Addition of 6 MW Turbine to Existing 2 x 18 MW … · Existing 2 x 18 MW Captive Thermal Power Plant for Operational Advantage Village Alathiyur, Taluk Sendurai, District Ariyalur,

The Ramco Cements Limited

Alathiyur Cement Plant

Addition of 6 MW Turbine to Existing 2 x 18 MW Captive Thermal Power Plant for

Operational Advantage

Village Alathiyur, Taluk Sendurai, District Ariyalur, Tamil Nadu

Environmental Clearance under EIA Notification 2006

Schedule Sl. No. 1(d); Category ’A’ Category ‘B’ (<500 MW) activity proposed in Category ‘A’ Cement Plant

Summary Environmental Impact Assessment Report

May 2015

EIA Consultant

Environmental System Consultants & Ambiente Lab Solutions Private Limited

(Accreditated by QCI-NABET for Sectors 1, 9, 31, 33 & 38 - Category ‘A’& Assessed for Sector 4; Sl. No. 57 of QCI List dated 07.05.2015)

Old 7, New 14, Shanmuga Naicker Street, K K Nagar, Chennai-600 078.

Phone : 044-2364 3663; Fax-044-2364 2663 e-mail : [email protected]

The Ramco Cements Limited EC for Addition of 6 MW Turbine to 2x18 MW CPP in Alathiyur Cement Plant, Ariyalur Dist., TN

Ensyscon & Amblabs, Chennai-78.

Summary Environmental Impact Assessment

1.0 Project Description

M/s. The Ramco Cements Limited (RCL) (formerly M/s.Madras Cements Limited) are one of the reputed

Cement Companies in India. The cement production of RCL is about 14.45 million tons per annum

(MTPA) from their cement plants in South India. RCL 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 Contact information of the RCL Corporate Office is :

The Sr. Vice President (Mfg.), The Ramco Cements Ltd. 5

th Floor, Auras Corporate Centre,

No. 98A, Dr.Radhakrishnan Road, Mylapore, Chennai-600 004.

Tel. No. : 044-28478666/28478661/28478656 Fax No. : 044-28478676 e-Mail : [email protected]

RCL had established its Alathiyur Cement Plant near Pennadam in Ariyalur District in the Year 1996 along

with its Township in an extent of 121.17 Ha falling in Alathiyur village, Sendurai Taluk in Ariyalur District

of Tamil Nadu (Fig 1.1). RCL is operating its Alathiyur Cement Plant (with Lines I & II) for the Clinker

production of 2.52 MTPA and Cement production of 3.0 MTPA @ 8200 TPD. The Cement Plant is

supported by its Captive Limestone Mines (4 Mines comprising of 7 Nos. of Mining Leases) over an

extent of 383.585 Ha in Alathiyur Region. RCL had established 2 x 18 MW Captive Power Plant (CPP)

(coal based; water cooled condensers) in the Year 2004 for the smooth operations of Alathiyur Cement

Plant, within the cement plant campus over an extent of 6.84 Ha in SF Nos. Parts of 7, 8, 9, 23, 25, 26,

etc. with a Project investment of Rs.95.00 crores.

The Plant operations are in full compliance with the conditions stipulated in the Environmental

Clearances awarded by the Ministry of Environment, Forests and Climate Change (MoEF&CC) and

Consents from the Tamil Nadu Pollution Control Board (TNPCB).

The power demand of existing Plant operations and Township is 32 MW and the Auxiliary consumption of

CPP is 4.2 MW. The activities on the expanded Cement Plant viz. Limestone Beneficiation Plant, Wagon

Tippler, Stacker & Reclaimer, Bulk Loading, etc. needs another 4 MW additionally. Thus, RCL has to

expand the existing CPP power generation capacity to meet the additional power demand.

The existing Captive Power Plant Boiler is a Conventional Rankine Steam Cycle Thermal Power Plant

with single drum natural circulation, Atmospheric Fluidized Bed Combustion Boiler (AFBC) with under-

bed fuel feeding system. The total steam generation capacity of existing two Boilers (of 76 TPH each) is

152 TPH. The steam requirement for 36 MW is only 148 TPH. There is a surplus steam capacity of 4

TPH unutilized now. Also, with Imported Coal as only fuel, the Boilers can generate additional steam @

10 TPH per Boiler and total 20 TPH additionally. Thus, 172 TPH steam from existing Boilers can be used

for the required power generation of 42 MW. Accordingly, RCL has proposed to augment the power

generation capacity of the existing CPP at Alathiyur by adding only 6 MW Turbine. The total power

generation of 2 x 18 MW CPP will be 42 MW.





Proposed CPP configuration :

Enhanced steam generation : 2x86 TPH & each at 89 atm. & 515 oC

Steam Turbine Generator : 2x18 MW + 1x6 MW

Condenser for 6 MW Turbine : Air cooled condensers

The Power Plant along with standby 6 MW DG sets and Switch Yard are established in an extent of 6.84

Ha within the Cement Plant with a builtup area of 32,525 sq. m. The additional Turbine will be installed in

the Building of 574 sq. m. Additionally, about 520 sq. m area will be utilized for housing the Air Cooled

Condensers (Fig. 2.1). There is no additional land is required for the Proposal as proposed within the

existing Premises, The Cement Plant has the Railway Sidings, Coal Storage, Township, etc. and the

existing CPP does not require dedicated infrastructures for its operations. Also, as the entire Ash being

generated in the CPP is being consumed in the Cement Plant for PPC manufacture, thus, there is no Ash

Storage (Pond/Dyke) in the CPP. there is no Rehabilitation & Resettlement (R&R) issue also. The Project

Cost for the addition of 6 MW Turbine is Rs.21.42 crores. The proposal will be completed in 12 months

after obtaining all statutory clearances

The Plant Heat Rate is 3250 Kcal/ Kwh. Mainly imported coal from Indonesia (with average 12% Ash

Content & average 0.75% Sulphur content; GCV maximum 6300 kcal/kg; receiving Port at Karaikkal) will

be used in the CPP. The Coal Supply Agreement has been made on 19th April 2014 with M/s.Devendran

Coal International (P) Ltd. for the uninterrupted coal supply. Presently, 490 TPD coal is used and on

augmentation additional 80 TPD is required and thus, a total of 570 TPD imported coal is required for the

total 42 MW power generation. By considering 12% Ash Content (mean) of the imported coal, the ash

generation will be 68.4 TPD, 9.6 TPD increase from existing 58.8 TPD. The entire ash generated from

the CPP is being transported pneumatically and fully utilized in the Cement Plant for PPC manufacture.

An effective ESP System of 99.98% efficiency is installed in the CPP to control the SPM emission <50

mg/Nm3 through the Boiler Stack of 90 m height (3.0 m dia). The same existing Stack is capable of

handling the increase Flue Gas volume of 2,50,000 cum/hr.Online monitoring system is provided

connected online to Care Air Centre of TNPCB.

The Cement Plant Complex water demand is 5,220 cu.m/day which includes the consented water

demand of existing CPP of 3,843 cu.m/day. In addition to the own Mine Pit Water supply of 3,720

cum/day, borewells within the Complex yield about 1,500 cu.m/day. RCL has obtained the NOC for

ground water drawl of 1,500 cu.m/day from TN State Water Resource Department vide its Certificate No.

OT9/G-1/478/NOC/Chennai/2014 dated 27.10.2014.

With domestic consumption of 3 cum/day, the total water demand for existing CPP operation is 3,826.5

cum/day only. On Augmentation of CPP, there will not be any man power addition and Air Cooled

Condensers are proposed with no water demand. Thus, additional water is required only for Boiler make-

up i.e. 16.3 cu.m/day. The proposed water demand of 3,842.8 cu.m/day is well within the consented

quantity by the Board. The entire quantity of 875 cu.m/day trade effluent from the CPP is neutralized and

treated in a Neutralisation Pit and pumped to the Cement Plant for equipment Cooling. Cycles of

Concentration (COC) of the CW system of existing CPP is 4.7 and there will not be any change on

Augmentation as ACCs are employed.



Fig. : 2.1 CPP Layout within Alathiyur Cement Plant



Existing CPP generates domestic sewage to the tune of 2 cu.m/day which is being treated in the

common STP of 300 cu.m/day at the Cement Plant. There is no addition to the sewage quantity on the

proposed Augmentation. In the total area of 121.17 Ha, so far 47.5 Ha was brought under green belt

(39.20% coverage) with about 1,20,300 trees, native tree species predominantly. Treated sewage is

being used for Green belt development and maintenance. As entrie effluents from the CPP are treated

and utilized within the Campus, Zero Effluent Discharge is maintained.

The existing and proposed salient features of the CPP are given in Table 1.1.

Table : 1.1 Existing & Proposed Salient Features of CPP

Component Existing CPP On Augmentation with 6 MW Turbine

Plant Capacity 2x18 MW = 36 MW 42 MW

Boiler Capacity Atmospheric Fluidized Bed Combustion Boiler (AFBC) of 2 x 76 TPH capacity (at 89 ata & 515

oC)

Same as existing which will be augmented to produce 172 TPH steam (2x86 TPH) at 89 ata & 515

oC

Cooling Tower Water cooled condensers 2 Nos. additional Air cooled condensers

Imported Coal Demand 490 TPD (490+80=) 570 TPD

Ash Generation 58.8 TPD; Pneumatically transported to the Cement Plant for PPC manufacture

68.4 TPD; Pneumatically transported to the Cement Plant for PPC manufacture

APC Measure ESP & 90 m height Stack Same as existing

Man Power 30 Same as existing

Water Demand 3843 cum/day (consented quantity) and actual utilsation is only 3826.5 cum/day

3843 cum/day (within the consented quantity)

Effluent Generation & Disposal

880 cum/day after neutralization transported to the Cement Plant for equipment cooling

883 cum/day after neutralization transported to the Cement Plant for equipment cooling

Sewage & its Disposal 2 cum/day to common STP Same as existing

Project Cost Rs.95.00 crores Additional Rs.21.42 crores

EMP : Capital Cost Rs.5.20 crores Additional Rs.1.00 crores

EMP : Operating Cost Rs.0.59 crores/annum Additional Rs.0.11 crores/annum

The proposed proposal was considered by MoEF&CC Expert Appraisal Committee (EAC)-Thermal

Power in its 20th Meeting held during 28

th & 29

th August, 2014 for determination of the Terms of

References (TORs) for undertaking EIA study in accordance with the provisions of the EIA Notification

2006. The TORs are awarded vide MoEF&CC Letter J-13012/9/2014-IA.I(T) dated 12.11.2014 for

carrying out the EIA Study with Public Hearing.

RCL has entrusted the EIA Study on M/s. Environmental System Consultants & Ambiente Lab Solutions

Private Limited (Ensyscon), Chennai. The EIA Consultant has been provisionally 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-7th May 2015). The EIA Report has been prepared as per the generic

structure proposed in EIA Notification 2006 and the Awarded TORs are also incorporated and submitted

for the Environmental Clearance.



2.0 Description of the Environment

2.1 Environmental Setting

Alathiyur Cement Plant is located inbetween 11o21’30”-11

o21’59” N Latitude & 79

o13’09”-79

o14’08” E

Longitude (Survey of India Topo Sheet No. 58 M/3; Fig. 1.2). The CPP is located inbetween 11o21’45”-

11o21’54” N Latitude & 79

o13’41”-79

o13’46” E Longitude. There are no National Parks, Biosphere

Reserves, Elephant Corridor, Mangroves, Archaeological/Historical Monuments, etc. within 10 km radius

area other than the Reserved Forests (RFs) viz. Mudukulam RF (@ 7.8 km in southeast) and Ayyur RF

(@ 8.3 km in southeast). Seasonal Vellar River is flowing at a distance of 1.1 km in the northeast from

CPP boundary. The seasonal Anaivari Odai flows near the eastern boundary of the Cement Plant @ 40-

60 m diatance and joins Vellar River.

The Plant is located at a distance of 4.5 km south of Pennadam. Echankadu Railway Station is at a

distance of 1.5 km in the west. Vridhachalam Railway Junction is at 20 km distance in northeast. Taluk

Headquarters Sendurai is at 13 km distance in southwest and District Headquarters Ariyalur is at 30 km

in southwest.

RCL Alathiyur Cement Plant and India Cement’s Dalavoi Cement Plant are located adjacent to each

other. The Captive Limestone Mines of RCL & ICL exist in the Region. Ambika Sugars, Eraiyur is at a

distance of 5 km in northwest.

2.2 Baseline Environmental Status

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 Micrometeorological Data (hourly readings from the Plant) on wind speed & direction

(wind roses), temperature, humidity, cloud cover, atmospheric pressure along with rainfall.

� Ambient Air Quality Monitoring at 14 locations (Fig. 3.1) on 24-hourly basis, continuously for 2 days in

a week for 4 weeks in a month during the season for the parameters PM2.5, PM10, SPM (for Heavy

Metals analysis in Particulates), Particulate Lead, SO2, NOx, CO, HC and other parameters as per

NAAQ Norms -Revised as per GSR 826(E) dated 16.11.2009.

� Noise Level Measurements at all air quality monitoring station for Leq, Lday and Lnight values once

in the Season.

� Water Quality Monitoring – grab sampling once in a Season - Surface Waters (8 locations) as per

CPCB Norms & Ground Waters (10 Locations) as per IS:10500 Norms.

� Soil Quality Monitoring at 6 locations in the study period for : Textural & Physical Parameters and

Nutrients.

� Land use pattern based on Satellite Imagery.

� Biotic Attributes for Flora & Fauna.

� Socio-Economic Profile, based on 2001-Census & Provisional 2011 and Household Survey in

selective villages.

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 (14 Locations; 24-hly), ug/m

3

PM2.5 12 32 20.2 60

PM10 26 61 40.9 100

SO2 6 13 7.5 80

NOx 4 17 8.3 80

Ambient Noise, dB(A) Leq-day 39.5 45.7 41.9 55

Leq-night 37.2 43.6 39.9 45

Surface Waters, mg/l TDS 240 430 - 500/2100

Ground Waters, mg/l TDS 260 420 - 500-2000

Soil Status

Texture - - Silty Loam -

EC, mmhos/cm 1.03 1.56 - 0.2-0.5

SAR 1.20 2.21 - <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 and Mitigating Measures

The proposed Project would create impact on the environment in two distinct phases :

� during the construction phase which may be regarded as temporary and short term and

� during the operation phase which would have long term effects.

Various impacts during the construction and operation phase on the environment have been studied to

estimate the impacts on the environmental attributes and are discussed.



3.1 Construction Phase

The Proposal involves only Augmentation of CPP with 6 MW Turbine addition and thus there is no

significant construction activities, other than structurals, during this Phase. Existing labours, water supply,

sewage treatment facilities, etc. are adequate for carrying out the Augmentation works. Thus, there will

not be any significant impacts on the existing baseline environment during Construction Phase.

3.2 Operation Phase

Land Use Pattern : The Power Plant along with standby 6 MW DG sets and Switch Yard are established

in an extent of 6.84 Ha within the Cement Plant with a builtup area of 32,525 sq. m. The additional

Turbine will be installed in the Building of 574 sq. m and additional 520 sq. m area will be utilized for

housing the Air Cooled Condensers. Thus, the proposed Project will not alter the existing land use

pattern significantly.

Transportation : The Cement Plant material transports are mainly by rail networks and also by road

networks. Presently, about 257 trucks & bulkers/bowsers are plying to the Cement Plant for transporting

the raw materials as well as finished product cement. The Cement Plant Complex is located near the SH-

141. The existing traffic volume in the Project vicinity was found to be 1,763 PCU/day. In the Post-Project

Scenario viz. on Augmentation of CPP, no additional Truck movements will be there as the entire coal is

transported to the Plant by rail mode. Thus, there is no impact on the existing baseline status and to the

surrounding environment due to the Augmentation Proposal.

Air Environment : On Augmentation of CPP by 6 MW Turbine addition, the computed stack heights for 42

MW is 81.59 m . Thus, the existing stack of 90 m is adequate. CPP is being operated for SPM emission

<50 mg/m3. AERMOD View is used for the Prediction Modelling. There is no incremental increase in PM

Levels, 2.08 ug/m3 incremental increase in SO2 Levels and no incremental increase in NOx Levels in the

atmosphere and thus, there will not be any significant impact on the Air Environment due to the Proposal.

Also, adequate Buffer exists in the Air Environment for the proposed Augmentation activities.

Noise Levels : Noise levels from turbine, fans, centrifugal pumps, electric motors etc, are kept below the

permissible level of 85 dB (A) at 1m away from the source by proper design. Ambient Noise levels at the

boundaries are monitored <55 dB(A) during day times and <45 dB(A) during night times well within the

MoEF Norms for Residential and Rural Areas.

Water Environment : Additional water is required only for Boiler make-up i.e. for generating additional

24 TPH steam. The existing water and proposed water demand are 3,826.5 cum/day and 16.3 cum/day.

Thus, a total of 3,842.8 cum/day is the water demand which is well within the consented quantity of 3,843

cum/day by the Board. The entire quantity of 880 cu.m/day trade effluent is collected in a Effluent

Collection Tank (14x10x3.9 m), neutralized and treated in a Neutralisation Pit (4.0x2.0x2.8 m) in the

CPP. About 720 cu.m/day treated effluent from the CPP is pumped to the Cement Plant for equipment

Cooling and 160 cu.m/day is used for Green Belt within the Complex. On Augmentation of power

generation, there will be a meager quantity of 3.0 cu.m/day Boiler & Aux. Cooling Tower blowdowns

which will also be treated and pumped to the Cement Plant for equipment cooling. There will not be any

trade effluent discharge from the Plant.



Existing CPP generates domestic sewage to the tune of 2 cu.m/day which is being treated in the

common STP of 300 cu.m/day at the Cement Plant. There is no addition to the sewage quantity on the

proposed Augmentation. Thus, the the Plant is a ‘Zero Effluent Discharge’ Unit. The water conservation

measures and rain water harvesting measures are also being undertaken in the existing Plant.

Solid Wastes : By considering 12% Ash Content, the ash generation now is 58.8 TPD. On Augmentation

of CPP, the ash generation will be 68.4 TPD with 9.6 TPD increased. Out of this, 58.2 TPD (85%) will be

Fly Ash and balance 10.2 TPD (15%) will be Bed Ash. Fly Ash is being transported pneumatically with

the help of dense phase pneumatic pumps to closed RCC storage silos. The Fly ash will be evacuated

from silo and transported to the Cement Plant. Bed ash is collected from overflow spouts into ash cooler

hoppers. Bottom Ash is partly recycled after screening in CPP and balance to the Cement Plant for

blending with the raw materials. Thus, 100% Ash generated is fully utilized in the Cement Plant. No Ash

Pond as the entire ash is being utilized and thus, no leaching and other environmental concern due to

ash handling.

Biological Environment : There is no cutting of trees or clearing of bushes, etc. due to the proposal

within the existing Industrial Campus. There is no habitat fragmentation or blocking of migratory corridors

due to Project activities since there is no wild life movement or migratory birds movement in the study

area. Also, there is no Schedule-I Fauna exists in the vicinity and thus, no Conservation Plan is

envisaged. Thus, there will not be any significant impact on the existing flora-fauna of the area. RCL has

developed an effective Green Belt and Lawns to the extent of 39.20% coverage of total area. The Green

Belt developed will have significant long term positive impact on the environment.

Socioeconomic Environment : The projects would help in generation of direct and indirect employment

for the local people. This would be a positive long term impact due to the Project. There will be a general

upliftment of standard of living in the region. Based on the details collected by Household Survey, the

following assessments are made. In general, there have been the following demands/expectations from

the public:

� Job opportunities.

� Training of local youths for suitable jobs.

� Training in computer typing, driving heavy vehicles, etc.

� Employment for older people as security personnel, watchman, etc., and unskilled women in

gardening, cleaning, etc.

� Facilities like ambulance, health care, educational, community centres, etc.

In responses to the need based assessment study, the following social measures are proposed by RCL :

� Joining Hands with District Administration in implementing Govt. Schemes and local development.

� Committed for Infrastructure Facility in the Region.

� Adoption of Govt. Schools.

� Adoption of Sub-Centres & Provision of Ambulance for the villages and other medical facilities.

� Contribution to Education in the area.

� Carrying out various welfare activities for the benefit of the local population.



The CSR activities will be carried out by providing social and welfare measures for the local residents

and nearby villages around the Plant area. The prime focus will be on the creating and maintaining of

drinking water facilities for the students at the nearby Government Schools, establishing toilets especially

for girl students at the schools, setting up of computer centres, maintenance of village roads & ponds,

providing solar street lights, conducting free medical camps, etc. About 2% of the Profit (in 3 Preceeding

Years) will be earmarked as Corporate Social Responsibility (CSR) Budget.

RCL has the CSR Committee as per the provisions notified by the Ministry of Corporate Affairs on

February 27, 2014. Based on the CSR Committee and declared CSR Policy of the Company.

4.0 Environmental Monitoring Programme

For effective implementations of Environmental Management Plan, RCL has the Environment Monitoring

Cell. Also, the quality of air, water, soil and noise levels are already being monitored as per specified

norms and the reports are being submitted to MoEF&CC and TNPCB on regular basis. The same

practice will be continued during the Augmentation period also.

5.0 Additional Studies

Detailed risk assessment and mitigative measures are delineated and an effective Disaster Management

Plan is also submitted.

6.0 Project Benefits

RCL Alathiyur Cement Plant has employed 470 direct employees and 620 Contract Workmen. The

proposal will give employment to about 25-50 local persons during Construction Phase. Though, there is

no increase in Man Power during the Augmentation of CPP, there will be indirect employment to about

50-100 persons in the transportation sector. In addition to the environmental benefits like utilization of Fly

Ash, etc., there will be positive impacts by way of employment, better socioeconomic conditions,

improved local & regional economy, etc.

7.0 Environmental Management Plan

The Environmental Management Plan (EMP) is formulated for mitigation of adverse impacts and is based

on present environmental status and impact appraisal. EMP includes formulation, implementation and

monitoring of environmental protection measures.

7.1 Construction Phase

The Proposal involves only Augmentation of CPP with 6 MW Turbine addition and thus there is no

significant construction activities, other than structurals, during this Phase. Additionally builtup area will

be added for housing the 6 MW Turbine and Air Cooled Condensers. Existing labours, water supply,

sewage treatment facilities, etc. are adequate for carrying out the Augmentation works. Thus, there will



not be any significant impacts on the existing baseline environment during Construction Phase. However,

the following EMP measures shall be undertaken by RCL:

� PPE shall be provided to the construction workers.

� Construction employees shall have access to the safe drinking water and to existing Toilet facilities.

� Protection devices viz. ear plugs/ear muffs shall be provided to the workers during welding works.

� Smooth flow of traffic should be ensured on the internal roads to avoid idling of vehicles.

� All the debris resulting from the site shall be disposed off effectivel as per existing Norms.

� EMP Cell ensure the periodical Monitoring of Environmental Parameters during the Construction

Period and ensure its compliance with Norms.

7.2 Operation Phase

Air Environment :

� Coal transportation by railway line shall be continued.

� Thermal insulation shall be provided wherever necessary to minimize heat radiation from the

equipment, piping, etc.

� Suction arrangements with suitably designed Bag Filters shall be provided at discharge points to

conveyors, conveyor transfer points, feeding hopper, fly ash discharge point, ash storage silos and

its transfer points to the cement mill, etc. to arrest the fugitive emissions. The collected dusts shall be

taken back to the system.

� Periodical evaluation for the efficiency performance of Bag Filters shall be carried out.

� SPM emission from Boiler ESP stacks shall be <50 mg/Nm3. Also, it may be noted that the new SPM

Norm for the Cement Plant will be <30 mg/Nm3 with effect from 01.01.2016 as per GSR 612(E) dated

25.08.2014.

� Fugitive emissions shall be in compliance with CREP Guidelines for the Cement Industries.

� Fugitive emissions due to storage, transportation, etc. and the leakages and spillages shall be

continuously monitored and controlled.

� Mechanised road sweepers shall be utilized for cleaning the roads.

� Coal dust explosion should be avoided by providing control measures and water sprinkling

arrangements.

� Green belt shall be effectively developed and maintained.

� Periodical monitoring of ambient air quality, stack emissions, etc. shall be carried out in addition to

the Online Monitoring Facilities available in the Unit.

Noise Levels :

� The design features of machineries shall be provided to ensure low noise levels in the working areas.

� Noise generating sources would be maintained properly to minimise noise and vibrations.

� Control cabins/chambers would be made sound proof and automatic door closures would be

provided for control cabins.

� All rotating items shall be well lubricated and provided with enclosures as far as possible to reduce

noise.

� For all fans, compressors etc. vibration isolators shall be provided to reduce vibration and noise.



� Though the total noise is expected to be well within the permissible limit at the boundary level, the

plant personnel working near to higher noise sources shall be provided with ear plugs/muffs.

� Green Belt shall be developed and maintained as noise barriers.

� Ambient Noise level at the boundaries are monitored <55 dB(A) during day times and <45 dB(A)

during night times, well within the MoEF Norms for Residential and Rural Areas.

Water Environment :

� Water consumption shall not be more than the consented quantity.

� The entire quantity of trade effluent from CPP shall be neutralized/treated in the Neutralisation Pit

and pumped to the Cement Plant for equipment Cooling there.

� No additional sewage shall be generated from the CPP on Augmentation.

� ‘Zero Effluent Discharge’ shall be practiced.

� Water control measures shall be undertaken.

� RCL shall develop additional rain water harvesting structuresas proposed.

� Periodical monitoring of Treated Effluents in compliance with CPCB/TNPCB Norms shall be done

regularly.

Land Environment :

� The entire ash generated from the CPP shall be fully utilized in the Cement Plant for PPC

manufacture.

� Fly ash is being transported pneumatically with the help of dense phase pneumatic pumps to RCC

storage silos.

� It should be ensured that there is no industrial solid waste from the Plant.

� Waste Oil shall be collected and sold to the MoEF&CC/TNPCB 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.

Biological Environment :

� An effective Green Belt shall be carried out in 33% of total extent and maintained with the guidance

of DFO.

� A mixture of fruit, fuel, fodder and quick growing timber tree saplings, predominantly local

flora/vegetations shall be planted keeping in view the agro-ecological and edaphic conditions of the

areas.

Rain Water Harvesting :

� An effective rain water harvesting shall be implemented and realized water shall be used effectively

to supplement the water supply from the river.



Occupational Health Measures :

� RCL shall provide a safety & healthy working conditions and continually improve the occupational

health and safety performance.

� Its objectives shall be to achieve zero accident and safe work environment, to improve moral and

health of all employees and to maintain the emission levels below the norms.

� RCL shall provide ergonomic support in work comfortness with periodical review.

Social Measures :

� As per the Companies Act 2013, Companies should spend at least 2% of the Profit after Tax of the

previous year for the CSR activities but not lower than 2% of average of previous three years Profit

after Tax.

� RCL is presently carrying out various Socio Measures for the local as well as regional populations

which shall be continued as per existing CSR Norms.

� In addition to the CSR Budget earmarked for the Year viz. 1.50 crores, additional Rs.24.85 lakhs will

be spent with a Recurring Cost of Rs.0.40 Lkahs/annum to address the issues raised by the Public

now.

EMP Budget : The capital cost of the Proposal is Rs.21.42 crores in addition to existing CPP Project

Cost of Rs.95.00 crores. Additional EMP Budget of Rs.1.00 crore has been earmarked to existing

Rs.5.20 crores EMP Budget. The Operating Cost will be Rs. 0.11 crore to existing Rs.0.59 crores/annum.

***

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Fig. : 2.1 CPP Layout within Alathiyur Cement Plant



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Leq-Night 37.2 43.6 39.9 45

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3, GÏ GÏ GÏ GÏ National Ambient Air Quality (NAAQ) Standrads revised as per GSR

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