project feasibility report - welcome to environment feasibility report (as per moef guidelines vide...

Anjani Portland Cement Ltd., Chennai EC for 0.95 MTPA Cement Grinding Unit at Athipattu, Tiruvallur District, TN

Ensyscon, Chennai-78.

Anjani Portland Cement Limited (A Subsidiary of Chettinad Cement Corporation Ltd.)

Chennai Cement Grinding Unit (0.95 MTPA) (Stand Alone)

Project Feasibility Report (As per MoEF Guidelines vide Circular No. J-11013/41/2006-IA.II(I) dated 30.12.2010)

1.0 Executive Summary M/s. Anjani Portland Cement Limited (APCL) was incorporated as M/s. Shez Chemicals Limited in 1983 at Hyderabad, Andhra Pradesh as a public limited company under the Companies Act, 1956. Subsequently, the name of the Company was changed to M/s. Anjani Portland Cement Limited in 1999. On March 12, 2014, the Promoter M/s. Chettinad Cement Corporation Limited (CCCL) has entered into a Share Purchase Agreement (SPA) with the erstwhile promoters of the Company. After the completion of the Open Offer under SEBI Regulations & SPA, the Promoter CCCL holds 75% of the Equity Share Capital in APCL. Anjani Cement Plant (2 Lines) is located in Chinatalapalem Village, Mellacheruvu Mandal, Nalgonda District of Telangana State with its Captive Limestone Mines. The Environmental Clearance (EC) has been obtained for 3.85 MTPA Cement (Clinker 2.31 MTPA) along with 16 MW Captive Power Plant (CPP) and Colony of 115 Quarters on Expansion from the Ministry of Environment, Forests and Climate Change (MoEF&CC) vide Letter F.No.J-11011/892/2008.IA.II(I) dated 05.01.2010 which has been extended for another 5 years vide Letter even reference dated 20.10.2015. The Consents to Operate (CTO) from Telengana State Pollution Control Board (TSPCB) were obtained for the proposed initial production of 1.925 MTPA Cement and 1.150 Clinker vide its Combined Order Nos. APPCB/PTN/NGL/37/CFO/HO/2011-1357 dated 04.08.2011 which is being renewed by TSPCB. The Plant operations are in compliance with MoEF&CC EC Conditions and TSPCB Norms. Anjani Cement (marketed in the name of Anjani Super Gold & Anjani Prathistta) is a popular brand in South India for its quality. With its exemplary growth in production and services, APCL has captured the market in Andhra Pradesh and now extended its reach to Tamil Nadu, Orissa and Karnataka and also made forays into the markets of Maharashtra, Kerala and Goa. APCL is marketing about 0.5 MTPA cement in Chennai and another 0.25 MTPA in other areas of Tamil Nadu. The Cement is being transported by the Trucks from the Cement Plant in Nalgonda District of Telangana State. With the available Fly Ash sources near Chennai like North Chennai Thermal Power Plant (NCTPP), Vallur NTPC Tamil Nadu Energy Corporation Ltd., Ennore Thermal Power Plant, etc. and Gypsum source (EID Parrys, Ennore), in tune with the Govt. of India Policy of encouraging Cement Grinding Units near the raw material sources and marketing centers, APCL proposes to have a Grinding Unit near Chennai. Also, Chettinad Cement is operating the Chettinad International Coal Terminal near Ennore Kamaraj Port. APCL Cement Plant requires about 0.50 MTPA Imported Coal, on Expansion, for its operations. APCL has the plan of utilizing the Group’s Coal Terminal for its coal requirement.



Coal @ 1320 Tons per day (TPD) will be received and transported to APCL Plant in Nalgonda District by Trucks. APCL proposes to utilize the same Trucks for transporting the Clinker to Chennai (instead of the product Cement for marketing Centres in Chennai & its neighbourhood). With this logistic advantages, APCL has identified a suitable site at Athipattu near Chennai for the Cement Grinding Unit of 0.95 MTPA (PPC/OPC). APCL has entered into an Agreement of Sale with on 24.02.2016 for purchasing a secured land site of 5.28 Ha (13.04 acres) for the Chennai Grinding Unit falling in Parts of Survey Nos. 297, 298, 299, 300, 301, & 302 of Athipattu Village, Ponneri Taluk, Tiruvallur District of Tamil Nadu. It is located on the Vallur-NCTPP-Ennore Port Road branching off from the State Highway SH-56 Tiruvottiyur-Minjur-Ponneri-Panchetti Road from Vallur Junction. The site is barren land with completely secured with Compound Walls on all sides and with required infrastructures and Road, Rail & Sea connectivity. No Railway sidings is proposed. No Township is also envisaged. Green Belt is proposed in an extent of 1.58 Ha (33% coverage). APCL has proposed the Chennai Cement Grinding Unit with a capacity of 0.95 MTPA PPC/OPC (@ 3000

TPD). Main raw material for manufacturing these Cement products are Clinker, Gypsum and Fly Ash. Clinker will be brought by road from APCL Plant (in Nalgonda District of Telangana State; 390 km-aerial distance). Gypsum will be procured from local source in Chennai/Thoothukudi, EID Parrys, etc. Fly Ash will be sourced from NCTPP, Vallur NTECL, etc. near the site. Main process of manufacturing PPC involves inter-grinding clinker, dry fly ash and gypsum in the ratio of about 65:30:5 (for OPC, Clinker-Gypsum ratio is 95:5). The Unit requires 10 MW power and the TANGEDCO Grid is the source. Standby DG sets of 4x500 KVA will be installed for standby operations. Bag Filters are proposed at stacks and all material transfer points to control SPM emission <30 mg/Nm3. As this is only a clinker grinding unit, water is mainly required for equipment cooling (30 cu.m/day), domestic consumption (5 cu.m/day) and Green belt & dust control measures (5 cu.m/day). Thus, the total

raw/fresh water demand would be 40 m3/day. The required water will be sourced from approved/authorized borewells nearby. There is no wastewater generation from the Process. Domestic sewage to the tune of 4.5 cu.m/day will be generated which is biologically treated in a Septic Tanks of adequate size followed by a Dispersion Trench. The dust collected from the various Air Pollution Control Measures like Bag Filters, etc. will be totally recycled in the process for cement manufacturing. Thus, there would not be any process wastes generation from the Unit. Project will be completed in about 12 months on approval of statutory clearances. The Project Cost of Rs.150.00 crores. A budgetary allotment of Rs.4.50 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs.25.00 lakhs per annum. The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Reserved Forests, Elephant Corridor, Archaeological/Historical Monuments, Heritage sites, etc. within 10 km from the proposed site boundary. India Cements Cement Grinding Unit, Vallur is located at 0.9 km in the south and



Zuari Cement Athipattu Grinding Unit is located at 1.5 km in the northeast. North Chennai Thermal Power Plant (NCTPP) is located at a distance of 3.6 km in the east and Vallur NTECL Power Plant is located at 1.5 km in southeast. Athipattu Pudhunagar is the nearest settlement 0.1-1.5 km east of the site. No

Rehabilitation/Resettlement is envisaged due to the proposal. There is no litigation/pending case against the proposal. As per Environmental Impact Assessment Notification 2006 [SO 1533 (E) dated 14.09.2006], all the Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category ‘B’ for the Environmental Clearance from the State EIA Authority (SEIAA) with applicability of General Conditions. Accordingly, Form-1 and Project Feasibility Report are being submitted to the SEIAA-Tamil Nadu for the environmental clearance of the Project under EIA Notification 2006. CCCL has entrusted the EIA Study on M/s. Environmental System Consultants & Ambiente Lab Solutions Private Limited (Ensyscon), Chennai. The EIA Consultant has been accredited for the Sectors 1 (Mining), 9 (Cement Plants), 31 (Industrial Estates/SEZs), 33 (Ports & Harbours), 38 (Building Proposals) and assessed for Sector 4 (Thermal Power Plants) – Category ‘A’ Projects by the National Accreditation Board for Education & Training (NABET), Quality Council of India (Sl. No. 57 in the List of Accredited EIA Consultants-8th February 2016).

***



2.0 Introduction of the Project 2.1 Project Proponent M/s. Anjani Portland Cement Limited (APCL) was incorporated as M/s. Shez Chemicals Limited in 1983 at Hyderabad, Andhra Pradesh as a public limited company under the Companies Act, 1956. Subsequently, the name of the Company was changed to M/s. Anjani Portland Cement Limited in 1999. The Company has listed its Equity Shares on the Bombay Stock Exchange and the Hyderabad Stock Exchange in 1994. In 2013, the Company’s Equity Shares were delisted from the Hyderabad Stock Exchange pursuant to the permission Order of SEBI dated January 25, 2013. On March 12, 2014, the Promoter M/s. Chettinad Cement Corporation Limited (CCCL) has entered into a Share Purchase Agreement (SPA) with the erstwhile promoters of the Company for acquisition of upto 61.62% of the Equity Share Capital. Further to the SPA, the Promoter made an Open Offer under the SEBI (Substantial Acquisition of Shares and Takeovers) Regulations, 2011, to acquire up to 26% of the Equity Share Capital. Pursuant to the Open Offer and the SPA, the Promoter CCCL has acquired 17.09% and 57.91% of the Equity Share Capital, respectively. After the completion of the Open Offer, the Promoter CCCL holds 75% of the Equity Share Capital in APCL. Anjani Cement Plant (2 Lines) is located in Chinatalapalem Village, Mellacheruvu Mandal, Nalgonda District of Telangana State. Starting with initial production capacity of 0.3 million tonnes per annum (MTPA) in 1999, the Company has now achieved a quantum shift in its production capacity to 1.925 MTPA (Ordinary Portland Cement-OPC, Portland Pozzolana Cement-PPC & Rapid Hardening Portland Cement-RHPC). The second line is powered with the latest and modern technology and infrastructure has started operations in 2010. The limestone mines of APCL are acclaimed as the best mines amongst the blocks of Nalgonda District, thus confirming the superior quality of the cement produced. The Environmental Clearance (EC) has been obtained for 3.85 MTPA Cement (Clinker 2.31 MTPA) along with

16 MW Captive Power Plant (CPP) and Colony of 115 Quarters on Expansion from the Ministry of Environment, Forests and Climate Change (MoEF&CC) vide Letter F.No.J-11011/892/2008.IA.II(I) dated 05.01.2010 which has been extended for another 5 years vide Letter even reference dated 20.10.2015. The Consents to Operate (CTO) from Telengana State Pollution Control Board (TSPCB) were obtained for the proposed initial production of 1.925 MTPA Cement and 1.150 Clinker vide its Combined Order Nos. APPCB/PTN/NGL/37/CFO/HO/2011-1357 dated 04.08.2011 which is being renewed by TSPCB. The Plant operations are in compliance with MoEF&CC EC Conditions and TSPCB Norms. Anjani Cement (marketed in the name of Anjani Super Gold & Anjani Prathistta) is a popular brand in South India for its quality. With its exemplary growth in production and services, APCL has captured the market in Andhra Pradesh and now extended its reach to Tamil Nadu, Orissa and Karnataka and also made forays into the markets of Maharashtra, Kerala and Goa. An excellent dealer network system ensures successful spread and sales of the cement within and outside the state. As a responsible Corporate, APCL has taken conscious and decisive measures to develop knowledge based society by providing quality education for the families of the employed and neighboring villages. An innovative venture, BV Raju Institute of Cement Technology, was initiated by the company to train the rural youth in cement technology for potential employment in cement industries.



The awards and accreditations of APCL are :

Year Awards and Accreditations

2004 Certificate of appreciation for meritorious performance in implementing the programmes of Environment Protection, Pollution Control and Plantation work – Andhra Pradesh Pollution Control Board

2008 Appreciation certificate for “Best Cleaner Production Practices and Waste minimization Techniques” – Andhra Pradesh Pollution Control Board

2009

Appreciation certificate for “Best Cleaner Production Practices and Waste minimization Techniques” – Andhra Pradesh Pollution Control Board Certificate of Merit for “Fastest Growing Cement Company (Small Category) - 1st rank” – 7th Construction World Annual Awards 2009 – ASAPB Media Information Group Excellence in Corporate Social Responsibility - Federation of Andhra Pradesh Chambers of Commerce and Industry

2013 Certificate of Excellence for Smart Innovation – INC - India innovative 100

2015 ISO 9001: 2008 for quality management system for manufacture and supply of cement BS OHSAS 18001:2007 for occupational health and safety management system for manufacture and supply of cement ISO 14001:2004 for environmental management system for manufacture and supply of cement

The Contact information of the APCL is : The Managing Director, Anjani Portland Cement Limited,

4th Floor, Rani Seethai Hall Building 603, Anna Salai,

Chennai-600 006. 044-42988653 044-42988661 [email protected]

2.2 Identification of the Project 2.2.1 Need for the Project APCL is marketing about 0.5 MTPA cement in Chennai and another 0.25 MTPA in other areas of Tamil Nadu. The Cement is being transported by the Trucks from the Cement Plant in Nalgonda District of Telangana State. With the available Fly Ash sources near Chennai like North Chennai Thermal Power Plant (NCTPP), Vallur NTPC Tamil Nadu Energy Corporation Ltd., Ennore Thermal Power Plant, etc. and Gypsum source (EID Parrys, Ennore), in tune with the Govt. of India Policy of encouraging Cement Grinding Units near the raw material sources and marketing centers, APCL proposes to have a Grinding Unit near Chennai. Also, Chettinad Cement is operating the Chettinad International Coal Terminal near Ennore Kamaraj Port. APCL Cement Plant requires about 0.50 MTPA Imported Coal, on Expansion, for its operations. APCL has the plan of utilizing the Group’s Coal Terminal for its coal requirement.



Coal @ 1320 Tons per day (TPD) will be received and transported to APCL Plant in Nalgonda District by Trucks. APCL proposes to utilize the same Trucks for transporting the Clinker to Chennai (instead of the product Cement for marketing Centres in Chennai & its neighbourhood). With this logistic advantages, APCL has identified a suitable site at Athipattu near Chennai for the Cement Grinding Unit of 0.95 MTPA (PPC/OPC).

2.2.2 The Site APCL has entered into an Agreement of Sale with M/s. Breeze Enterprises Private Limited on 24.02.2016 for purchasing a secured land site of 5.28 Ha (13.04 acres) for the Chennai Grinding Unit falling in Parts of Survey Nos. 297, 298, 299, 300, 301, & 302 (Table 1.1) of Athipattu Village, Ponneri Taluk, Tiruvallur District of Tamil Nadu (Fig. 1.1).

Table : 1.1 Land Extent Details

Sl. No. Survey Numbers & Parts Extent, acres 1 297/6B1 0.049

2 297/6B2 0.321

3 297/6B3 0.037

4 297/6B4 0.025

5 298/5A 0.099

6 298/5B 0.284

7 298/5C 0.222

8 299/1 2.989

9 300/2 2.964

10 300/4 0.062

11 300/5 0.062

12 300/6 0.049

13 300/14 0.049

14 300/16 0.099

15 300/17 0.062

16 300/18 0.074

17 300/20 0.0005

18 300/1A2 0.158

19 300/1A3 0.099

20 300/1C 0.062

21 300/1D 0.111

22 301/3A 0.716

23 301/3B 0.865

24 301/4A 1.853

25 301/4B 0.630

26 302/1 1.099

Total Area ( acres) 13.04



The identified site FMB Sketch is appended.

Site FMB Sketch

The site is shown in the Regional Map (Plate I) and in the High Resolution Satellite Imagery (Plate II). It is located on the Vallur-NCTPP-Ennore Port Road branching off from the State Highway SH-56 Tiruvottiyur-Minjur-Ponneri-Panchetti Road from Vallur Junction. The Chennai-Gudur Section of Southern Railway Broad Gauge Line runs at a distance of 0.53 km east of the Site. The site is barren land with completely secured with Compound Walls on all sides and with required infrastructures and Road, Rail & Sea connectivity. Athipattu Pudhunagar is the nearest settlement 0.1-1.5 km east of the site (Plates III-IV).

2.3 Brief Description of the Project APCL has proposed the Chennai Cement Grinding Unit with a capacity of 0.95 MTPA PPC/OPC (@ 3000 TPD). Main raw material for manufacturing these Cement products are Clinker, Gypsum and Fly Ash. Clinker will be brought by road from APCL Plant (in Nalgonda District of Telangana State; 390 km-aerial distance). Gypsum will be procured from local source in Chennai/Thoothukudi, EID Parrys, etc. Fly Ash will be sourced from NCTPP, Vallur NTECL, etc. near the site. Main process of manufacturing PPC involves inter-grinding clinker, dry fly ash and gypsum in the ratio of about 65:30:5 (for OPC, Clinker-Gypsum ratio is 95:5). All ingredients are selected in such a way that they qualify respective BIS specifications. The PPC/OPC so produced will be catering the local markets in Chennai and other Districts of Tamil Nadu as well as southern parts of Andhra Pradesh.



Clinker, Fly Ash and Cement will be stored in RCC Silos. All silos are provided with suitable bag filters to control the fugitive emissions. Gypsum will be stored in covered sheds. The Project Cost is Rs.150.00 crores with the following breakup: Land Cost : Rs. 17.00 crores Buildings : Rs. 13.00 crores Plant & Machineries : Rs.120.00 crores ----------------------- Total : Rs. 150.00 crores ----------------------- A budgetary allotment of Rs.4.50 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs.25.00 lakhs per annum.

2.4 Project Benefits The proposed Project will give direct employment to about 50 persons and indirect employment to about 100 persons. In addition to the environmental benefits waste materials like utilization of Fly Ash, Gypsum, etc., there will be a huge positive impact due to the proposal, by way of employment, better socioeconomic conditions, improved local and regional economy, etc.

3.0 Project Description 3.1 Type of Project As per Environmental Impact Assessment Notification 2006 [SO 1533 (E) dated 14.09.2006], all the Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category ‘B’ for the Environmental Clearance from the State EIA Authority (SEIAA) with applicability of General Conditions. Accordingly, Form-1 and Project Feasibility Report are being submitted to the SEIAA-Tamil Nadu for the environmental clearance of the Project under EIA Notification 2006. CCCL has entrusted the EIA Study on M/s. Environmental System Consultants & Ambiente Lab Solutions Private Limited (Ensyscon), Chennai. The EIA Consultant has been accredited for the Sectors 1 (Mining), 9 (Cement Plants), 31 (Industrial Estates/SEZs), 33 (Ports & Harbours), 38 (Building Proposals) and assessed for Sector 4 (Thermal Power Plants) – Category ‘A’ Projects by the National Accreditation Board for Education & Training (NABET), Quality Council of India (Sl. No. 57 in the List of Accredited EIA Consultants-8th February 2016).

3.2 Location/Site & Its Environmental Setting The Cement Grinding Unit is to be located inbetween 13o14’59”-13o15’07” N Latitude & 80o17’23”-80o17’38”

E Longitude (Survey of India-SOI Topo Sheet No. 66 C/7) (Fig. 1.2). Environmental Setting of the Project Site is given as Fig. 1.3.



There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere Reserves, Reserved Forests, Elephant Corridor, Archaeological/Historical Monuments, Heritage sites, etc. within 10 km from the proposed site boundary. SH-56 Tiruvottiyur-Minjur-Ponneri-Panchetti Road runs through Vallur Junction @ 1.7 km in the west. NH-5 runs through Ponneri at 12.5 km in southwest. The Chennai-Gudur Section of Southern Railway Broad Gauge Line runs at a distance of 0.53 km east of the Site. Ennore Kamaraj Port is at 4.7 km in ENE direction. L&T Kattupalli Port is at 6.3 km in northeast. Chettinad International Coal Terminal is located at a distance of 3.5 km in northeast. India Cements Cement Grinding Unit, Vallur is located at 0.9 km in the south and Zuari Cement Athipattu Grinding Unit is located at 1.5 km in the northeast. Ennore Power Plant is at 5.5 km in southeast. North Chennai Thermal Power Plant (NCTPP) is located at a distance of 3.6 km in the east and Vallur NTECL Power Plant is located at 1.5 km in southeast. Vallur Camp/Township is located adjacent to the site in west. LPG Import/Export Terminal & Indane LPG Bottling Plant is located at 0.5 km in northeast. Reliance & HPCL Terminals are located at 1.6 km (south) and 1.9 km (SE) from the site. Athipattu Pudhunagar is the nearest settlement 0.1-1.5 km east of the site. Athipattu village is at 0.1-2.0 km (N) from the site. No Rehabilitation/Resettlement is envisaged due to the proposal. There is no

litigation/pending case against the proposal. Physiography : The minimum and maximum elevation of the study area is 0 m and 24 m AMSL respectively (Fig. 1.4). Site is almost flat with gentle gradient towards southeast. Drainage : Seasonal Korttalaiyar River drains the area 2.4 km in southwest.Kosasthalaiar River/Backwater flows 2.2 km in east. Both Rivers are confluencing with Bay of Bengal through Ennore Creek (Fig. 1.5). Buckingham Canal is @ 2.8 km in the east.

3.3 Alternative Sites The Project has been proposed in the Patta land near the Fly Ash source and the site is environmentally and techno-economically feasible site. Therefore, no alternate site has been considerd.

3.4 Size/Magnitude of Operation APCL has proposed the Chennai Cement Grinding Unit with a capacity of 0.95 MTPA (@ 3000 TPD). The Plant Layout is given as Fig. 2.1. No Railway sidings is proposed. No Township is also envisaged. Green Belt is proposed in an extent of 1.58 Ha (33% coverage). The proposed Land Use at the site is as follows :

Builtup Areas : 0.8256 Ha Roads & Paved Areas : 0.8822 Ha Green Belt : 1.5800 Ha Vacant Area : 1.9895



3.5 Process Main raw material for manufacturing these Cement products are Clinker, Gypsum and Fly Ash. Clinker will be brought by raod from APCL Nalgonda Cement Plant. Dry fly ash will be taken from the power plant located near the site. Gypsum will be procured from fertiliser factory located in Tamil Nadu. Main process of manufacturing PPC involves inter-grinding clinker, dry fly ash and gypsum in the ratio of about 65:30:5 and for OPC Clinker-Gypsum ratio is 95:5. All ingredients are selected in such a way that they qualify respective BIS specifications. The Process Flow Diagram for OPC & PPC manufacturing are appended:

Clinker and gypsum from storage will be transported to respective feed hoppers with the help of belt conveyors. Measured quantities of clinker and gypsum in desired proportion will be fed to the ball mill.



Weigh feeders will be installed under each feed hopper to ensure accurate measurement of input quantities of materials to the mill. While producing PPC, Fly ash of desired dosage will be extracted from fly ash silo and pneumatically transported and fed through a solid flow meter to the mill and the ground cement will be stored in a separate silo. A closed circuit ball mill with a grinding capacity of 150 metric tons per hour will be installed to grind clinker, Fly ash and gypsum together to make PPC. A bucket elevator is used to carry the ball mill discharge material to classifier. In the classifier, the mill output material will be divided into two streams viz., fines and coarse. Fine material of required fineness from classifier will be collected as product and the coarse material will be sent back to the mill for further grinding. The fine material collected in bag filters is the final product and it will be transported to respective product silos, where it is stored. Cement stored in silos will be packed in 50 kg bags using electronic packers. Apart from the facility to pack cement in bags, there will be facility to load cement in bulker so that it can be despatched in bulk. All point sources and material transfer points are provided with Bag Filters to control SPM emission <30 mg/Nm3. The dust collected from the Bag Filters will be recycled in the PPC Cement manufacturing process and thus, no solid waste generation.

3.6 Plant Configuration Cement Production/year : 0.95 MTPA (PPC/OPC). Operating days : 315 days per Year Avg. Mill run hours : 22 hrs per day Ball mill Capacity : 150 TPH Storages Capacity :

Material Storage Capacity

Clinker Silo 28,000 Tons Gypsum Shed (50x21 m) 1,400 Tons Fly Ash Silo 2,000 Tons Cement Silos 8,000 Tons x 2

3.7 Power Demand & Source The Unit requires 10 MW power and the TANGEDCO Grid is the source. Standby DG sets of 4x500 KVA will be installed for standby operations.

3.8 EMP Measures 3.8.1 Air The main pollutant expected from the Cement Grinding Unit will be Particulate Matter, SPM. The identified sources of dust/SPM are : Truck unloading (Tippler), Clinker hopper, Clinker storage silo, Weigh feeders for Clinker, Gypsum and solid flow meter for flyash, Flyash storage silo, Clinker Grinding Mill, Cement Silos and Packing Machines. Emissions from these sources, other than Cement Mill &



Packing Plant, would be fugitive in nature and Bag Filters are proposed to control SPM emission <30

mg/Nm3. Dust collected from the Bag Filters will be recycled in the Cement manufacturing process. 3.8.2 Water As this is only a clinker grinding unit, water is mainly required for equipment cooling (30 cu.m/day), domestic consumption (5 cu.m/day) and Green belt & dust control measures (5 cu.m/day). The water demand is as follows :

Water Demand for Total Demand, KLD Equipment Cooling 30 Domestic Use 5 Green Belt & Dust Suppression

5

Total 40 Thus, the total raw/fresh water demand would be 40 m3/day. The required water will be sourced from approved/authorized borewells nearby. There is no wastewater generation from the Process. Domestic sewage to the tune of 4.5 cu.m/day will be generated which is biologically treated in a Septic Tanks of adequate size followed by a Dispersion Trench. The water balance diagram is given below :

Water Budget/Balance

Domestic Sewage 4.5

40

Raw Water (Ground Water)

Grinding Unit

Green Belt & Dust Control

Cooling (to be evaporated fully)

Domestic Use

Septic Tank followed by Dispersion Trench

Unit : cum/day

30 5 5



3.8.3 Solid Wastes The dust collected from the various Air Pollution Control Measures like Bag Filters, etc. will be totally recycled in the process for cement manufacturing. Thus, there would not be any process wastes generation from the Unit. Municipal (organic) solid wastes from the Plant will be composted and used as manure for the green belt. Inorganic wastes (Non-biodegradable) will be sent to TNPCB Authorised Recyclers. Spent/Waste oil to the tune of 0.2 TPA will also be sold to TNPCB Authorised Recyclers. 3.8.4 Noise Levels Cement Grinding Mill be the main source of noise. The noise level within the plant building at a distance of one meter from the source shall be maintained at less than 85 db(A). Noise level at the nearest plant boundary will be <55 dB(A) during day times and <45 dB(A) during night times. Thus, the noise levels will be well within the permissible MoEF&CC Norms for residential areas. 3.8.5 Green Belt Green Belt, preferably native flora species, will be developed in 3-Tiers along the boundaries as well as inside the Plant @ 33% of total area viz. 1.58 Ha @ 750-1000 trees/Ha.

3.8.6 Rain Water Harvesting An effective rain water harvesting will be implemented and realized water will be used effectively. The percentage of water harvested at the site will be about 75-80% by keeping the natural runoff as such.

3.8.7 Occupational Health An industrial worker may be exposed to five types of hazards, depending upon his occupation : Physical, Chemical, Biological, Mechanical and Psychosocial hazards. All efforts will be taken and followed by APCL to avoid the accidents and have a good ‘Occupational Environment’. Entry Level and Periodical Medical Examinations of the Employees will be undertaken by the Unit. The Medical Reports will be reviewed and evaluated for Occupational Health related problems.

4.0 Site Setting & Analysis 4.1 Connectivity The Plant is well connected by road, rail & sea modes. It is located on the Vallur-NCTPP-Ennore Port Road branching off from the State Highway SH-56 Tiruvottiyur-Minjur-Ponneri-Panchetti Road from Vallur Junction. The Chennai-Gudur Section of Southern Railway Broad Gauge Line runs at a distance of 0.53 km east of the Site. Ennore Kamaraj Port is at 4.7 km in ENE direction. L&T Kattupalli Port is at 6.3 km in northeast. Chettinad International Coal Terminal is located at a distance of 3.5 km in northeast.



4.2 Land Use Pattern Being in sub-urban area, Built-up land occupies 32.18% of the study area. Built-up areas are further classified/demarked as residential, commercial, industrial, recreational, etc. Built-up land Open Space is predominant (11.52%) followed by Residential (10.39%) and Industrial (7.83%) lands. Fallow land occupies 20.22% and salt pans occupies 17.05%. The water bodies occupy 13.06% of the study area.

4.3 Existing Infrastructures/Industries North Chennai Thermal Power Plant (NCTPP) is located at a distance of 3.6 km in the east and Vallur NTECL Power Plant is located at 1.5 km in southeast.India Cements Cement Grinding Unit, Vallur is located at 0.9 km in the south and Zuari Cement Athipattu Grinding Unit is located at 1.5 km in the northeast. Ennore Power Plant, EID Parrys, etc. are located at 5.5-6.0 km distance in southeast. LPG Import/Export Terminal & Indane LPG Bottling Plant is located at 0.5 km in northeast. Reliance & HPCL Terminals are located at 1.6 km (south) and 1.9 km (SE) from the site. CPCL Refineries, Madras Fertilizers, etc. are located at 9-10 km in the south.

4.4 Soil Classification Very deep, imperfectly drained, calcareous, cracking clay soils are the predominant soil type in the study area. Silty loam texture is dominant in the study area. Brown soils with medium compaction are predominant. Soil pH values are found to be slightly alkaline. Low Nitrogen, Phosphorous and Potassium (NPK) values were monitored. Wilting coefficient in significant levels would mean that these soils would support the vegetation, if amended suitably. The soil water properties reveals that the soil will suit for salt tolerant and semisalt tolerant plants.

4.6 Climatic Data from Secondary Source

The study area receives moderately good amount of rainfall during North east monsoon. The site falls in the rainfall range 1270-1290 mm.

4.7 Social Infrastructure Available In the study area, there are about 3.64 lakh persons in about 40 villages. Major parts of the study area falls within New Greater Chennai Corporation Area with all social infrastructures. As part of our corporate social responsibility initiatives, APCL is carrying out various social welfare activities such as providing drinking water, financial assistance to poor and needy, medical camps and laying of external roads and bore-wells at neighbouring villages to the Cement Plant and Mines. APCL has Smt. Sita Memorial School (Pre-primary to Class X) near the factory for the children of employees and neighboring villages.



5.0 Planning Brief 5.1 Planning Concept & Amenities/Facilities The Cement Grinding Unit is proposed in 5.28 Ha with no Railway sidings. No Township is also envisaged. Green Belt is proposed in an extent of 1.58 Ha (33% coverage).

5.2 Land Use Planning The Satellite Imagery of the study area is given as Fig. 1.6 and Land Use prepared based on the Imagery is given as Fig. 1.7.

6.0 Proposed Infrastructure 6.1 Industrial Area The Cement Grinding Unit is proposed in a industrial belt. North Chennai Thermal Power Plant (NCTPP) is located at a distance of 3.6 km in the east and Vallur NTECL Power Plant is located at 1.5 km in southeast.India Cements Cement Grinding Unit, Vallur is located at 0.9 km in the south and Zuari Cement Athipattu Grinding Unit is located at 1.5 km in the northeast. Ennore Power Plant, EID Parrys, etc. are located at 5.5-6.0 km distance in southeast. LPG Import/Export Terminal & Indane LPG Bottling Plant is located at 0.5 km in northeast. Reliance & HPCL Terminals are located at 1.6 km (south) and 1.9 km (SE) from the site. CPCL Refineries, Madras Fertilizers, etc. are located at 9-10 km in the south.

6.2 Residential Area As such no Township is proposed by APCL. 6.3 Green Belt Green Belt will be developed in an area with 33% coverage of the total area with native tree species predominantly.

6.4 Social Infrastructure The company is carrying out a number of CSR activities in its Cement Plant and Limestone Mining Areas which include construction of Balwadi’s, Bore wells, OHT, Temple renovation, improving roads, donation during & temple festivals, donations for operations or health care during emergency etc.

7.0 Rehabilitation & Resettlement (R&R) Plan The Project does not involve any R&R and thus no R&R Plan is envisaged.



8.0 Project Schedule & EMP Budget 8.1 Project Schedule Project will be completed in about 12 months on approval of statutory clearances. Periodical monitoring of the ambient air quality as per Revised NAAQ Norms, fugitive emissions, noise levels, surface and ground waters will be undertaken as per the MoEF/OSPCB Norms. The periodical status reports will be submitted to the Authorities.

8.2 Project Cost The Project Cost of Rs.150.00 crores. A budgetary allotment of Rs.4.50 crores has been made as Capital Cost for Pollution Control Measures and Rs.5.00 lakhs per annum towards Operating Cost. An amount of Rs.3.00 lakhs per annum has been earmarked for Occupational Health measures. About 5% of the Project Cost will be earmarked for the Corporate Social Responsibility (CSR) measures for the period of 30 years viz. Rs.25.00 lakhs per annum.

9.0 Analysis of Proposal 9.1 Financial & Social Benefits This is a Cement Grinding Unit proposed for the nearby the marketing centres and for effective utilization of the Fly Ash and coal transportation. It does not require financial viability analysis/assessment. Adequate budgetary provisions are made for the Project establishment.

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