Pre Feasibility Report

PRE FEASIBILITY REPORT

CHAPTER 1: EXECUTIVE SUMMARY

Malabar Cements Ltd., a fully owned Govt. of Kerala Undertaking, is synonymous with superior quality cements, vouched by customers spread across the state of Kerala. The Company was incorporated in April 1978 and commenced production in April 1984 at its cement plant located at Walayar. Malabar cement limited has more than 30 years of experience in cement industry and limestone Mining. The project involves production of limestone from the existing mine over a lease area of 234.9407 ha, located at S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Village, Palakkad Taluk & District, Kerala.

Limestone requirement of the Walayar cement plant is being sourced from subject captive mine of 234.9407 ha located about 5.0 km aerial distance from the cement plant area. Limestone Mine with about 10 Million Tons of mineable reserves will last for about 16 years with annual production capacity of 6,00,000 Tons. The life of the mine is expected to revise after completing exploration of the current scheme of mining and reassessment of reserves.

Open Cast Mechanized Method of Mining is adopted. The Limestone produced is crushed within the mine and transported through ropeway to the cement plant. The anticipated waste generation during the entire life of mining is about 9.587 Million Tons. During the scheme period of 2016-2021, waste generation is expected as 6,72,280 m3 (4,76,200 m3 Overburden + 1,96,080 m3 Intercalated) which is being dumped in the existing dump area of 27.47 ha.

Water requirement for the operation of mine is about 25 m3/day for dust suppression, plantation and domestic purposes. This requirement is being met from mine pit water.

The topography of the area is highly rugged with steep slopes towards south. The lease area in general consists of rugged hill ranges with steeply rising ridges and narrow valleys forming a part of the Western Ghats. The area falls on the slope of hillock tending east west in the eastern part, highest point of 635m RL and the lowest point of 285m RL have been recorded. The deposit, situated at an altitude of over 520m RL, lies to the North of the famous “Palakkad Gap”. The limestone deposit occurs along an east-west trending ridge, designated as 475.8m in the toposheet.

The cost for the production of Limestone is Rs. 521.23 per Ton. All infrastructural facilities are already available in the Mining lease area.

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Table - 1.1 : SALIENT FEATURE OF THE PROJECT SITE

Description Details Project Name Pandarathu Limestone Mine Mining Lease Area 234.9407 ha Location of Mine Pudussery East and Malampuzha I Village, Palakkad Taluk and District, Kerala Topo sheet number 58 B/13 Nearest city/town Palakkad - 12.6 km, SW (Aerial) Production capacity 6,00,000 Tons/Annum Total Waste generation 6,72,280 m3/annum (5 years) Method of mining Open Cast mechanized method Drilling/Blasting Controlled Blasting and drilling No. of working days 300 days Water demand 25 KLD Sources of water Mining Pit. Man power 222 Nos. Nearest railway station • Walayar Railway Station - 5.8 km, ESE • Palakkad Junction - 15.25 km, SW Nearest airport Coimbatore International Airport - 32 km (NE) Infrastructure The mine is having a dedicated road from the plant, which is well maintained by company. The Office complex contains all facilities like canteen, first aid room, Store, Generator room etc. which is well maintained. The mining labour are deployed locally and there is no need for housing or shelters. Temperature Max temp - 37.30 0c; Min Temp - 21.80 0c Rainfall - 2,135 mm/annum Project Cost Rs. 30.0 Crores

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CHAPTER 2: INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and project proponent

Malabar Cement Limited (MCL) is a Govt. of Kerala Undertaking Company incorporated in April 1978 and commenced production in April 1984 at its cement plant located at Walayar. Malabar cement limited has more than 30 years of experience in cement industry and limestone Mining. MCL has a mine lease for the production of Limestone in an area of 234.9407 ha at S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Villages, Palakkad Taluk, Palakkad District, Kerala.

Malabar Cement Limited, has already obtained grant of Mining lease to produce Limestone over an extent of 234.9407 ha at S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Villages, Palakkad Taluk, Palakkad District, Kerala for 20 years.

The mining lease was granted in G.O (MS) No.44/2000 Industries Department dated 25.09.1979 for 20 years up to 24.09.1999. The lease deed was executed on 04.08.1980. The lease has been renewed on 26.08.2003 for the period of 20 years up to 2023. Copy of mine lease and renewed lease deed is enclosed as Annexure – I & II.

The Mining Plan was approved by Indian Bureau of Mines (IBM) vide Letter No.MP/PAL/Lst-29/SZ, dated 14.05.2002 under Rule 24(A) of MCR, 1960. The 1st Scheme of Mining was approved vide Letter No.MP/PAL/Lst-65/SZ dated 21.04.2006 under Rule 12 of MCDR, 1998. The 2nd scheme of mining was approved vide Letter No.MS/PAL/LST-173/SZ, dated 28.11.2011 for the period 2011-12 to 2015-16. The 3rd scheme of mining plan for the period 2016-17 to 2020-21 was approved vide Letter No. 279/464/95/BNG/336 dated 11.03.2016. Copies of above said approvals are enclosed as Annexure – III.

Malabar Cement Limited is mining limestone of 6,00,000 Tons per Annum from August 1983 onwards from its existing mine lease area by open cast mechanized mining technique. This feasibility report is prepared towards obtaining the Environmental Clearance for the existing mine lease.

For obtaining Environmental Clearance, as per MoEF&CC Notification of September 2006 and its subsequent amendment, TOR application consists of Form - 1 & Pre-Feasibility Report has to be submitted along with proposed Terms of Reference (ToR) for appraisal of the project by EAC and grant of ToR.

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Accordingly the lessee has to evaluate the possible environmental aspects and their associated impacts that will be raised due to the production of Limestone and to delineate the management plan to prevent, control, mitigate or minimize the adverse environmental impacts envisaged. In this regard, the applicant has appointed M/s. ABC Techno Labs India Private Limited, Chennai, who is accredited by National Accreditation Board for Education and Training (NABET) to prepare Environmental Impact Assessment (EIA) report including Environmental Management Plan to mitigate any adverse impacts to the Environment.

2.2 Brief description of nature the project

Pandarathu Limestone Mine lease area is a Vested Forest Land (234.9407 Ha), situated at S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Village, Palakkad Taluk & District, Kerala and adopts the open cast Mechanized method (drilling & blasting) of mining. The Limestone is extracted with the help of machineries for digging, excavation. All operations of mining, including drilling, blasting, excavation, loading & transportation on three shift basis shall form the complete mining operation.

2.3 Need for the project and its importance to the country and region

The Limestone produced from these mines is captive consummations of Malabar Cements Limited. The mine is in operation from the year 1980 onwards in an interior backward rural area with very little social and infrastructural facilities. It is a Government of Kerala undertaking company and it is the only cement manufacturing company in Kerala which is controlling the price of cement in Kerala.

The mining operations by Malabar Cements in this area have brought improvement in social, infrastructural and employment sectors in the area. Besides above benefits, financial accruals will be derived by Central, State governments and local Panchayat on account of royalty, cess, duties, etc., from project output.

Cement being a core infrastructural sector component, limestone supplies for cement manufacture also assumes great importance. In view of above aspects, it can be seen that the project is a prime need for growth of backward area of the region and for GDP growth in state/central areas. The project will also improve the Human Development Index (HDI) of the area.

2.4 Demand Supply Gap

Limestone is the main raw material for cement production; the demand is always there with that of cement. The mine produces good grade limestone leading to conservation of

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mineral resources. The cement market has growth due to the central government liberalization policies and new schemes for housing, road projects. The cement demand growth is anticipated to increase on infrastructure development and the higher demand from the housing sector & industrial projects.

2.5 Import Vs Indigenous Production

There is no import of Limestone at present in India. India especially the southern India has good resource of Limestone and has a great demand in the international super market. Indigenous Limestone almost shares more than 50% requirement in the world.

2.6 Export Possibility

Export is not envisaged as the entire quantity of limestone is being consumed by the captive cement plant located in Walayar.

2.7 Domestic/Export Markets

As the entire quantity of limestone is being consumed by the captive cement plant located in Walayar, no domestic / export marketing required.

2.8 Employment Generation (Direct & Indirect) Due to the Project

The mine is providing direct employment comprising of managerial, skilled, semiskilled and unskilled staff. Due to proximity of villages near the mine lease area there is not much problem about the labor forces for mining operation such as loading and other associated jobs. Total manpower on site is 222 persons can derive benefits in allied services like logistics, polishing, loading/ unloading repair works trading etc.

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CHAPTER - 3: PROJECT DESCRIPTION

3.1 Type of project including Interlinked and Interdependent project, if any.

The project is Limestone mining by opencast mechanized method in the lease hold area of 234.9407 Ha. The project meets the Limestone requirement for the production of clinker for cement in its captive cement plant located at Walayar which is at an aerial distance of 5.0 km from the mine lease area. The limestone extracted from the mine is of good grade limestone and is directly utilized for the cement production. It is categorized as Category ‘A’ Project, under Schedule 1(a) as the mining lease area is more than 50 ha hence it requires Environmental Clearance from the Ministry of Environment, Forest and Climate Change (MoEFCC), New Delhi.

3.2 Location (map showing general location, specific location, and project boundary & project site layout) with coordinates.

The existing mine is located at S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Village, Palakkad Taluk & District, Kerala and the entire mining lease area falls in Vested Forest Land with hilly terrain. The mine lease area is covered in parts of Survey of India Toposheet No. 58 B/13 and having elevation of 645 m AMSL and located at Latitude of 10°51’29.08” N & Longitude of 76°46’30.20” E.

TABLE 3.1 - LOCATION OF THE PROJECT SITE

District Extent of Village & Taluk S. F. No. Ownership & State area (ha) Palakkad Pudussery East & 1580/2 and 1580/3 of 234.9407 Vested Malampuzha I Pudussery East Village Forest Land Villages, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, Palakkad Taluk 874/33 Malampuzha I Village

The location map of the Mining Lease area is shown in Figure - 3.1. Satellite image showing the boundary of mine lease area is provided in Figure - 3.2. The Topo map of 10 km radius is given in Figure - 3.3. Surface Plan of the mine lease is provided in Mining Plan.

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FIGURE - 3.1: LOCATION MAP OF THE PROJECT SITE

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FIGURE - 3.2: SATELLITE IMAGERY SHOWING THE PROJECT SITE AND ITS BOUNDARIES

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FIGURE - 3.3: TOPO MAP SHOWING 10 KM RADIUS OF THE PROJECT SITE

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3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental consideration gone into should be highlighted.

The occurrence of mineral is site specific and the mining/exploitation is to be taken up to that particular location only therefore no alternative sites were required to be explored.

3.4 Size or magnitude of operation

The mining of Limestone will be carried out from the existing mine lease area of 234.9407 ha. The annual production capacity of the limestone mine is 6,00,000 Tons.

RESERVES

Based on the data obtained from the existing mining pits the reserves have been re- estimated freshly with the help of Geological Plan & Cross-Sections drawn at 100m interval across strike of the ore horizon. The exposures are marked on the plan and projected in the sections & the proved ore limit is marked up the pit bottom of the exposed ore bodies of Limestone.

The estimation of ore reserves is made by using the cross sectional area method. The Geological Cross-Sections are prepared at an interval of 100 m, across the ore body. The area of individual litho-units in each cross-section is measured and multiplying sectional interval. The bulk density is considered as 2.7 T/cum for Limestone Ore & waste. The percentage of recovery is taken as 85% & 15% is considered as overburden and Intercalated waste for Limestone Ore. The resources and reserves are estimated as per UNFC guide lines.

Proved (G-1 scale of exploration) reserves are the reserves established based on the area enclosed in the CBH boreholes No.WR-5, WR-11, WR-12, WR-16, WL-6, BH-3 (Ph- II), BH-4 (Ph-II), BH-9 (Ph-II), BH-10 (Ph-II), BH-15 (Ph-II), BH-16 (Ph-II) & BH-17 (Ph-II) and available existing working pit no.1 within the 50m interval in the Limestone ore zone, is considered for G1 scale of exploration. All the proved reserves are mineable reserves. The proved reserves are considered upto 289m RL on section A-A’ and the scale of exploration is G-1.

Inferred (G-3 scale of exploration) resources are the resources, in the unexplored area with outcropping of the Limestone Ore and distance covering pits more than 200 m is considered as inferred resource.

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TABLE - 3.1: ESTIMATION OF GEOLOGICAL RESERVES

UNFC CATEGORY-111 & 211 Sectional Qty @ 2.7 B.D. with Rec Intercalated waste @ 2.7 BD with Sections Area in m² Volume in m³ Influence in m 85% in tonnes 15% Rec in tonnes A-A' 3,404.9751 100 340,497.51 781,441.7855 137,901.4916 B-B' 4,101.7654 100 410,176.54 941,355.1593 166,121.4987 C-C' 5,644.0447 100 564,404.47 1,295,308.2587 228,583.8104 D-D' 10,346.7998 100 1,034,679.98 2,374,590.5541 419,045.3919 E-E' 8,811.8348 100 881,183.48 2,022,316.0866 356,879.3094 F-F' 15,311.3522 100 1,531,135.22 3,513,955.3299 620,109.7641 TOTAL IN TONNES 10,928,967.174 1,928,641.266 TOTAL IN MILLION TONNES 10.929 1.929

UNFC CATEGORY-333 Sectional Qty @ 2.7 B.D. with Intercalated waste @ 2.7 BD Sections Area in m² Volume in m³ Influence in m Rec 85% in tonnes with 15% Rec in tonnes A-A' 2,187.1496 100 218,714.96 501,950.8332 88,579.5588 B-B' 485.7346 100 48,573.46 111,476.0907 19,672.2513 F-F' 3,403.2120 100 340,321.20 781,037.1540 137,830.0860 TOTAL IN TONNES 1,394,464.0779 246,081.8961 TOTAL IN MILLION TONNES 1.394 0.246

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TABLE - 3.2: ESTIMATION OF MINEABLE RESERVES

UNFC CATEGORY-111 Intercalated Sectional Qty @ 2.7 B.D. Qty @ 2.7 B.D. Volume in waste @ 2.7 BD Area in Volume in Total Waste in Sections Area in m² Influence with Rec 85 % in with Rec 85 m³ with 15% Rec m² m³ Tonnes in m tonnes % in tonnes in tonnes A-A' 2,666.3453 100 266,634.53 6,11,926.2464 1,07,986.9847 2,737.3052 273,730.52 739,072.404 847,059.3887 B-B' 4,101.7654 100 410,176.54 9,41,355.1593 1,66,121.4987 777.6078 77,760.78 209,954.106 376,075.6047 C-C' 5,644.0447 100 564,404.47 12,95,308.2587 2,28,583.8104 2,457.1085 245,710.85 663,419.295 892,003.1054 D-D' 10,346.7998 100 1,034,679.98 23,74,590.5541 4,19,045.3919 6,500.3832 650,038.32 1,755,103.464 2,174,148.8559 E-E' 8,764.3774 100 876,437.74 20,11,424.6133 3,54,957.2847 8,023.2071 802,320.71 2,166,265.917 2.521,223.2017 F-F' 15,311.3522 100 1,531,135.22 35,13,955.3299 6,20,109.7641 7,985.2560 798,525.60 2,156,019.120 2,776,128.8841 Total in Tonnes 1,07,48,560.1616 18,96,804.7344 7,689,834.306 9,586,639.0404

Total in Million Tonnes 10.749 1.897 7.690 9.587

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TABLE - 3.3: SUMMARY OF BLOCKED RESERVES & RESOURCES

RESOURCE IN SCALE OF CATEGORY MILLION TONNES EXPLORATION Blocked Mineral Resource (211) 0.180 G1 Inferred Mineral Resource (333) 1.394 G3 TOTAL 1.574

The reserves & resources blocked due Ultimate Pit Limit are tabulated in a tabular form as enclosed in the following Table No.7 for Limestone ore.

TABLE - 3.4: BLOCKED RESERVES & RESOURCES CALCULATIONS

UNFC CAYEGORY-211 Sectional Qty @ 2.7 B.D. Intercalated waste Area in Volume Sections Influence with Rec 85 % @ 2.7 BD with 15% m² in m³ in m in tonnes Rec in tonnes A-A' 738.6298 100 73,862.98 169,515.5391 29,914.5069 E-E' 47.4574 100 4,745.74 10,891.4733 1,922.0247 TOTAL IN TONNES 1,80,407.0124 31,836.5316 TOTAL IN MILLION TONNES 0.180 0.032

UNFC CATEGORY-333 Intercalated Sectional Qty @ 2.7 B.D. Area in Volume in waste @ 2.7 BD Sections Influence with Rec 85% m² m³ with 15% Rec in m in tonnes in tonnes A-A' 2,187.1496 100 218,714.96 501,950.8332 88,579.5588 B-B' 485.7346 100 48,573.46 111,476.0907 19,672.2513 F-F' 3,403.2120 100 340,321.20 781,037.1540 137,830.0860 TOTAL IN TONNES 1,394,464.0779 246,081.8961 TOTAL IN MILLION TONNES 1.394 0.246

The reserves are furnished according to UNFC guidelines, the cut-off grade and threshold values considered for reserves estimation. For the ascertaining of UNFC code following procedure is adopted.

i) The category of the deposit as per UNFC guidelines which comes under Category - I of Stratiform & Tabular deposit of regular Habit.

ii) The status of exploration is taken as G-1 scale, because lessee has drilled 43 No’s of core boreholes and one working pit in the lease area are available. The proved reserves considered up to 289m RL on section A-A’. The area enclosed in the CBH boreholes No.WR-5, WR-11, WR-12, WR-16, WL-6, BH-3 (Ph-II), BH-4 (Ph-II), BH-9 (Ph-II), BH- 10 (Ph-II), BH-15 (Ph-II), BH-16 (Ph-II) & BH-17 (Ph-II) and available existing working pit no.1 within the 50m interval in the Limestone ore zone. Hence, it is geologically explored and considered as Geological Axis ‘1’.

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iii) The Feasibility is considered as F1. The exploration is carried out with 43 no’s of core boreholes and 1 no of working pit. The percentage of recovery is taken as 85% and 15% which is considered as Intercalated waste for Limestone Ore. Hence, it is considered as feasible for mining which is taken as Feasible Axis ‘1’.

iv) Based on the exploration with 43 no’s of core boreholes and existing 1 no. of working pit and its analysis, Scheme of mining plan is prepared as per the provisions & will be submitted to the IBM. The reserves have been ascertained above economic cut-off grade and by considering all above factors the mining is economical. Hence it is considered as Economical Axis ‘1’. v) Based on the exploration with 43 no’s of core boreholes and existing 1 no. of working pit and its analysis, scheme of mining plan is prepared as per the provisions & will be submitted to the IBM. The reserves have been ascertained above economic cut-off grade, but the reserves are blocked in the ultimate pit and by considering all above factors the mining is economical. Hence it is considered as Economical Axis ‘1’. vi) The unexplored area with outcrops in the area and the distance is more than the 200m from the trails pits. The working pits are considered as Geological Axis ‘3’. vii) The Feasibility is considered as F3. The exploration is not carried out in the area & with the influence of trail pits and working pits the resource are taken for Feasibility Axis 3. Hence, it is considered as Feasible Axis ‘3’. viii) The reserves have been ascertained without proper exploration the value of ore is taken as assumption value. Hence it is considered as Economical Axis ‘3’. ix) The combining of EFG axis the UNFC code for reserves is assigned as 111, 211 and resource is 333. x) The data of drilled 43 no’s of core boreholes & 1 no of working pit the Limestone Ore is exposed in three dimensional views the mining area taken into consideration for reserve estimation.

Based on the exploration, available measured field data, exposure in the lease area and adjoining area entire geological sections are updated and ore reserves have been freshly-estimated as on 30.10.2015.

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l) Mineral Reserves/Resources:

TABLE 3.5 - SUMMARY OF RESERVES FURNISHED UNDER

RESERVES IN MILLION SCALE OF CATEGORY TONNES EXPLORATION Proved Mineral Reserves (111) 10.749 Feasibility Mineral Reserves (211) 0.180 G-1 TOTAL 10.929

TABLE 3.6 - SUMMARY OF RESOURCES IS FURNISHED UNDER

RESOURCE IN MILLION SCALE OF CATEGORY TONNES EXPLORATION Inferred Mineral Resource (333) 1.394 G-3 TOTAL 1.394

3.5 Project description with process details (a schematic diagram/ flow chart showing the project layout, components of the project etc. should be given).

The Pandarathu Limestone deposit forms a part of the Khondalite suite of rocks, intruded by later granites, all of the Archaean Age. The general rock units in the area include Granetiferous sillimanite biotite gneisses, Calc Granulates and crystalline limestone. The biotite gneisses and Granulates have some intrusive of Pegmatite and Quartz vines. The crystalline limestone band are closely associated with calc-granulites. The Granetiferous biotite gneisses form the hanging wall of the crystalline limestone, whereas the Calc granulates and Granetiferous Sillimanite - biotite gneisses are on the footwall side.

The gneisses are weathered at the upper levels and compact at depth. Generally the biotite gneisses on the hanging wall and foot wall sides are similar in character except that the proportion of sillimanite is more on the footwall side. The rocks show a general strike of N 800 to 850W with steep dip towards the South, ranging from 550 to 800.

Joints are prominent and comprise both dip and strike joints. Solution cavities are present and filled with soil. The deposit is of cement grade with lowering in grade at the contact zones as well as in the areas of cavities and joints. The limestone is clearly demarcated and is distinctly coloured white.

The limestone occurs in the form of a continuous band extending over a length of 560m and width varying from 100 to 250m. It is hard, crystalline with varying colour of white, cream, light/dark gray and pink. It is medium to coarse-grained and has a saccarodial texture. Granetiferous-biotite-gneiss band running in the central part of the deposit area in east-west direction bisects the limestone deposit into northern and southern bands.

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The limestone is in crystalline nature. Joints are predominant and comprise both dip and strike joints. Solution cavities are present and filled with soil. As the mine has advanced to deeper benches, there is marked improvement in respect of quality and also reduction in production related to industrial / soil pockets.

Rate of Production and expected life of the mine:

The mineable reserves is estimated by cross-sectional method having considered the recovery factor, depth of mining, safety barriers etc., Based upon re-estimated and updated ore reserves by considering only proved reserves of 3,980,948 Cu.M (10,748,560 tonnes), existing rules & regulations of the mines as on 30.10.2015.

The maximum production capacity is 2,22,222 Cu.M (6,00,000 tonnes) per annum and captive demands the life of the mine [Total reserves (in Cu.M) annual production (in Cu.M) = 3,703,703/222,222] is expected to be about 16 years. The life of the mine will be revised after completing exploration of the current scheme of mining and reassessment of reserves.

Method of Mining:

Limestone mining in the subject lease area was worked during the persistence of the earlier lease periods by open cast mechanized method. Considering various technical parameters like surface topography, quality variations, geo-technical aspects, requires rate of production & available resources etc.

The mine will be operated by fully mechanized method category ‘A’ by drilling & blasting. The working operation will be continued from the same existing pits with systematic and scientific method of mining, it will extend in all the directions for extraction of the mineral.

Mining works will be continued on the deposit by adopting 9 m bench height and with an ultimate pit slope 500-550 as per the Slope Stability Report issued by the NIRM. The benches shall be 9m height and the width of the benches will be more than 9min working benches and gradient of the haulage roads shall be kept 1 in 16 as required to be maintained under Metalliferous Mine Regulations-1961 specified by DGMS.

The present dimension of the pit is shown below in the Table – 3.7.

TABLE 3.7 - THE LOCATION, DIMENSION OF EXISTING WORKING PITS WORKING DIMENSIONS EASTING NORTHING LITHOLOGY PIT ID LENGTH WIDTH DEPTH 693291 to 1200668 to 342m Limestone WP-1 790 550 694080 1201257 RL Ore body

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During this scheme of mining period, about 6,00,000 Tons of limestone per annum will be produced by mechanized method from the existing mine pit.

The mine operations involve blasting for hard strata and big boulders are breaking by rock breakers. Most of the ore/waste formation is hard and it can be excavated with the use of drilling/blasting. The Ore is broken by blasting and loaded by excavators into dumpers and transported to the crusher/stock yard. The ROM will be transported to crushing/screening unit where it will be processed to get the specified material.

Mineral excavation is carried out by use of shovels and loaded by excavators into dumpers of 35 Tonnes capacity and transported to the crushing & screening plant. The Excavator will be used for extraction and loading of the mineral & waste.

The OB waste, will be dumped in the specified dump yard. Haulage roads will be maintained at 1 in 16. Ramps will be developed from pit bottom to top through benches for easy movement of men/machinery.

All the activities will be carried out by adhering to provisions of MMR/1961, MCDR-1988 & other acts and regulations in force.

ULTIMATE PIT LIMIT

Taking into consideration the available exploration data, structural parameters of the ore body and the updated geological mapping, final Pit layout is designed by maintaining 500-550 pit slope angle along the hanging wall side and foot wall side. The Final Pit Limit so defined may remain tentative as the exploration is yet to be taken.

MINE MACHINERIES

TABLE 3.8 - THE LIST OF MINING MACHINERIES

S. No. Machineries Make Capacity Numbers BE-700 3.7 m3 bucket 01 BEML 404 HP EX-400 2.6 m3 bucket 1. Hy. Excavators 01 TATA 280 HP Zaxis-450 2.7 m3 bucket 02 TELCON 315 HP BE-220 0.9 m3 bucket 2. Hy. Back hoe 02 BEML 150 HP Hy. Rock BE-240 F-22 3. 01 breaker BEML 180 HP Haulpak BH 35-2 35 T 4. Dumper 09 BEML 375 HP D-155 303 HP 02 BEML 5. Dozers D-60 165 HP 01 BEML

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S. No. Machineries Make Capacity Numbers XAH-210 440 CFM, 12 bar 03 Atlas Copco 180 HP 6. Compressors XAHS-186 400 CFM, 14 bar 01 Atlas Copco 160 HP BVB 2510 100 mm dia. 7. Wagon Drills 04 Atlas Copco 8. Explosive van Ashok Leyland 07 T 01 9. Mobile Unit Tata 05 T 01 10. Diesel tanker Tata 3000 Ltr. 01 11. Lorry Tata 10 T 01 12. Jeeps Mahindra 6 seat 04 13. Water tanker BEML 28000 Ltr 01 14. Water tanker Tata 8000 Ltr 01

Mineral Processing:

The crushing plant installed in the mine have both Primary & Secondary Crushers. The Primary crusher receives feed from the mines with a maximum size of 1000mm and the product size shall be 200mm. The average output is 250 tons/hour. The type of crusher is double toggle jaw crusher. The secondary crusher is reversible impact hammer type of crusher with 48 No’s of hammers. The size of the crusher is 1500mm x 1800mm. The average output rate is 180 tons/hour. The product obtained will be of 20 mm size.

Mineral Storage and Transportation:

Mineral storage facility is available within the mine lease area to store the mined out minerals. Land of 0.9 ha has been allotted for mineral storage. The processed minerals after screening if required, will be sent to the nearer Cement factory of Malabar Cements Limited by ropeway. The cut-off grade for Limestone ore is 35% CaO.

YEAR WISE EXCAVATION OF LIMESTONE

I. INSITU TENTATIVE EXCAVATION

During scheme of mining plan period working will be done in section A-A’, B-B’, C-C’, D- D’, E-E’ & F-F’ and the mining depth will varies from 429m RL to 321m RL in Limestone ore. The year wise production and development along with the sections are shown on the Production & Development Plan and is enclosed as Plate No.6A to 6E. The year wise production and development details are furnished in the following table.

TABLE 3.9 - THE YEAR WISE EXCAVATION DETAILS OF LIMESTONE ORE

Total ROM (Cum) Top OB/SB/ ROM Pit Tentative Ore Mineral Mineral Year Soil IB Waste No Excavation (Cu.M) reject reject (Cu.M) (Cu.M) Ratio (Cu.M) * (Cu.M) 1 2 3 4 5 6 7 8 9 2016-17 1 3,72,938 Nil 1,50,716 222,222 -- -- 0.68 2017-18 1 3,41,938 Nil 1,19,716 222,222 -- -- 0.54

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2018-19 1 3,37,638 Nil 1,15,416 222,222 -- -- 0.52 2019-20 1 3,58,438 Nil 1,36,216 222,222 -- -- 0.61 2020-21 1 3,72,438 Nil 1,50,216 222,222 -- -- 0.68 * Tentative tonnage of the ore may be arrived by computing approximate 2.7 bulk density and 85% recovery factor as these data are variable and may be established on time series. TABLE 3.10 - LOCATION OF THE WORKING PIT FROM 2016 - 17 Scheme of Location Mining Plan Section Working RL m Northing Easting Period 2016-17 N:1200891 to 1201149 E:693806 to 693922 F-F’ 429 to 366 2017-18 N:1200922 to 1201098 E:693742 to 693845 E-E’ 357 to 321 2018-19 N:1200891 to 1201096 E:693642 to 693742 D-D’ 363 to 321 N:1200888 to 1201069 E:693491 to 693642 C-C’ 366 to 321 2019-20 N:1200888 to 1201035 E:693472 to 693542 B-B’ 366 to 321 2020-21 N:1200898 to 1201053 E:693396 to 693478 A-A’ 402 to 339

Table 3.11- DETAILED CALCULATION OF YEARWISE PRODUCTION & DEVELOPMENT 2016-17 LIMESTONE WASTE Qty @ Intercalated Total 2.7 B.D. Qty @ Area Sectional waste @ 2.7 Area Waste Volume with Volume 2.7 B.D. Sections in Influence BD with in In in m³ Rec 85 in m³ in m² in m 15% Rec in m² Tonnes % in tonnes tonnes tonnes F-F' 2,614 100 261,438 600,000 105,882 1,115 111,500 301,050 406,932 TOTAL IN TONNES 600,000 105,882 301,050 406,932 TOTAL IN CU.M 222,222 39,216 111,500 150,716 2017-18 LIMESTONE WASTE Qty @ Intercalated Total 2.7 B.D. Qty @ Area Sectional waste @ 2.7 Area Waste Volume with Volume 2.7 B.D. Sections in Influence BD with in In in m³ Rec 85 in m³ in m² in m 15% Rec in m² Tonnes % in tonnes tonnes tonnes E-E' 2,614 100 261,438 600,000 105,882 805 80,500 217,350 323,232 TOTAL IN TONNES 600,000 105,882 217,350 323,232 TOTAL IN CU.M 222,222 39,216 80,500 119,716 2018-19 LIMESTONE WASTE Qty @ Intercalated Total 2.7 B.D. Qty @ Area Sectional waste @ 2.7 Area Waste Volume with Volume 2.7 B.D. Sections in Influence BD with in In in m³ Rec 85 in m³ in m² in m 15% Rec in m² Tonnes % in tonnes tonnes tonnes D-D' 2,614 100 261,438 600,000 105,882 762 76,200 205,740 311,622 TOTAL IN TONNES 600,000 105,882 205,740 311,622 TOTAL IN CU.M 222,222 39,216 76,200 115,416 2019-20 LIME STONE WASTE Total Area Sectional Volume Qty @ Intercalated Area Volume Qty @ Waste Sections in Influence in m³ 2.7 B.D. waste @ 2.7 in in m³ 2.7 B.D. In

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m² in m with BD with m² in Tonnes Rec 85 15% Rec in tonnes % in tonnes tonnes C-C' 1,250 100 125,038 286,962 50,640 512 51,200 138,240 188,880 B-B' 1,364 100 136,400 313,038 55,242 458 45,800 123,660 178,902 TOTAL IN TONNES 600,000 105,882 261,900 367,782 TOTAL IN CU.M 222,222 39,216 97,000 136,216 2020-21 LIME STONE WASTE Qty @ Intercalated Total 2.7 B.D. Qty @ Area Sectional waste @ 2.7 Area Waste Volume with Volume 2.7 B.D. Sections in Influence BD with in In in m³ Rec 85 in m³ in m² in m 15% Rec in m² Tonnes % in tonnes tonnes tonnes A-A' 2,614 100 261,438 600000 105,882 1,110 111,000 299,700 405,582 TOTAL IN TONNES 600,000 105,882 299,700 405,582 TOTAL IN CU.M 222,222 39,216 111,000 150,216

TABLE 3.12 - LOCATION, DIMENSION OF EXISTING WORKING PITS

EXISTING WORKING PITS LOCATIONS WORKING DIMENSIONS S.NO EASTING NORTHING LITHOLOGY PIT ID LENGTH WIDTH DEPTH 693291 to 1200668 to 342 m Limestone Ore 1 WP-1 790 550 694080 1201257 RL body

3.6 Raw material along with estimated quantity, likely source marketing area of final products, mode of transport of raw material and Finished product.

There is no requirement of any raw material for the production of Limestone from this project except the explosives required for blasting, diesel for movement of machinery and electricity. The Limestone excavated from the mine is crushed within the mine and transported through ropeway to the cement plant. No marketing is required for limestone as it is for captive consumption in cement plant.

3.7 Resource optimization / recycling and reuse envisaged in the project, if any, should be briefly outlined.

No optimization / recycling and reuse envisaged in the mine lease area.

3.8 Availability of water its source, Energy / power requirement and source should be given.

The quantity of water required for the mine lease area is 25 m3/day. Drinking water is available from the streams flowing adjacent to the site which is potable and will fulfill the requirement of drinking water.

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TABLE 3.14 - WATER CONSUMPTION DETAILS

S. No. Description Requirement in KLD 1 Domestic Water use (For Labors) 13 2 Dust Suppression (Material Transportation) 10 3 Greenbelt Development 2 Total 25

Power Requirement - The mining work is restricted to one general shift during daytime only. Electricity is not needed for Mine operations as mainly diesel operated machineries are used for Mining. However, the power requirement of the administrative buildings, Crushing & Screening Plant, Rope lines and other site services can be met from state grid through the existing 66 kV power line. Besides, standby generator is available to meet the emergency power requirement of the mines.

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their Management /disposal.

The anticipated waste generation during the entire life of mining is about 9.587 Million Tons. During the scheme period of 2016-2021, waste generation is expected as 6,72,280 m3 (4,76,200 m3 Overburden + 196080 m3 Intercalated) which is being dumped in the existing dump area of 27.47 ha.

Table 3.15 - Quantity of waste to be generated during the scheme of mining period (2016 - 2021)

Waste in Intercalated Total Waste Location of Dump Year Cu.M Waste in Cu.M in Cu.M Easting Northing 693323 to 1200478 to 2016 -17 111,500 39,216 150,716 694063 1200616 693323 to 1200523 to 2017 -18 80,500 39,216 119,716 694064 1200658 693333 to 1200559 2018 -19 76,200 39,216 115,416 694052 to1200678 693361 to 1200603 to 2019 -20 97,000 39,216 136,216 694052 1200711 693427 to 1200650 to 2020 -21 111,000 39,216 150,216 694021 1200746

Wastewater:

There will not be any process effluent generation from the mine lease area. Domestic effluent from the mine office is discharged in septic tank and soak pit. There is no toxic effluent expected to generate in the form of solid, liquid and gases and hence no requirement for treatment of waste.

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3.10 Schematic representation of the feasibility drawing which give information of EIA purpose

Form - 1 Along with Pre-Feasibility Report & Scheme of Mining with Annexure to MoEFCC

TOR Presentation

TOR

Draft EIA Report to PCB

Public Hearing

Final EIA Report to MoEFCC

Final EC Presentation

22 December 2017

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CHAPTER 4: SITE ANALYSIS

4.1 Connectivity.

The subject area is spread over an area of 234.9407 ha at SF.No.1580/2 & 1580/3 of Pudussery East & Sy. No. 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Villages, Palakkad Taluk & District, Kerala.

The applied area is about 2.8 km, away from Pudussery East Village. Mine lease area is well connected with roadways, the nearest roadway is NH 544: Salem - Kochi Road 5.5 km South East. Nearest Railway station is Walayar Railway Station which is located at 5.8 km ESE away from the Mine lease area.

Coimbatore International Airport is located at the distance of about 32 km NE from the Mine lease area. Nearest Port is Kochi Port which is available at a distance of 103 km SSW. The Existing area is easily accessible by means of roadways (Lorries and trucks).

Infrastructural Facilities and basic human welfare needs such as schools, communications facilities and commercial centers etc are available at Palakkad located at a distance of 12.6 km from the South West side of the mining area.

The area is approachable by well-developed road network. The road connectivity map for the Mine lease area is given below.

FIGURE 4.1 - SITE CONNECTIVITY MAP

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FIGURE 4.2: MAP SHOWING ROAD & BUILTUP 10 KM RADIUS OF THE PROJECT SITE

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4.2 Land form, Land use and Land ownership.

Pandarathu Mine lease area is a Vested Forest Land with total land area of 234.9407 ha with hilly terrain. The land is leased by Govt of Kerala to Malabar Cements Limited for 50 years vide lease deed dated 1st July 1980 and copy of same is enclosed as Annexure – IV.

4.3 Topography (along with map).

The hills on both northern and southern sides of the ridge rise to elevations of 900m to 1100m above mean sea level with valleys in between these hills and the ridge occupied by Cheemanthy Nallah and Pandarathu Nallah respectively.

Two seasonal streams, Cheemanthy Nalla and Pandarathu Nalla flow on the Northern and Southern sides of the deposit, respectively. The Pandarathu nallah flows from east to west direction in the southern part of the lease area. It is a seasonal nallah. The Cheemanthy nallah, originally flowing from the central part of the area has been shifted towards northern part of lease area for accommodating the mining activities.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forest, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.

The mine lease of 234.9407 ha is categorized as Vestsed Forest Land is being used for extraction of Limestone. The detailed site surrounding features are given in the 10 km radius Topo map already provided. Significant features in 10 Km radius (aerial distance) of the project are tabulated below.

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TABLE 4.1 ENVIRONMENTAL SETTING OF THE PROJECT SITE

S. No. Description Details 1. Site Location S.F. Nos. 1580/2 and 1580/3 of Pudussery East Village, 866/1, 867/12, 867/13, 867/14, 868/2, 869/1, 874/33 of Malampuzha I Village, Palakkad Taluk & District, Kerala. 2. Latitude and Longitude 10 ̊ 51’ 07.99” to 10 ̊ 51’ 47.01” N & 76 ̊ 45’ 47.99” to 76 ̊ 47’ 24.00” E 3. Topography Hilly Terrain 4. SOI Toposheet 58 B/13 5. Above Mean Sea Level in m 645 m AMSL 6. Nearest City/ Town District & Taluk Headquarters Palakkad -12.6 km (SW) 7. Nearest Roadways NH 544 : Salem - Kochi Road - 5.5 km (SE) 8. Nearest Air port Coimbatore International Airport - 32 km (NE) 9. Nearest Railway Station Walayar Railway Station - 5.8 (ESE) Kottekkad Railway Station - 10 km (SW) 10. Interstate Boundary Tamil Nadu - Kerala Border - 1 km (E) 11. Hills/valleys Chemanthi Malai – Within 12. National parks / Wildlife Nil within 10 km radius Sanctuaries 13. Reservoir / Lake/River/Sea • Malampuzha Dam - 5.2 km (SW) • Walayar Dam - 6.5 km (ESE) • Walayar River - 8.7 km (SE) 14. Reserved/ Protected Forests Solakarai R.F - 6.7 km (ESE) 15. Archaeological Important Nil within 10 km radius Places 16. Seismicity Seismic Zone III (Moderate Damage Risk zone) as per IS 1893 (Part-1): 2002 17. Defence Installations Nil within 10 km radius 18. Nearest Port Kochi Port - 103 km (SSW) 19. Nearby mines Nil within 10 km radius

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4.5 Existing Infrastructure

The mine is having a dedicated road from the Malabar Cement Factory to mine, which is well maintained by company. The Office complex contains all facilities like canteen, first aid room, workshop, Store, Generator room, rest shelter room etc. which is well maintained.

4.6 Soil classification

The top soil is fine to small coarse grained, gray color having no organic matter and nutrients which are 0.3 to 0.5 m thickness from the general surface, the same is collected wherever mining operation is conducted in the lease area. During the scheme of mining plan no top soil is generated. If top soil is generated, it will be utilized for afforestation and plantation purposes in the safety zone & dumps for stabilizing.

4.7 Climatic data from secondary sources.

Palakkad has a tropical wet & dry climate. The climate is tropical with temperatures ranging between 20 degree centigrade and 40 degree centigrade with an annual rainfall of between 1100 to 1300 mm. The rainy season is restricted to 4 months from May to August. The temperatures remain moderate throughout the year, with exception in March & April being hottest months. March is the warmest month of the year. The temperature in March averages 30.7°C. The lowest average temperatures in the year occur in July, when it is around 25.5°C. A very high amount of precipitation is received in Palakkad, mainly due to the south-west monsoon. The driest month is January, with 3mm of rain. The greatest amount of precipitation occurs in July, with an average of 565mm. The summers are much rainier than the winters in Palakkad. According to Köppen and Geiger, this climate is classified as Aw. The average annual temperature in Palakkad is 27.8°C. In a year, the average rainfall is 1200 mm. There is a difference of 562 mm of precipitation between the driest and wettest months. The variation in temperatures throughout the year is 5.2°C.

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CHAPTER 5 : PLANNING BRIEF

5.1 Planning Concept (type of Industries, facilities, transportation etc) Town and country planning/Development authority Classification.

Open cast mechanized mining method is adopted for exploitation of Limestone from this area. Transportation and commodities infrastructure facilities are available near the project site. The mineral is transported from mine head to processing plant by tippers.

5.2 Population Projection

About 222 workers will be deployed locally for the mining activity. Other than that, there are few villages located in the 5 km radius of mining site and approximate distance and population are given below.

Direction Village Distance in Km Population South West Malampuzha 5.1 km 11,870 North Alanthurai 5.2 km 7,221 South East Pudussery East 2.8 km 14,416

Basic human welfare needs such as schools, communications facilities and commercial centers etc. are available at Palakkad located at a distance of 12.6 km from the South West side of the mining area.

5.3 Land use planning (breakup along with green belt etc.)

Pandarathu Mine lease area is a Vested Forest Land with total land area of 234.9407 ha with hilly terrain. The land use break-up of the Mine lease area is shown below.

TABLE 5.1 - LAND USE BREAK-UP

Scheme of Mining Conceptual S. Present Land Plan Period Period (2026- Particulars No. Use (in ha) (2016-17 to 2020- 27 to 2028- 21) 29) 1 Area under Mining 30.90 30.90 40.02 2 Storage for Top Soil 0.00 0.00 0.00 3 Waste Dump Site 27.47 27.47 35.47 4 Mineral Storage 0.90 0.90 0.90 5 Infrastructure 7.35 7.35 7.35 6 Roads 5.39 5.39 9.39 7 Railways 0.00 0.00 0.00 8 Tailing Pond 0.00 0.00 0.00 9 Effluent Treatment Plant 0.00 0.00 0.00 10 Crushing & Screening Plant 3.30 3.30 3.30 11 Township area 0.00 0.00 0.00 12 Green Belt 2.50 8.19 138.5107 Others Unbroken Area 157.1307 151.4407 -- Total 234.9407 234.9407 234.9407

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GREENBELT DETAILS

In the existing mines about 24,000 no of native species are planted and maintained in an area of 11.0 ha land. During this 3rd scheme of mining, 2,500 native tree species is being planted over an area of 5.69 ha along the boundary, haul roads & NE corner of the lease area. The plantation plan for this scheme of mining period is given below.

TABLE 5.2 - GREENBELT DEVELOPMENT PLAN

S. No. of Year Location Species No. Samplings 1 2016-17 500 Neem, 2 2017-18 On available space along the 500 Teak, 3 2018-19 boundary, haul roads & NE corner 500 Tamarind, 4 2019-20 of Lease area. 500 Jackfruit, 5 2020-21 500 Bamboo, Mango Total 2,500 etc.

5.4 Assessment of Infrastructure Demand (physical & social)

The establishment of the Cement Plant and Mine would aid in the overall social and economic development of the region. The mines is providing employment to about 222 peoples directly and in addition there will be indirect employment to about 1000 people in the form of contractual jobs, business opportunities, service facilities etc. This will enhance the economic status. Apart from jobs the company will provide medical facilities to the employees which will be availed by around the plant.

5.5 Amenities/Facilities

Infrastructural facilities like post and telegraph office, telephone, police station, and primary health centre, etc. are available at Palakkad town. The mine is having a dedicated road from the main road to mine, which is well maintained by company. The Office complex contains all facilities like canteen, first aid room, Store, Generator room, etc. and Malabar Cements Limited will establish a dispensary in the plant premises.

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CHAPTER 6: PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area).

In the total ML area, 3.30 ha of land has been allotted for mineral processing which involves crushing of mined out limestone to the reduced size. The crushed product after screening if required, will be sent to the nearby factory of Malabar Cements Ltd for further processing and production of Cement.

6.2 Residential Area (Non processing Area).

No Residential area are envisaged

6.3 Green Belt.

Greenbelt is being developed on available space along the boundary, haul roads & NE corner of Lease area by planting native species of Neem, Teak, Tamarind, Jackfruit, Bamboo, Mango etc. at a rate of 500 trees per annum with the interval of 5m.

6.4 Social Infrastructure.

Social infrastructure like primary school, educational institutions, banks and hospitals are located at District & Taluk headquarters Palakkad. Since the mine site is located nearer to Palakkad City, it has all the essential facilities like school, hospitals etc., Project Site is also well connected with roads and railways.

6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.)

Adequate road facility is available from the mine lease area.

6.6 Drinking Water management (Source & Supply of water)

Total water requirement for the project site is about 25 KLD. Out of this, drinking / domestic water requirement of 13 KLD will be met through the streams flowing adjacent to the site.

6.7 Sewerage System

The sewage generated in the mine lease area is treated through septic tank followed by soak pit.

6.8 Industrial Waste Management.

No industrial waste will be generated from the project.

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6.9 Solid Waste Management.

6.10 Power Requirement & Supply / Source.

Due to the adoption of simple methods and limited scale of activities for limestone mining, it does not require high tension electric power. The mining work is restricted to one general shift during daytime only. No electricity is needed for Mine operations etc as mainly diesel operated mining machinery are used for Mining. However, the power requirement of the administrative buildings, roads etc can be met from state grid. Besides, standby generator will be available to meet the emergency power requirement of the mines.

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CHAPTER 7: REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (central/state) in respect of the project affected person including home oustees, land oustees and landless laborers (a brief outline to be given.)

There is no rehabilitation and resettlement involved. The deployed labors will be insured as per government norms. The mine does not cover any habitation. Hence the mining activities do not involve any displacement of human settlement. No public buildings, places, monuments, etc., exist within the lease area or in the vicinity.

CHAPTER 8: PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE & COST ESTIMATES

Total cost spent towards development of mines, deployment of machinery and creation of infrastructural facilities like approach road, Mine office / Workers Shed, First Aid Room etc. including electrifications and water supply is about is Rs. 30.0 Crores. No additional capital cost is required as entire infrastructure is available.

8.2 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) i) Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.

The project is been giving direct and indirect benefits to the peoples in around the project site, beside the government. As the Limestone mining operations in the project mine has employed about 222 persons through allied opportunities in logistics, trading, repining works etc., good employment potential will arise in this internal rural backward area, which will provide a great fillip for raising income levels and standard of living in the area.

The socio- Economic conditions of the village and distance has enhanced due to the project, hence, the project should be allowed after considering all the parameters. The detail furnished in this report is based on information provided by the State Government and the lessee.

32 December 2017