestone Mines: Use of sharp drill bits for drilling holes; Wet drilling is being done. Controlled blasting is being practiced. Water spray on haul roads to avoid dust generation during transportation. Crusher will be provided with water spray on the hopper and at material transfer points. 7.1.2 Management of Stack emission - High efficiency ESP and bag dust collectors will be installed to meet the PM emission level of less than the prescribed limits by regulatory bodies. - ESP will be installed with boiler and cooler. - Bag house/esp will be installed with cement mill. Bag house will be installed with coal mill and kiln. M/s Revati Cements Pvt. Ltd. 8
Table - 8 Pollution Control Equipment S. No. Section Pollution control Emission Level equipment (PM mg/nm 3 ) 1. Raw Mills/Kiln Bag House <50 2. Clinker Cooler ESP <50 3. Coal Mill Bag House <50 4. Cement Mill Bag House/ESP <50 5. Boiler ESP <100 Source: Pre Feasibility Report 7.2.3 Management of fugitive emission - Concreted roads with vacuum sweeping - Silo for storage of fly ash. - Silo / stock pile for clinker storage - Covered storage for gypsum - Covered storage with water spray for coal storage - Covered unloading hoppers with water sprinkling arrangement for unloading of limestone and coal. - Covered unloading hopper for fly ash unloading - Water sprinkling arrangement in limestone crusher and reclaimer. - Bag dust collectors at all material transfer points. 7.3 Water Management For Limestone mine: Water collected in the pit will be pumped out & will be used for water sprinkling on haul roads, Crusher site, watering of plants, drilling and other dust suppression measures. The mine water may also be supplied to Cement plant. The water will not be discharged into any surface water source directly. Domestic waste water generated from mine is being disposed off in soak pits via septic tank. Cement Plant /CPP: Industrial 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 outside the plant premises. 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. Rain water harvesting will be practiced at plant and colony area. M/s Revati Cements Pvt. Ltd. 9
7.4 Solid Waste Management ML Area 766.22 ha: The mine waste will be generated in the form of shale and intercalated clay during mining operation. At the conceptual stage, 13.48 million m 3 of soil and 29.44 million m 3 of OB/waste will be generated. Soil and OB/waste generated during first 3 years will be stacked towards east & simultaneous backfilling will be carried out afterwards. ML Area 140.618 ha: At the conceptual stage, 3.45 million m 3 of soil and 3.575 million m 3 of OB/waste will be generated. Soil and OB/waste generated during first 3 years will be stacked within the lease area & simultaneous backfilling will be carried out afterwards. Cement Plant /CPP: 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. Solid waste generation from Cement Plant/CPP and its disposal is given in following table: Table - 9 Solid waste generation from Cement Plant/CPP & its Disposal S. No. Type Method of disposal 1. STP Sludge Will be used as a manure for green belt development within the plant boundary 2. Fly Ash 100% Fly ash will be used for cement manufacturing with in the plant premises. 3. Waste oil Will be sold to authorized vendors. 7.5 Noise Environment Limestone mines Drilling will be done with sharp drill bits. Controlled (NONEL) blasting will be practiced. Crushing and screening activity will be done in a closed environment, which will help in minimizing generation of noise. Cement Plant/CPP Silencers will be provided in the areas generating high noise. Proper care will be taken by incorporating sound-proof enclosures for equipments and providing earmuffs and earplugs for operators. Walls and ceilings of the concerned buildings will be lined with sound absorbing materials. Green belt will be developed which will help in reducing noise levels. Regular monitoring of noise level will be carried out and corrective measures in concerned machinery will be adopted accordingly. 7.6 Greenbelt Development Limestone Mines Out of ML area of 766.22 ha, about 90.72 ha will be developed under green belt & plantation (including 80.72 ha of unworked area & 10.00 backfilled area). M/s Revati Cements Pvt. Ltd. 10
Out of ML area of 140.618 ha, green belt/plantation will be raised on around 33.6 ha. area (including 31.618 ha of unworked area & 2.00 backfilled area). Cement Plant/CPP The total area for the proposed cement plant, CPP & colony is about 60.59 ha., out of which, approx 19.8 ha. (33% of the total plant area) area will be covered under Green Belt /Plantation. The density of trees will be kept approx. 2000 trees per hectare. The tree species selected for green belt will include the native species like Mengifera Indica, Cassia fistula, Tectona grandis, Acacia nilotica, Agave spp., Dalbergia latifolia, Azadirachta indica, Bauhinia variegate, Delonix regia, Pongamia pinnata, Syzygium cumini. Plantation of local species will be done in consultation with DFO as per the CPCB norms. 8.0 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 this proposed Integrated Cement Project. M/s Revati Cements Pvt. Ltd. 11