English and Tamil) Along with EIA Report Have Been Submitted for Conducting the Public Consultation & Public Hearing and for the Environmental Clearance

Proposed Modernization & Expansion of Ramasamy Raja Nagar Cement Plant (Replacement of Kiln-II with New Kiln & Shifting of Line-II Operations)

Existing Production : Clinker 1.09 MTPA & Cement 2.0 MTPA Proposed Production on Modernization : Clinker 1.44 MTPA & Cement 2.7 MTPA

Tulukkappatti, Thammanayakkanpatti & Vachchakarapatti Villages Taluk & District Virudhunagar, Tamil Nadu

Environmental Clearance under EIA Notification 2006 Sl. No. 3(b); Category ‘A’

Summary Environmental Impact Assessment (after TOR; for Public Hearing) Awarded TOR : MoEF&CC Letter No. J-11011/119/2009.IA.II(I) dated 11.11.2020

January 2021

EIA Consultant

ABC Techno Labs India Private Limited, Chennai (Sl. No. 3 of QCI/NABET List dated 18.12.2020) 2

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The Ramco Cements Limited

Proposed Modernization & Expansion of Ramasamy Raja Nagar Cement Plant (Replacement of Kiln-II with New Kiln & Shifting of Line-II Operations) Existing Production : Clinker 1.09 MTPA & Cement 2.0 MTPA Proposed Production on Modernization : Clinker 1.44 MTPA & Cement 2.7 MTPA

Summary Environmental Impact Assessment

1.0 Project Description 1.1 Project Proponent

Ramco Group is one of the leading, highly reputed and Second Largest Industrial Group in South India. It is well diversified in the fields of Cement, Ready Mix Concrete, Cement Fiber Products, Cotton and Synthetic Yarn, Software Systems, Wind Farms, Research & Development, Dry Mortar Plants, Cotton Textiles and Surgical. The total employees are about 15,700 and the Turnover of the Group is Rs.8,000 Crores.

The Ramco Cements Limited (RCL) of RAMCO Group is one of the reputed Cement Companies in India. The Company is the Second Largest cement producer in South India and sixth largest manufacturer of cement in the Country. The cement production of RCL is about 17.70 million tonnes per annum (MTPA) from the Cement Plants in India. RCL is producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC), Slag Cement (PSC), Composite Cement (CC), etc. The cement produced by RCL is marketed in the brand name of ‘RAMCO’. The market centers are mainly in Tamil Nadu, Andhra Pradesh, Telangana, Kerala, Karnataka, Odisha and West Bengal States.

RCL which has always been striving for Total Quality, possesses International Certificate ISO:9001, ISO:14001, ISO:45001 (18001) and ISO:50001. The company has achieved various awards for 'Best Performance' in the Cement Industry and also Green Rating Project Awards 4 Leaves from Centre for Science and Environment for the Year 2005.

The Ramco Cements Limited is managed by a Board of Directors comprising of eminent personalities as its members. Under the dynamic leadership of Late Shri.P.R.Ramasubrahmaneya Rajha, the company has grown into a massive organization. Shri.P.R.Venketrama Raja is the Chairman & Managing Director (CMD) of the Board. Shri.A.V.Dharmakrishnan, Chief Executive Officer (CEO) is heading the Cement Division dealing with the environmental issues and EC compliances. Each Unit is headed by a Unit Head in the President/Vice President Level Executive. RCL has the well laid down Safety, Health and Environmental (SHE) Policy approved by the CMD. The Environmental Management Plan (EMP) Cell is functioning under the Unit Head and Corporate Social Responsibility (CSR) Committee is functioning under the Corporate Office. The Contact information of RCL Corporate Office is :

Shri.M.Srinivasan, Executive Director (Operations), The Ramco Cements Limited, 5th Floor, Auras Corporate Centre, No. 98A, Dr.Radhakrishnan Road, Mylapore, Chennai-600 004. Tel. No. : 044-28478666/28478661/28478656 Fax No. : 044-28478676 e-Mail : [email protected]

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

1.2 Ramasamy Raja Nagar Cement Plant

RCL is operating their Ramasamy Raja Nagar (RR Nagar) Cement Plant/Complex in Tulukkappatti, Thammanayakkanpatti & Vachchakkarappatti Villages, Virudhunagar Taluk & District of Tamil Nadu State (Fig. 1.1). The Plant was established in the Year 1959 and commenced production from the Year 1961- 62. Wet Process to Dry Process conversion (Line-I) was carried out in the Year 1977 (India’s First Dry Process Kiln of 1,200 TPD capacity). An additional Line-II of 650 TPD Kiln was commissioned in the Year 1994 and upgraded to 1,000 TPD Kiln in the Year 2001. After obtaining the Environmental Clearance (EC) from the Ministry of Environment, Forest and Climate Change (MoEF&CC), Replacement & Upgradation of old Line-I Kiln (1,200 TPD Kiln with a new 1,800 TPD Kiln) and Modernization of Line-II were undertaken in the Year 2011.

RCL is very much concerned to comply with the stipulated Norms. To control the Fugitive Emissions fully from the Complex, RCL has thus constructed RCC Silos for Raw Materials storages & Cement storages, complete covered Stacker & Reclaimer Sheds for Coal, Limestone, Additives, etc. To utilize the Railway Line effectively for Materials Transportation, the Railway sidings are extended for a Wagon Tippler Facility. These facilities are located/being located in RCL’s own Patta lands in Tulukkappatti, Thammanayakkanpatti and Vachchakkarappatti Villages oven an extent of 191.434 Ha (Plate I) (Survey Nos. details appended).

With Lines I & II now, the Clinker production from the Plant is 1.09 MTPA and Cement production is 2.0 MTPA of various grades. Utilization of Clinker from other Units of 0.28 MTPA was also permitted. The Plant has 25 MW Captive Thermal Power Plant (CPP) (since 2012), Occupational Health Centre (OHC) and a well established Township within its Complex. Cement Plant Limestone requirements are met from Captive Limestone Mines in Pandalgudi Region. These Captive Mines are in operation since 1976. EC & Consent Quantity of Run-Off Mine (ROM) Production from these Mines is about 2.44 MTPA.

The common Centralised Crushing Plant with Optical Ore Sorting Facility (2.0 MTPA Throughput & 1.88 MTPA Clean Ore capacity) is located at Pandalgudi at about 18 km (SE) from the Cement Plant. RCL has recently received Precise Area Coomunication for 5 Nos. Lime Kankar Quarry Leases (with 16.48 Million Tonnes Reserves) which are located at a distance of 20-33 km (E & SE) from the Plant. Also, a Lime Kankar Beneficiation Plant (Throughput Capacity 2.00 MTPA) is now proposed at Pandalgudi.

These Captive Mines and Pandalgudi Crusher are connected with RCL’s own Tar Road (40+10 km) for transportation of the Ore. National Highway-44 (earlier NH-7) (4-Lane Madurai-Kanniyakumari Section) and Southern Railway BG Line (Madurai-Kanniyakumari Section) run parallel to the Plant. There is a Road- over-Bridge on the NH-38 at Pandalgudi and an Underpass in the NH-44 at RR Nagar to avoid the impact on Public Transport. The Railway siding for the Plant is from Thulukkapatti Railway Station (0.5 km in E).

Ordinary Portland Cement (OPC 43, OPC 53 Grades), Rapid Hardening Portland Cement (RHPC), Portland Pozzolana Cement (PPC), etc. are being manufactured at this Plant. About 40-45% of cement produced from RR Nagar Cement Plant is being dispatched to the marketing centres in Southern Districts of Tamil Nadu and about 55-60% to the marketing centres in South Kerala including Thiruvananthapuram. RR Nagar Plant has obtained the required ISO Certifications and also bagged various Awards for its operations.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

RCL Patta Lands in Tulukkapatti Village

Survey No. & Extent in Ha 1/1 0.680 12/2 0.465 39/4 0.415 221/4 0.420 1/2 0.565 12/3 0.415 39/6 0.190 221/5 0.245 1/3 0.555 12/4 0.310 39/7 0.385 221/6 0.150 1/4 0.565 12/5 0.730 49/5 1.390 222/1 1.010 1/5 0.470 12/6 0.235 50/1A 0.565 222/2 0.415 1/6 0.480 12/7 0.665 50/2A 0.200 222/3 0.420 1/7 0.965 12/8 0.785 50/2C 0.245 222/4A 0.385 2/1 0.820 12/9 0.260 51/1 0.655 222/4B 0.370 2/2 3.325 12/10 0.225 51/2 0.260 222/5 0.210 3/1 1.070 13/2 0.115 52/1 0.335 221/7 0.105 3/2 1.140 13/3 0.125 52/2 0.270 221/8 0.910 3/3 0.140 13/4 0.535 56/1 0.245 226/1 1.110 3/4 0.350 13/5 0.250 56/5 0.275 226/5 0.640 3/5 0.695 13/6 1.000 57/3A 0.050 227/1 0.995 4/1B 1.005 13/7 0.605 57/3B 0.670 227/2A 2.025 4/2A2B 1.315 13/8 0.325 57/4 0.315 227/2B 1.215 4/2B 0.075 14/1 0.350 58/1A 0.035 227/2C 1.050 4/3 0.640 14/2 0.370 58/1B 0.825 227/3 0.535 5/1 0.415 14/3 0.275 58/1C 0.565 228/1 0.805 5/2 0.395 14/4 0.345 58/2 0.555 228/2 0.685 5/3B 0.500 14/5 1.155 59/2 0.480 228/3C 0.430 5/4B 0.465 14/6 0.555 59/3 0.695 228/3B 0.175 5/5B 0.500 14/7 0.315 59/4 0.225 228/3D 0.205 5/6 0.495 16/1 0.585 59/5 0.300 228/3A 0.260 5/7 0.375 16/2 0.795 59/6A 0.015 228/3E 0.225 5/8 0.140 16/3 0.550 59/7A 0.020 228/4 0.390 5/9 0.565 16/4 0.335 59/6B 0.435 229/1 0.420 5/10 0.455 22/1 0.335 59/6C 0.160 229/2 1.095 6/2 1.670 22/2A 0.545 59/6D 0.160 229/3A 0.510 6/3 0.705 24/1 0.590 59/6E 0.100 229/3B 0.380 6/4 0.330 24/2 0.600 59/7B 0.130 229/4 0.625 6/5 0.625 24/3A 0.712 59/7C 0.190 230/1 0.080 6/6 0.590 24/4 1.117 59/8A 0.080 230/2A 0.180 6/7 0.350 30/1C 0.055 59/8B 0.055 230/2B 0.250 7/1 0.380 30/2 0.215 59/8D 0.295 230/3 0.340 7/2 0.615 30/3 0.830 60/1 0.455 230/4 0.220 8/1 0.415 31/1 0.315 60/2 0.345 230/6 0.200 8/2 0.530 31/2 0.310 60/3 0.520 230/7 0.205 8/3 0.350 31/3A 0.600 65 2.430 230/8 0.495 8/4 0.250 31/5 0.545 65 2.830 230/9 0.009 9/2 0.860 31/6 0.340 65 2.695 230/10 0.325 9/3 0.545 32/2 0.100 66/1 0.845 230/11 0.265 9/4 0.550 32/3 0.095 210/1 0.420 9/5 0.630 32/4 0.140 210/2 0.010 9/6 0.380 32/5 0.525 210/3 0.290 9/7 1.210 32/6 0.575 210/4 0.001 10/1 0.725 32/7 0.350 210/5 0.325 10/2 0.775 32/8 0.335 210/6 0.180 10/3 0.710 32/9A 0.725 212/1 0.170 10/4 0.435 34/4 0.235 212/2 0.325 10/5 0.330 34/5 1.130 214/1A 0.070 10/6 0.255 35/2 0.800 214/4 0.410 10/7 0.175 35/3 0.550 214/6 0.410 11/1 1.365 36/2 1.430 214/7 0.310 11/2 0.945 37/2 0.405 221/1A 0.330 11/3 0.565 38/5B 0.985 221/1B 0.130 11/4 0.300 38/6 0.165 221/2 0.290 11/5 0.480 38/7 0.340 221/3 0.465

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

RCL Patta Lands in Thammanaickanpatti Village

Survey No. & Extent in Ha 192/3B 0.265 199/3 0.595 207/1B 0.860 192/6 0.565 199/4 0.550 207/2B 1.380 192/7 0.010 200/2 1.020 209/1 0.795 192/8 0.010 200/3 1.040 209/6 1.050 194/1 0.330 200/4 0.985 209/7 0.675 194/2 0.325 200/5 0.965 210/1 1.185 194/3 0.295 201/2A 2.685 210/2 0.405 194/4 0.130 201/2B 0.370 210/3 0.420 194/5 0.725 201/3 0.315 210/4A 0.335 194/6 0.115 201/4 0.545 210/4B 0.365 194/7 0.310 202/1 0.695 210/5A 0.360 194/8 0.225 202/2 0.095 210/5B 0.755 194/9 0.055 202/4 0.975 211/4 0.500 194/10 0.530 202/5 0.875 211/5 0.310 194/11 0.395 203/1 0.630 211/7 0.720 195/7 1.605 203/2 0.115 212/1 0.085 195/8 0.615 203/4 0.995 212/2 2.140 196/2 0.180 203/5 1.285 212/3 1.050 196/3A 0.005 204/2A 0.345 215/4 0.630 196/3B 0.175 204/2B 0.215 215/5B 0.810 196/4 0.285 204/3 0.795 216/3 0.515 196/5 0.280 204/4 1.305 216/4 0.225 196/6 0.595 205/1 0.410 216/8 1.265 196/7 1.720 205/2 0.425 216/9 0.075 197/5 0.345 205/3A 0.480 287/1B 1.205 197/6B 0.130 205/4 1.330 287/2 1.965 197/6C 0.060 206/1 0.945 197/8 1.045 206/2 0.370 198/2 0.300 206/3A 0.300 198/4 0.030 206/4A 1.070 198/7 0.545 206/5A 0.645 198/8 0.555 206/6 0.350 199/2 0.540 206/7A 0.575

RCL Patta Lands in Vachchakarapatti Village

Survey No. & Extent in Ha 100/1A2 0.675 100/2 0.305 100/3A 0.247 100/4A 0.096 100/5A 1.395 100/5B1 0.075 100/6A 0.064 101/1 0.615 101/2 0.595 101/3 1.025 101/4 0.570 101/5 0.525 102/1 1.010 102/2 2.146 103/2 1.020 108/1 0.975 108/2 0.840 108/3 0.960 108/4A 0.215 109/1A 0.590 109/2A1A 0.102 112/1 0.245 112/2 1.500 112/3 0.455 112/4 0.355 112/5 1.425 113/1A1 0.585 113/1B1 0.040 113/1C1 0.030 113/2 0.500 113/3A 1.285 113/3B 0.175 113/3C2 0.225 Total Extent of RCL’s own Patta Lands : 191.434 Ha 8

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The Contact Information of RR Nagar Cement Plant is as follows :

Mr.S.Ramalingam, Sr. Vice President (Mfg.), The Ramco Cements Limited, Ramasamy Raja Nagar Post, Virudhunagar District, Tamil Nadu-626 204. Tel. Nos. : 04562-256201 to 256203 Fax : 04562-256268. Contact email : [email protected]

1.3 Statutory Clearances and their Compliances

The Plant’s establishment and operations were carried out Pre-EIA Notification 1994 period. The first EC for the Plant was obtained for Replacement of Line-I Kiln and Modernization and Upgradation of both Lines vide MoEF&CC F. No. J-11011/119/2009 IA.II (I) dated 06.07.2009 (1.0 MTPA to 2.0 MTPA Cement). MoEF&CC has also awarded the EC for 25 MW CPP vide F. No. J-13012/112/2011 IA.II (T) dated 06.02.2012. Again EC from MoEF&CC was obtained for the addition of 3rd Packer vide F. No. J- 11011/119/2009 IA.II (I) dated 29.11.2017. RCL has obtained the Certified EC Compliance Reports from the Regional Office (RO), MoEF&CC, Chennai and there is no Non-compliance.

The Consents to Establish (CTEs) and Consents to Operate (CTOs) from Tamil Nadu Pollution Control Board (TNPCB) were obtained and Renewal CTOs are being renewed periodically. Present RCTOs for the Cement Plant are 1908121827195 (Water Act) & 1908221827195 (Air Act) dated 18.09.2019 which are valid till 31.03.2022 and RCTOs for CPP are 180818261322 (Water Act) & 180828261322 (Air Act) dated 12.03.2018 which are valid till 31.03.2022.

The Cement Plant, CPP and Captive Mines operations are in compliance with conditions/Norms stipulated in ECs and CTOs by TNPCB.

1.4 Need for the Proposal

The present Line-II of 1,400 TPD (Kiln-II) has undergone lot of modifications during upgradation periods and now requires replacement on account of its ageing factor as it is in operation for the last 27 years. Also, the enhanced operation of Line-I Kiln has resulted in its ‘under performance’ and also in higher Energy consumption. Thus, Line-I’s Volumetric Load has to be reduced for its sustainable operations. Though the Plant is able to comply with the latest emission norms, operating cost is relatively high while comparing with modern Cement Plants due to the high energy consumption (both Fuel & Power).

With increasing trends towards benchmarking methods, RR Nagar Cement Plant Modernization is necessary : (i) to increase the plant efficiency by adopting the state-of the-art technologies & machineries and (ii) operation of the Plant for optimum standards and lower emissions. Modernization will benefit the Plant in terms of reduction in Electrical Energy and Fuel Consumption, lower Maintenance Cost, etc. Thus, RCL has proposed the Modernization of RR Nagar Cement Plant with the New Kiln of 3000 TPD in-lieu-of Line-II Kiln of 1400 TPD

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

1.5 The Proposal

The Proposal now mainly involves construction of New Kiln (upto Clinkerisation as Line-II) along with other facilities for both Lines I & II and shifting the Line-II operations to a new location within the Plant Premises so as to decongest the Operational Areas of the oldest Cement Plant. The following activities are proposed for the Modernization & Expansion: v Replacing the existing Line-II Kiln (1400 TPD) with a New Kiln of 3,000 TPD with all latest technologies. v For enhanced Cement Grinding, addition of 0.7 MTPA (160 TPH) Cement Mill (No. 3). v For Packing 1x240 TPH, 4th Packer with double discharge. v One Wagon Tippler of 1,300 TPH (now considered as 1,500 TPH). v One Pre-Heater (PH) Boiler & one Air Quenching Cooler (AQC) Boiler addition to Line-I. v Operating the existing Line-I Kiln (1800 TPD) by reducing volumetric loading (1485, say 1,500 TPD). v Existing Ball Mill of Line-I Raw Mill to be stopped and proposed a new highly energy efficient Raw Mill for both Lines. v Existing Ball Mill of Line-I Coal Mill to be stopped and a high energy efficient Coal Mill to be installed for both Lines. v Two new RCC Silos for storage of Raw Meal produced from the new Raw Mill with storage capacity of 14,000 MT and 6,000 MT. v Four Fine Coal Bins to be installed (3 Bins for New Kiln and the 4th Bin as an intermediate to pump it to the existing Fine Coal Bins in Line-I Coal Mill). v One RCC Clinker Silo for a storage capacity of 30,000 MT for the New Kiln. v Two RCC Silos of 9,000 MT capacity and one Steel Silo of capacity 1,000 MT for cement storage. v Bag Storage Godown (Capacity 50 Lakhs Bags). v STP for Labour Quarters (50 KLD). v Existing Limestone Linear Stacker & Reclaimer (30,000 Tons) will be utilized as Additives Stacker & Reclaimer. Circular Limestone Stacker & Reclaimers of 2x18,000 Tons are proposed now. v Also, additional E-Type (5,770 sq. m) and F-Type (6,050 sq.m) Quarters in the Township are required and proposed accordingly to existing 38,161 sq.m builtup area in the Township. The proposed construction of E&F Type Quarters will comply with Directorate of Town and Country Planning (DTCP) Norms and necessary Approvals from DTCP will be obtained.

For the proposed developments, clearance & shifting of existing Electrical & Instrumentation Service Room, Fuel Storage Tanks, Plant STP & Colony STP, part of Sub Station Area, etc. are required and they will be shifted to new locations northerly. Line-II existing Kiln of 1400 TPD will be kept idle and there will be no Clinker production. Alternatively, it may be utilised for converting materials into Pozzolana materials for cement manufacturing.

Due to the proposed Modernization and Expansion activities, there will be an addition of 0.35 MTPA Clinker (32.11% increase) and 0.7 MTPA Cement (35% increase) to the existing Production. The existing and proposed Plant Productions will be as given in Table 1.1. The proposed activities fall in RCL’s own Patta Land in both Tulukkapatti and Thammanayakkanpatti villages for its establishment. The Survey Nos. and (full) extent are given in Table 1.2. In addition, RCL has also in its possession the vacant lands in and around the activities area. The Project does not involve any Rehabilitation & Resettlement (R&R). Also, there is no litigation against the Proposal. The proposed Layout is given as Fig. 2.1.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

Table : 1.1 Production on Modernization & Upgradation

Proposed Change on Cumulative on Existing Modernisation Modernisation Production Line-II Line-I Line-II Total Line-I Lines I & II (New Kiln) Clinker Mfg., MTPA 0.61 0.48 1.09 0.48* 0.96** 1.44 Clinker from other - - 0.28 0.42-0.50 0.50 Units/Imported, MTPA With Own 0.90 0.70 0.80 1.50+ Cement Clinker 2.00 2.70 Mfg., MTPA With Import 0.40 0.40 Clinker 1 PH Boiler & Cement Waste Heat - - - 1 AQC No WHRB - Recovery (CWHR) Boilers ++ Boiler Standby Standby DG Power 1x7 MW; 2x4 MW 15.0 MW No addition 15.0 MW Sets Generation

* : Reduction of Volumetric Load of Line-I Kiln for its sustainable operation. ** : Replacement of 1400 TPD Kiln (27 year old) with New Kiln of 3000 TPD; Five stage- inline calciner, CB cooler with ABC inlet & with NOx control system. + : With additional 0.7 MTPA Cement Mill. ++ : 1 PH Boiler & 1 AQC Boiler addition to Line-I; 11.80 TPH of High Pressure Steam & 6.2 TPH of Low Pressure Steam will be generated to be used for preheating the feed water of existing CPP. Note : The Cement Plant has 25 MW CPP and 0.5 MW DG set as its power sources, in the Complex.

Table : 1.2 Location of the New Units

Own Patta Land Survey Nos. Land Extent, Ha Sl. Thamma Plant Unit Thamma- Tulukka Remarks No. Tulukkapatti naickan naickanpatti -patti patti 1 Line-II New Kiln of 4/1B, 5/5B, 5/6, 5/7, 5/8, 199/2 Drains are 3000 TPD with 5/9, 5/10, 6/3, 6/4, 7/1, 7/2, being 6.423 0.540 Units upto 9/2 maintained as Clinkerization such 2 New Clinker Silo 7/2 - 0.615 - - 3 Limestone 198/7, 198/8, Circular Stacker & 200/2, - - 7.256 - Reclaimer 201/2A, 210/1, 216/8 4 New Cement Mill 9/4, 9/5, 9/6 - 1.562 - - th 5 4 Packer 9/3, 12/2, 12/3, 12/4, 12/5 - 2.460 - - 6 Wagon Tippler 59/2, 59/3, 59/4, 59/5, 60/1, - 3.019 - 60/2, 60/3 7 Railway Sidings- 50/1A, 50/2A, 50/2C, 51/1, 202/1, 202/2, ROBs are Wagon Tippler 51/2, 52/1, 52/2, 58/1A, 202/4, 202/5, provided for 58/1B, 58/1C, 58/2, 59/6A, 203/4, 203/5, Deemed Cart 6.155 6.220 59/6B, 59/6C, 59/6D, 204/4 Tracks with 59/6E, 59/7A, 59/7B, Dist. Admin. 59/7C, 59/8A, 59/8B, 59/8D Permission. 8 New Locations for 1/6, 5/2, 5/7 196/7 Fuel Tanks, STP, Sub-station, Elecl. 1.246 1.720 - & Inst. Service Room, etc. 9 Labour/Employee 2/2, 4/1B Quarters E & F - 1.821 - - Type 10 Labour Colony & 22/1, 22/2A, 24/3A, 24/4 - 2.709 - - 50 KLD STP

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

1.6 Process

Well established Dry Process utilising the Precalciner technology along with the technological advances in the area of grinding and homogenisation has been incorporated in the Cement Plant. Limestone along with other additives is metered in suitable proportions and sent to Raw Mill where the raw material is ground to the required size. The powdered Raw Meal is stored in the Raw Meal Silo. Belt bucket elevator is used to feed the raw material to Preheater Cyclones / Precalciner. The calcined material from the Preheater enters the Kiln and is subjected to physical and chemical changes to form Clinker. The hot molten Clinker is allowed to pass through a modern high efficient Clinker Cooler to cool it down to 150 oC. Cooled Clinker is then stored in Clinker Silo. Clinker is then ground along with Gypsum and Fly Ash to produce various grades of Cement. The cement is then conveyed to the Silos through elevators. There are Electronic Packers with two discharges for automatic weighing and packing the cement in HDPE and Paper Bags. Facilities are available to despatch Cement through Trucks as well as Rail Wagons to the Marketing Centers. Material Balance for 2.70 MTPA Cement production is given as Fig. 2.2.

Waste Heat Recovery Boilers (WHRBs) are to be installed to recover the waste heat from Line-I Kiln. There are two types of Boilers proposed viz. Pre Heater (PH) Boiler and Air Quenching Cooler (AQC) Boiler. The waste heat from Line-II New Kiln will be fully utilized for heating & removing the moisture from the raw materials.

1.7 Awarded TOR & EIA Study

The proposed Modernization and Expansion of RR Nagar Cement Plant (>1.0 MTPA) falls under Sl. No. 3(b) - Category A of EIA Notification 2006 (as amended) and requires prior EC from the Central Authority in MoEF&CC. Thus, RCL has submitted the TOR Application with Form-1, PFR and other required Documents to the Ministry on 27.10.2020 vide Online Proposal No. IA/TN/IND/180849/2020.

The Ministry has awarded the Standard TOR with Public Hearing vide Letter No. J-11011/119/2009.IAII(I) dated 11.11.2020. Accordingly, the EIA Report has been prepared and submitted as per awarded TORs and also as per the generic structure proposed in EIA Notification 2006. The baseline data pertaining to December 2019-February 2020 (Winter Season) are utilised for the EIA Study in compliance with MoEF&CC Office Memorandum No. J-11013/41/2006-IA-II(I)(Part) dated 29.08.2017. The Summary EIA Reports (both in English and Tamil) along with EIA Report have been submitted for conducting the Public Consultation & Public Hearing and for the Environmental Clearance. The EIA Consultant, M/s. ABC Techno Labs India Private Limited, Chennai has been accredited for various Sectors including Sector-9 (Cement Plants) for Category ‘A’ by the National Accreditation Board for Education & Training (NABET), Quality Council of India vide Certificate NABET/EIA/1922/RA 0155 with validity 22.05.2022 (Sl. No. 3 of QCI/NABET List dated 18.12.2020). The ABC Techno Labs India Private Limited Laboratory is accredited by the National Accreditation Board for Testing and Calibration Laboratories (NABL) and also recognised by MoEF&CC. The services of M/s. Ensyscon, Chennai are utilised for the coordination of the Study on behalf of RCL.

COVID-19 Pandemic : RCL is strictly complying the Norms stipulated by both State & Central Governments during the Lockdown Phases as well as now on account of Corona Virus Disease-2019 (COVID-19) Pandemic. Employees are instructed to wear all PPEs like Mask, Gloves, etc. Sanitization and Social Distancing are ensured at the work places. 13

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

2.0 Description of Environment 2.1 Environmental Setting

RR Nagar Plant area falls in Survey of India Topo Sheet No. 58 G/15 (Fig. 1.2). The Administrative Unit within 10 km radius zone comprises of parts of Virudhunagar, Aruppukottai, Sattur and Sivakasi Taluks of Virudhunagar District. Presently, Line-II exists in-between the Coordinates 09o27’20”-09o27’23” North and 77o55’39”-77o55’44‘’ East. The Coordinates of the Plant after this Modernization, including CPP & Township, will be as follows:

o o Latitude : 09 26’57” to 09 27’47” North o o Longitude : 77 55’05” to 77 55’56‘’ East

There are no Eco Sensitive Areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Wildlife Corridors, Ramsar Sites, Tiger/Elephant Reserves, Reserved Forests, etc. (existing as well as proposed), within 10 km from the Plant. The elevation of the Plant area ranges from 73 m to 89 m above MSL. The region falls in Seismic Zone II.

There is no perennial river in the study area. The seasonal nallas Arjuna River (1.0 km in Southwest) and Mannarkottai Nalla (2.0 km in Northeast) are flowing near the Plant and confluences into River Vippar. The Streams are flowing towards south to southeast and confluences at Golvarpatti Dam (7.0 km in SE).

The nearest habitations are Thammanaickanpatti, Vachchakaranpatti and Tulukkappatti. The Cement Plant is located at a distance of 15 km in the south from District Head Quarters Virudhunagar. Sattur Town is at a distance of 10 km in the south and Sivakasi Town is at 11 km in the West from the Plant.

The Cement plant is well connected by Road and Rail networks. National Highway-44 (earlier NH-7) (4- Lane Madurai-Kanniyakumari Section) and Southern Railway BG Line (Chennai-Madurai-Kanniyakumari Section) run parallel to the Plant. Madurai is the nearest Airport (50 km in the north). Thoothukudi VOC Port is the nearest Port at a distance of 80 km in SE from the Plant.

2.2 Baseline Environmental Status

Existing Cement and Power Plants are the major industries in operation within the Study Area. Sivakasi Region and this part of Virudhunagar District are famous for Match Industries, Fire Cracker and Printing Industries. Project Area dose not fall in Critically Polluted Industrial Clusters listed by CPCB. The study area of 10 km radius (from boundary) (Fig. 3.1) has been considered for assessing the baseline environmental status. Considering the Environmental setting of the project, project activities and their interaction, following Environmental Attributes have been included in EIA Study. v Site specific Micrometeorological Data for the parameters Wind Speed & direction, Temperature, Humidity, Cloud Cover and Rainfall for one Season. v Ambient Air Quality (at 14 locations) on 24-hourly basis, continuously for 2 days in a week for 4 weeks in a month for a season for all 12 parameters as per NAAQ Norms. v Noise Level Measurements at 14 Locations for both Leq-Day and Leq-Night values. v Water Quality-Surface Waters (8 Locations) and Ground Waters (10 Locations) for CPCB/IS Norms. v Soil Quality (6 Locations) for Textural & Physical Parameters, Nutrients, etc. v Land Use Pattern based on Satellite Imagery.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

v Biotic Attributes : Flora & Fauna -Core & Buffer zones. v Socio-Economic Profile, based on 2011-Census and also Household Survey once in the study period for : Total Population, Household Size, Age, Gender Composition, SC/ST, Literacy Level, Occupational Structure, etc.

The findings of baseline environmental status of the Study Area are summarized in Table 2.1.

Table : 2.1 Environmental Baseline Status

Envl. Component Parameters Minimum Maximum Mean Applicable Norms PM2.5 10 46 24.2 60 Ambient Air Quality PM10 18 74 41.7 100 (24-hly), SO2 6 22 10.9 80 ug/m3 NOx 6 26 13.1 80 Leq-day 40.4 48.1 43.2 55 Ambient Noise, dB(A) Leq-night 38.2 44.7 40.9 45 Surface Waters, mg/l TDS 360 580 - 500/2100 Ground Waters, mg/l TDS 480 620 - 500-2000 Texture - - Silty Loam - Soil Status EC, mmhos/cm 0.6 1.3 - 0.2-0.5 SAR 2 3 - <5

Legend : PM2.5-Particulate Matter size less than 2.5 um; PM10-Respirable Particulate Matter size less than 10 um; SO2-Sulphur dioxide; NOx-Oxides of Nitrogen; Leq-Day & Leq-Night : Equivalent Noise Levels during Day & Night Times; TDS : Total Dissolved Solids; EC-Electrical Conductivity & SAR-Sodium Absorption Ratio. v The collected meteorological data during this season represented the local weather phenomena. v While comparing with the National Ambient Air Quality (NAAQ) Standards revised as per GSR 826(E) dated 16.11.2009, all monitored values were found to be well within the respective limit values for 24- hourly periods for Industrial, Residential, Rural and other Areas.

Exceedence Factor (EF) : (Monitored Avg. Value of criteria Pollutant/NAAQ Norm of the Pollutant) : Critical Pollution if EF is 1.5; High Pollution if EF is between 1.0-<1.5, Moderate Pollution if EF is between 0.5-<1.0 and Low Pollution if EF is <0.5. Study Area is falling under Low Pollution as monitored Pollutant Levels were <0.5 EF.

Pollutant Mean Concentration NAAQ Norm Exceedence Factor (EF) Pollution Category PM2.5, ug/m3 24.2 60 0.40 Low PM10, ug/m3 41.7 100 0.42 Low 3 SO2, ug/m 10.9 80 0.14 Low 3 NO2, ug/m 13.1 80 0.16 Low v Ambient equivalent Noise Levels (Leq) during day and night times were found to be well within the MoEF&CC Norms. v Workzone Noise Levels were well within the Limit of 85 DB(A) for 8-hours exposure v The water quality of surface waters were found to be in compliance with CPCB/BIS Norms. v The ground water quality was found to be in compliance with the IS:10500-2012 Norms. 18

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

v The soil in the study area would very well support vegetation after amending it suitably. v There is no eco sensitive area exists in the study area and only domesticated animals exist. v Schedule I Fauna, Peafowl are found inhabiting the Study area. Accordingly, the Peafowl Conservation Plan has been prepared and submitted v The area is thinly populated and basic amenities are available almost in all villages.

Thus, there is adequate buffer for the proposed Project in the physical, biological and edaphic environments of the study area.

3.0 Anticipated Environmental Impacts

Any Project would create impact on the environment in two distinct phases viz. Construction Phase which may be regarded as temporary & short term and Operation Phase which would have long term effects. The impacts have been assessed for the Project by assuming that the existing industrial activities has already been covered under baseline environmental status and continue to remain same till the operation of the Project.

3.1 Construction Phase

The Proposal mainly involves construction of New Kiln (upto Clinkerisation as Line-II) along with other facilities for both Lines I & II like Silos, Stackers & Reclaimers, Cement Mill, Packers, Wagon Tippler, etc. Also, additional E-Type (5,770 sq. m) and F-Type (6,050 sq.m) Quarters in the Township are required and proposed accordingly to existing 38,161 sq.m builtup area in the Township. The proposed construction of E&F Type Quarters will comply with Directorate of Town and Country Planning (DTCP) Norms and necessary Approvals from DTCP will be obtained. Required construction materials will be sourced from approved quarries only. Predominantly, M-sand will be utilized in place of River sand. Both local & other State labourers will be engaged @ 150-200 persons/day (in an average) for the construction period of 12 months. Water, electricity, toilet facilities, etc. will be provided to the Construction Labours in the available and proposed Quarters during the Construction Phase.

3.2 Operation Phase 3.2.1 Land Use

After this Modernization, the total Builtup Area of the Complex will be 61.266 Ha (with Roof Top Area of 27.570 Ha) and Paved Area of 17.012 Ha (Table 3.1).

Table : 3.1 Proposed Plant Land Use – On Modernization

Land Use On Modernization, Ha Land Use Cement Plant Township CPP Total Builtup Area 50.638 9.998 0.630 61.266 Asphalt/Paved Area 15.552 1.110 0.350 17.012 Solid Waste Storage 7.000 - - 7 Green Belt 52.500 9.500 2.500 64.5 Vacant Land 29.588 5.525 4.050 39.163 RWH Ponds & Drains 2.493 - - 2.493 Total 157.771 26.133 7.53 191.434

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The total Green Belt Area after Modernization will be (52.50+9.5+2.5=) 64.50 Ha in the total extent of 191.434 Ha with 33.69% coverage. Green Belt of 10.00 Ha will be developed during the Construction Period and balance 21.50 Ha will be carried out during the Operation Phase. With DFO Guidance, local species will be planted @ 2,500 Trees/Ha. Existing Green Belt Survival Rate is about 90%.

3.2.2 Traffic Impact

Raw and Finished Materials are being transported by both Rail and Road Modes. Limestone from Captive Mines & Primary Crusher at Pandalgudi is transported by 30 Tons Tippers through RCL’s dedicated transportation road. There are 532 Truck movements in a day now. On Modernization & Expansion, 191 Truck movements in a day will be the additional traffic volume (35.90% increase) (Table 3.2).

Table : 3.2 Traffic Volume - Existing & Proposed

No. of Trucks per Day Increase in Existing On Modern. Sl. Raw Mode of (one way) No. of Trucks Demand, & Expn., No. Material Transportation On per Day (one TPD TPD Existing Modern. way)

By 30 T Tippers to 158 225 67 Crusher. From (Dedicated (Dedicated 1 Limestone 4730 6740 (Dedicated crusher by closed Own Own Own Road) conveyors to Plant Road) Road)

Covered 18 Ton 2 Copper Slag 50 63 3 4 1 Trucks by road

Petcoke / 50% by Rail & 50% by Road Covered 3 Imported 362 423 12 14 2 15-18 Ton Trucks Coal

Imported 75% by Rail & 25% 4 810 1220 10 15 5 Clinker by Road

Covered 18 Ton 5 Gypsum 230 290 13 16 3 Trucks by road

30/40 Tons 6 Fly ash 1600 2050 40 51 11 Bowsers

Covered 18 Ton 7 Wet Fly Ash 30 50 2 3 1 Trucks by road

Covered 18 Ton 8 Slag 50 63 3 4 1 Trucks by road

CPP : Covered 15-18 Ton 9 Imported 240 No change Trucks by road 16 0 16 Coal

25% by Rail & 75% 10 Cement 5500 7500 by Road 275 375 100

Total 532 707 191

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The Traffic Survey based on Indian Road Congress-IRC: 64/106 Norms were carried out at Mukku Road Junction on NH-44 during a Week Day and also during the Week end. Based on the Survey, the existing Traffic Volumes at the Junction is computed in Passenger Car Units (PCUs) and was found to be 14,318 PCU/day.

In the Post-Project Scenario, there will be an addition of 382 Vehicles (in 2 ways) to the existing traffic. Cumulatively, the traffic volume in the Project vicinity on Modernization & Expansion will be 14,993 PCU/day. The net increase (cumulative) will be 675 PCU/day only. Thus, there will not be any impact on the existing baseline traffic volume during Modernization Period also. The existing Roads/NHs are adequate to handle the proposed traffic volume due to the Project.

3.2.3 Air Environment

On Modernization, significant reduction in Specific CO2 Emissions will be there because of the reduced Electrical Energy and Heat Energy consumption. Expecting a Specific Heat reduction of about 325 kcal/kwh in the existing CPP due to WHR from Line-I. The Plant operations will be in compliance with new Emission Standards issued by MoEF&CC for Cement Industry vide Notifications dated 25.08.2014 and amended on 09.05.2016 & 10.05.2016. All Main Stacks are now provided with Online Monitors and the Real Time Emission Levels are connected to the TNPCB Care Air Centre and one Continuous AAQ Station is connected with CPCB & SPCB Servers. All Main Stacks of Line-II with New Kiln-II will also be provided with Online Monitors and the Real Time Emission Levels will be connected to the TNPCB Care Air Centre. The Line-II New Kiln will be provided with Jet Pulse Air Bag House, Cooler will be provided with ESP, Coal Mill and Wagon Tippler will be with Bag Filters so as to control the Particulate Matter Emissions <20 mg/Nm3.

Prediction Modelling : AERMOD View is used for the Prediction Modelling. The Model was run for both Existing Operations and for the proposed Modernization & Expansion operations.

Pollutant Emissions (g/sec) - Existing Emissions (g/sec) – On Modernization* PM 5.937 9.598

SO2 4.409 19.528 NOx 9.661 91.661

The predicted GLCs (cumulative impact) are given in Table 3.3. Also, adequate Buffer exists in the Air Environment for the proposed Expansion activities.

Table : 3.3 Predicted GLCs

Distance Background Max. Predicted Revised from the Total Buffer Available Sl. Concentration Ground Level NAAQ Pollutant Plant Concentration, in the No. (24-hly. Avg.), Concentration, Norms, (max.), ug/m3 Atmosphere ug/m3 ug/m3 ug/m3 km 1 PM10 Existing i. 2.103 0.2 43.803 100 56.197 Operations 41.7 ii. On Expansion 3.700 0.2 45.400 100 54.600 iii. Incremental Increase in PM10 1.597 21

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

2 SO2 Existing i. 0.743 0.1 11.649 80 85.44 Operations 10.9 ii. On Expansion 2.637 0.1 13.537 80 83.08

iii. Incremental Increase in SO2 1.894

3 NOx Existing i. 1.654 0.2 14.754 80 81.56 Operations 13.1 ii. On Expansion 13.444 0.2 26.544 80 66.82

iii. Incremental Increase in NOx 11.790

3.2.4 Water Environment

The Unit has been permitted for the drawl of 1,500 KLD from the nearby Seasonal Arjuna River vide Tamil Nadu State Government GO 1446/PWD dated 04.10.1975 (through pipeline for 2.1 km). Presently, the fresh water demand of the Cement Complex is 900 KLD (kilo liter per day) and CPP is 280 KLD. Thus, present total Water Demand is 1,180 KLD. There is an Intake Well in the River Basin for tapping the required water.

Alternately, for Summer Season periods, Permission/No objection Certificate for tapping 1,170 cum/day ground water, from own borewells & dugwells within the Complex & abandoned mine pits, has been obtained from the Central Ground Water Authority (CGWA) vide its Letter No. 21- 4(294)/SECR/CGWA/2011-3316 dated 22.03.2012. The NOC has been Renewed by the TN State Government Public Works Department (PWD) Water Resources Department vide Lr. No. DD(G)/OT10/G-6/304/Renewal NOC/Karaikudi/2020 dated 26.05.2020 with validity 21.03.2021 for 800 KLD from permitted Sources within the Plant and outside areas. About 400 KLD is also drawn from the abandoned RCL Mine Pits nearby (total 1,200 KLD).

On Modernization, the fresh water demand of the Cement Plant will be restricted to 445 KLD (210 KLD- 32.06% less due to Upgradations & Modifications). With 280 KLD for CPP, 175 KLD for Township and 100 KLD for E&F-Type Labour Qtrs. the Total Water Demand of the Complex will be 1,000 KLD (cumulatively 180 KLD viz. 15.25% less to the existing Demand).

There is no trade effluent from the Cement Plant. Workshop washings of 4 KLD and 16 KLD Rejects from CPP are individually neutralized in the Neutralization Tanks of adequate capacity and the Treated Effluent of 20 KLD is taken to the Cement Plant for equipment cooling (where it is evaporated fully). The same practice will be continued after the Modernization also.

Domestic Sewage & Canteen wastewaters of 25 KLD from the Cement Plant, 9 KLD Domestic Sewage from CPP, 160 KLD Domestic Sewage from the Township and another 86 KLD Domestic Sewage from Labour Qtrs., thus, a total of 280 KLD will be generated. All the Domestic Sewages will be combinely treated in a 300 KLD Sewage Treatment Plant at the new location near CPP. 22

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The Treated Sewage will be in compliance with TNPCB Norms for On-land Irrigation. The Treated Sewage of 250 KLD will be fully used for the Green Belt development. Thus, it is a Zero Effluent Discharge Plant

Dedicated Strom Water Drains exist and are connected to Rain Water Harvesting Wells and Ponds. Harvested water is supplementing the Raw Water Demand.

Impact on Surface Waters : As per Micro Watershed Atlas of India, the Plant Area falls in Micro Watershed Map 4A1C7f7 which is appended below.

In the Watershed Area of 1300 Ha, only a seasonal well marked Stream originates near Thammanayakkanpatti village, flows western side of the Plant and joins the Seasonal Arjuna River. In the Plant Area, there are few first order Streams/Drains (Survey Nos. 6/1, 9/1, 12/1, 13/1, 14/2, 52/3 & 54 of Tulukkapatti Village and Sy. No. 202/3) generate during the rainy periods, flow towards south so as to join the Arjuna River. These Drains are maintained as such. The Cart Track in Sy. No. 201/1, 204/1 have been developed as a Road at the Plant western boundary for Ethiliapparpatti Village use. The required NOC/Permission from the District Administration is obtained for the Road and ROBs for this purpose.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The 70 year Normal Rainfall of the Plant Area (Sattur Rain Gauge Station) is 835 mm. Pre-Project and Post Project Surface Runoffs from the Plant Area is estimated as per Manual of Artificial Recharge of Ground Water (CGWB, 2007).

Pre-Project Runoff : 3,42,666 KL/Year Post Project Runoff : 5,55,193 KL/Year

Existing wells and created Ponds in the Plant vicinity are utilised for harvesting the Rain Water in the Plant vicinity. The Roof Top Collection of 2,09,738 KL/Year will be directly collected and used @ 575 KLD in supplementing the Raw Water Demand. Additionally, 20,081 KL/Year will be collected in RWH Ponds and utilized for Green Belt development. The balance 3,25,373 KL/Year Rain waters reach the natural Drains to discharge into the Arjuna River. Thus, there is no impact on the Surface Waters.

Impact on Ground Waters : During the lean flow periods of Arjuna River, about 1,170 KLD ground water is tapped from permitted own borewells & dugwells within the Complex and also from RCL abandoned mine pits. In the remaining Periods, the Mine Pits as well as RWH Ponds receive the Rain water and recharge the ground water-table in the vicinity regularly.

3.2.5 Solid Wastes

The solid waste generated from the process and dust collected from various air pollution control equipment is being recycled in the process. TNPCB has issued Hazardous Waste Authorization vide No. 16HFC5144632 dated 01.12.2016 which is valid till 01.12.2021. Spent Oils (94.62 TPA) are collected, stored and disposed to authorized recyclers. About 9,125 TPA Oil Wastes and 6,000 TPA Chemical Sludges from CPP-ETP are used for Co-processing in the Kilns. Solid waste from the Sewage treatment plant is vermi-composted and used as manure for Green belt development. There will not be significant change to the existing Status of Solid Waste Generation, Treatment and Disposal from the Complex on Modernization.

3.2.6 Power Demand

The power demand of existing plant operations and township is 22.34 MW. Stoppage of line II equipment and some machineries of Line-I will reduce about 7.65 MW and the Line-II with New Kiln will require 10.00 MW and other new Units about 8.16 MW. Thus, additional Power Demand will be 18.16 MW and the total Power Demand will be 33.00 MW. RCL is operating 25 MW CPP along with 1x7 MW furnace oil CPP and DG sets for standby operations. In addition to the utilization of 24 MW from CPP, balance Power demand of 9.00 MW will be met from TANGEDCO Grid or by wheeling it from RCL’s other Captive Power Plants located within the State.

3.2.7 Occupational Health

RCL is committed to provide safe and healthy working conditions and continuously improving the occupational health and safety performances. RCL’s SHE Policy objectives are: v To achieve zero accident and safe work environment. v To improve moral and health of all employees.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

The Upgraded Occupational Health Centre (OHC) for In & Out Patients Treatment with Emergency Care, Ambulance, etc. (Medical Officer with MBBS, DIH qualification) has all the Facilities to take care any emergency.

Periodic medical checkups are carried out to determine the employee’s current health status. Any deviations are investigated and appropriate preventive and remedial measures are suggested. Records of these examinations are maintained at the OHC. Tie-ups with Tertiary Health Care Referral Centres ensure that the best possible care is provided in case of any emergency.

4.0 Environmental Monitoring Programme

Continuous online stack monitoring equipment/systems for PM, SO2 and NOx) are installed at all main stacks and the online real time monitoring data is being transmitted to TNPCB & Central Pollution Control Board (CPCB) servers regularly. The Cement Plant & Captive Power Plant are being operated for Particulate Matter (PM) Emission Limit <30 mg/Nm3 and <50 mg/Nm3 respectively. There was no exceedence of the Limit values so far.

Continuous online stack monitoring equipment/systems will be installed for Line-II with New Kiln also for PM Emission <20 mg/Nm3 and will be connected to TNPCB & CPCB Servers.

One number Continuous Ambient Air Quality Monitoring Stations are installed in the Plant for online real time monitoring data which are connected to CPCB & TNPCB Servers round-the-clock. Data on PM2.5,

PM10, SO2 and NOX are displayed outside the premises for the general public view also.

Periodical monitoring of the ambient air quality as per Revised NAAQ Norms, fugitive emissions (4 locations), stack emissions, noise levels (at boundaries), water (once in a season) and soil quality (once in a season) shall be undertaken. The periodical status reports shall be submitted to TNPCB monthly, and MoEF&CC, Regional Office, Chennai as Half Yearly Status Reports.

5.0 Additional Studies

Detailed risk assessment and mitigative measures are delineated and an effective Disaster Management Plan, for natural and man-made disasters, is in place.

6.0 Project Benefits

Environmental Benefits : Plant Modernization is necessary to increase the plant efficiency by adopting the state-of the-art technologies, machineries and operation of the Plant for optimum standards and lower emissions. Modernization will benefit the Plant in terms of reduction in Electrical Energy and Fuel

Consumption, lower Maintenance Cost, etc. Significant reduction in Specific CO2 Emissions because of the reduced Electrical Energy and Heat Energy consumption.

Financial Benefits : The Project will bring Rs.300.00 Crores investment to the Region, improve the local and regional economy.

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

Social Benefits : There are 465 Direct Employees working in the Cement Complex. Indirect Employment to about 600 persons has been provided. About Rs.2.50 Crores will be allotted as Corporate Environmental Responsibility (CER) Budget for execution in 2 years period, in compliance with MoEF&CC OM F. No. 22-65/2017.IA.III dated 01.05.2018.

7.0 Environmental Management Plan

An Environmental Management Plant (EMP) is formulated for mitigation of adverse impacts and is based on present environmental status and impact appraisal. It is mandatory to comply with the various regulatory Norms for Prevention and Control of Pollution. The following environmental management plans are proposed for mitigation of impacts on the environment :

7.1 Construction Phase v PPE shall be provided to the construction workers. v Construction employees shall have access to the safe drinking water and to existing Toilet facilities. v Protection devices viz. ear plugs/ear muffs shall be provided to the workers during welding works. v Smooth flow of traffic should be ensured on the internal roads to avoid idling of vehicles. v All the debris resulting from the site shall be disposed off effectively as per existing Norms. v EMP Cell ensure the periodical Monitoring of Environmental Parameters during the Construction Period and ensure its compliance with Norms.

7.2 Operation Phase 7.2.1 Air Environment

RCL has installed adequate air pollution control systems viz. Electro statistic precipitators, Bag house, bag filters, etc. are installed in the stacks to control the emissions. Also, adequate dust collection and extraction systems are installed at various transfer points raw mill handling (unloading, conveying, transporting, stacking), vehicle movement, bagging and packing areas, etc. The dust collected from all APC Equipments is being totally recycled in the process. v All efforts shall be undertaken to maintain the PM emission levels from the main stacks of Line-II New Kiln as <20 mg/Nm3. v NOx emission levels from Line-II with New Kiln shall be <600 mg/Nm3. v The periodical evaluation for the efficiency performance of ESPs and Bag Filters shall be carried out. v Fugitive emissions due to storage, transportation, etc. and the leakages and spillages shall be continuously monitored and controlled. v Thermal insulation is provided wherever necessary to minimize heat radiation from the equipment, piping etc, to ensure protection of personnel. v Periodical Ambient Air Quality and Stack Emissions shall be undertaken and the Status Reports shall be submitted to the Authorities as required.

7.2.2 Noise Levels v All rotating items are well lubricated and provided with enclosures as far as possible to reduce noise termination. 26

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

v Extensive vibration monitoring systems are provided to check and reduce vibrations. v For all fans, compressors etc. vibration isolators are provided to reduce noise. v Provision of silencers are made wherever possible. v Proper lubrication and housekeeping are maintained. v The operator provided with necessary safety and protection equipment like ear plugs, ear muffs etc.

7.2.3 Water Environment v Water consumption shall not be more than the consented quantity. v No trade effluent shall be discharged from the Plant. v Cooling water is put into closed circuit to minimize the evaporation losses. v The domestic sewages from the Cement Plant, Power Plant and Township shall be treated effectively in the Sewage Treatment Plant so to meet the TNPCB Discharge Norms and the treated sewage shall be used for Green Belt. v ‘Zero Effluent Discharge’ shall be practiced. v No percolation of treated water to the deep ground water table is done. v Periodical monitoring for specific parameters shall be done regularly. v Effective Rain Water Harvesting Systems shall be adopted and harvested water shall be utilized for the industrial needs so as to conserve the fresh water demand.

7.2.4 Land Environment v It should be ensured that there is no industrial solid waste from the Plants. v The dust collected from APC Measures will be consumed in the Cement Plant fully. v Solid wastes from STP Plant shall be vermi composted and used as manure for Green Belt. v Waste Oil shall be collected and sold to the CPCB/TNPCB Authorised Agency for further treatment & disposal. v The municipal wastes shall be collected, transported, treated in a landfill (composting) within the Plant vicinity to make use of it as manure for Green Belt.

7.2.5 Biological Environment v Green Belt shall be maintained effectively. v Local species and fruit bearing trees may also be developed to have a thick canopy cover. v The treated sewage shall be used fully for the Green Belt development.

7.2.6 Rain Water Harvesting v An effective rain water harvesting shall be implemented and realized water shall be used effectively to supplement the water supply from the river.

7.2.7 Occupational Health Measures v RCL shall provide a safety & healthy working conditions and continually improve the occupational health and safety performance. 27

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

v Its objectives shall be to achieve zero accident and safe work environment, to improve moral and health of all employees and to maintain the emission levels below the norms. v RCL shall provide ergonomic support in work comfortness with periodical review.

7.2.8 Social Measures v As per the Companies Act 2013, Companies should spend at least 2% of the Profit after Tax of the previous year for the CSR activities but not lower than 2% of average of previous three years Profit after Tax. v RCL is presently carrying out various Socio Measures for the local as well as regional populations which shall be continued as per existing CSR Norms. v About Rs.2.50 Crores will be allotted as Corporate Environmental Responsibility Budget for execution in 2 years period. v The District Administration and RCL has executed a MOU and constituted an Environmental Monitoring Committee in two tiers (i) District Level Community Development, Environmental Monitoring & Approval Committee (ii) Village Level Community Development, Environmental Monitoring & Approval Committee to look after implementation of CSR activities which is valid till March 2022.

Based on the CSR Committee and declared CSR Policy of the Company, the following CSR activities will be covered and Reported (& also displayed in the Company website) : v Promotion of education & vocational skills. v Ensuring environmental sustainability. v Contribution to the Prime Minister's National Relief Fund or any other fund set up by the Central Government or the State Governments for socioeconomic development and relief.

The basic amenities are being developed in coordination with the District Administration. RCL has spent an amount of Rs.8.95 Crores during 2015-16 to 2019-20 for the CSR activities (Table 7.1), in addition to the Covid-19 Relief Works to the tune of Rs.70.00 Lakhs.

Table : 7.1 RR Nagar –Yearwise CSR Amount Spent

Year 2015-16 2016-17 2017-18 2018-19 2019-20 April - September 4078238 2035588 8506290 9329180 12345374 October - March 8348850 4263878 8348515 21110673 11232243 Total 1,24,27,088 62,99,466 1,68,54,805 3,04,39,854 2,35,77,617

7.2.9 Plastic Waste Management

There will be ban on one time use and throw away Plastic usage in the Plant in compliance with Tamil Nadu, Environment and Forests (EC-2) Department, G.O.(D) No. 84 dated 25.06.2018. The use of 'use and throwaway plastics', such as Plastic sheets used for food wrapping, spreading on dining table etc., plastic plates, plastic coated tea cups and plastic tumbler, water pouches and packets, plastic straw, plastic carry bag and plastic flags irrespective of thickness is restricted at the premises. Instead, RCL will 28

The Ramco Cements Limited Proposed Modernization & Expansion of RR Nagar Cement Plant, Virudhunagar Dist., TN

encourage the use of eco friendly alternative such as banana leaf, areca nut palm plate, stainless steel glass, porcelain plates / cups, cloth bag, jute bag etc.

7.2.10 EMP Budget

The Project Cost of the existing Cement Plant Complex is Rs.594.00 Crores. A budget Rs.9.20 Crores is presently the EMP Capital Cost and Rs.3.40 Crores/annum is the EMP Recurring Cost. For proposed Modernization & Expansion, the Project Cost will be Rs.300.00 Crores with existing infrastructures and facilities. A budget Rs.5.00 Crores as EMP Capital Cost and Rs.0.50 Crores/annum as EMP Recurring Cost are proposed additionally.

The proposed budget for Peafowl Conservation Plan will be Rs.1.00 Lakhs/annum for Habitat improvement, Community participation in Conservation, etc.

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