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The Ramco Cements Limited Kumarasamy Raja Nagar Cement Plant
Addition of 3rd Kiln (Line-III) for 1.50 MTPA Clinker Production
Clinker Production Enhancement from Existing 3.185 MTPA to 4.685 MTPA Cement Production : Existing 3.65 MTPA (No Change on Expansion);
Addition of Waste Heat Recovery Boilers (7 Nos.) for 27 MW Power Generation & Downsizing of existing 42 MW Thermal Power Generation to 24 MW
Village-Jayanthipuram, Mandal-Jaggayyapeta, District-Krishna, Andhra Pradesh
EC under EIA Notification 2006
Schedule Sl. No. 3(b); Category ‘A’
Summary Environmental Impact Assessment (TOR awarded by MoEF&CC F. No. J-11011/403/2006-IA.II(I) dated 21.12.2018)
May 2019
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
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 Fibre Products, Cotton and
Synthetic Yarn, Software Systems, Wind Farms, Research & Development, Dry Mortar Plants, Cotton
Textiles and Surgical. The total employees are about 8,500 and the Turnover of the Group is Rs.6,200
Crores.
M/s. The Ramco Cements Limited (RCL) of Ramco Group are one of the reputed Cement Companies in
India. The cement grinding capacity of RCL is about 19.10 million tons per annum (MTPA) from their
cement plants and cement grinding units in India. Ramco is producing Ordinary Portland Cement (OPC),
Portland Pozzolana Cement (PPC) and Slag Cement (PSC).
The cement produced by RCL is marketed in the brand name of ‘RAMCO’. The brand name RAMCO
SUPER GRADE is very popular PPC and RAMCO SUPER STEEL is the slag cement brand. The market
centres are mainly in Tamil Nadu, Andhra Pradesh, Kerala, Karnataka, Odisha and West Bengal States.
RCL has in its possession IS/ISO 9001, IS/ISO 14001, IS 18001 and ISO 50001 certifications.
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.Venketarama Raja is the Chairman & Managing Director of
the Board. Shri.A.V.Dharmakrishnan, Chief Executive Officer (CEO) is heading the Cement Division and
dealing with the environmental issues and EC compliances. Any non-compliance/violations of
environmental norms and the corrective actions taken will be reported by the Unit Heads to CEO and by
CEO to the Chairman, the Board and the Shareholders. RCL has the well laid down Safety, Health and
Environmental Policy approved by its Board of Directors.
Each Unit of RCL is having the Unit Head under whom the Environmental Management Plan (EMP) Cell
and Corporate Social Responsibility (CSR) Committee are functioning. The Units are having their
Integrated Management System (IMS) Policy. The Contact information of the Corporate Office is :
Shri. M.Srinivasan,
President (Mfg.), 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 : ms@ramcocements.co.in
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
1.2 RCL Jayanthipuram Cement Plant
RCL had established its Kumarasamy Raja Nagar (KSR Nagar) Cement Plant in the Year 1986 in Sy.
Nos. 235, 236, 238, 240, etc. at Jayanthipuram Village, Jaggayyapeta (Jaggaiahpet) Mandal, Krishna
District of Andhra Pradesh State (Fig. 1.1). The Cement Plant is in operation for the last 3 decades and is
periodically expanded with two Process Lines (Lines I & II) over an Extent of 329.00 Ha (812.75 Acres). The
Cement Plant now has the Production Capacity of 3.185 MTPA Clinker and 3.650 MTPA Cement of various
grades (OPC, PPC, PSC, etc).
The Cement Plant is supported with (2x18 MW + 6 MW Turbine) 42 MW Captive Thermal Power Plants
(CTPPs) for its Power Demand (Table 1.1).
Table : 1.1 Cement Plant - Existing Production Details
Production of Source Existing Status
Clinker
Line I 1.610 MTPA
Line II 1.575 MTPA
Total 3.185 M
Cement Total (2 Lines) 3.650 MTPA
Captive Thermal Power Generation 2x18 MW CTPP & 6 MW Turbine 42 MW
DG Sets Standby 4 MW
Clinker Export To RCL CGUs by Rail mode 0.385 MTPA
The existing Land Use of the Plant Site is as follows :
Cement & Power Plant : 47.97.5 Ha Railway Sidings : 9.69.2 Ha Colony : 17.67.6 Ha Green Belt : 172.74.5 Ha (coverage is 52.50%) On recent Expn. : 80.91.2 Ha ----------------- Total : 329.00.0 Ha ----------------- Captive Limestone Mines in the Region viz. Jayanthipuram North Band & South Band, Ravirala (Forest)
and Budhavada Mines are fulfilling the Plant’s Limestone Demand. The centralised Crusher is being
operated at the Cement Plant. There is a Colony of about 346 Quarters adjacent to the Plant.
There are 388 direct employees and 1,398 indirect employees, thus, total 1,786 employees working in
Jayanthipuram Cement Plant, Power Plant and Captive Mines. It is to be mentioned that about 185
employees (10.34% of total employees) are from Jayanthipuram village and about 985 employees
(55.15% of total employees) are from local villages of Jaggayyapeta Mandal.
RCL Jayanthipuram Plant has in its possession IS/ISO 9001, IS/ISO 14001, IS 18001 and ISO 50001
certifications.
The Cement Plant & Its Environs along with Green Belt photographs are shown as Plate I.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
The Contact Information of KSR Nagar Cement Plant is as follows :
Shri. N.Ravishankar,
President (Mfg.),
The Ramco Cements Limited,
Kumarasamy Raja Nagar Post,
Jaggayyapeta Mandal,
Krishna District,
Andhra Pradesh-521 457.
Tel. Nos. : 08654-224400 (10 Lines); Fax : 08654-222532
e-mail : nrs@ramcocements.co.in / mcljpm@ramcocements.co.in
1.3 Statutory Clearances and their Compliances
Ramco Cement has obtained the required Environmental Clearances (ECs) from the Ministry of
Environment, Forest and Climate Change (MoEF& CC; earlier MoEF) under EIA Notification 2006 (as
amended) and Consents for Establishments (CFEs) & Consents for Operation (CFOs) under Air & Water
Acts from Andhra Pradesh Pollution Control Board (APPCB). The Cement Plant, Captive Power Plant
and Captive Limestone Mines operations in Jayanthipuram Region are in full compliance with the
conditions stipulated in the Environmental Clearances awarded by MoEF&CC and Consent Orders
issued by APPCB. The Monitoring Cell, Regional Office (SE Zone), MoEF&CC, Chennai has inspected
the Plants and Mines on 05.06.2018 for compliance of EC Conditions and issued the Certified EC
Conditions Compliance Report vide F. No. EP/12.1/2016-17/7/AP/1345 dated 17.08.2018.
1.4 Need for the Proposal
Part of Clinker from KSR Nagar Cement Plant is being transported to RCL Grinding Units at
Visakhapatnam and Kolaghat which are being expanded to each 2.0 MTPA cement grinding capacity
now. RCL is also establishing a Cement Grinding Unit of 0.90 MTPA capacity in the State of Odisha at
Haridaspur (District Jajpur). The required Clinker Demand for the Grinding Units, thus, increased many
fold. Accordingly, RCL is now proposing to increase its clinker production facility of KSR Nagar Cement
Plant by putting up an additional new Kiln Line (Line-III) having a capacity of 1.50 MTPA.
1.5 The Proposal
The additional 3rd
Clinker Line of 1.50 MTPA production capacity to existing 3.185 Clinker and 3.650
Cement productions (no increase in Cement production) along with 7 Nos. of Waste Heat Recovery
Boilers (WHRBs) to each Clinkerisation Line. The generated steam will be mixed and taken to a common
steam header and in turn will be given to 3 Nos. of Steam Turbine generator (STG) of capacity 3x9 MW
(total 27 MW) along with 3 Nos. Air Cooled Condensers. With this installation of WHR Boilers, we are
proposing to downsize the operation of coal based TPP from 42 MW to 24 MW only (Table 1.2).
The activities are proposed within the existing Industrial Premises with no additional Land requirement.
Line-III will give direct employment to about 50 persons and indirect employment to another 100 persons.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Table : 1.2 Cement Plant - Proposed Production Details
Production of Source Unit Existing On Expn. Cumulative % Increase (+)
or Decrease (-)
Clinker
Line I MTPA 1.610 -
4.685 (+) 47.10% Line II MTPA 1.575 -
Proposed Line III
MTPA - 1.500
Cement Total MTPA 3.650 - 3.650 0%
Captive Thermal Power Generation
2x18 MW CTPP & 6 MW Turbine
MW 42
Downsized CTPP
1x18 MW & 6 MW Turbine
24 (-) 42.86%
Proposed WHRB Power Generation
All 3 Kilns MW - 27 27 -
DG Sets Standby MW 4 - 4 -
Clinker Export
- (by Rail)
MTPA 0.385 1.500 1.885 (+) 111.5%
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. The basic raw materials used in clinker
manufacturing are Limestone, Iron ore and Laterite. At present, because of difficulty in sourcing the iron
ore, we are using iron rich Laterite as an alternative for iron ore. Indian coal received from Singareni
Collieries, Imported coal from Indonesia and South Africa are being used in the process. For Clinker
manufacturing, Petcoke is also used and it is being imported from USA, Australia, Middle east and also
sourced indigenously.
Limestone excavated from the mines is being crushed to the required size and being sent to stacker /
reclaimer by means of Belt conveyor. In order to obtain better quality of Kiln feed the limestone of various
grades are mixed in the stacker. Limestone along with other ingredients is being mixed in suitable
proportions and is 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 deg C. 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 activities are proposed within the Industry Premises as shown in the proposed Plant Layout (Fig.
2.1). Material Balance for 1.5 MTPA Clinker production is appended.
The Project does not involve any Rehabilitation & Resettlement (R&R). Also, there is no litigation against
the Proposal.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Fig. : 2.1 Proposed Layout
231513
2
S30
1
S35
S31
3
4
S19
S21
5
S15 S20
22 S17
29
S35S23
7
S25
9
8
12
11
S24
43
STK628
46
S22
14
16 17
16
18
19
21
20
S18
44
49
STK11
S33 45
47
2634
30
31
34
32
35
50
5148
S13
40
38
41
39
T2 WATER TREATMENT PLANT
T23 CRUSHER & SCREEN HOUSE
T28 HP & LP DOSING SKIDS
T25 D.M TANK
T30 CHP MCC ROOM
T27 CBD & IBD TANKS
T26 COMPRESSORS HOUSE &
T3 RAW&FIRE WATER PUMP HOUSE
T12 AUXILLARY TRANSFORMERS
T6 AUXILLARY COOLING WATER PUMPS
T21 P.A FANS
T22 TRANSFER TOWER
T19 F.D. FANS
T18 LDO SERVICE TANK
T17 BED ASH SILO
T20 BOILERS 2 Nos
T16 FLY ASH SILOST15 I.D FANS
T11 BFP AREA
T9 STG UNLOADING BAY
T4 COOLING TOWER
T7 SIDE STREAM FILTERS
T8 TURBINES HALL
T10 DEAERATOR
T5 COOLING WATER PUMPS
T1 RAW WATER RESERVOIR
G.K.Ramesh 180612
S18
S4S12
S11
S9
S10
S5S1
S6
S8
S2
S34
P7
P2
P2
P6
P8
P18
P17
P31
P14
P10
P12
PSTK1
PSTK2
PSTK3
P22P23
P5
P9
5
P19
P21
P4
P3
T14 CHIMNEY
T24 DAY STORAGE BIN
T29 PLANT AIR RECEIVERS
T31 AIR WASHER UNIT
T32 ASH HANDLING AIR RECEIVERS
S3
P26
10
2 SECONDARY SCREEN
19 COAL BAG HOUSE
29 ALTERNATE FUEL SHED
30 DPC TO CEMENT MILL
31 CEMENT MILL HOPPERS
25 CLINKER SILO NO.2
27 COAL & GYPSUM YARD
28 COAL CRUSHER BUILDING
26 UNBURNT CLINKER SILO
22 COOLER ESP
20 CENTRAL CONTROL ROOM
21 GRATE COOLER
24 CLINKER SILO NO.1
23 DPC FROM COOLER TO SILO
15 KILN FEED BELT BUCKET ELEV.
12 RAW MILL BELT BUCKET ELEV.
16 KILN
17 HOT ESP
18 COAL MILL
14 PREHEATER
13 C.F. SILO
9 RAW MILL CYCLONES
10 RAW MILL RECIRCULATION SYS.
4 CBA SYSTEM
5 L.S PREBLENDING YARD
7 RAW MATERIAL HOPPERS
3 CBA HOPPERS
6 ADDITTIVE STORAGE SHED
8 RAW MILL
1 LIME STONE CRUSHER
48 PADDLE MIXER
49 COMPRESSOR HOUSE FOR SLAG MILL
45 BAG HOUSE FOR SLAG MILL
39 WAGON TIPPLER MCC&PUMP HOUSE
57 OIL TANKS
47 SILO FOR GROUND SLAG
46 SILO FOR GROUND CLINKER
44 SLAG MILL
43 FEED HOPPERS FOR SLAG MILL
42 SLAG STORAGE YARD
41 TRUCK TIPPLER
40 WAGON UNLOADING HOPPERS
38 WAGON TIPPLER
51 CEMENT SILOS No. 1,2,3&4
52 PACKING PLANT
53 TRUCK LOADING BUILDING
54 WAGON LOADING CONVEYORS
55 WAGON LOADING PLATFORMS
56 POWER PLANT BUILDING
32 CEMENT MILL BUILDING
LINE-I MAIN BUILDINGS SERVICE BUILDINGS
S5 FIRE FIGHTING EQUIPMENT SHED
S9 WEIGH BRIDGE FOR TRAILERS
S8 WEIGH BRIDGE & CDS OFFICE
S16 CEMENT MILL SUB-STATION
S12 132KV MAIN SUB-STATION
S18 CAR & SCOOTER PARKING
S17 COOLER ESP FAN SPRS ROOM
S2 SECURITY OFFICE
S20 OVER HEAD WATER TANK
S11 SWITCH YARD.
S15 WORK SHOP
S14 STORES
S13 GUNNY BAG GODOWN
S19 PUMP HOUSE
S4 CYCLE STAND
S7 ADMINISTRATIVE OFFICE
S6 CDS OFFICE & I.T DEPT.
S3 CANTEEN
S10 APSEB SWITCH YARD
S1 TIME OFFICE
S23 DINING HALL AT RAW MILL
S21 GROUND LEVEL WATER TANK
S26 MINES DEPT. FIELD OFFICE
S24 RAW MILL MCC ROOM
S25 KILN FEED MCC ROOM
S22 RAW MILL SUB-STATION
S27 AUTO GARAGE
S34 IN-MOTION WAGON WEIGHING SYS.
S29 HSD CONSUMER PUMP STATION
S28 DUMPERS MAINT. SHED
S32 DINING HALL AT PACKING PLANT
S31 DINING HALL AT CRUSHER DEPT.
S33 SLAG MILL SUB-STAION & MCC
S35 TOILET BLOCK
S30 CRUSHER SUB-STATION
POWER PLANT BUILDINGS
P32
P33
S32
S35
P1
STK2
STK3
STK12
58 UNDER GROUND CABLE TUNNEL
T13 ESPs 2 Nos
65
P34
ESP CONTROL ROOM
P16 P30
66
59 OVER HEAD CABLE GALLERY
P25
EXISTING BUILDINGS
P20 MODIFICATION FOR CEMENT MILL
P4 ADDITIVES STORAGE YARD
P18 CLINKER EXPORT SYSTEM.
P13 COAL STORAGE YARD 2
P12 COAL CRUSHER
P17 CLINKER SILO No. 3 & HANDLING SYS.
P14 LINE-II HOT ESP.
P6 LINE-II RAW MILL
P7 LINE-II RAW MILL BAG HOUSE &
P10 LINE-II KILN
P5 LINE-II RAW MATERIAL HOPPERS
P8 KILN FEED SYSTEM
P9 LINE-II PREHEATER
P11 LINE-II COOLER & COOLER E.S.P
P2 LINE-II L.S STORAGE YARD
2nd LINE ADDITTIONS
P1 BAG FILTER FOR L.S CRUSHER
P3 ADDITIVES CRUSHER
RAW MILL SUBSTATION
P19 CLINKER PREGRINDING VRPM
Pos Description
P15 LINE-II COAL MILL&COAL MILL BAG FILTER
P16 INERT GAS GENERATOR HOUSE
P28
P29
TRUCK & WAGON LOADING PLANT
P21 BULK LOADING SYSTEM
P24 EXTENSION OF PACKING PLANT,
P23 NEW FLY ASH SILO
P22 NEW CEMENT SILO
P25 RAIN PROTECTION SHED AT PP
Pos Description
P27 LINE-1 RM BAG HOUSE DUCTING
P26 VRPM SUB STATION BUILDING
P29 CEMENT SILO FEEDING SYSTEM
P28 LINE-1 RAW MILL BAG HOUSE
P31 LINE-II COOLER MCC ROOM
P30 DINING HALL AT LINE-II COOLER AREA
P33 MCC ROOM FOR ADDITIVE HANDLING SYS.
P32 MCC ROOM FOR CLINKER EXPORT SYS.
P34 ELECTRICAL WORK SHOP
P11
S1
25
24
P35 TOILET AT WORK SHOP
P36 TOILET BLOCK AT LINE-II COOLER AREA
P37 TOILET BLOCK AT CEMENT MILLS AREA
P36
P38
P37
P35
P38 DINING HALL AT CEMENT MILLS AREA
TE
NN
ICO
IT C
OU
RT
1
TE
NN
ICO
IT C
OU
RT
2
BA
SK
ET
BA
LL
CO
UR
T
Old AnFo Mixing Shed
Mines R
oad
Old Storage Room
for Ammonium Nitrate
Existing AnFo Mixing Shed
P41
P40
P39 OPEN STORAGE YARD FOR COAL
P40 SURGE BIN FOR CLINKER DROP TEST
P41 TRUCK LOADING SYS. FOR EXPORT CLINKER
11 BARE SUPP. STR. OF REMOVED R.M ESP
52
53
55
55
54
55
55
P24 P24
P24
33
34 CEMENT MILL RECIRCULATION ELEVATOR
35 CLOSE CIRCUIT SYSTEM FOR C.MILL
33 300T FLY ASH FEED BIN FOR C.M
37
37 C.M ESP SUPP. STR CONVERTED AS
STORE ROOM FOR VRPM SECTION
36
50 FLY ASH SILO No.1
36 BAG HOUSE FOR CLOSE CIRC. SYSTEM
Lay/Line3/0001-5EK
FACTORY LAYOUT
P13
P42 CONV FOR FEEDING GYPSUM FROM SLAG YARD
60 BELT CONV FROM L1 COAL HOPPER
DISCHARGE TO L-2 HOPPER BOTTOM
61 BELT CONV FOR FEEDING GYPSUM
FROM SLAG YARD TO CEMENT MILL
60
UP
TOILET
6'0" x 8
'0"1.8
M x 2.4
M
TOILET
6'0" x 8
'0"1.8
M x 2.4
M
DINING
14'9" x
14'9"
4.5 M x
4.5 M
LIVING
21'0" x
14'9"
7 M x 4
.5 M
STORE
5'0" x 6
'0"
utility
KITCHE
N
10'0" x
13'0"
3.3 M x
4.0 M
LOUNG
E
12'3" x
13'0"
3.8 M x
4.0 M
OFFICE
10'0" x
13'0"
3.0 M x
4.0 M
POOJA
6'0" x 1
3'0"
1.8 M x
4.0 M
PORC
H
dn
ENTR
ANCE
sitout
PROPOSED
'A' TYPE QTR.
F
F
27
SCHOOL
S7
TP1 TP2
COOLER-1
ESP(Old)
HYD ROOM
Cooler-2
ESP(New)
C.F SILO
COALBIN
COAL
MILL
CCR
Pulley Top Elevation
+95.500m MSL
P18
1
Proposed PHBoiler Horiz(1)
Proposed PH
Boiler Vert.(2)
Proposed PH
Boiler Vert.(4)
Pro
posed G
ypsum
Conv(L
3L1)
for C
em
ent M
ill
Pro
posed S
lag &
Gypsum
Conv(L
3S
1A
04A
) fo
r S
lag M
ill
P13
6
RM
BH
RAW MILL
SILO
MCC ROOM
LOW
GRADE L
IME S
TON
E F
OR 3
rd L
INE R
AW
MIL
L
HIG
H G
RADE L
IME S
TON
E F
OR 3
rd L
INE R
AW
MIL
L
LOW
GRADE L
IME S
TON
E F
OR 2
nd L
INE R
AW
MIL
L
HIG
H G
RADE L
IME S
TON
E F
OR 2
nd L
INE R
AW
MIL
L
Stacker & Reclaimer for Coal
2
Proposed WHRB
3
AQC Boiler(3)
2
1
1
WHRGenerators
New Compound Wall
Mining Lease Boundary
Mining Lease Boundary
L.S C
rush
er
1600
tph
Seco
ndary
Scr
een
CBA CBAHoppers
Rec
laim
er C
onv
New
Roa
d
Proposed Road
Existing Slag Hoppers Super Structure
will be used for supporting the Proposed
Fine Coal Bins and connecting Equipment
S1A04 C0NV. TO BESHORTENED
L- C0NV. TO BESHORTENED
SLAG/GYPSUM STACKER C0NV.
S1C11 C0NV.TO BE DIMANTLED
TO BE DISMANTLED
COAL OPEN YARD TO BE DISMANTLED
Proposed compound wall
Pro
po
se
d M
ech
anic
al
Fab
rication Y
ard
Existing compound Wall
New
Com
pound W
all
New
Com
pound W
all
New Compound Wall
RelocatedMines Office
RelocatedAuto Garage
Existing Mines OfficeConflicting with 3rd Line
RelocatedAnFo Storage
Shed
Sta
cker
Con
v
Existing AnFo Storage Room
Conflicting with 3rd Line
Existing Auto Garage
and Facilities Conflicting
with 3rd Line Buildings
Proposed
Open Coal Yard
Exis
ting C
om
pound W
all
and S
ola
r F
encin
g
Exis
ting K
acha R
oad
Pro
pose
d K
ach
a R
oad
Relocated Slag/Gypsum
Handling System
Exis
ting K
-Conv.
to b
e D
ism
antle
d
Exis
ting S
1C
05 C
onv.
to b
e S
hortened
Relocated
Drop Test
Bin
Port
ion o
f S
1C
05 C
onv. to
be D
ism
antle
d
Prop. Belt Conv.(L3S1CO6A) Proposed Slag/GypsumFeed Hoppersfor Slag/Cement Mills
Proposed Raw Materials Belt Conveyors
Existing Toilet Block,
Dining Hall &
AC Workshop
Existing Old Quarters
Conflicting with
3rd Line& WHRS
Proposed Truck Tippler
&Samson Feeder
Proposed L3S1C12 Conv.
Pro
posed L
3S
1C
11 C
onv.
Proposed L3S1C10 Conv.
Proposed L3S1C09 Conv.
Proposed L3S1C06 Conv.
Proposed WHRBAQC Boiler(7)
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Material Balance for Kiln-III of 1.5 MTPA Clinker
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
The Line-III and WHRBs are proposed within the existing Industry Premises. Thus, there is no
additional Land requirement for the Proposal.About 5.0 Ha of vacant land inside the Cement Plant
will be utilised for the Proposal. Also, additional Green Belt to an extent of 42.505 Ha (12.78% increase)
is proposed during the Expansion Proposal. The total Green Belt will be 172.74.5 Ha (52.51%) of total
329.00 Ha (Table 1.3).
Table : 1.3 Land Use Pattern – On Expansion
Land Details Existing On Expn. Cumulative % Increase (+) or
Decrease (-)
Plant Area, Ha 329.000 0 329.000 0%
Land Use, Ha :-
Cement & CPP 47.975 5.000 52.975 (+) 10.42%
Railway Sidings 9.692 - 9.692 -
Colony 17.676 - 17.676 -
Green Belt 130.240 (39.59%)
42.505 (12.78%)
172.745 (52.37%)
(+) 12.78%
Northern Lands 80.912 (-42.505) 38.407 -
Vacant Lands 42.505 (- 5.000) 37.505 -
Total, Ha 329.000 0 329.000
Raw Materials, Source and the mode of Transportation are given in Table 1.4.
Table : 1.4 Raw Material, Source & Mode of Transportation
Material Source Demand,
MTPA Demand,
TPD Mode of
Transportation By
Rail By
Road
No. of Trucks per Day
Remarks
Existing
Limestone Own
Mines nearby
4.47 12950 By Conveyers
from the Crusher
- - - By closed
Belt conveyor
Laterite Andhra
Pradesh & Telangana
0.14 415 By Road
(Covered 20 Ton Trucks)
- 100% 21 There is no
railway siding as the
mines are located in the hills,
hence there is no
possibility of transporting through Rail
Iron rich Laterite
Andhra Pradesh
&Telangana
0.17 485 By Road
(Covered 20 Ton Trucks)
- 100% 24
Petcoke/ Imported
Coal
South Africa
Indonesia 0.43 1256 By Rail 100% 0 0 Only by Rail
Gypsum Vizag & Local
Market 0.18 500
By Rail & Road (Covered 20 Ton Trucks)
25% 75% 19
100 % by Railway
transport is not possible
due to presence of Phosphoric acid which
may corrode the wagon
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Material Source Demand,
MTPA Demand,
TPD Mode of
Transportation By
Rail By
Road
No. of Trucks per Day
Remarks
boxes.
Fly Ash (max–PPC)
TPPs nearby
0.91 2500 By 30/40 Tons
Bowsers - 100% 84
Fly ash is sourced
within 100 km, hence
closed wagon is not
available
Coal for CPP 100%
Imported
South Africa
Indonesia 0.21 605 By Rail 100%
Only by Rail
Clinker Export
- 0.385 - By Rail 100% - - Only by Rail
Cement - 3.650 10000 By Rail & Road
(Covered 20 Ton Trucks)
50% 50% 250 Based on
Market Demand
No. of Trucks – Existing Status 398
On Expansion
Limestone Own
Mines nearby
2.10 6087 By Conveyers
from the Crusher
- - - By closed
Belt conveyor
Laterite Andhra
Pradesh & Telangana
0.07 196 By Road
(Covered 20 Ton Trucks)
- 100% 10 There is no
railway siding as the
mines are located in the hills,
hence there is no
possibility of transporting through Rail
Iron rich Laterite
Andhra Pradesh & Telangana
0.08 228 By Road
(Covered 20 Ton Trucks)
- 100% 11
Petcoke/ Imported
Coal
South Africa
Indonesia 0.20 591 By Rail 100% 0 0 Only by Rail
Clinker Export
- 1.500 - By Rail 100% - - Only by Rail
Cement - - - - - - -
No. of Trucks – On Expansion 21
Total No. of Trucks - Cumulative 419 5.3%
Water Demand : The fresh water demand of the Complex is 6788 Kilo Litres per Day (KLD) which is met
from nearby RCL Captive Mine pits. Ramco has obtained the necessary permission from the AP Ground
Water Department, Vijayawada for water drawl from these sources at the rate of 7000 KLD vide Letter No.
11/Hg/MC/2006 dated 29.03.2007. The proposed expansion activities require an additional 752 KLD
water for the Line-III (Equipment Cooling 240 KLD & Domestic Use 12 KLD and WHRBs-Makeup water
for Boilers, etc. 500 KLD) which will be met from the permitted sources only.
There will be no trade effluent from Line-III. Domestic sewage to the tune of 10 KLD will be generated and
will be treated in the Combined STP. Trade effluents from WHRB @ 40 KLD will be neutralized and used
for Dust Suppression measures. Thus, ‘Zero Effluent Discharge’ will be maintained at the Complex.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Power Demand : Power requirement of 13.5 MW for operating the Line-III expansion will be availed from
the existing Sources.
Fuel Storage :-
At Dispensing Pump - 2 tankers for HSD storage- 20 KL capacity-1 No. & 15 KL capacity-1 No.
DG set for HSD storage: 75 KL capacity -1 No. & 12 KL capacity -1 No.
HFO storage : 16 KL capacity -3 Nos. & 375 KL capacity-2 Nos.
1.7 Project Cost on Expansion
A total of Rs.1,040.31 Crores has been invested by Ramco in Jayanthipuram Cement & Power Plants and
Captive Limestone Mines. The estimated project cost for Line-III Expansion project along with 27 MW
WHRPP is Rs.680.00 Crores. An EMP Budget of Rs.3.50 Crores is earmarked additionally for the
Proposal with an Operating Cost of Rs.0.75 Crores per annum. For the additional Investment of
Rs.680.00 Crores, Ramco will be spending Corporate Environment Responsibility (CER) Fund of Rs.4.75
Crores for the villages located around the Cement Plant in compliance with MoEF&CC OM F. No. 22-
65/2017.IA.III dated 01.05.2018, in addition to the CSR Works being carried out now.
1.8 Awarded TOR
As per the Environmental Impact Assessment (EIA) Notification 2006, all Cement Plants with >1.0 MTPA
capacity have been kept at Sl. No. 3 (b) under Category ‘A’ for the Environmental Clearance from the
Ministry of Environment, Forest and Climate Change (MoEF&CC). Accordingly, RCL has submitted the
Application for Additional 3rd
Clinker Line to MoEF&CC on 10.11.2018 (Application No.
IA/AP/IND/85032/2018). The Proposal was deliberated by the Expert Appraisal Committee (EAC)-
Industry-1 as Item No. 2.4 in its 2nd
Meeting held during 10.12.2018 and recommended the TOR with
Public Hearing. TOR for carrying out the EIA Study has been awarded by the Ministry vide F. No. J-
11011/403/2006-IA-II (I) dated 21.12.2018.
1.9 EIA Study
The EIA Report has been prepared and submitted as per awarded TOR and also as per the generic
structure proposed in EIA Notification 2006. The Baseline Study has been carried out during Jan.-Mar.
2019, Winter Season by engaging the services of Chennai Testing Lab, accredited by the National
Accreditation Board for Testing and Calibration Laboratories (NABL) with Certificate No. TC-6133 dated
08.06.2017 (valid till 07.06.2019) and recognised by MoEF&CC Sl. No. 132 valid from 02.06.2016 to
01.06.2021.
The EIA Consultant, M/s. Pioneer Enviro Laboratories & Consultants Pvt. Ltd., 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 (Sl. No. 120 in the List of Accredited EIA
Consultants dated 10th April 2019. The services of M/s. Environmental System Consultants & Ambiente
Lab Solutions Private Limited, Chennai are utilised for the coordination of the Study.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
2.0 Description of Environment 2.1 Environmental Setting
The Plant area falls in Survey of India Topo Sheet No. 65 D/1 (Fig. 1.2). The Plant Location Coordinates
are :
Latitude : 16
o52’06” to 16
o53’33” North
Longitude : 80o06’59” to 80
o07’59‘’ East.
RCL Jayanthipuram North Band (Pits 1 & 2) and South Band Mines are located at a distance of 0.1 and
1.1 km (aerial distance) respectively in southwest of the Cement Plant. Ravirala (Forest) Mine is at a
distance of 2.8 km (SSE) and Budavada Mine is at a distance of 5.1 km in (WSW).
The region falls in Seismic Zone II. The general elevation of the Plant area ranges from 51 m to 78 m
above MSL. The elevation contour indicates the area is sloping towards south and east. Telangana State
Border is at 7.4 km in SW direction from the Plant. Vedadri Temple, a famous Pilgrimage Centre is at 5.9
km in south.
The Environmental Setting is given as Fig. 1.3. No ecologically sensitive areas viz. National
Park/Sanctuary/Biosphere Reserve exist within 10 km radius of the Plant. There are 6 Reserved Forests
falling fully/partly within 10 km radius area from the boundary:
Jaggayyapeta Extension RF (0.2 km; E & SE)
Budavada RF (2.0 km; W)
Ballusupadu RF (5.6 km; WNW)
Gandrayi RF (8.5 km; NNW)
Kuntimaddi RF Part (7.1 km; SSW) & Ginjupalli RF (9.6 km SSW) in Venkatayapalem RF Range.
Ramco had applied and obtained the No Objection Certificate (NOC) for establishment of the Industry
from the Divisional Forest officer, Krishna Division, Vijayawada.
River Palleru drains the area, flows northwest to south at a distance of 1.2 km and confluences into River
Krishna which flows at a distance of 5.2 km in the south from the Plant. Nagarjuna Sagar Left Bank Canal
flows at about 4.1 km in ENE direction. K L Rao Multi Purpose Irrigational Project is being established at
13 km (SSW) along with Pulichinthala Hydro Power Plant (12.8 km; SSW).
Cement plant is well connected by Road and Rail networks. National Highway (NH)-65 (earlier NH-9)
connecting Hyderabad-Vijayawada is at a distance of 2.0 km in NE direction from the Plant. South
Central Railway BG Line Motamarri-Jaggayyapeta Branch runs at a distance of 2.5 km. The Railway
Sidings for the Plant is branching off at Jaggayyapeta. The nearest railway station is Bonakalu at 20 km
in NE direction in Kazipet-Vijayawada Railway Section. The nearest Airport is Vijayawada (Gannavaram)
at a road distance of 80 km (SE). Machilipatnam Port is at 160 km distance in SE direction.
Mandal Head Quarters Jaggayyapeta is at a distance of 0.6-2.0 km in northwest. Chillakallu (1.7 km:
NE), Dharmavarapupadu (0.2 km; E), Jayanthipuram 1.2 km; S), Kavutuvari Agraharam 1.6 km; SW) and
Ravirala (2.8 km; SSE) are the minor settlements near the Plant. Vijayawada Town is at a distance of 62
km in SE and Capital Amaravathi is at 48 km in SE direction from the Plant.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
There are major Cement Plants along with their Captive Limestone Mines and Captive Power Plants in
the study area. The aerial distance of the various industries in the study area are :
Amoda Sponge Iron Plant, Jayanthipuram (0.5 km; SE).
Hemadri Cements Ltd., Plant & Mines (6.4 km; SE); Power Plant is at 5.4 km in S.
KCP/Ultratech Cements Ltd. (6.6 km; SW).
Mines & Plant of Vizag Steel Plant, Budavada (5.7 km; W).
Kakatiya Cement Plant & Mines (7.8 km; WSW).
Zuari Cement Plant & its Thermal Power Plant Complex, Sitapuram (9.0 km; SW),
2.2 Baseline Environmental Status
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. The monitoring stations are selected in such a way that the baseline environmental data reflects
the Cumulative Impact of existing Industries/Mines in the Study area. Considering the Environmental
setting of the project, project activities and their interaction, environmental regulations and Standards,
following Environmental Attributes have been included in EIA Study.
Site specific Micro-meteorological Data from Core Zone for a Season on wind speed, wind direction
(wind roses), temperature, humidity, cloud cover, atmospheric pressure, rainfall, etc.
Ambient Air Quality Monitoring at 12 locations on 24-hourly basis, continuously for 2 days in a week
for 4 weeks in a month for a season for the parameters PM2.5, PM10, SO2, NOx, CO, HC and
Particulate Lead as per NAAQ Norms (Revised as per GSR 826 (E) dated 16.11.2009 for Industrial,
Residential, Rural and other Areas).
Noise Level Measurements at all air quality monitoring station for Leq, L day and L night values once
in the season.
Water Quality Monitoring – grab sampling once in the Season for :
Surface Water (8 locations) as per CPCB Norms
Ground Water (10 Locations) as per IS:10500 Norms.
Existing Mine Pit Water (2 Mines).
Soil Quality Monitoring at 6 locations in the study period for:
Textural & Physical Parameters
Nutrients
Land use pattern based on Satellite Imagery.
Biotic Attributes for : Flora & Fauna - Core zone & Buffer zones
Socio-Economic Profile, based on 2011-Census and also Household Survey, once in the study
period for:
Total Population / Household Size / Age
Gender Composition; S.C / S.T
Literacy Level; Occupational Structure
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
The summary of baseline status is given 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 43 22.4 60
PM10 17 63 38.2 100
SO2 6 16 9.9 80
NOx 5 21 11.8 80
Ambient Noise, dB(A) Leq-day 40.1 48.7 43.6 55
Leq-night 38.4 45.4 41.3 45
Surface Waters, mg/l TDS 270 380 - 500/2100
Ground Waters, mg/l TDS 340 440 - 500-2000
Soil Status
Texture - - Silty Loam -
EC, mmhos/cm 1.02 1.56 - 0.2-0.5
SAR 2.00 2.46 - <5
The findings of baseline environmental status of the study area are summarized below :
The collected meteorological data during this season represented the local weather phenomena.
The monitored ambient air quality in the study area was found to be in compliance with the Revised
National Ambient Air Quality (NAAQ) 24-hourly Norms of 60 ug PM2.5/m3, 100 ug PM10/m
3, 80 ug
SO2/m3 and 80 ug NOx/m
3 for Industrial, Residential, Rural and other areas.
Ambient equivalent Noise Levels (Leq) during day and night times were found to be well within the
MoEF&CC Norms.
The water quality of surface waters were found to be in compliance with CPCB Norms.
The ground water quality was found to be in compliance with the IS:10500 Norms.
The soil in the study area would very well support vegetation after amending it suitably.
There is no eco sensitive area exists in the study area and only domesticated animals exist.
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 assuming that the pollution due to the existing industrial
activities has already been covered under baseline environmental status and continue to remain same till
the operation of the project.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Salient Features - Existing and Proposed Activities
Sl. No.
Particulars Existing Plant (Lines-I & II)
Addition on Expansion (Clinker
Line-III) Cumulative
1 Product OPC/PPC/PSC OPC/PPC/PSC OPC/PPC/PSC
2 Production in MTPA :-
Clinker 3.185 1.500 4.685
Cement 3.650 0 3.650
Captive Power Generation 2x18 MW &
6 MW Turbine WHRBs 27 MW
WHRBs 27 MW
1x18 MW & 6 MW Turbine
3 Clinker Export, MTPA 0.385 1.500 1.885
4 Plant Area, Ha 329.00 0 329.0
5 Land Use, Ha :- Cement & CPP Railway Sidings Colony Green Belt Northern Parts Vacant Total
47.975 9.692 17.676
130.240 (39.64%) 80.912 42.505
329.000
5.000
- -
42.505 (-42.505) (- 5.000)
0
52.975 9.692 17.676
172.745 (52.5%) 38.407 37.505
329.000
6 Direct Employment 388 50 438
Indirect Employment 1398 100 1498
Total Employees 1786 150 1936
7 Water Requirement, KLD 6788 (-) 1438 5350
8 Source of Raw Water Mine Pits Mine Pits Mine Pits
9 Ground Water NOC for 7000 KLD - 7000 KLD
10 Effluent Generation, KLD 1439 40 & (-) 489 (from
downsizing of CPP) 990
11 Sewage Generation, KLD 660 10 670
12 PM Emission, mg/Nm3 <30 <30 <30
13 Project Cost, Rs. Crores 1040.31 680.00 1720.31
14 EMP Capital Cost, Rs. Crores
98.54 3.50 102.04
15 EMP Operating Cost, Rs. Crores
18.31 0.75 19.06
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
3.1 Construction Phase
Expansion activities are proposed in northwestern parts of the cement plant with clearance of 2 storage
sheds. Line-III and WHRB Plants are to be established. The proposed Builtup Area of the Plants are
about 5,750 sq. m.
Storage Facilities :
Limestone in the covered Limestone stock Pile of 80,000 T capacity.
Existing closed additive yard of capacity 15000 MT will be adequate.
Raw meal : One additional new RCC silo (Silo 2) of 20000 MT capacity in addition to existing silo
(Silo 1) of 22000 MT capacity.
Clinker : One additional new RCC silo (Silo 4) of 35000 MT capacity will be constructed in addition to
the existing 3 silos (Silo 1,2,3) of 72000 MT capacity.
Additional coal stock yard of 20000 MT capacity.
Construction Materials :
PCC : 5000 m3
RCC : 35000 m3
Brick Works : 1000 m3
RR Wall : 1000 m3
Steel - 40 mm : 7500 m3 (from SAIL)
Steel - 20 mm : 35000 m3
RF Steel : 4500 Tons Bricks : 6,00,000 Nos. (local kilns) RR structures : 70,000 m Sand : 20000 m
3 (from approved quarries)
Cement : 20000 Tons (own source) Water for curing & others : 100 KLD.
Mostly local labourers pooled from the local population @ 150 persons/day (in an average) for the
construction period of 18 months. The existing temporary sheds made of A.C sheets (30 Nos. are
adequate. Provision of water, electricity, adequate toilet facilities, etc. are existing.
3.2 Operation Phase
The Line-III and WHRBs are proposed within the existing Industry Premises. Thus, there is no
additional Land requirement for the Proposal. About 5.0 Ha of vacant land inside the Cement Plant
will be utilised for the Proposal. Also, additional Green Belt to an extent of 42.505 Ha (12.78%
increase) is proposed during the Expansion Proposal. The total Green Belt will be 172.74.5 Ha
(52.51%) of total 329.00 Ha.
Due to the removal of 1x18 MW CTPP on Expansion, there will be 21.87% Reduction in the Fuel
Demand due to the Proposal.
While comparing the combustible CO2 Emission from CTPPs and Proposed 3rd
Kiln Line, there will
be a Reduction of 3.52% CO2 Emission on Expansion due to stoppage of 1x18 MW CTPP.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
There is significant reduction of load based emissions of PM, SO2 and NOx from the current levels
from the Plant Stacks as explained in the following table. Thus, Pollution Load is decreasing in the
Air Environment due to the Proposal.
Predicted GLCs : AERMOD Views used for the Prediction Modelling based on one month Met. Data.
There is significant decrease of PM, SO2 and NOx Levels in the atmosphere due to the addition of
Kiln-3 and Downsized CPP (42 MW to 24 MW).Also, adequate Buffer exists in the Air Environment
for the proposed Expansion activities.
With the addition of 3rd
Line and WHRBs, the total water demand of the Plant on Expansion will be
5,350 KLD only against the existing 6,788 KLD which will be within the Permitted 7,000 KLD. There
is a Reduction of 21.18% in the total water demand during the Expansion.
There will be a reduction of Cooling Tower Blowdowns to the tune of 489 KLD due to the stoppage of
one 18 MW CTPP. The net Reduction in Wastewater generation on Expansion will be 20.91%.
4.0 Environmental Monitoring Programme
Continuous online stack monitoring equipment/systems (Forbes Marshall, DCEM 2100 & Durag DR
216/IFI for PM and ABB EL3020 for SO2 and NOx) are installed at all main stacks and the online real
time monitoring data is being transmitted to APPCB & 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 exceedance of the Limit values
so far.
Continuous online stack monitoring equipment/systems will be installed for Line-III also and will be
connected to APPCB & CPCB Servers.
Two number Continuous Ambient Air Quality Monitoring Stations are installed in the Plant for online real
time monitoring data which are connected to CPCB & APPCB Servers is transmitted to APPCB and
CPCB 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 APPCB monthly,
and MOEF&CC Monitoring Cell 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.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
6.0 Project Benefits
Ramco is investing an additional amount of Rs.680.00 Crores for the Expansion Activities to the
Existing Project Cost of Rs.1,040.31 Crores. Thus, the Total Project Cost on Expansion will be
Rs.1,720.31 Crores (65.36% increase in Investments).
For the additional Investment of Rs.680.00 Crores, Ramco will be spending Corporate Environment
Responsibility (CER) Fund of Rs.4.75 Crores for the villages located around the Cement Plant in
compliance with MoEF&CC OM F. No. 22-65/2017.IA.III dated 01.05.2018, in addition to the CSR
Works being carried out now.
There are 388 direct employees and 1,398 indirect employees, thus, total 1,786 employees (as on
15.03.2018) working in KSR Nagar Cement Plant, Power Plant and Captive Mines. It is to be
mentioned that about 185 employees (10.34% of total employees) are from Jayanthipuram village
and about 985 employees (55.15% of total employees) are from local villages of Jaggayyapeta
Mandal.
Proposed Expansion will give direct employment to about 50 persons and indirect employment to
another 100 persons. There will be 8.40% additional Employment due to the Proposal.
There will be a huge positive impact due to the proposal by improved local and regional economy.
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 :
Air Environment : Ramco 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. About
88 Nos. of Air Pollution Control Equipments (APCE) has been installed in the Cement Plant and 9 Nos. of
APCE are in operation in TPP. Bag filters are provided for additive crusher machines, truck loading and
all packing machines areas. The dust collected from all APCE is being totally recycled in the process.
All conveyors are covered with GI sheets. Closed sheds are provided for additive stacker and its
reclaimer, coal stacker and its reclaimer and also for gypsum. Fly ash received from outside and clinker
are stored in closed silos and fly ash generated from TPP is conveyed through pneumatic system.
Water fogging arrangements at raw material hopper area, coal handling area, limestone crusher hopper
and additive handling areas are installed. Water spraying system is provided around coal stacker and its
reclaimer and on internal roads. All mine haul roads permanent water sprinkling system has been
installed in addition to this, water sprinkling is being done with truck mounted sprinklers on roads of
cement plant and mines internal haul roads.
All efforts shall be undertaken to maintain the PM emission levels from the main stacks within 30
mg/Nm3.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
The periodical evaluation for the efficiency performance of ESPs and Bag Filters shall be carried out.
Fugitive emissions due to storage, transportation, etc. and the leakages and spillages shall be
continuously monitored and controlled.
Thermal insulation is provided wherever necessary to minimize heat radiation from the equipment,
piping etc, to ensure protection of personnel.
Noise Levels :
All rotating items are well lubricated and provided with enclosures as far as possible to reduce noise
termination.
Extensive vibration monitoring systems are provided to check and reduce vibrations.
For all fans, compressors etc. vibration isolators are provided to reduce noise.
Provision of silencers are made wherever possible.
Proper lubrication and housekeeping are maintained.
The operator provided with necessary safety and protection equipment like ear plugs, ear muffs etc.
Water Environment :
No trade effluent shall be discharged from the Plant.
Cooling water is put into closed circuit to minimize the evaporation losses.
The domestic sewages from the Cement Plant, Power Plant and Township shall be treated
effectively in the Sewage Treatment Plants to meet the APPCB Discharge Norms and the treated
sewage shall be used for Green Belt.
No percolation of treated water to the deep ground water table is done.
Periodical monitoring for specific parameters shall be done regularly.
Ramco has created 48 number of rain water harvesting (RWH) pits in the Colony and 4 Nos. of rain
water harvesting systems in the Plant premises. The Roof Top Water collection is about 26,039 KLD
per annum and Runoffs collection at the Storage-cum-Recharge Pits is about 67,877 KL/annum
which are utilized for the industrial needs so as to conserve the fresh water demand.
RCL shall maintain the existing rain water harvesting structures effectively to supplement the water
supply from the borewells.
Land Environment :
It should be ensured that there is no industrial solid waste from the Plants.
The dust collected from APC Measures will be consumed in the Cement Plant fully.
Solid wastes from STP Plant shall be used as manure for Green Belt.
Waste Oil shall be collected and sold to the CPCB authorised Agency for further treatment &
disposal.
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.
Green Belt :
Green Belt shall be maintained effectively.
RCL, Jayanthipuram Addition of 3rd Kiln of 1.50 MTPA Clinker Capacity & 27 MW WHRB, Krishna Dist., AP
Local species and fruit bearing trees may also be developed to have a thick canopy cover.
The treated sewage shall be used fully for the Green Belt development.
Occupational Health :
The Cement Plant has its Occupational Health Centre with the following Facilities:
X-ray ECG Spirometry (lung function test) Audiometry Semi-auto analyser to carryout bio-chemical tests Clinical lab for micro-biological tests (including sputum test) Checking colour blindness Dental chair Ambulance
EMP Budget :
The estimated project cost for Line-III Expansion project is Rs.680.00 Crores. An EMP Budget of Rs.3.50
Crores is earmarked additionally for the Proposal with an Operating Cost of Rs.0.75 Crores per annum.
***
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