EXECUTIVE SUMMARY

FOR THE

“PROPOSED CEMENT MANUFACTURING PLANT”

(13.24Acres)

[Project termed under Schedule (3b) Category ‘b’ – Cement Plants as per EIA Notification

2006 and it’s Amendments]

AT

VILLAGE: VAYALUR

THESIL: KRISHNARAYAPURAM

DISTRICT: KARUR

STATE: TAMILNADU

PROPOSED BY

V. V. CEMENTS PRIVATE LIMITED.

9/454 – 4 KUMARAN NAGAR, VENUS SCHOOL BACKSIDE,

C.A.K. ROAD, KARUR – 639001

REPORT PREPARED BY

(NABET Accredited vide Certificate No: NABET/EIA/1618/SA0015 &

MoEF Recognized lab vide F.No Q-15018/29/2007-CPW)

HUBERT ENVIRO CARE SYSTEMS PVT LTD, CHENNAI.

SEP 2017

EXECUTIVE SUMMARY

1. INTRODUCTION

M/s. V. V. Cements Pvt. Ltd proposes to install 0.2 MTPA cement Manufacturing unit in

Vayalur village, Krishnarayapuram taluk, Karur District in the state of Tamil Nadu, consisting

of a 13.24 Acre land proposed with related infrastructures. It is proposed to manufacture

Ordinary Portland Cement (OPC) in the proposed plant. The proposed project cost is Rs.40

Cr.

The proposed cement production capacity of the plant is 600 TPD. The limestone

requirement of the unit is 0.255 MTPA which will be met from Imported (Limestone from

Oman).The proposed project under Category – B as per Environmental Impact Assessment

(EIA) Notification SO 1533, of 14-09-2006 which necessitates obtaining the Environmental

Clearance from Ministry of Environment, Forests & Climate Change (MoEF&CC), New

Delhi.

2. DESCRIPTION OF PROJECT

Project Location

The proposed site is located at Sy.Nos: 411/9, 411/10, 416/1, 417/4, 417/3, 413/2B and

413/2A at Vayalur Village, Krishnarayapuram Taluk, in Karur district of Tamilnadu. The site

is falls in 58J/5 of SOI Topo sheet and spatial location of the site is 100 51’ 31.21” N to 100

51’ 42.18” N and 780 20’ 24.47” E to 780 20’ 33.93” E. The site is strategically situated at

11.75 Km SSW of Kulithalai town.

Figure 0. Satellite View of proposed project site location

Table 1 Project details & Environmental Settings

S.No Item Details

1. Name of the Project Proposed 600TPD Pyro Process Cement Plant

2. Schedule and Category of Project 3(b) , Category B

3. Proposed total area 13.24Acres

4. Location

Plot/Survey/Khasra No. Sy.Nos: 411/9, 411/10, 416/1, 417/4, 417/3, 413/2B and 413/2A

Village Vayalur

Tehsil Krishnarayapuram

District Karur

State Tamilnadu

5. Nearest Railway Station/Airport Lalpet Railway station –10.16KmTrichy International Airport -41.5 Km

6. Nearest Town, City, District Town: Lalpet -9.5 KmCity: Karur-28.0 KmDistrict Hq: Karur-28.0 Km

7. Nearest habitat Nadupatti Village –0.4 Km

8. Inland water bodies Vayalur Tank - 0.170 Km NEPanjapatti Lake - 5.7 Km SW

9. Elevation 114 m

10. Project Cost Rs.4000 Lakhs

11. Present Land use Barren

12. Presence of Any Sensitive Areas Nil

13. Nearby Industries Nil

14. Environmental Consultants Hubert Enviro Care Systems Pvt. Ltd.

Land Requirement

Currently the project land is predominantly barren, the site is relatively flat on the northern

side and therefore the property has been identified as land suitable for Factory

Development. Out of the 13.2 acres total site area, 5.58 acres land area will not be used for

development and will be retained as open space.

Error! Reference source not found. – Project Site Land Use Breakup

S.No Description Area (Sq.mt) Area (Acre)

1 Factory Coverage Area 4364.58 1.0785

2 Road area 3121.54 0.7714

3 Raw Material Storage 3762.57 0.9298

4 Greenbelt (33%) 18217.26 4.5016

5 Parking 464.51 0.1148

6 Quarters 618.73 0.1529

7 Utilities 232.25 0.5739

8 Vacant Area 22613.06 5.5878

Total 53580.34 13.24

Raw Material Requirement

The major raw material for manufacture of cement is Limestone. The limestone will be

imported from Oman through ships and will be conveyed to proposed plant through trucks.

The other raw materials required for the cement manufacture are Bauxite, Iron ore, Fly ash

and Gypsum. Coal is used as fuel for combustion in the kiln.

S.No Raw Material Quantity per day (MT)

1 Lime stone 900

2 Gypsum 30

3 Fly ash 400

4 Coal 60

Water Source and Requirement

In this project water will be used for domestic and greenbelt purposes. Total fresh water

demand is 55.5 KLD and the domestic water requirement is 12.5KLD. Water will be sourced

from local panchayt water supply.

Error! Reference source not found. – Water Demand Calculation

S.No Description Fresh Water

Demand (KLD)

Treated Water

Demand (KLD)

Total Water

Demand

(KLD)

1 Domestic - Factory 3.75 - 3.75

2 Flushing - Factory 3.0 - 3.0

3 Domestic - Quarters 3.0 - 3.0

4 Washing & Flushing - Quarters 2.0 - 2.0

5 Visitors –Factory

(Domestic & Flushing)

0.75 - 0.75

6 Gardening 43 11 54

Total 55.5 11 66.5

Man Power Requirement

Total Man power requirement of this project is around 150 nos. The semi skilled and non skilled

man powers are recruiting from the nearest villages.

Power Supply Requirement

The total power requirement of this project is 3.5 MWA which is sourced from TANGEDCO. A

stand by Diesel Generator of 125KVA capacity with 20 liters per hour diesel consumption is also

used.

Manufacturing Process

The manufacturing process basically comprise of the following operation:

Cement is typically made from limestone and clay or shale.

These raw materials are extracted from the quarry crushed to a very fine powder and

then blended in the correct proportions.

This blended raw material is called the ’raw feed1 or ’kiln feed’ and is heated in a rotary

kiln where it reaches a temperature of about 1400 C to 1500 C.

In its simplest form, the rotary kiln is a tube up to 200 metres long and perhaps 6 metres

india meter, with a long flame at one end.

The raw feed enters the kiln at the cool end and gradually passes down to the hot end,

then falls out of the kiln and cools down.

The material formed in the kiln is described as ’clinker’ and is typically composed of

rounded nodules between 1mm and 25mm across.

After cooling, the clinker may be stored temporarily in a clinker store, or it may pass

directly to the cement mill.

The cement mill grinds the clinker to a fine powder.

A small amount of gypsum - a form of calcium sulphate - is normally ground up with the

clinker. The gypsum controls the setting properties of the cement when water is added.

Figure – 2: Process Flow Diagram

3. BASE LINE ENVIRONMENTAL STATUS

The baseline data for ambient air quality, surface and ground water quality, noise, and soil

quality was collected and analyzed for various parameters. The analysis results show that the

values are within the prescribed limits for ambient air quality and stack emissions. The water

quality of the area is found to be within the prescribed limits for drinking water. The fluoride

levels of the ground water samples are within prescribed limit. The noise levels are found to be

within limits. The soils are having good pH and have good water holding capacity.

4 IDENTIFICATION AND QUANTIFICATION OF IMPACTS

The major contributions of pollution in the proposed plant are emissions from the kiln, apart from

emissions from utilities, and fugitive emissions from handling, transfer and storage of minerals

and coal. The impact assessment report identified various sources of pollution, quantified the

pollution loads and identified the technologies to be adopted for the mitigation and control of the

same. The impacts on air quality due to the project are emissions from the kiln, raw mill, apart

from fugitive emissions during transfer of raw materials and solid wastes. The major pollutant is

suspended particulate matter followed by sulfur dioxide and oxides of nitrogen generated due to

combustion in the kiln at high temperature. The air quality impacts are quantified using

AERMOD, The results indicate marginal increase in the ambient air quality parameters and the

cumulative concentrations of predicted values and baseline data are within the prescribed limits

of National Ambient Air Quality standards. The required water shall be drawn from panchayat

water. The noise levels may increase due to the motors, DG set and other activity. The solid

wastes generated mainly contain dust from the control equipment, while the hazardous wastes

from DG sets contain recyclable materials like spent oil, used lead acid batteries. The fly ash

from the captive power plant is reused in cement mill. There are no endangered flora and fauna

in the impact area. Employment generation and socio economic development of the local area

is the major benefit of this project. The area which has low industrial density and medium

agricultural activity will have positive benefits due to this project.

5 ENVIRONMENT MANAGEMENT PLAN

The management plan is drawn in consultation with the project proponents, technical

consultants after evaluating various technologies available for mitigation and control of pollution.

The environment management plan is drawn to address the impacts monitored, identified and

predicted.

Construction Stage

The potential of pollution during the construction phase will be less compared to the operational

stage. During the dry season it is necessary to mitigate uplift of dust during the excavation,

levelling and transportation by spraying water in the paths, and along the temporary roads. The

clearing of plants, shrubs and trees will be kept to the minimum so as to leave sufficient space

for erection of mechanical units and for few civil constructions. The facilities like toilets, drinking

water and proper shelter for the persons staying in the construction site will be provided with

utmost importance. The toilets will be attached to septic tank so as to minimize the percolation

and to control the subsequent impact on the environment. The construction activity may involve

movement of heavy vehicles for earth moving and to move the equipment like dozers and

cranes, etc. The vehicles and equipment will be maintained periodically so as to minimize the

emissions from exhaust. The hazardous wastes of waste oil and used batteries will be sold to

authorized recyclers. The construction wastes shall be used for levelling purpose.

Operation Stage

Air Pollution

The atmospheric emissions from the cement plant constitute of flue gases from raw mill/Kiln and

DG sets, emissions from other plant operation of Crusher, Raw Mill, cement mill, packer, and

flue gases of Boiler used for captive power generation and emissions from transfer points and

transport of materials. The major emission is particulate matter from all operations, while. SO2

and NOx are generated from the kiln, Boiler, DG sets and transport vehicles.

Electrostatic precipitators are provided to the cooler stack to control/mitigate emissions from the

kiln and Boiler. The ESP has interlocking mechanism with kiln and boiler operation. Bag House

is provided to the raw mill/kiln, while bag filters are mainly used as control equipment for the

cement mills, crushers, packers and transfer points. The electrostatic precipitator and all other

control equipment shall limit the outlet dust concentration to 50 mg/Nm3. Sulphur dioxide (SO2)

originates from cement raw materials and fuel (coal); however calcium compounds bind most of

the sulphur into the clinker. Thus, the conditions within the cement kiln essentially "scrub out"

the majority of potential SO2 emissions from cement manufacturing. Emissions monitoring have

shown that SO2 emissions generally are at very low levels. The cement dust collected in the

pollution control devices is recycled back to the cement manufacturing process.

The following measures are adopted to mitigate and control fugitive emissions based on CPCB

guidelines; the transfer points of material handling section is enclosed, airborne dust at all

transfer operations/points is controlled either by spraying water or by extracting to bag filter, all

conveyor systems are closed, feeding and discharge points of conveyor belts provided with skirt

boards to avoid spillage, coal storage area is clearly earmarked, the pathways in coal yard for

vehicle movement are paved, coal is stored in covered shed, closed clinker silo system and bag

filter for clinker hoppers, regular dust suppression with water sprinkler on the haul roads, plant

roads and approach roads are made of bitumen/concrete, raw materials/Cement is fully covered

during transportation to/from the site by road/rail, open areas within the plant premises and

along the boundary of the plant premises are provided with plantation.

Noise Level Mitigation

Plant machinery like Crusher, raw mill, cement mill, compressors etc are the major sources of

noise and vibration. The following are the noise control measures under taken to ensure low

noise levels; all rotating items are well lubricated and provided with enclosures to reduce noise

transmission, extensive vibration monitoring systems are provided to check and reduce

vibrations, in general, noise-generating items such as fans, blowers, compressors, pumps,

motors etc. are specified as to limit their speeds to less than 1500 rpm to reduce noise levels,

static and dynamic balancing of equipment are carried out periodically, provision of acoustic

dampeners in foundations and insulators in the interiors.

The employees working near noise generating equipment shall be provided with personal

protective equipment like ear plugs and ear muffs. The noise levels are monitored periodically

within the plant area to check the exposure levels. The occupational safety with respect to noise

levels is evaluated periodically to ensure compliance with occupational safety standards. The

density of greenbelt around the plant boundary shall be enhanced to act as noise attenuator.

Solid Wastes

In cement manufacturing, there is no solid waste generation. The dust collected in the air

pollution control equipment is recycled in the process at the respective stage. The spent oil, oil

sludge and used batteries are collected from various sections and stored in the designated

place. The spent oil and oil sludge are co-incinerated in the Kiln. The used batteries are sent to

authorize recycler. The fly ash from CPP plant will be used in cement manufacturing process.

Wastewater

No wastewater is generated from cement manufacturing process. The main waste water is from

the domestic usage, which will be sent to sewage treatment plant. The treated wastewater is

reused for the development of green belt. Domestic wastewater of 13 KLD shall be sent to STP.

The proposed STP Capacity of 25 KLD is sufficient even after expansion.

6 OCCUPATIONAL SAFETY AND HEALTH

Occupational health centre is provided. All employees will undergo check-up on recruitment and

periodically during employment. Standard operating procedures for all occupations and

operations with respect to occupational safety and health are provided. The management and

Occupational hazards control team shall follow the hierarchy of; hazard elimination, risk

reduction at source, isolation of people from the hazard, controlling the risk by other means, and

provision of personal protection equipment.

7 PREVENTION, MAINTENANCE AND OPERATION OF ENVIRONMENT

CONTROL SYSTEM

The pollution control equipment and the waste water treatment systems are monitored

periodically and checked for their performance. Pro-active maintenance is adopted. The

environmental monitoring results are evaluated to identify the problems/under performance of

the equipment. Necessary steps are taken to rectify the identified problems/defects. The

management agrees to evaluate the performance of pollution control measures and

occupational safety measures to arrive at their efficiency and agrees to adopt mitigate measures

for efficient pollution control. All pollution control equipments are adequately designed and it is

ensured that the operating staffs of APC’s have good experience in the operation and

maintenance of the equipment. Interlocking system is provided at all critical equipment like raw

mill, kiln and cooler. Preventive maintenance is done as per the schedule to avoid breakdown.

8 TRANSPORT SYSTEMS

The raw materials and finished products are mainly transported by trucks. Trucks transporting

raw materials from the vendor yards/place to plant are covered so as to reduce emissions to the

surrounding environment. Sufficient truck parking spaces will provide near the gate, and traffic

signs are placed in the battery limit. The entry for raw material transport vehicles is kept

separate as well as exit trucks.

9 SOCIO ECONOMIC ENVIRONMENTS - CORPORATE SOCIAL RESPONSIBILITY

The V.V.Cements (Pvt.) Ltd will take responsibility for CSR activities and other social

development programs in the surrounding areas. The company has been involved in social

development activities like provision of infrastructure to schools and hospitals, provision of

toilets in schools, provision of toilets in village peoples, provision of drinking water facility in

surrounding villages, campaign for health, savings and social awareness about social evils like

dowry etc. The company employs locals as employees based on suitability. It will helps in the

upliftment of the socioeconomic status of the area.

10 GREEN BELT DEVELOPMENT

Green belt is recommended as one of the major components of Environmental Management

Plan. The industry will proposed the green belt area of 4.50 acres (33%) in the plant area. The

plant species shall be selected from CPCB guidelines of green belt development, to enhance

environmental quality through; mitigation of emissions, attenuation of noise levels, balancing

eco-environment, consumption of treated wastewater, prevention of soil erosion, and creation of

aesthetic environment.

11 POST PROJECT MONITORING

Environmental monitoring for water, air (both ambient air quality and stack emissions), noise

and soil quality shall be conducted periodically either by the proponent or a third party. The

frequency of monitoring and the quality parameters shall be as suggested by the Ministry of

Environment and Forests, Government of India as explained in the environmental monitoring

chapter. The monitoring results are assessed periodically to identify compliance related

deviations if any, to be informed to the site head and corporate environment division to take

immediate remedial action.

12 ENVIRONMENT MANAGEMENT CELL

The environment management is headed by the Manager who is assisted by EHS Head. EHS

Head interacts with Manager and other staffs in the respective unit’s environment management

cells. The responsibility of the environment management cell includes monitoring overall

environmental performance with respect to compliance, policy decisions in case of

deviations/violations, identification alternative technologies, fuels, cement constituents etc. The

environment management cell at the plant level is headed by plant head who is assisted by

environment officer, safety officer and medical officer. The chief function of each of these

officers is to monitor the compliance with the statutory regulations, and to monitor the safety,

health and environmental aspects of the plant activity. The pollution control equipment

maintenance and operation is supervised by GM (Production) who will report to plant head.

13 COST ESTIMATE FOR ENVIRONMENT MANAGEMENT

The cost estimate for the environment management proposed is presented in the following

table;

S. No. Purpose Capital Cost Lakhs (INR) Recurring Cost Lakhs (INR)

1. Greenbelt development 5 0.5

2. Solid waste Management 0.20 0.1

3. Housekeeping 0.5 0.5

4. Air Pollution Control 1.50 0.4

5. Noise Pollution Control 0.2 0.02

6. Water Pollution Control 0.5 1

7. Environmental Monitoring 1.0 0.5

Total Capital Cost 8.9 3.02

14 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

Hazard analysis involves in the identification and quantification of the various hazards (unsafe

conditions) that exist in the proposed Cement manufacturing plant. On the other hand, risk

analysis deals with the recognition and computation of risks, the equipment in the plant and

personnel are prone to, due to accidents resulting from the hazards present in the plant.

Risk analysis follows an extensive hazard analysis. It involves the identification and assessment

of risks the neighbouring populations are exposed to as a result of hazards present. This

requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of

population etc. Much of this information is difficult to get or generate. Consequently, the risk

analysis is often confined to maximum credible accident studies are discussed in detail in the

EIA report.

15 PROJECT BENEFITS

• The proposed project will create employment opportunities for the surrounding

populations directly or indirectly during and after development, which will enhance the

overall socio-economic growth of the surrounding regions.

• This cement manufacturing unit will create indirect employment for loading, unloading,

transportation and other peripheral activities like, shops and small hotels around the

area.

• Contribute to increase GDP (Gross Domestic Product).

• Socio-economic benefit to the local population as it would provide employment during

construction and in operation phase

• The project will undertake CSR activities that will additionally benefit to the

development of the population living in the area.

16 SUMMARY & CONCLUSION

VVC strongly believes in the concept of Eco friendly industrialization. This has been amply

demonstrated in the operation of cement plant in Vayalur as per standard prescribed by the

State and Central pollution Control Boards. Apart from eco-friendly operations, various socio

economic development activities have been undertaken to bring about overall socio economic

development in the area.

With the same commitment and dedication, VVC will commission the new cement plant in

Vayalur village, Krishnarayapuram Taluk, Karur District in Tamilnadu.