The Ramco Cements Limited

The Ramco Cements Limited Expansion of Ramco Vizag Cement Grinding Unit (0.95 MTPA to 2.00 MTPA) (Stand Alone) Gobburupalem & Gobburu Villages, Kasimkota Mandal, Visakhapatnam District, AP

Project Summary

M/s. The Ramco Cements Limited (RCL), are one of the reputed Cement Companies in India. The cement production of RCL is about 14.45 million tons per annum (MTPA) from their cement plants in South India : v Ramasamy Raja Nagar near Virudhunagar, Tamil Nadu (established in 1959) : 2.0 MTPA (2 Lines). v Kumarasamy Raja Nagar, Jayantipuram near Vijayawada, Andhra Pradesh (1986) : 3.65 MTPA (2 Lines). v Alathiyur near Viridhachalam, Tamil Nadu (1997) : 3.0 MTPA (2 Lines). v Mathodu near Chithradurga, Karnataka : 0.3 MTPA (since 2000). v Govindapuram near Ariyalur, Tamil Nadu :5.5 MTPA (established in 2009)(2 Lines).

RCL is also operating Cement Grinding Units at : v Kolaghat (0.95 MTPA; being expanded to 2.0 MTPA) in West Bengal. v Kattuputtur (0.75 MTPA) near Chennai, Tamil Nadu. v Valapadi (2.0 MTPA) near Salem, Tamil Nadu. v Vizag (0.95 MTPA) near Anakapalli, Andhra Pradesh.

It is operating a Packing Plant at Nagercoil.

RCL is producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) and Slag Cement (PSC). The cement produced by RCL is marketed in the brand name of ‘RAMCO’. The brand name RAMCO SUPER GRADE is very popular PPC and RAMCO SUPER STEEL is the slag cement brand. The market centers are mainly in Tamil Nadu, Andhra Pradesh, Kerala, Karnataka, Odisha and West Bengal States.

RCL, which has always been striving for Total Quality, possesses International Certificate ISO:9001, ISO:14001,ISO:18001and IS/ISO:50001. The company has achieved various awards for 'Best Performance 'in the Cement Industry.

RCL is marketing about 1.5-2.0 MTPA cement in the Eastern Districts of Andhra Pradesh from its Jayanthipuram Cement Plant located in Krishna District. NTPC has commissioned its Simhadri Super Thermal Power Station near Visakhapatnam which is a potential Fly Ash Source in the Region. Thus, in tune with the Govt. of India Policy of encouraging Cement Units near the raw material sources and marketing centers, RCL has proposed and established the Vizag Cement Grinding Unit with a capacity of 0.95 MTPA (@3000 Tons per day, TPD) with a Project Cost of Rs.360.00 crores.

Main raw material for manufacturing these Cement products are Clinker, Gypsum, Fly Ash and Slag. Clinker is being brought to the Unit by rail / road from Jayanthipuram Plant (near Jaggayyapet; 310 km- aerial distance). Gypsum is procured from Coromandel Fertilizers, Visakhapatnam. Fly Ash is received from NTPC Simhadri Super Thermal Power Station, Parawada (@ 20 km in the east). For PSC manufacture, granulated blast furnace slag from Vizag Steel Plant is used.

Initially, the Grinding Unit was established in an extent of 43.46 Ha in own Patta Lands and additional land of 10.09 Ha is added mainly for Approach Roads from the National Highway, Truck Parking, etc. Thus, the Grinding Unit is located in an extent of 53.55 Ha (132.31 Acres) in Gobburupalem & Gobburu Villages, Kasimkota Mandal, Visakhapatnam District of Andhra Pradesh State.

The Unit is located bear the National Highway (NH) 16 (earlier NH-5) inbetween Tuni-Anakapalli Towns. It is about 13.5 km from Anakapalli (in north-northeast), 9 km from Kasimkota (in NE; Mandal Head Quarters) and 35 km from Visakhapatnam (District Head Quarters) in northeast. Tallapalem (@ 1.2 km in north), Gobburupalem/AS Peta (@ 0.5 km in east) and Narsingapalli (@ 1.3 km in southwest) are the nearest villages.

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The Cement Grinding Unit is located inbetween 17o36’53.22”-17o37’21.64” N Latitude & 82o52’53.69”- 82o53’47.95”- E Longitude (Survey of India Topo Sheet No. 65 K/14). There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Elephant Corridor, Archaeological/Historical Monuments, Heritage sites, etc. within 10 km from the proposed Plant boundary. Kondakarla Bird Sanctuary/Ava is at a distance of 10.3 km in the East. Also, there are 9 Reserved Forests (RFs) within 10 km radius of the Plant Area viz. Gobburu RF (1.26 km), Bayyavaram RF (1.6 km), Panduru RF (4.70 km), Gokieda RF (6.31 km), Panchadaria RF(6.91 km), Mallam RF (7.41 km), Pangidi RF (7.90 km), Paddapalli RF (9.20 km) and Theeda RF (9.80 km). The Principal Chief Conservator of Forests, Hyderabad has issued the NOC for establishment of the Unit in the Area vide Letter Rc. No. 45195/2012- F3 dated 01.10.2013.

The minimum and maximum elevation of the area is 21 m and 30 m AMSL respectively. River Sarada drains the region and flows north to south in the east of the Plant at a distance of 1.3 km from the Plant. Seasonal Mamidivakka Gedda/Nalla flows north of the Plant at a distance of 600-700 m and joins River Sarada.

RCL had obtained the Environmental Clearance (EC) for Vizag Cement Grinding Unit (0.95 MTPA) from the State Level EIA Authority-AP (SEIAA-AP) vide Order Letter No. SEIAA/AP/VSP-86/2013/661 dated 03.05.2013. The combined Consents for Establishment (CFE) was obtained from Andhra Pradesh Pollution Control Board (APPCB) vide Order No. 312/PCB/CFE/RO-VSP/HO/2013-2253 dated 08.07.2013. The combined Consents for Operation (CFO) under Air & Water Acts was obtained from APPCB vide Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated 21.04.2015. The CFO is being renewed by the Board periodically and the recent CFO Order No. APPCB/VSP/VSP/312/CFO/HO/2016 dated 24.02.2016 is valid upto 28.02.2021.

The Plant is in Operation from March 2014. The maximum production of Cement (PPC) achieved is 0.65 MTPA in the Year 2015-16 and there is no violation in the Production Quantity. There is no litigation against the Project. The Unit has not received any Notice under Section 5 of the Environment (Protection) Act, 1986 or Show Cause Notices from APPCB under Air and Water Acts.

The Plant operations are in full compliance with the EC Conditions stipulated by SEIAA-AP and CFE Conditions stipulated by the APPCB. Periodical EC Compliance Reports are submitted to the MoEF&CC Monitoring Cell, Southern Region, Chennai.. The recent Certified Compliance Status to EC Conditions has been issued by the MoEF&CC, Chennai vide its Letter No. EP/12.1/2013-14/SEIAA/151/AP/058 dated 11.04.2017.

The Cement Grinding is a Dry Process. Thus, the Raw Water is required for Equipment Cooling (60 cu.m/day), Dust Control Measures (1 cu.m/day), Green Belt (20 cu.m/day) and for Domestic Use (15 cu.m/day). The total Water Demand of 96 cu.m/day is met from permitted 2 Nos. Borewells within the Plant under the Andhra Pradesh Ground Water & Water Audit Department, Visakhapatnam vide Letter No. 207/Tech/2016-17 dated 23.03.2017. There is no trade effluent generation from the Unit. Domestic sewage to the tune of 12 cu.m/day is generated now which is biologically treated in the Septic Tanks (about 7 Nos.) followed by a Dispersion Trenches.

The entire Dust from Bag Filters is being fully utilized in the Cement grinding. Used Lubricating Oil (Cat. 5.1) of 600 Lits./year is stored and sold to CPCB Authorised Recyclers for recovery and use.

An effective Green Belt is developed and maintained over an extent of 15.50 Ha (28.95% coverage) with about 15,250 Trees @ 980 trees/Ha (Survival Rate : 85-90%). Also, 2 Nos. Recharge Pits are constructed and maintained for Rain Water Harvesting. A fully equipped Occupational Health Centre is established and an Onsite Emergency Preparedness Plan are in place in the Unit.

The Project Cost of the existing Plant is Rs.367.57 crores. An EMP Budget of Rs.5.00 crores has been spent as Capital Cost for Environmental Management Plan (EMP)/Pollution Control Measures and Rs.5.00 lakhs per annum towards EMP Operating Cost.

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In order to meet the increasing Cement Demand in the Region, RCL is, now proposing to increase the Cement Grinding capacity of Vizag Cement Grinding Unit from existing 0.95 MTPA (Line I) to 2.00 MTPA by introduction of Line II (of 1.95 MTPA) with the following Components :

v Vertical Roller Mill - VRM (Mill 2) for a capacity of 130 TPH. v One Hot air Generator (HAG - 2) of 12 MKcal/hr for driving out the moisture in the raw materials. v One concrete Silo (Silo 2) for storing clinker of Capacity 35000 MT v Two concrete Silos (Silo 3 and 4) for storing Cement of capacity 8000 MT each. In addition to this, Two steel silos (Silo 5 and Silo 6) of 500 MT capacity is also considered for storing cement. v One steel silo (Silo 2) of capacity 1000 MT for storing dry Flyash v Covered storage yard for storing chemical Gypsum and Wet slag of capacity 3000 MT and 5000 MT respectively. v One number of electronic rotary packer (Packer 3) of capacity 180 TPH with double discharge will be shifted from our Jayanthipuram plant and will be installed. v Two nos of double discharge Electronic rotary packers (Packer 4 and 5) of capacity 240 TPH respectively. v 8 nos of Truck loading machines for loading packed cement bags in trucks / trailers. Additionally, 4 nos of Wagon loading machine is also proposed to reduce the loading time. v 2 nos of Bulk loading facility to despatch cement through closed bowsers. v One weigh bridge for weighing raw materials and finished goods of capacity 100 Tonnes.

Bag Filters are proposed at new stacks and all material transfer points to control PM emission <30 mg/Nm3. The dust collected from the various Air Pollution Control Measures like Bag Filters, etc. will be totally recycled in the process for cement manufacturing.

The additional Water Demand for Equipment Cooling (30 cu.m/day) and for Domestic Use (4 cu.m/day) will also met from the existing Permitted source only. There is no wastewater generation from the Process. Domestic sewage to the tune of 3.5 cu.m/day will be generated which will be biologically treated in a Septic Tanks of adequate size followed by a Dispersion Trench. Existing Infrastructures are adequate for the proposed Expansion activities. The Project Cost for the Expansion activities is Rs.250.00 crores with the following breakup:

Land Cost : Nil (proposed within the existing Industrial Premises) Buildings & Structurals : Rs.128.00 crores Plant & Machineries : Rs.117.00 crores Others & Contingencies : Rs. 5.00 crores ------Total : Rs. 250.00 crores ------

A budgetary allotment of Rs.5.00 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 2.5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs.20.00 lakhs per annum. The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. In addition to the environmental benefits waste materials like utilization of Fly Ash, Gypsum, etc., there will be a huge positive impact due to the proposal, by way of employment, better socioeconomic conditions, improved local and regional economy, etc.

As per Environmental Impact Assessment Notification 2006, all Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category ‘B’ for prior Environmental Clearance from the State Level Environmental Impact Assessment Authority (SEIAA) with applicability of General Conditions. The proposed Expansion of Vizag Cement Grinding Unit (Stand Alone) requires prior EC from SEIAA-AP. Accordingly, Application/Form-1 and Project Feasibility Report are submitted herewith for your kind perusal in awarding TOR for the EIA Study. As the Expansion is proposed within the existing Industrial premises with the combined water demand, sewage/effluent treatment & disposal, solid wastes disposal, etc., the Spatial Impacts due to the Proposal is negligible/insignificant. Accordingly, the proposal may be considered by the Authority with Public Hearing Exemption under Clause 7(ii) of EIA Notification 2006, as amended, for according the environmental clearance.

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