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Environmental Impact Assessment ENVIRONMENTAL IMPACT ASSESSMENT FOR EXPANSION OF INTEGRATED CEMENT PLANT FROM 3.6 TO 7.2 MTPA CLINKER AND 5.0 TO 10.0 MTPA CEMENT BY INSTALLATION OF LINE-II AT VILLAGES BHARAULI AND ITAHARA, TEHSIL MAIHAR, DISTRICT SATNA, MADHYA PRADESH EXECUTIVE SUMMARY Project Proponent: M/s. RELIANCE CEMENT COMPANY PRIVATE LIMITED EIA Consultant: Baseline Studies Conducted by: Bhagavathi Ana Labs Ltd Vimta Labs Ltd. #8-2-248/5/A/42, Venkateswara Hills 142 IDA, Phase-II, Cherlapally Road No.3, Banjara Hills Hyderabad–500 051 Hyderabad – 500 034 [email protected], www.vimta.com April 2013 1 EIA Report for the Expansion of Integrated Cement Plant from 3.6 to 7.2 Reliance Cement MTPA Clinker and 5.0 to 10.0 MTPA Cement by Installation of Line-II at Company Private Villages Bharauli and Itahara, Tehsil Maihar, District Satna, Madhya Pradesh Limited Executive Summary 1.0 Project Description 1.1 Introduction Reliance Cement Company Private Limited (RCC) is a constituent of the Reliance – Anil Dhirubhai Ambani Group (ADAG), which has planned to set up Cement Plants in the various parts of the country preferably near Group’s own Power Plants for the sourcing of fly ash. RCC has cement plant with production capacity of 3.6 MTPA clinker and 5.0 MTPA cement and 75 MW CPP under phase-I (Maihar Line-I) at Bharauli and Itahara villages, Maihar tehsil, Satna district, Madhya Pradesh. On the basis of market demand, RCC is planning to enhance the existing cement plant capacity of 3.6 MTPA to 7.2 MTPA clinker and 5.0 MTPA to 10.0 MTPA cement plant by installing one additional Line-II 3.6 MTPA clinker and 5.0 MTPA cement within the existing plant premises. Total project cost is estimated to be Rs. 1663 crores. The proposed project can be classified as 3 (b) type activity under the category ‘A’ as per EIA notification dated 14 th September 2006. 1.2 Environmental Setting The study area map of 10 km radius around the proposed site is given in Figure- 1. The environmental setting of the proposed expansion is as follows: The proposed expansion of cement plant falls at the intersection of Latitude 24°09'27.5"N - 24°10'48.6"N and Longitude 80°41’21.2"E - 80°42'7.0"E and at an elevation of about 340 - 350 m above Mean Sea Level (MSL). The proposed expansion of cement plant is located at about 15 km (aerial) from Maihar in NE direction. Tamas river is flowing at a distance of 0.6 km in SSE from the project site. There are no ecological sensitive locations, archaeological monuments, places of tourist interests and defence installations within 10 km radius. One reserved forest and one protected forest blocks exists within 15 km radius. Nearest hill is situated at a distance of 1.0 km in S from the project site. Nearest major town from the plant is Maihar and city is Satna which is located at about 35.0 km in N. Nearest village from the plant is Bharauli is located at about 0.1 km in SW direction. Nearest railways station from the plant is Bhadanpur at about 1.5 km in W direction. Proposed plant site does not fall in any critically polluted areas as per the CPCB/MoEF circular dated January 2010. Bhagavathi Ana Labs Ltd, Hyderabad 1 EIA Report for the Expansion of Integrated Cement Plant from 3.6 to 7.2 Reliance Cement MTPA Clinker and 5.0 to 10.0 MTPA Cement by Installation of Line-II at Company Private Villages Bharauli and Itahara, Tehsil Maihar, District Satna, Madhya Pradesh Limited Executive Summary 80° 40' 80° 45' Maihar N 24° 24° 15' 1 5 ' Hardua Dhatura Kudra Birma Khaira Kherwa Kalan Hinauta Kusendi A B 24° 24° 10' Ithahar 10' 10 Bharauli D C Ghunwara Matwara Piparhar Sarhera Barroh Deori Mandura Khirwa Ajwain Ghorwal Bandhi 24° 24° 05' 05' SCALE 80° 40' 80° 45' Topo Sheet No.63 D/12, D/16. 1 01 2 Km LEGEN Cement Plant Township Points Latitude Longitude A 24 0 10’ 15.9” N 80 0 41’ 12.0” E B 24 0 10’ 20.5” N 80 0 42’ 05.9” E 0 0 C 24 09’ 29.7” N 80 42’ 07.4” E D 24 0 09’ 27.3” N 80 0 41’ 38.9” E FIGURE-1 STUDY AREA MAP (10 KM RADIUS) Bhagavathi Ana Labs Ltd, Hyderabad 2 EIA Report for the Expansion of Integrated Cement Plant from 3.6 to 7.2 Reliance Cement MTPA Clinker and 5.0 to 10.0 MTPA Cement by Installation of Line-II at Company Private Villages Bharauli and Itahara, Tehsil Maihar, District Satna, Madhya Pradesh Limited Executive Summary 2.0 PROCESS DESCRIPTION AND SOURCES OF POLLUTION 2.1 Process Description The plant is operated on dry basis, which offers more advantages, particularly in fuel consumption. The proposed plant comprises of rotary kiln, preheater and precalciner. Cement manufacturing principally involves grinding and blending of raw materials in a definite proportion - a material containing calcium oxide (such as limestone, chalk, marl) with a siliceous material (such as clay, shale, sand) along with certain additive or corrective materials (such as laterite) and then calcining the mixture at high temperatures in a kiln. The resulting ‘clinker’ is cooled and then ground with gypsum to produce the finished product, Ordinary Portland Cement (OPC). Gypsum is added to control the setting time of cement. Portland Pozzolona Cement (PPC) is manufactured by adding approximately 30% fly ash to clinker and gypsum during the grinding operation. 2.2 Infrastructural Facilities and Raw Material Requirement • Land Requirement The total area acquired for the cement plant is about 166 Ha out of which the proposed expansion will be set up in an area of 16 Ha. No additional area is required for the proposed expansion. • Raw Material Requirement The major raw material requirement for proposed expansion will be limestone, laterite, coal, gypsum and flyash. The details of raw materials requirement, the source and mode of transportation are provided in Table-1. TABLE-1 RAW MATERIALS AND SOURCE Quantity (TPD) Distance (km) Sr. Raw Proposed Source & Mode of No Material Line I Total Line II Transportation 1. Limestone 5.4 5.4 10.8 o Captive Limestone ~ 7.5, Belt mines Conveyer/Road 2. Fly ash 1.75 1.75 3.5 o Reliance’s Power ~ 250 Plant, Sasan By Road/Rail o Proposed Captive Power Plant 3. Coal 0.6 0.6 1.2 SECL/NCL/CCL/ ~ 250, Imported coal By Rail 4. Gypsum 0.25 0.25 0.5 o Rajasthan Chemical ~ 700, Gypsum from nearby By Rail/Road Industries 5. Laterite 0.07 0.07 0.14 Katni / Maihar ~ 75 / 15, By Rail & Road Bhagavathi Ana Labs Ltd, Hyderabad 3 EIA Report for the Expansion of Integrated Cement Plant from 3.6 to 7.2 Reliance Cement MTPA Clinker and 5.0 to 10.0 MTPA Cement by Installation of Line-II at Company Private Villages Bharauli and Itahara, Tehsil Maihar, District Satna, Madhya Pradesh Limited Executive Summary • Water Requirement The total fresh water requirement for the proposed plant expansion is about 1350 m3/day which will be met from underground. • Manpower The manpower required for the proposed project will be about 100 including skilled and unskilled workers. • Township A full-fledged township developed for existing plant will be utilized for accommodating the staff of proposed expansion of cement plant. Other amenities such as school, community center, hospital, shopping complex, post office, bank etc are well established in the surrounding areas. 2.3 Sources of Pollution and Control 2.3.1 Source Emissions and Fugitive Emissions The major sources of pollution are particulate matter from cement plant. For kiln, cement mill, coal mill, bag house will be installed to control particulate matter emission to less than 50 mg/Nm 3 and incase of clinker cooler, ESP of >99.9% efficiency will be installed to limit the particulate matter emission to 50 mg/Nm 3. 2.3.2 Wastewater Generation and Treatment As the proposed cement plant will be operated on the dry process and air is used as cooling media, no wastewater will be generated. Additional domestic waste water generated due to expansion of the project will also be treated in the existing Sewage Treatment Plant (STP) and used in greenbelt development. 2.3.3 Solid Waste Generation and Utilization No solid waste is generated in the cement manufacturing process. Dust collected from air pollution control equipment will be 100% recycled in process. Solid waste in the form of sludge will be generated from the sewage treatment plant and same will be used as manure for greenbelt development. 2.3.4 Noise Levels The noise generation from various equipments of the proposed plant (Cement Plant) will not exceed 90 dB(A). All the equipment will be designed to comply with the Factories Rules and Stipulations. 3.0 BASELINE ENVIRONMENTAL STATUS Primary baseline environmental monitoring studies were conducted during winter season of 2012-2013 and details are as follows: Bhagavathi Ana Labs Ltd, Hyderabad 4 EIA Report for the Expansion of Integrated Cement Plant from 3.6 to 7.2 Reliance Cement MTPA Clinker and 5.0 to 10.0 MTPA Cement by Installation of Line-II at Company Private Villages Bharauli and Itahara, Tehsil Maihar, District Satna, Madhya Pradesh Limited Executive Summary • Soil Environment A total of 8 samples within the study area were collected and analyzed. It has been observed that the texture of soil is mostly clay in the study area.
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