Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.

5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

EXECUTIVE SUMMARY
1.0 INTRODUCTION
Ambuja Cements Limited (ACL) is a leading manufacturer of various types of cements in India, part of the Holcim group, worlds largest cement manufacturer. Ambuja Cement has an excellent track record with respect to productivity, energy conservation, quality control and environmental pollution control. ACL is operating 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. ACL proposes for Integrated Cement Project i.e. Clinker (3.0 MTPA), Cement (4.5 MTPA), Captive Power Plant (2x25 MW) & Waste Heat Recovery Boiler (5.0 MW) at Villages: Marwar Mundwa, Tehsil & District: Nagaur (Rajasthan). The project was considered in front of Expert Appraisal Committee (EAC) (Industry-1) for ToR approval on 28th August, 2010. The Terms of References (ToR) have been issued by MoEF, New Delhi for preparation of the Draft EIA / EMP Report vide letter No. -11011/394/2010-IA-II (I) dated 16th Sep, 2010. As per the New EIA Notification dated 14.09.2006, this project falls in category A.

1.1

DETAILS OF THE PROJECT

Table No. : 1.1
S.No. 1. Location Villages Tehsil & District State 2. 3. 4. 5. 6. Latitude Longitude Cost of the project Cost for Environmental Protection Particulars Details

Marwar - Mundwa Nagaur Rajasthan

27 04 9.09 N - 27 05 6 N 73 48 30.3 E- 73 49 21.71 E Project Detail Rs 1500 Crores Rs. 120 Crores

Recurring cost per annum for Rs.100 lakhs/annum environmental pollution control measures Total Area (Including Green Belt) Green belt Area 285.10 ha 85.10 ha

7. 8.

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

S.No.

Particulars

Details

Climatology (Summer Season: March to May, 2010) 9. A. B. Temperature Relative Humidity At 8:30 hrs. At 17:30 hrs. 10. 11. Dominant Wind Direction Nearest Village 20.8 C 48.3 C 32% to 55% 26% to 35% From SW Project Site Vicinity Details

Mundwa 2.0 km in South Khain 1.5 km in North Marwar-Mundwa South) (0.2km in

12.

Nearest Railway Station

Merta Road Junction (40 km)

13. Nearest National Highway

NH 89 (Near boundary in East) NH - 65 (20 km in West) SH02 (21 km in West) Connecting ----&----via-----city

14.

Nearest State Highway

15.

Nearest Airport

Jodhpur (165 km in West) Jaipur (250 km) Nagaur (20 km in West) Mundwa (2.0 km.) None within 10 km radius Pond (4.0 km in West)
No National Park, Biosphere Reserve, Wild Life Sanctuary, Reserve Forest, Protected Forest within 10 km radius the study area.

16. 17. 18. 19.

Nearest town/city Nearest River Nearest Water Body Ecological Sensitive Areas

20. 21.

Industries/Mines falling in 10 km Hanuman Cement Factory radius of the area (Near Plant Boundary in West) Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

FIGURE 1.1: LOCATION MAP OF THE PROJECT SITE

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

1.2
1.2.1

MAJOR REQUIREMENTS FOR DIFFERENT UNITS OF THE INTEGRATED PROJECT

Water Requirement
TABLE 1.2.1 Total Water Requirement S. No. 1. 2. 3. 4. 5. Utility Cement Plant Captive Power Plant including WHRB Colony Green belt development Total Water Requirement (in KLPD) 1100 500 250 150 2000

Source: Pre-feasibility Report

Source: Water requirement of the project including Cement plant, CPP and colony is 2000 KLPD. Permission for 2000m3/day Ground Water abstraction obtained from CGWA vide letter No. 21-4 (16)/WR/CGWA/05-1491dated Dec.02, 2005.

1.2.2 Power Requirement

The Power required at Cement Plant is worked out based on the various loads for 3.0 MTPA clinker production 4.50 MTPA cement, 2 x 25 MW CPP and 5 MW WHRB TABLE 1.2.2 POWER REQUIREMENT DETAILS S. No. 1. 2. 3. 4. Particulars Average Power Demand of Clinkerisation Average Power requirement of Grinding Auxiliary power consumption of 50 MW CPP including (5.0 MW WHRB) Total power required to generate Power Requirement 32 MW 11 MW 6 MW 49 MW

Source: Pre-Feasibility Report

Hence, it is proposed to Install 2x25 MW Thermal Power Plant within the plant premises. Excess power generated from both 2x25 MW CPP and Waste Heat Recovery Systems of 5.0 MW (after considering present requirement of Cement Plant net load of 43 MW and CPP Auxiliary Consumption of 6 MW) will be used for Peak load demand & future requirements.
Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

1.2.3

Manpower Requirement
During construction phase the peak manpower requirement shall be around 20002500 people and during operation phase it shall be as under: TABLE 1.2.3 DETAILS OF MAN POWER

S. No. 1 2 3

Type Of Manpower Skilled Manpower Semi-Skilled Manpower Un-Skilled Manpower

Mode Of Employment Company Owned Contractor Contractor

Persons 391 125 375

Source: Pre-feasibility Report

ACL will provide employment to the local populace and also labour of unskilled and semi-skilled categories will be taken from the nearby villages and towns.

2.0

PROJECT DESCRIPTION
Table No. : 2.1 RAW MATERIAL REQUIREMENT, SOURCE & TRANSPORTATION

2.1 Raw Material Requirement

S. No.

Raw Material/Fuel

Quantity Required (MTPA)

Source

Mode of transportation Overland Conveyor belt (at a distance of approx. 1.5 km from plant site) Road

1.

Limestone

4.50

Captive mines (ML I & ML II) Rajasthan State Mines & Minerals Ltd.

2.

Gypsum

0.32

3.

Fly Ash

1.35
0.46

Captive power Plant

Coal Badgaon Mines, imported Lignite Mines Matasukh

via closed circuit system

4.

Fuel -Kiln

considering Mix of coal (40%)/ pet coke (27%)/ lignite (33%)

Coal-Rail Lignite Road Petcoke Road/Rail

Pet coke-IOCL/Reliance 5

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

5.

Fuel- CPP

0.23 considering coal as fuel 0.31 0.04

Coal Badgaon Mines, SECL Collieries In close vicinity of plantBhadana Quarry Merta

Road

6. 7.

China Clay Silica

Road Road

Source: Prefeasibility Report

2.2
2.2.1

PROCESS DETAILS
Cement Manufacturing Process
The cement plant will adopt 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. Raw Material Transport and Storage 2. Raw material preparation, grinding and blending operations 3. Calcinations in the kiln 4. Clinker cooling and stocking 5. Cement grinding and packing

2.2.2

Captive Power Plant

ACL has also proposed to install Captive Power Plant (2X25 MW considering coal as fuel) within the cement plant premises. The required coal as fuel for the CPP would be sourced from Badgaon mines and SECL Colliers. The Indian coal would be transported from the source to plant site by road.

3.0

DESCRIPTION OF ENVIRONMENT
Baseline study of the study area (i.e. 10 km radius from the project boundary) was conducted during Summer Season (March to May, 2010). Monitoring for ambient air quality (as per CPCB standards), ambient noise levels, water quality, soil quality was conducted at respective sampling locations. The study for land use pattern using satellite imagery, study for hydro- geology, demography and flora & fauna has also been conducted. The concentration for all the 8 AAQM stations for PM10 ranges between 28.52 g/m3 to 68.31 g/m3, PM2.5 ranges between 12.62 g/m3 to 32.12 g/m 3, SO2 ranges between 6.8 g/m3 to 14.3 g/m3 and NO2 ranges between 8.7 g/m3 to 16.4 g/m3. The ground water analysis for all the 8 sampling stations shows that pH varies from 7.67 to 8.19, total hardness varies from 126.72 mg/l to 330.24 mg/l & total dissolved solids varies from 1270 mg/l to 1982 mg/l. The analysis results for soil shows that soil is neutral in nature as pH value ranges from 7.20 to 8.38 & is sandy loam in texture. The concentration of Nitrogen, Phosphorus & Potassium has been found to be in good amount in the soil samples. 6

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

3.1

SOCIO-ECONOMIC ENVIRONMENT
The population as per 2001 Census records is 41316 (for 10 km radius buffer zone). Scheduled Caste fraction of the population of the study area (10 km) is 20.73 %% and Scheduled Tribe is 0.0004 %. Literacy rate is 40.79 %. Total no. of households are 6514.

4.0

ANTICIPATED ENVIRONMENTAL MITIGATION MEASURES

IMPACTS

AND

The key emissions generated from Plant process are particulate matter, Oxides of Nitrogen (NO2) and Sulphur dioxide (SO2). High efficiency ESP/bag house will be installed with boilers, cooler, Raw Mill, 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. Installation of bag filters and proper water sprinkling shall be carried out at the material transfer points. No industrial waste water will be generated from cement manufacturing process. Industrial waste water will be generated from power plant only and will be used for cooling, Plantation & ash quenching after proper treatment. 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. The study area (10 km radius from the project site) is not having any National Park, Wild Life Sanctuary or Biosphere Reserve etc. Flora found in the study area includes Acacia arabica (Babool), Acacia senegal (Kumat), Calotropis procera (Aak), Ailanthus excelsa (Ardu), Azadirachta indica (Neem), Ziziphus mauritiana (Ber), Prosopis juliflora (Khejri) etc. Fauna observed in the area are Blue bull (Boselaphus tragocamelus), Hare (Lepus nigricollis), Pigeon (Columba livia), Common Myna (Acridotheres tristicus), Five stripped squirrel (Funambulus pennanti), House crow (Corvus splendens), camel (Camelus Dromedarius), Weaver bird (Ploceus philippinus), Rat (R. rattus) etc.

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

5.0
S. No. 1. 2. 3. 4. 5. 6. 7.

ENVIRONMENTAL MONITORING PROGRAMME

Table No. : 5.0 DESCRIPTION Meteorological Data Ambient Air Quality at project site Stack Emissions Water Quality Noise Level Monitoring Soil Quality Health Check-up FREQUENCY OF MONITORING Daily Twice a week Weekly Quarterly Quarterly Quarterly As per the Factory Act.

6.0

ADDITIONAL STUDIES
The Additional Studies conducted as per the additional Terms of References vide MoEF letter no.- F. No. J-11011/394/2010-IA-II (I) dated 16th Sep, 2010 are Biological Study, Hydro-geological Study & Rain water Harvesting Plan, 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 will be 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, is some of the highlights of the CSR activities which will be operated by the plant.

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 from 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
All major sources of air pollution (Raw Mill Kiln, Clinker Cooler, Coal Mill, Cement Mill) of proposed new kiln will be provided with ESP, Bag filters to maintain limits of 50 mg/Nm3 for the PM emissions. All material transfer points will be provided with bag filters to entrap the emissions at the source itself.

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

Clinker will be stored in silos /covered stock piles and gypsum in covered shed. Fly ash will be stored in silos and closed shed. CPP Boiler will be provided with ESP. Better maintenance and installation of proper pollution control equipment like Bag Houses, Bag filters and ESP will help in reducing such emissions. CPCB guidelines for fugitive emissions will be followed. Green belt will be developed along the roads and around the plant premises as dust preventive barrier. Automized Water sprinkling system will be provided at limestone and coal unloading hopper and handling area.

8.2

WATER ENVIRONMENT
No industrial waste water will be generated during cement manufacturing process. Waste water generated from CPP will be recycled back to the process after proper neutralization. Domestic waste water generated from the project will be treated in STP and used for green belt development / horticulture activities & for dust suppression. Rain water harvesting will be practiced at plant and colony area.

8.3

NOISE ENVIRONMENT
Silencers will be provided in the machineries generating high noise. Properly insulated enclosures will be equipped for noise producing equipments to minimize high noise. PPE like earplugs and earmuffs will be provided to the workers exposed to high noise level. Sufficient green belt will be maintained around the cement plant. Regular monitoring of noise level will be carried out and corrective measures in concerned machinery will be adopted.

8.4

SOLID WASTE MANAGEMENT

No solid waste will be generated from the cement manufacturing process. Dust collected from air pollution control equipment will be 100% recycled in process. Sludge from Sewage Treatment Plant (STP) will be used as manure for green belt development. Fly ash generated from Captive Power Plant will be utilized in the manufacturing of Cement.

8.5

GREENBELT DEVELOPMENT
Out of total project area i.e. 285.10 ha, about 85.10 ha area will be developed under green belt / plantation. A thick green belt all along the roads, colony and plant will be developed under afforestation program. Local species will be planted as per guidelines.

Ambuja Cements Ltd.

Marwar - Mundwa Integrated Cement Project: Clinker (3.0 MTPA), Cement (4.5 MTPA) & Captive Power Plant (2 x 25 MW) At Villages: Marwar-Mundwa, Tehsil & District: Nagaur (Rajasthan)

Executive Summary of EIA Report

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 ACL.

Ambuja Cements Ltd.

10