summary environmental impact assessment (after tor; for

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

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)

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, 5

th 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]

2


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.

3


4


5


RCL Patta Lands in Tulukkapatti Village

Survey No. & Extent in Ha

1/1 0.680 1/2 0.565 1/3 0.555 1/4 0.565 1/5 0.470 1/6 0.480 1/7 0.965 2/1 0.820 2/2 3.325 3/1 1.070 3/2 1.140 3/3 0.140 3/4 0.350 3/5 0.695 4/1B 1.005 4/2A2B 1.315 4/2B 0.075 4/3 0.640 5/1 0.415 5/2 0.395 5/3B 0.500 5/4B 0.465 5/5B 0.500 5/6 0.495 5/7 0.375 5/8 0.140 5/9 0.565 5/10 0.455 6/2 1.670 6/3 0.705 6/4 0.330 6/5 0.625 6/6 0.590 6/7 0.350 7/1 0.380 7/2 0.615 8/1 0.415 8/2 0.530 8/3 0.350 8/4 0.250 9/2 0.860 9/3 0.545 9/4 0.550 9/5 0.630 9/6 0.380

9/7 1.210 10/1 0.725 10/2 0.775 10/3 0.710 10/4 0.435 10/5 0.330 10/6 0.255 10/7 0.175 11/1 1.365 11/2 0.945 11/3 0.565 11/4 0.300 11/5 0.480

12/2 0.465 12/3 0.415 12/4 0.310 12/5 0.730 12/6 0.235 12/7 0.665 12/8 0.785 12/9 0.260 12/10 0.225 13/2 0.115 13/3 0.125 13/4 0.535 13/5 0.250 13/6 1.000 13/7 0.605 13/8 0.325 14/1 0.350 14/2 0.370 14/3 0.275 14/4 0.345 14/5 1.155 14/6 0.555 14/7 0.315 16/1 0.585 16/2 0.795 16/3 0.550

16/4 0.335 22/1 0.335 22/2A 0.545 24/1 0.590 24/2 0.600

24/3A 0.712 24/4 1.117

30/1C 0.055 30/2 0.215 30/3 0.830 31/1 0.315 31/2 0.310 31/3A 0.600 31/5 0.545 31/6 0.340 32/2 0.100 32/3 0.095 32/4 0.140 32/5 0.525 32/6 0.575 32/7 0.350 32/8 0.335

32/9A 0.725 34/4 0.235 34/5 1.130 35/2 0.800 35/3 0.550 36/2 1.430 37/2 0.405 38/5B 0.985 38/6 0.165 38/7 0.340

39/4 0.415 39/6 0.190 39/7 0.385 49/5 1.390 50/1A 0.565 50/2A 0.200 50/2C 0.245 51/1 0.655 51/2 0.260 52/1 0.335 52/2 0.270 56/1 0.245 56/5 0.275 57/3A 0.050 57/3B 0.670 57/4 0.315 58/1A 0.035 58/1B 0.825 58/1C 0.565 58/2 0.555 59/2 0.480 59/3 0.695 59/4 0.225 59/5 0.300 59/6A 0.015 59/7A 0.020 59/6B 0.435 59/6C 0.160 59/6D 0.160 59/6E 0.100 59/7B 0.130 59/7C 0.190 59/8A 0.080 59/8B 0.055 59/8D 0.295 60/1 0.455 60/2 0.345 60/3 0.520 65 2.430 65 2.830 65 2.695 66/1 0.845 210/1 0.420 210/2 0.010 210/3 0.290 210/4 0.001 210/5 0.325 210/6 0.180 212/1 0.170 212/2 0.325 214/1A 0.070 214/4 0.410 214/6 0.410 214/7 0.310 221/1A 0.330 221/1B 0.130 221/2 0.290 221/3 0.465

221/4 0.420 221/5 0.245 221/6 0.150 222/1 1.010 222/2 0.415 222/3 0.420 222/4A 0.385 222/4B 0.370 222/5 0.210 221/7 0.105 221/8 0.910 226/1 1.110 226/5 0.640 227/1 0.995 227/2A 2.025 227/2B 1.215 227/2C 1.050 227/3 0.535 228/1 0.805 228/2 0.685 228/3C 0.430 228/3B 0.175 228/3D 0.205 228/3A 0.260 228/3E 0.225 228/4 0.390 229/1 0.420 229/2 1.095 229/3A 0.510 229/3B 0.380 229/4 0.625 230/1 0.080 230/2A 0.180 230/2B 0.250 230/3 0.340 230/4 0.220 230/6 0.200 230/7 0.205 230/8 0.495 230/9 0.009 230/10 0.325 230/11 0.265

6


RCL Patta Lands in Thammanaickanpatti Village


192/3B 0.265 192/6 0.565 192/7 0.010 192/8 0.010 194/1 0.330 194/2 0.325 194/3 0.295 194/4 0.130 194/5 0.725 194/6 0.115 194/7 0.310 194/8 0.225 194/9 0.055 194/10 0.530 194/11 0.395 195/7 1.605 195/8 0.615 196/2 0.180 196/3A 0.005 196/3B 0.175 196/4 0.285 196/5 0.280 196/6 0.595 196/7 1.720 197/5 0.345 197/6B 0.130 197/6C 0.060 197/8 1.045 198/2 0.300 198/4 0.030 198/7 0.545 198/8 0.555 199/2 0.540

199/3 0.595 199/4 0.550 200/2 1.020 200/3 1.040 200/4 0.985 200/5 0.965 201/2A 2.685 201/2B 0.370 201/3 0.315 201/4 0.545 202/1 0.695 202/2 0.095 202/4 0.975 202/5 0.875 203/1 0.630 203/2 0.115 203/4 0.995 203/5 1.285 204/2A 0.345 204/2B 0.215 204/3 0.795 204/4 1.305 205/1 0.410 205/2 0.425 205/3A 0.480 205/4 1.330 206/1 0.945 206/2 0.370 206/3A 0.300 206/4A 1.070 206/5A 0.645 206/6 0.350 206/7A 0.575

207/1B 0.860 207/2B 1.380 209/1 0.795 209/6 1.050 209/7 0.675 210/1 1.185 210/2 0.405 210/3 0.420 210/4A 0.335 210/4B 0.365 210/5A 0.360 210/5B 0.755 211/4 0.500 211/5 0.310 211/7 0.720 212/1 0.085 212/2 2.140 212/3 1.050 215/4 0.630 215/5B 0.810 216/3 0.515 216/4 0.225 216/8 1.265 216/9 0.075 287/1B 1.205 287/2 1.965

RCL Patta Lands in Vachchakarapatti Village


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

7


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

8


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.

9


Table : 1.1 Production on Modernization & Upgradation

Production

Existing Proposed Change on

Modernisation Cumulative on Modernisation

Line-I Line-II Total Line-I Line-II

(New Kiln) Lines I & II

Clinker Mfg., MTPA 0.61 0.48 1.09 0.48* 0.96** 1.44

Clinker from other Units/Imported, MTPA

- - 0.28 0.42-0.50 0.50

Cement Mfg., MTPA

With Own Clinker

0.90 0.70 2.00

0.80 1.50+

2.70 With Import Clinker

0.40 0.40

Cement Waste Heat Recovery (CWHR) Boilers

- - - 1 PH Boiler &

1 AQC Boiler

++

No WHRB -

Standby Power Generation

Standby DG Sets

1x7 MW; 2x4 MW 15.0 MW No addition 15.0 MW

* : 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

Sl. No.

Plant Unit

Own Patta Land Survey Nos. Land Extent, Ha

Remarks Tulukkapatti

Thamma- naickanpatti

Tulukka-patti

Thammanaickan

patti

1 Line-II New Kiln of 3000 TPD with Units upto Clinkerization

4/1B, 5/5B, 5/6, 5/7, 5/8, 5/9, 5/10, 6/3, 6/4, 7/1, 7/2, 9/2

199/2

6.423 0.540

Drains are being maintained as such

2 New Clinker Silo 7/2 - 0.615 - -

3 Limestone Circular Stacker & Reclaimer

-

198/7, 198/8, 200/2, 201/2A, 210/1, 216/8

- 7.256 -

4 New Cement Mill 9/4, 9/5, 9/6 - 1.562 - -

5 4th 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, 60/2, 60/3

- 3.019 -

7 Railway Sidings-Wagon Tippler

50/1A, 50/2A, 50/2C, 51/1, 51/2, 52/1, 52/2, 58/1A, 58/1B, 58/1C, 58/2, 59/6A, 59/6B, 59/6C, 59/6D, 59/6E, 59/7A, 59/7B, 59/7C, 59/8A, 59/8B, 59/8D

202/1, 202/2, 202/4, 202/5, 203/4, 203/5, 204/4

6.155 6.220

ROBs are provided for Deemed Cart Tracks with Dist. Admin. Permission.

8 New Locations for Fuel Tanks, STP, Sub-station, Elecl. & Inst. Service Room, etc.

1/6, 5/2, 5/7 196/7

1.246 1.720 -

9 Labour/Employee Quarters E & F Type

2/2, 4/1B - 1.821 - -

10 Labour Colony & 50 KLD STP

22/1, 22/2A, 24/3A, 24/4 - 2.709 - -

10


11


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.

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13


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”-09

o27’23” North and

77o55’39”-77

o55’44‘’ East. The Coordinates of the Plant after this Modernization, including CPP & Township,

will be as follows:

Latitude : 09o26’57” to 09

o27’47” North

Longitude : 77o55’05” to 77

o55’56‘’ 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.

14


15


16


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

Ambient Air Quality

(24-hly),

ug/m3

PM2.5 10 46 24.2 60

PM10 18 74 41.7 100

SO2 6 22 10.9 80

NOx 6 26 13.1 80

Ambient Noise, dB(A) Leq-day 40.4 48.1 43.2 55

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

Soil Status

Texture - - Silty Loam -

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

SO2, ug/m3 10.9 80 0.14 Low

NO2, ug/m3 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.

17


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 Land Use On Modernization, Ha

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

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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

Sl. No.

Raw Material

Existing Demand,

TPD

On Modern. & Expn.,

TPD

Mode of Transportation

No. of Trucks per Day (one way)

Increase in No. of Trucks per Day (one

way) Existing On

Modern.

1 Limestone 4730 6740

By 30 T Tippers to Crusher. From crusher by closed conveyors to Plant

158 (Dedicated

Own Road)

225 (Dedicated

Own Road)

67 (Dedicated Own Road)

2 Copper Slag 50 63 Covered 18 Ton Trucks by road

3 4 1

3

Petcoke /

Imported

Coal

362 423

50% by Rail & 50% by Road Covered 15-18 Ton Trucks

12 14 2

4 Imported

Clinker 810 1220 75% by Rail & 25%

by Road 10 15 5

5 Gypsum 230 290 Covered 18 Ton Trucks by road

13 16 3

6 Fly ash 1600 2050 30/40 Tons Bowsers

40 51 11

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

2 3 1

8 Slag 50 63 Covered 18 Ton Trucks by road

3 4 1

9

CPP :

Imported

Coal

240 No change Covered 15-18 Ton Trucks by road 16 0 16

10 Cement 5500 7500 25% by Rail & 75% by Road

275 375 100

Total 532 707 191

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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

Sl.

No. Pollutant

Background

Concentration

(24-hly. Avg.),

ug/m3

Max. Predicted

Ground Level

Concentration,

ug/m3

Distance

from the

Plant

(max.),

km

Total

Concentration,

ug/m3

Revised

NAAQ

Norms,

ug/m3

Buffer Available

in the

Atmosphere

1 PM10

i. Existing

Operations 41.7 2.103 0.2 43.803 100 56.197

ii. On Expansion 3.700 0.2 45.400 100 54.600

iii. Incremental Increase in PM10 1.597

20


Sl.

No. Pollutant

Background

Concentration

(24-hly. Avg.),

ug/m3

Max. Predicted

Ground Level

Concentration,

ug/m3

Distance

from the

Plant

(max.),

km

Total

Concentration,

ug/m3

Revised

NAAQ

Norms,

ug/m3

Buffer Available

in the

Atmosphere

2 SO2

i. Existing

Operations 10.9 0.743 0.1 11.649 80 85.44

ii. On Expansion 2.637 0.1 13.537 80 83.08

iii. Incremental Increase in SO2 1.894

3 NOx

i. Existing

Operations 13.1 1.654 0.2 14.754 80 81.56

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.

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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.

22


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.

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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/Nm

3 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.

24


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.

25


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.

26


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

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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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