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

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. 1. Particulars Location Village Tehsil District State Latitude & Longitude Details Rabriyawas Jaitaran Pali Rajasthan Cement Plant: 26o1756 N & 74o0740 E

2.

Ambuja Cements Ltd.

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

3.

Topo Sheet Number

Limestone Mine (Ras I): 26o2314 N to 26o2416N 74o1334 E to 74o1439 E 45 J/3 (1:50000 scale)

Area Details 4. Total Plant Area (Cement 354.74 ha Plant, CPP, Colony) (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 Rs. 250 Crores o o Capital Cost : Rs. 20 Crores Recurring Cost: Rs. 50 Lakhs / Annum

Cost Detail 7. Total Cost of the Project 8. Cost of Environmental Protection Measures (Rs)

Climatology (Post Monsoon Season: October to December, 2010) 9. Temperature 6.6 oC to 37.0 oC Relative Humidity At 8:30 hrs. 34% to 48% At 17:30 hrs. 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 None within 10 km radius Sanctuaries, Biosphere Reserves 15. Reserves / Protected Forests 5 Nos protected forests within 15 km 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

Ambuja Cements Ltd.

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

FIGURE 1.1: LOCATION MAP OF THE PROJECT SITE

Ambuja Cements Ltd.

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

1.2 1.2.1

MAJOR REQUIREMENTS FOR DIFFERENT UNITS OF THE INTEGRATED PROJECT 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) 1600 250 80 70 2000

Quantity (M3/Day) (After Proposed Enhancement) 1859 290 110 141 2400

1. 2. 3. 4 4.

Industrial Activity (Plant + CPP) Domestic Use (Colony) Limestone Mines (Ras - I & Ras- II) Others (Environmental Maintenace & ACF activities) Grant Total
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 Workmen
Total
Source: Pre-Feasibility Report

276
253 529

281
273 554

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

Ambuja Cements Ltd.

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

2.0 2.1

PROJECT DESCRIPTION Mining Details TABLE 4

S. No. 1. 2. 3. 4. 5. 6. 7.

Details ML area Mineable Reserve Life of the Mine Method of mining Drilling Blasting Extent of mechanization

Explanation 183.50 ha 54.62 million tones 196 years Opencast fully mechanized 100 millimeter 115 millimeter diameters drill Deep hole blasting DTH Drills, Exploders, Crawl Mounted hydraulic excavators, Highway rear Tippers, Dozer, Water sprinkler etc. 8 m (except one of 6m) 18 m (advance side) About 400 mRL 4 m mbgl (396 mRL) 45 m bgl (355 mRL) during Post Monsoon season 60o

8. 9. 10. 11. 12. 13. 14. 15.

Bench Height (H) Bench Width General Ground Level Ultimate working depth Ground Water Table Bench Slope

Number of Working Days in 300 days a year Number of shifts per day
Source: Mining Plan

2 (8 hrs per day)

2.2 2.2.1

Cement Plant, Captive Power Plant and RAS-I Limestone Mine Raw Material and Fuel Requirements TABLE - 5

S. No.

Raw Material

Existing

Total requirement After enhancement 3.879

Source

Mode of transportation

1.

Limestone (MTPA) Gypsum (MTPA) Fly ash (MTPA)

3.6

Captive mines Conveyor belt & (Ras II & Ras I) by road respectively. nearby areas Own CPP Suratgarh TPP By Road Closed system circuit

2. 3. 4.

0.124 0.55

0.124 0.55 0.389

Coal / Petcoke / 0.274 Lignite (mixed fuel)

From Coal India Transportation Ltd. Rajnagar & by Road from 2 Badgaon and railway sidings

Ambuja Cements Ltd.

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

(Cement Plant) (MTPA) 5. Red ochre / Iron 0.0462 scale, China clay (MTPA) Furnace (D.G. Set) Oil 0235 g/kwh (1692 kg/year) 0.0520

existing identified (approx. 80 km source away from the plant) Near by market By Road

6.

0235 g/kwh kg/year)

(1692 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

Ambuja Cements Ltd.

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

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 g/m3 to 85.04 g/m3, PM2.5 ranges between 16.37 g/m3 to 43.67 g/m3, SO2 ranges between 5.4 g/m3 to 10.04 g/m3 and NO2 ranges between 21.38 g/m3 to 89.6 g/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

Ambuja Cements Ltd.

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

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.

Ambuja Cements Ltd.

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

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. 1. 2. 3. 4. 5. 6. 7. 6.0

DESCRIPTION Meteorological Data Ambient Air Quality at project site Stack Emissions Water Quality Noise Level Monitoring Soil Quality Health Check-up ADDITIONAL STUDIES

FREQUENCY OF MONITORING Daily Twice a week Weekly Quarterly Quarterly Quarterly As per the Factory Act.

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.

Ambuja Cements Ltd.

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

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.

Ambuja Cements Ltd.

10

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

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. 11

Ambuja Cements Ltd.

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

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.

Ambuja Cements Ltd.

12