Ambuja Cement Ltd., Darla Ghat - Himachal Pradesh State Pollution ...

DRAFT ENVIRONMENTAL IMPACT ASSESSMENT REPORT of EXPANSION OF CLINKERIZATION UNIT AT RAURI AND KASHLOG LIMESTONE MINES Tehsil ARKI, Dist SOLAN (HIMACHAL PRADESH)

AMBUJA CEMENT LIMITED

Prepared By EMTRC Consultants Private Limited (Accredited by NABET-QCI & NABL - ISO17025) B-16, Plot 10-A, East Arjun Nagar, Delhi-32 Email: [email protected] website www.emtrc.com

JULY 2012

EMTRC CONSULTANTS PVT LTD. DELHI CERTIFICATE This Draft EIA Report has been prepared for the Expansion of Rauri Cement Plant and Kashlog Limestone Mines of Ambuja Cements Limited near Darlaghat in tehsil Arki, district Solan (Himachal Pradesh) for Public Hearing. The Terms of Reference for this EIA was approved by the Ministry of Environment & Forests, GOI vide Letter No. F.No.J11011/986/2008-IA;II (I) dated 12 March, 2009. Technical data related to the process, plant design, layout was provided by Ambuja Cements Limited. Information related to land, water, fuel, Mining Plan, compliance with existing EC, existing pollution data of plant and CSR activities is provided by ACL. Baseline data on ambient air, noise, water and soil quality, flora-fauna and socioeconomics has been generated by Scientists of EMTRC as well as collated from authentic documents. Additional data related to Biological Environment, Hydrogeology, GIS and Traffic Survey provided by ACL has been also included in the EIA. Impact Assessment was done using scientific tools and methods prescribed in EIA Manual as well as by applying analytical reasoning and professional judgment of the subject experts. The EIA Report fully complies with all the points mentioned in the TOR approved by MOEF. The data submitted in this EIA Report, as generated by EMTRC, is true and factually correct.

DR. J.K.MOITRA MANAGING DIRECTOR

Issue Record: Ref.

Date

EMTRC Consultants Private Limited EIA Coordinator

68 Rev-7

5/8/2009 14/07/2012

Dr. J. K. Moitra

Ambuja Cement Limited Checked and Approved by Mr. A. Solankey

Remarks Draft Report for Public Hearing

ii

AMBUJA CEMENT LIMITED DARLAGHAT UNDERTAKING

(As per OM No. J.11013/41/200/IA-II (I) dated 5. 10.2011Ministry of Environment & Forests, Govt. of India) This Draft EIA Report has been prepared by EMTRC Consultants Private Limited, Delhi for the proposed Expansion of Clinkerization Unit at Rauri and Kashlog limestone mines at Kashlog for public hearing .The terms of Reference for preparation of EIA was issued by the Ministry of Environment & Forests ,GOI vide letter No. J-110-11/986/2008-IA-II (I) dated 12.3.2009. Information and Data on the Project Technical Details, Land, Water, Fuel, Raw Materials, Pollution Mitigation Measures, Stack Details, Project Cost and Schedule, Manpower, Project Layout and Location Maps used in this EIA report has been given by Ambuja Cements Ltd, Darlaghat. EMTRC has generated the baseline environment data for this project. The draft EIA report, as prepared by EMTRC is approved by AMBUJA CEMENTS LTD, DARLAGHAT for submission to HPSPCB for Public Hearing. The EIA Report fully complies with all the points mentioned in the TOR prescribed by MoEF. EMTRC conducted the impact assessment and prepared EMP based on information supplied by Ambuja Cements Ltd, Darlaghat. The data submitted in this EIA Report is true and factually correct. We hereby submit this undertaking on the 3rd day of July 2012 as per OM dated 05.10.2011 that the contents and information submitted in this EIA report is owned by Ambuja Cements Ltd, Darlaghat.

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CONTENTS Section

TITLE

CHAPTER 1. 1.1 1.2 1.3 1.4 1.5 1.6

2.1 2.2 2.2.1 2.2.2 2.3 2.4 2.5 2.6 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.4.1 2.7.4.2 2.7.5 2.7.6 2.7.7 2.7.8 2.7.9 2.7.10 2.7.11 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6

INTRODUCTION

Purpose of the Report Identification of Project and Project Proponent Nature and Size & Location of the Project Importance of the Project to Country & Region Compliance with CREP Recommendations Scope of EIA study CHAPTER 2.

PAGE

1 2 3 7 8 9

PROJECT DESCRIPTION

Project Profile Type of Project Mining Clinkerization Unit Need of Project Lay out Maps Size and Magnitude of Operation Schedule for Approval & Implementation Mining Process Background Information Mining Plan Mining Methodology Mining Plan Details Western (Kashlog) Block Eastern (Mangu) Block Drilling & Blasting Transportation of Limestone and Shale Mining Equipment Water for Limestone Mime Expansion Power Supply Employment Infrastructure Description of Mitigation Measures - Mining Movement of HEMM on Haul Road Drilling of Holes for Blasting Blasting Crushing Overland Belt Conveyor (OLBC) Noise

13 13 13 14 14 15 15 19 19 19 20 22 23 23 28 35 40 40 43 44 44 44 45 45 45 47 48 48 48

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2.8.7 2.8.8 2.8.9 2.9 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.9.7 2.9.7.1

Solid Waste / Hazardous Waste Waste Water Safe Mine Practices Clinkerisation Process Water for Cement Plant Power Requirement Automation & Instrumentation Instrumentation & Control Civil Structures Manpower Pollution Mitigation Measures Fugitive Dust Emission Control CHAPTER 3

3.1 3.2 3.3 3.3.1 3.4 3.4.1 3.5 3.5.1 3.6 3.6.2 3.7 3.7.1 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.9 3.10

4.1 4.2 4.2.1 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5

DESCRIPTION OF ENVIRONMENT

Study Area, Period and Methodology Geology and Hydrogeology Meteorology Meteorological Observations Ambient Air Quality Observation on AAQ Ambient Noise Quality Observation on Ambient Noise Quality Surface & Ground Water Quality Observation on Water Quality of Study Area Soil Quality Observation on Soil Quality Ecology Flora Flora of the Mining Site Fauna Wild Life Sanctuary Land Use Pattern Socio-economic Features

CHAPTER 4

49 49 49 53 59 59 59 60 60 61 61 62

64 65 72 72 75 80 82 83 84 91 91 93 93 93 96 100 102 105 109

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

Identification of Impact Impact Assessment Construction Stage Impact Operational Stage Impact Impact on Landform Impact on Natural Resources Impact on Climate Impact on Ambient Air Impact on Ambient Noise

112 112 112 113 113 116 117 117 128

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4.3.6 4.3.7 4.3.7.1 4.3.8 4.3.9 4.3.10 4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16 4.4

Impact Due to Blasting, Vibrations and Flyrock Impact on Drainage and Water Bodies Protection and Conservation of Water Bodies Impact of Solid Waste Disposal Impact on Soil Quality Impact on Ecology Impact on Occupational Health Impact Due to Accident Impact on Public Health and Safety Impact on Traffic Movement Social Impacts Impact of Change of Land use Assessment of Significance of Impact CHAPTER 5

5.1 5.1.1 5.1.2 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.1.11 6.2 6.3 6.4

ADDITIONAL STUDIES

Risk Analysis Emergency Response Plan Risk Mitigation Measures Wild life Conservation Plan Reclamation & Rehabilitation Plan Proposal for Next Five Year Scheme Period Stabilization of Mine Slopes Check Dams & Retaining Walls Plantation Rehabilitation of Displaced Persons CHAPTER 6

156 159 166 168 170 171 173 173 173 174

ENVIRONMENTAL MONITORING PLAN

Monitoring Plan Stack and Fugitive Emission Monitoring Ambient Air Quality Monitoring Meteorological Monitoring Equipments & Ambient Noise Water & Waste Water Monitoring Solid & Hazardous Waste Monitoring Flora & Fauna Monitoring Workers Health & Safety Monitoring Community Health Monitoring Monitoring of DMP Monitoring of CSR Activities Action During Abnormal Operational Conditions Budget for Environmental Monitoring Reporting

CHAPTER 7

133 136 140 143 144 145 146 147 148 149 153 154 154

PROJECT BENEFIT

175 177 177 178 178 179 180 180 180 181 181 181 182 182 182

183-184

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CHAPTER 8 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.9.1 8.9.2 8.10

ENVIRONMENTAL MANAGEMENT PLAN

EMP During Construction Stage Management of Labour Camp EMP for Air Pollution During Construction Phase EMP for Water Pollution During Construction Phase EMP for Noise Pollution During Construction Phase EMP for Solid Waste During Construction Phase Reclamation and Closure Plan EMP for Air Pollution Control Fugitive Emission Control during Mining Operation Fugitive Emission Control from Cement Plant Air pollution Control from Cement Plant EMP for Water Pollution During Operational Stage EMP for Noise Pollution During Operational Stage EMP for Controlling Vibration EMP for Solid Waste Utilization and Disposal Slop Stability Investigations by IBM Soil Conservation and Slope Stabilization Green Belt Development Plan Occupational Health & Safety Plan Green House Gas Emission Reduction Socio-economic Development Plan Environment Management System Structure of Environment Management Department Budget for Environmental Management Resource Conservation Plan CHAPTER 9

CHAPTER 10

185 186 186 188 188 189 189 190 190 191 193 194 197 199 201 201 202 206 218 221 223 234 235 237 237 241-252

SUMMARY AND CONCLUSION

DISCLOSURE OF CONSULTANTS ENGAGED

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LIST OF APPENDIX Appendix 1: Point-wise Compliance to TOR Conditions Issued by MOEF

LIST OF ANNEXURES Annexure-1: Single Window Clearance from State Government (dated 21-5-2012) page 267-269 Annexure-2: NOC from Principal Chief Conservator of Forests (dated 24-1-2012) page-270 Annexure-3 Letter from MOEF Regarding Renewal of Mining Lease (dt27-9-2011) page 271 Annexure-4: Letter from State Govt Regarding Renewal of Mining Lease (dt 7-6-2012) page 272-275 Annexure-5: Letter from GWB and NOC from Gram Panchayat for Taking Groundwater page 276-277 Annexure-6: Extract from Hydrogeology Report of Plant and Mine Site page 278-281 Annexure-7: Biological Environment Report of Study Area page 282-328 Annexure-8: Extract from Traffic and Air Pollution Surveys on Road Network Report page 329-341 Annexure-9: Pollution Testing Report of Existing Cement Plant and Mines page 342-358

LIST OF TABLES Table No.

Name of the Table

Page No.

Table 1.1

Name of Forest within 10 km Radius of Study Area

6

Table 2.1

Conceptual Plan for Limestone & Shale Production (in Million tones)

21

Table 2.2

Proposed Year-wise Development Plan (Western Block)

28

Table 2.3

Proposed Year-wise Development Plan (Eastern Block)

29

Table 2.4

Planned Production for Next Five Years

30

Table 2.5

Coordinates of Proposed Working – Eastern Block

35

Table 2.6

List of Mining Equipment

42

Table 2.7

List of Miscellaneous Mining Equipments

42

Table 2.8

List of Proposed Additional Mining Equipments (Expansion)

43

Table 2.9

List of Proposed Additional Miscellaneous Equipments - Expansion

43

Table 3.1

Component, Study Area, Period and Methodology of EIA

54

Table 3.2

AAQ Monitoring Location

76

Table 3.3

AAQ Monitoring Results (Winter Season 2008-09)

76

Table 3.4

AAQ Monitoring Results (Summer Season 2011)

77

Table 3.5

Chemical Characterization of RSPM (Winter Season 2008-09)

80

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Table 3.6

Chemical Characterization of RSPM (Summer Season 2011)

80

Table 3.7

Ambient Noise Quality Results(Winter Season 2008-09)

82

Table 3.8

Ambient Noise Quality Results(Summer Season 2011)

83

Table 3.9

Water Sampling Locations

84

Table 3.10

Analysis Results of Surface Water (Winter Season 2008-09)

85

Table 3.11

Analysis Results of Surface Water (Summer Season 2011)

86

Table 3.12

Analysis Results of Ground Water (Winter Season 2008-09)

87

Table 3.13

Analysis Results of Ground Water (Summer Season 2011)

89

Table 3.14

Soil Sampling Locations

91

Table 3.15

Soil Analysis Results (Winter Season 2008-09)

92

Table 3.16

Soil Analysis Results (Summer Season 2011)

92

Table 3.17

List of Flora In Kunihar Forest Division

94

Table 3.18

Phytosociological Studies near Chandi Village

96

Table 3.19

Phytosociological Studies near Giyana Village

97

Table 3.20

Phytosociological Studies near Banli Village

98

Table 3.21

Phytosociological Studies near Mangu Village

98

Table 3.22

Phytosociological Studies near Dhar Village

99

Table 3.23

List of Fauna In Kunihar Forest Division

101

Table 3.24

List of Flora found inPiplughat Wild Life Sanctuary

103

Table 3.25

List of Fauna found in Piplughat Wild Life Sanctuary

103

Table 3.26

List of Flora In Majhathal Wild Life Sanctuary

104

Table 3.27

List of Fauna In Majhathal Wild Life Sanctuary

105

Table 3.28

Land use Pattern of Study Area

105

Table 3.29

Area under Principal Crops (in ha)

109

Table 3.30

Production of Principle Crops (in tons)

109

Table 3.31

Population Figures in Arki Tehsil and Solan District

110

Table 3.32

Rural & Urban Population Arki Tehsil and Solan District

110

Table 3.33

SC & ST Population Arki Tehsil and Solan District

110

Table 3.34

Occupational Pattern of the Workforce

111

Table 3.35

Classification of Main Workers

111

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Table 4.1

Cement Plant Stack Emission Inventory

120

Table 4.2

Emission Inventory of Lime Stone Mine

121

Table 4.3

Impact of Air Emission due to Mining Activity

124

Table 4.4

Impact of Air Emission due to Clinkerization Activity

124

Table 4.5

Monitored Noise Level of Mining Machinery

129

Table 4.6

Monitored Noise Level of Cement Plant

133

Table 4.7

Top Soil Utilization During Last Five Years

145

Table 4.8

Results of Traffic Modeling (1-hr avg values in µg/m3)

151

Table 5.1

Details of Proposed Reclamation Area During Next 5 Years

171

Table 6.1

Man Power for Environmental Monitoring

176

Table 6.2

Instruments for Environmental Monitoring

176

Table 8.1

Soil Additives and Their Properties

208

Table 8.2

Nutrient Contents of Some Organic Manure

208

Table 8.3

Location – wise Plantation Status in Mines

210

Table 8.4

Proposed Year wise Plantation for Next 5 Years

213

Table 8.5

Status of Plantation in Existing Cement Plant

215

Table 8.6

Mining use Area and Rehabilitated Area in First 5 years

216

Table 8.7

Mining use Area and Rehabilitated Area in Next 5 years

216

Table 8.8

Mining use Area and Rehabilitated Area in Next 5 years

217

Table 8.9

Recommended Medical Examination for Employees

219

Table 8.10

CSR Budget

233

LIST OF FIGURES Figure No.

Name of the Figure

Page No. 10

Figure 1.1

Location of Plant Site and Mines

Figure 1.2

11

Figure 1.3

Map showing the cement plant, limestone mines, Majhathal and Piplughat Sanctuary along with the distance Google Map Showing Features Around 10 Km Area of Mines andPlant

Figure 2.1

Layout Map (Clinkerization Plant)

16

Figure 2.2

Surface Layout (Mine Area)

17

Figure 2.3

Land use Map of Mining Lease Area

18

12

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Figure 2.4

Landuse Plan (Pre-Operational)

24

Figure 2.5

Landuse Plan( Operational)

25

Figure 2.6

Mining Plan : Post-Operational

26

Figure 2.7

Hydraulic Rock Breaker

39

Figure 2.8

Working of Backhoe and Dumper

41

Figure 2.9

Drilling Machine

46

Figure 2.10

Hole for Blasting

46

Figure 2.11

Rock Breaker

50

Figure 2.12

Backhoe for Excavation

50

Figure 2.13

Benches of Mining Area

51

Figure 2.14

Process Flow Chart for Clinker Manufacturing

58

Figure 3.1

Hydro-geological Map of Soaln District

69

Figure 3.2

Wind Rose Diagram of Site (Winter 2008-09)

73

Figure 3.3

Wind Rose Diagram of Site (Summer 2011)

74

Figure 3.4

Map Showing AAQ Monitoring Locations

81

Figure 3.5

Satellite Imagery of 10 km area around Plant Site

107

Figure 3.6

Satellite Imagery 10 km area around Mine Site

108

Figure 4.1

Isopleths Showing GLC of PM within the Mines Boundary

125

Figure 4.2

Isopleths Showing GLC of PM Along the Mines Boundary

125

Figure 4.3

Isopleths Showing GLC of PM Outside the Mines Boundary

126

Figure 4.4

Isopleths Showing GLC of PM around Clinker Unit (5 km)

126

Figure 4.5

Isopleths Showing GLC of PM around Clinker Unit (2.5 km)

127

Figure 4.6

Isopleths Showing GLC of SO2 around Clinker Unit (5 km)

127

Figure 4.7

Isopleths Showing GLC of NOx around Clinker Unit (5 km)

127

Figure 4.8

Air Quality Contours of Incremental GLC

128

Figure 4.9

Predicted Noise Level Contours from DG Set

131

Figure 4.10

Predicted Noise Level Contours from Crusher

131

Figure 4.11

Predicted Noise Level Contours from Blasting Site

132

Figure 4.12

Predicted Noise level Contours From Clinker Plant

132

Figure 8.1

Water Flow & Balance of Proposed Mines Expansion

195

Figure 8.2

Water Flow & Balance of 2.6 MTPA Clinker Plant

196

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EIA of Expansion of Cement Plant at Rauri and Limestone Mines at Kashlog Tehsil Arki, District Solan, HP Ambuja Cement Limited

CHAPTER 1 : INTRODUCTION 1.1

Purpose of Report

Ambuja Cement Ltd. (ACL) contributes about 10 percent of total cement production of India. ACL’s existing plant in Himachal Pradesh is located at Suli, tehsil Arki in district Solan. The clinkerization capacity of Suli plant is 2.6 Million Tons Per Annum (MTPA). ACL has obtained the environmental clearance for 5.5 MTPA limestone mining at Kashlog, Patti and Mangu villages, located in the Arki tehsil. ACL has also obtained environment clearance for installation of another clinkerization plant of 1.8 MTPA capacity adjacent to Suli plant at village Rauri. This plant is under operation. Considering the increasing demand of the cement in the Himachal Pradesh and other northern states, availability of cement grade limestone and viability of similar unit size, ACL decided to expand the 1.8 MTPA clinkerization plant at Rauri to 2.6 MTPA. The limestone and shale mining capacity shall be enhanced from 5.5 MTPA to 7.6 MTPA, so as to cater to the demand of both Suli and Rauri plant. Renewal of Kashlog limestone mine lease of ACL was due on 27-05-2012. ACL has applied to State Government for renewal of lease vide letter dated 24-01-2011. Geology Wing of Department of Industries, Govt. of Himachal Pradesh vide letter No. Udyog-Bhu (Khani-4) Major-289/2011-2089 dated 07-06-2012 approved the renewal of mining lease for extraction of limestone and shale for captive use in existing cement plants for a period of 20 years. Amendment dated 4th April 2011 in EIA Notification 2006 stipulates prior environmental clearance at the time of mine lease renewal. MoEF vide letter No. Z-11013/26/2011 (M) dated 27th September 2011 informed that since ACL has already obtained the ToR from MoEF vide their letter no. J-11011.986/2008-IA-(I) dated March 12, 2009 for preparation of EIA report of expansion of Rauri Cement Plant and Kashlog Limestone Mines (5.5 MTPA to 7.6 MTPA), no fresh application for ToR is required for renewal of mine lease, however appraisal of mining component will be done by EAC (Mines).

1


The draft EIA Report has been prepared in line with the TORs issued by MoEF vide their letter no. J-11011.986/2008-IA-(I) dated March 12, 2009 for preparation of EIA report. The EIA Report complies with the TORs prescribed by MOEF. Any comments, shortcomings, etc obtained / noted during the Public Hearing shall be included in the Final EIA Report.

1.2

Identification of Project and Project Proponent

Project: The project under EIA study comprises the following: 1. Clinkerisation capacity enhancement from 1.8 MTPA to 2.6 MTPA of Rauri plant .(increase by 0.8 MTPA). 2. Limestone and shale mining capacity enhancement from 5.5 MTPA to 7.6 MTPA at Kashlog Mines (increase by 2.1 MTPA; out of which 1.84 MTPA is limestone and 0.26 MTPA is shale). The limestone deposits were investigated by ACL with the help of the Geological Department of Government of Himachal Pradesh. Availability of limestone of cement grade quality in adequate quantity, economical viability of mining of limestone and its processing has been the major factors for identification of the location of cement plant. The production of the limestone shall be done in the existing mining lease area, whose mining plan has been approved by the Indian Bureau of Mines. No additional land will be acquired for the mines and cement plant expansion. Considerations of site selection for cement plant are as follows: • •

The proposed site is based on Kashlog deposit of limestone located at an aerial distance of about 2.8 km from Rauri. The overland belt conveyor from Kashlog mines to plant site exists.

•

Sufficient non-forest land is available for the clinker plant and its associated facilities

•

There is sparse agriculture land around the site

•

There are no irrigation facilities in the area.

•

There is no wildlife in the identified mining lease area and plant area.

Project Proponent: Ambuja Cement Limited is a leading manufacturer of various types of cement in India. Ambuja Cement has an excellent track record with respect to 2


productivity, energy conservation, quality control, environmental management and pollution control. Environment Management Division (EMD) has been established at all the ACL plants. EMD consists of experts in the field of Environmental Engineering, Environmental Science, Environment Management, Wastewater Treatment and Horticulture. EMD involves implementation of all necessary measures to protect environment and monitor various environmental parameters in and around the units.

ACL is the first cement plant in the country to have been conferred Quality System Certificate License as per IS 9002 by Bureau of Indian Standards in recognition of its Quality Standards.

It ranks amongst one of the most efficient cement plants in India and comparable with the best plants in the world. It has clinker manufacturing facilities in Gujarat, Himachal Pradesh, Chattisgarh, Rajasthan and Maharashtra. Besides, the company has split clinker-grinding units at Ropar and Bhatinda in Punjab, Surat in Gujarat, Sankrail and Farakka in West Bengal and Roorkee in Uttarakhand. ACL’s total manufacturing capacity is 20.0 million tones per annum, which amounts to be around 10% of the total production share and to meet out the market demand, the company has taken up steps to enhance the total capacity to more than 25 million tones per annum in next two to three years. Installation of this cement plant is one more mile stone in this direction.

1.3

Nature, Size and Location

The project activities (Clinkerization and Limestone Mining) falls under Category ‘A’ of EIA Notification dated 14-9-2006. ACL has obtained environmental clearance from MOEF for clinkerisation capacity of 1.8 MTPA in the year 2006 for its plant at Rauri. Since identical plants are easy to maintain and operate, ACL decided to expand the Rauri plant to 2.6 MTPA.

The mining of limestone and shale will be 7.6 million tones, as per the demand for the two units (Suli and Rauri, 2 x 2.6 – 5.2 MTPA clinkerisation capacity). Kashlog Limestone Mine will meet out the requirements. 3


Location - Mining

The Mining Lease area comprises total area of about 488.06 ha falling in Kashlog, Chakru, Serwala, Banjan, Pati, Banli, Banog, Rathoh, Mangu, Chola, Ghamaru, Serjeri, Gyana, Rauri, Sangoi villages of Tehsil Arki in Solan District of Himachal Pradesh. Geographically, the area falls between Latitudes 31o13’50.5” to 31o15’28” North and Longitude 76 o55’38.5” to 77o9.5” East with elevations in the range of 1280 to 1740 m above Mean Sea Level (MSL). National Highway, NH-88 connecting Shimla to Bilaspur passes about 4 km south of the mine. The aerial distance between plant and the mine is 2.8 km while the road distance is 19 km. The nearest railway station is Shimla which has a narrow gauge rail line from Kalka. Shimla is 45 km road distance from Darlaghat.

Kashlog is 109 km from Kiratpur Sahib Railway Station via Swarghat, Nauni, Darlaghat and Kararaghat off National Highway 88 and from there partly metalled and partly unmetalled road links Kashlog over a distance of 10 km. This road is motorable throughout the year. The mining lease area includes mining area, site office and canteen for the employees. No additional land is required for the proposed capacity expansion of the mine.

Location – Cement Plant The project site is located by the co-ordinates latitude 31o14’ – 31o16’ North and longitude 76o57’ – 76o59’ East at an elevation of 1505 - 1565 m above Mean Sea Level (MSL). The project site is located at village Rauri about 500 m from Suli village (existing cement plant) and it can be approached from Darlaghat by road, which is well connected by good road network to Bilaspur, Ropar, Shimla, Kalka and Chandigarh. The plant site is well connected with communication facilities like telephone, fax, wireless, telex and internet. No additional land is required for expansion of the Rauri plant. The existing land of 23.35 ha will be sufficient. The salient features of the project and site are given below:

1 2

Salient Features Elevation of hill ranges (highest) Nearest National Highway

Location 1740 m in SE direction NH-88 connecting Shimla-Bilaspur at 4.0 km 4


3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18

by road. Shimla at 48 km (by road) and 22 km (aerial) Jubber Hatti (Shimla) located at about 45 km (by road) from site Nearest Tourist Place Shimla at 48 km (by road) and 22 km (aerial) Archeological important places None within 10 km radius Wild Life Sanctuaries within 10 Majathal sanctuary km area of mines and plant site 2.7 km north east of Rauri plant & 1 km north of Kashlog limestone mine Piplughat sanctuary 4.0 km south of Rauri plant & 5 km southwest of Kashlog limestone mines. . Reserved/Protected Forest within 24 Protected forest blocks within 10 km 10 km radius radius Industries in 10 km radius ACL Cement Plant at Suli Nearest major city with 2,00,000 Shimla at about 48 km (by road) population Nearest Town Arki at about 16 km (by road) Villages within 1 km radius Ghamaru, Ghyana, Chola, Pati, Chakru and surrounding the mining project Sangoi, Kashlog, Mangu Nearest River Sutlej river at 6.0 km (aerial distance) NE of mine Nearest Lake Govindsagar Lake at 22.5 km in NNW (aerial) Source of water for existing Pazeena (pagoda) Khud a tributary of River plants and limestone mine Sutlej located at about 5.5 km (aerial). Source of water for expansion Recycled water supplemented with plant and mines groundwater Surrounding terrain Hilly terrain Major Crops Maize and wheat Nearest Railhead Nearest Airport

1. The key map showing location of the plant site and mines is shown in Figure 1.1. 2. Map showing the cement plant, limestone mines, Majhathal and Piplughat Sanctuary along with the distance is shown in Figure 1.2. 3. Google Map showing the features around 10 km area of cement plant and mines is shown in Figure 1.3.

The lower sub-Himalayan area around Kashlog, is basically hilly, the cultivated area is negligible, only few farms on the flanks of the hills have been created by terracing. Most of the high rising hills surrounding Kashlog limestone ridge bear the Chil plantations. The intervening valleys are habited. Most of the streams flowing through the valley are seasonal. 5


The origin is young and the hill ranges are severely affected by denudational agencies like snow in the northeastern parts and by rivers and streams in the rest of the area. Differential erosion in different rock formations can be noticed in ranges with irregular indefinite pattern. The ranges are divided by “V” or fan shaped valleys. The drainage of the area shows dendritic to sub-dendritic patterns. They are generally dry during dry seasons and water flows in the rainy season on the upper slopes, whereas in the lower portion, they change into perennial streams. Sutlej is the major river in the area, which flows in the north direction at about 5.5 km from the mine site. The area is intersected by various nallahs and other small tributaries of the Sutlej river. Pazeena khud collects the drainage of the area with a dendritic pattern of feeder branches. Most of the streams are dry during the non-monsoon period. Part of the study area is covered with protected forest blocks. The name of forests is given in Table 1.1. The mining lease area is covered by a thin layer of soil with patches of stony outcrops. Main crop of the study area is maize. However, people also grow mustard, wheat for their own use. The soil is of sandy loam variety.

Table 1.1 Name of Protected Forests within 10 km Study Area Sr. Name of the Direction wrt plant Distance wrt Plant No. Protected Forest site site 1 Majathal NE 5.1 2 Harshing ENE 6.5 3 Skor NNE 7.7 4 Troht NNE 8.75 5 Banaula N 6.2 6 Seri SSE 9.7 7 Gharakhru SE 6.5 8 Ser gharkhru SE 5.0 9 Barall SE 4.5 10 Manlog Bhagal W 1.1 11 Darana SE 7.5 12 Paniharu SSW 8.4 13 Bari SW 6.3 14 Bani SW 8.25 15 Koil SW 6.75 16 Bahadurpur SW 5.25 17 Shilru SW 5.6 18 Shalnu SSW 4.4 19 Siarli E 8.5

Area(Ha) 1491 768.00 34.80 74.40 270.40 48.00 69.60 330.40 146.0 182.80 25.00 58.60 66.00 41.00 40.00 45.00 16.80 47.82 21.52 6


20 Samtiari NNW 21 Matrech NNW 22 Malen WSW 23 Sharma SE 24 Baraghat SW (Source: Forest Working Plan and Toposheet)

1.4

9.4 6.6 9.6 7.7 8.8

36.20 25.60 44.40 19.20 182.00

Importance of the Project to Country & Region

In India, limestone of cement grade quality is not evenly scattered, but occurs in large clustered deposits mainly in six states namely Andhra Pradesh, Karnataka, Madhya Pradesh, Chhattisgarh, Gujarat, Rajasthan and Meghalaya. The result has been that cement plants have been located in these states, despite markets not being in proximity, or favorably placed, in relation to location of the plant. Total decontrol on price and distribution of cement was introduced by the Government in March 1989, and all subsidies relating to freight equalization were withdrawn. Consequently the cost incurred on cement transportation has now become an important factor for deciding on the location of the cement plant.

North Zone is a deficit zone and deficiency in the states of north zone (i.e. Punjab, Haryana, Chandigarh, Delhi, Himachal Pradesh) is met by supply from Rajasthan. A large quantity of cement is being fed into these deficit states, and considerable expenditure being incurred on freight. Around 4 MTPA cement gets transported to deficit area of north zone from surplus states.

The demand for northern states like Punjab, Jammu Kashmir, Chandigarh, Haryana, Himachal Pradesh, and Delhi will be met from the proposed plant in Himachal Pradesh. Due to this, there will be reduction in transportation and as a result there will be significant reduction in pollution. Thereby the installation of cement plant in the Rauri village of Himachal Pradesh would be in the interest of the nation as well as for the states of North Zone. It would also increase the prospects of direct and indirect job opportunities for the residents of nearby villages and Himachal Pradesh. The project will improve the quality of life of people living in and around Darlaghat and Kashlog as well of the entire state of Himachal Pradesh. 7


1.5

Compliance with CREP Recommendations CREP RECOMMENDATION

COMPLIANCE

1

Cement Plants, which are not complying* with notified The proposed clinker unit is standards, shall do the following to meet the meeting the emission limit of 50 standards: • Augmentation of existing Air Pollution mg/Nm3 from all sources. Control Devices — by July 2003 • Replacement of existing Air Pollution Control Devices — by July 2004

2

Cement Plants located in critically polluted or urban The proposed clinker unit is areas (including 5 km distance outside urban meeting the emission limit of 50 boundary) will meet 100 mg/Nm3 limit of particulate mg/Nm3 from all sources. matter by December 2004 and continue working to reduce the emission of particulate matter to 50 mg/Nm3.

3

The new cement kilns to be accorded NOC / The proposed clinker unit is Environmental Clearance w.e.f. 01.04.2003 will meet meeting the emission limit of 50 the limit of 50 mg/Nm3 for particulate matter mg/Nm3 from all sources. emissions.

4

CPCB will evolve load based standards by December ACL will comply with the proposed 2003. load based standards

5

CPCB and NCBM will evolve SO2 and NOx emission ACL will comply with the proposed standards by June 2004. standards

6

The Cement industries will control fugitive emissions from all the raw material and products storage and transfer points by December 2003. However, the feasibility for the control of fugitive emissions from limestone and coal storage areas will be decided by the National Task Force (NTF). The NTF shall submit its recommendations within three months.

7

CPCB, NCBM, BIS and Oil refineries will jointly ACL will comply with the proposed prepare the policy on use of petroleum coke as fuel in policy cement kiln by July 2003.

8

After performance evaluation of various types of continuous monitoring equipment and feed back from the industries and equipment manufacturers, NTF will decide feasible unit operations/sections for installation of continuous monitoring equipment. The industry will install the continuous monitoring systems (CMS) by December 2003.

ACL has provided elaborate fugitive dust emission control systems in its plant. Details are described in chapter 2 and 7 of the EIA Report

ACL proposed continuous monitoring system in major stacks. Details are given in EIA report, Chapter 6.

8


9

Trippings in kiln ESP to be minimized by July 2003 as ACL will comply per the recommendation of NTF.

10

Industries will submit the target date to enhance the ACL has designed its Kiln to use / utilization of waste material by April 2003. fire hazardous wastes having adequate calorific value along with coal. Two type of burners has been considered for fuel injection into the kiln

11

NCBM will carry out a study on hazardous waste As above utilization in cement kiln by December 2003.

12

Cement industries will carry out feasibility study and ACL is exploring the feasibility of submit target dates to CPCB for co-generation of co- generating power from its power by July 2003. plant

1.6

Scope of EIA Study

The environmental impact assessment study has been carried out as per the Terms of Reference (TOR) communicated by Ministry of Environment & Forests vide letter dated 12-03-2009. Copy of TOR letter and point-wise compliance with the TOR conditions is provided in Appendix 1.

9


ru ng Ta

Changar Dhooru

Biog

SULI

KASHLOG

Pati

ur asp Bil

Manlog Bhagal PF

Panalog

Bodag Gamaru Rauri

Chakau

Naniwala

Sarsnun

MANGU

Sangal Dhor

Dehti

88 NH- Darla Majer

MATIAN KALAN

Palani Ghati

SCALE:

0

Koti 300 600 900 1200 1500

Figure 1.1

Sameli

Saguad Nal Shimla

Badog

Malaun

Mangu

Chalyan Kotla

Sulaa Badog Hanuman

Banjani

Chola Gyanu

Dabotan

Dori

Dhar

PATI Rotaha

Belt Conveyor

Juh

Kiarty Chandi

Kotla Phagwand

Kalata

Banli Kashlog

RAURI Auhar

Mation kalan

Samara

Jablu

N

Sirali

Kalewar

ad Kh

Kanswala

Damras

BARIAL P.F Karara Suken

Satoti Koti

Patharagal Ladi

Sharla

Bombira Kun Seri - Plant Area Karajyara

- Mining Lease Area

Locations of Plant Site and Mine

10


Figure 1.2

Map showing the cement plant, limestone mines, Majhathal and Piplughat Sanctuary along with the distance

11


Fig. 1.3

Google Map Showing Features Around 10 Km Area of Mines and Plant

12


CHAPTER 2 - PROJECT DESCRIPTION 2.1

Project Profile

Limestone Mining: Ambuja Cement Limited has obtained Environmental Clearance from Ministry of Environment and Forest for extraction of 5.5 MTPA limestone and shale. The requirement of limestone and shale for 5.2 MTPA clinker production (2.6 MTPA at Suli and 2.6 MTPA at Rauri) is 7.6 MTPA. Exploration results of Kashlog mines have estimated the total mining reserves of 224.5 MT of limestone and 24.94 MT of shale for about 32 years in the 488.06 hectares mining lease area. The additional 2.1 MTPA limestone and shale (1.84 MTPA limestone and 0.26 MTPA shale) would be extracted from the existing mining lease area.

Clinkerization Unit: The clinkerization plant at Rauri is oprating for production of 1.8 MTPA clinker, which would be increased to 2.6 MTPA. The plant of 2.6 MTPA is found to be techno-economically feasible. Similar size units are also easy to operate and maintain. Therefore, ACL decided to enhance the clinkerisation capacity from approved 1.8 MTPA to 2.6 MTPA. The expansion will be done within the land area of 23.35 ha.

2.2

Type of Project

2.2.1

Mining

The maximum and minimum elevations of the mining lease area are 1740 m and 1240 m above Mean Sea Level. The existing ML area is 488.06 ha. The expansion is related to additional mining capacity within this 488.06 ML area. 121.49 ha land is agriculture land, 226.95 ha is wasteland and balance 139.62 ha is forest-land. Forest clearance for 139.62 ha has been obtained. Thickness of limestone varies from 20 to 100 m in the deposit area. Block wise mineable reserves are as follows; Western Block upto 1250 MSL, Central Block upto 1350 MSL and Eastern Block upto 1340 MSL. The mine is being operated by open cast bench slicing method. Excavations are being carried out by gradual slicing off from the top of mineralized hill. 13


2.2.2

Clinkerization Unit

In order to ascertain the economic viability and type of plant, the qualitative assessment of the limestone (surface samples and samples collected from the geological exploration) were carried. The weighted average analysis of the various areas yielded the following results, and this is representative of the quality of limestone. Serial No. 1 2 3 4 5

Constituents SiO2 Al2O3 Fe2O3 CaO MgO

Kashlog Mines (%) 7.73 – 10.23 1.32 – 2.06 0.78 – 0.88 46.56 - 48.79 0.52 – 0.97

The CaO content in the range of 46 to 51 % is suitable for dry process. A suitable raw mix design can be obtained by blending limestone, shale and iron ore / oxides approximately in the following proportions: 1. 2. 3. 4.

Limestone Shale Iron Ore/Oxides Red Ochre

-

96.8% 1.0% 1.6% 0.6%

The ratio of raw mix to clinker production shall be 1.48:1. The quality of limestone available is suitable for manufacturing clinker, by dry process, using a suspension Preheater and a Pre-calciner. Coal is added as fuel for calcimation.

2.3

Need of Project

Statistics of the data collected with respect to the production of the cement for the last 10 years reveals that there is sharp increase in production because of development of various

infrastructure

facilities

including

demand

of

houses,

road

network,

industrialization etc. The cement production in India for the 2005 was 136.67 MT against the consumption of 131.06 MT. This was an increase of 8.46% cement consumption over the previous year. The cement production in the financial year 2007-08 was 168.31 MT which has increased to 181.35 MT in the year 2008-2009 against the installed capacity of over 200 MT. Further, the installed capacity is likely to be around 241 MT by 14


the financial year 2010-11. Even though the rapid increase of the production of the cement, still the northern zone is cement deficient and the shortage of cement production is met by the other zones. About 4 MTPA of cement needs to be transported to deficit area of north zone from surplus states. The proposed plant has enough market within the distance 300 kms in view of the growing demand in Himachal Pradesh, Punjab, Haryana and Delhi. The plant shall ease the requirement of the supply of the cement apart from the easement of traffic congestion due to movement of trucks from the longer distances as well as significant reduction in air pollution. Therefore it is at most necessary to install the cement plant at Rauri village near the limestone deposits.

2.4

Layout Maps

The layout map of the clinker project is shown in Figure 2.1. The surface layout map of mines is shown in Figure 2.2. Land use of mining lease area is given in Figure 2.3.

2.5

Size & Magnitude of Operation

Mining: Expansion of limestone and shale mining from the existing 5.5 MTPA to 7.6 MTPA for its two cement plants at Suli and Rauri in the existing mining lease area i.e. 488.06 ha. The survey has revealed that the total minerable reserves of 224.5 MT of limestone and 24.94 MT of shale for about 32 years. Expected cost of the project is Rs. 89.50 Crores. About 110 people will be employed during operation of the mines.

Clinkerization Unit: Civil construction of clinker unit at Rauri is under progress covering land area of 23.35 ha. No additional land will be acquired for the proposed expansion. Expected cost of the project is Rs.976 Crores. About 344 people will be employed during operation of project at the plant.

15


Figure 2.1 Layout Map (Clinkerization Unit) 16


Figure 2.2 Surface Layout (Mine Area) 17


Figure 2.3 Land use Map of Mining Lease Area

18


2.6 Schedule for Approval & Implementation

MOEF has already approved the TOR for EIA vide letter dated 12.03.09 and the draft EIA is hereby placed for Public Consultation. After public hearing final EIA report will be prepared by incorporating and considering the views and comments expressed during the hearing.

The total implementation period for the project is about 12 months. The mines development will be planned and executed independent of the cement plant so that by the time the plant is ready for commissioning the required quantity of limestone and shale would be available to the plant.

2.7 Mining Process

2.7.1

Background Information

The Mining Plan of Kashlog limestone mine was approved by Indian Bureau of Mines, Dehradun (U.P) vide their letter no.614(2)/76-ddn dated 12.04.93. “Modifications in Mining Plan” were approved vide letter no 614(2)/MP-A-2/96-MCCM (N) DDN dated 5.3.98. First Scheme of Mining for the period 1 April 1999 to 31 March 2004 was approved vide letter no. 614(2)/MS-A-69/99-DDN dated 14-10-1999. The second Scheme of Mining for the period 1 April 2004 to 31 March 2009 was approved vide letter no. 614(2)/MSA-139/2003-DDN dated 21-06-2004. The third Scheme of Mining for the period 1 April 2009 to 31 March 2014 was approved vide letter no. 614(2)/MPA182/2009-DD dated 20-04-2009.

The Kashlog Limestone Mine mainly comprises three blocks viz. Western (Kashlog), Eastern (Mangu) and Central (Pati). The Western Block is characterized by limestone in the hanging wall side and shale occurs in the foot wall area besides volcanic trap rock. Shale also occurs in the northern sub-block of Western Block as separate band along with some minor limestone intercalations besides some shale occurs in the central portion of the Western Block as minor bands. The Eastern Block comprises mainly 4 19


limestone bands separated by shale formation. The bands have been numbered from hanging wall towards foot wall side.

The topography is rugged and the elevations in the area vary between 1250 to 1739 MRLs, the highest point being situated in the Eastern Block. The hillocks are barren or comprise euphorbia plants at majority of places. Some of the patches are characterized by Chill plantation. The intervening lower horizons are inhabited in the form of small villages or hamlets at some locations. The hillocks are characterized by seasonal nallahs which receive some flow during rainy period and are dry during rest of the time. The valley portions outside the lease area have a few springs which emerge in the weak planes. Overall, the area is characterized by dendritic to sub-dendritic drainage pattern.

The indicated reserves of cement grade limestone in existing ML area are over 224.5 million tonnes. The limestone is black to blueish grey and hard, with a medium to fine crystalline matrix. The appearance is thickly bedded to platy. Occasionally, few centimeter thick intercalations of shale are sometimes encountered. The thickness of limestone varies from 20 m to 100 m in the deposit area.

2.7.2

Mining Plan

The limestone of the lease area is hard and is characterized by fine grained matrix. Limestone comprises fine to coarse grained calcite veins. Shale occurs between limestone bands in the area besides forming foot wall in Western and Eastern Blocks. The strata are traversed by numerous joints and fractures. Detailed exploration has been carried out in all the Blocks and it is in progress in the Eastern Block. The deposit has been adequately explored and further exploration is in progress to prepare a block model for the deposit. It is anticipated that exploration shall be completed during next five years period by 2014. The mineral production from Eastern Block would commence from third year of proposed scheme of mining. During first and second years, developmental activities

20


would be continued. About 4.5 km long haul road would be constructed and two benches would be opened up.

As on 01-4-2009, Western Block is having residual mineable reserves of 76.57 million tonnes while the Eastern and Central Blocks have mineable reserves of 95.95 and 48.74 million tonnes respectively. Hence, as per current estimates, a total of 221.26 million tonnes of mineable reserves of limestone are available in the lease. As per the present expansion plan of the company, the available reserves would last for next 32 years of company's requirement subject to renewal of existing lease conditions. Lease is due for renewal in the year 2012.

Table 2.1: Conceptual Plan of Limestone & Shale Production* (In Million Tonnes) Eastern Block Central Block Total Lime Lime Shale Bench MRL Shale Bench MRL stone stone Tonnage 2009-14 2.67 1730-1650 7.92 0.88 35.51 2014-19 1.9 1650-1590 17.1 1.9 38 2019-24 1.9 1590-1540 17.1 1.9 38 2024-29 1.9 1540-1490 17.1 1.9 38 2029-34 .1 1490-1440 17.1 3.7 1560-1440 15.87 38 2034-39 1440-1370 17.1 3.8 1440-1390 17.1 38 2039-41 1370-1340 2.53 2.01 1390-1350 15.77 20.31 76.57 8.47 95.95 16.09 48.74 245.82 *Based On Likely Mineable Reserves (as per Mine Plan, beginning 2009) Year

Western Block Lime Bench MRL stone 1480-1270 24.04 1410-1260 17.1 1380-1250 17.1 1350-1250 17.1 1260-1250 1.23

Hence a total of 221.26 million tonnes of limestone and 24.56 million tonnes of shale would be raised by the end of the deposit life (Year: 2040-41). As stated earlier, the mine is being worked by adopting conventional open cast mining by drilling and blasting. The ultimate pit of Western, Eastern and Central Blocks would extend to coordinates W100-E800 / N500-S1100, E1500-E3300 / S1000-S2200 and E1000E1900 / N400-S100 respectively and will be mined up to 1250 MRL, 1340 MRL and 1350 MRL respectively. The dimensions of ultimate pit of Western, Eastern and Central Blocks would be approximately 1450m X 550m, 1200m X 1500m and 850m X 450m respectively. This is as per present envisaged plan and may change with time as the mining progresses. The bench height will not be more than 10 m and benches would be 21


regularly dressed to prevent overhangs or undercuts. The slope stability investigations for the mine were carried out by Indian Bureau of Mines, Nagpur and as per the suggestions, ultimate bench slope would be 450. Further studies are being conducted by CMRI, Dhanbad. Haul roads will not have gradient more than 1 in 16.

The Western Block has been fully developed and the regular planned production from this Block shall be @ 3.8 MTPA of limestone and shale except during four years of proposed scheme when enhanced levels shall be mined from this block. Details of the mining plan of western block for the next five year (2009-2014) are shown in Figure 2.15 to 2.29 attached at the end of this chapter. Similarly, the Eastern Block will be fully developed during fifth year (2013-14) of Scheme of Mining period and the planned production is @ 3.8 MTPA of limestone and shale. Details of the mining plan of Eastern block for the next five year (2009-2014) is given in Appendix 3. This comprises 3.42 MTPA of limestone and 0.38 MTPA of shale from an individual Block. Hence, the Kashlog Limestone Mine has been designed to produce a total of 6.84 MTPA of limestone and 0.76 MTPA of shale from two blocks. The above raw materials will be used for cement production at existing and proposed (Suli/Rauri) Darlaghat units having capacities of 2.6 MTPA each.

2.7.3

Mining Methodology

The limestone of the lease area is hard and is characterized by fine to occasionally medium grains material. The strata are traversed by numerous joints and fractures. Due to the differential erosion limestone horizon stands out prominently while the shale occurs in the topographic depressions. The shale formation is also occurring between limestone bands in the ML area. The mine is being operated by opencast bench slicing method.

Excavations are being carried out by gradual slicing off from the top of

mineralized hill. The operations comprise pre production development stage and the production stage. During the pre production stage haul roads are laid and the faces are developed and made ready for raising limestone. Western Block which was earlier divided in three sub-blocks is today being worked in two sub-blocks since central and

22


southern sub-blocks have been merged. ACL has an approved Mining Scheme by IBM and the salient features are as given below: Working Benches: Height:10 Metres Width: Minimum 25 meters or 3 times of the width of working equipment when bench is in operation and 10 Meters at the time of finalization. Slope: 700 - 900 Primary Blast Holes: Size - 150 mm, Depth -11.0 m, Angle-900 ANFO based slurry explosive will be used along with other accessories. About 2500 kg/day Ammonium Nitrate & Bulk emulsion shall be used.

2.7.4

Mining Plan Details

The mining would be undertaken by the open cast mining method in the Western and Eastern Blocks during next five years period. Details of proposed mine development in the two Blocks are discussed below.

The predevelopment plan, development plan and post development plan is shown in Figures 2.4, 2.5 and 2.6. 2.7.4.1

Western (Kashlog) Block

Haul road and bench development work would be undertaken between section line S100 and N 400 in the northern sub-block and S1000 and S100 in the southern sub-block. The part of existing road to Kashlog village passing through the northern sub-block would also be shifted. Apart from this some minor changes would be made to haul roads passing through both the sub-blocks and benches 1320 to 1270 MRL would be opened up. The lower benches up to 1270 MRL would be connected with the new road which has been built up to Crusher.

23


Figure 2.4

Pre Operational Landuse Plan 24


Figure 2.5

Operational Landuse Plan 25


Figure 2.6

Post Operational Landuse Plan 26


Further, a road will also be made to connect office area to 1320 MRL which will serve the purpose of approach road once the existing road from office to 1400 MRL comes under mining. All the roads are designed based on geo-technical parameters, shape of the ore body and size of the equipment plying in the mines. Approach roads to the working faces have been planned with an aim to minimize traffic congestion and the number of spots that slow down the traffic flow. The main haul road and arterial roads approaching the faces would continue to be 8 - 10 m wide. In general, the width of the haul roads would always be kept more than three times the width of the largest machine plying in the mines and nowhere the width would be less than the height of the bench. In general, the roads would be prepared maintaining a gradient not steeper than 1 in 16 except for ramps, where a maximum of 1 in 10 gradients would be observed. All corners and bends in roads would be made in such a way that the operators and drivers of vehicles have clear view for a distance of not less than 30 meters along the road. Any road existing above the level of the surrounding area would be provided with strong parapet walls made of stones or concrete structures depending on the location and suitability. It would be around 1 meter wide and not less than 1 meter in height to prevent any vehicle from getting off the road. Road signs would continue to be placed at strategic locations to provide guidance to drivers. Adequate drainage would be provided towards hill side along the roads to prevent accumulation of water and erosion from runoff water. Roads would be given 10 slopes towards drainage to avoid accumulation of water.

Presently, all the mined material is supplied to plant while in future there is likelihood of formation of some sub-grade dumps characterized by shale and sub-grade limestone. Part of such material will be used for construction of haul roads in the mine. Dumps would be made from top down by end tipping method in the areas which are stable and provide a stable foundation. Provision of garland drains all around the dump base would be made. A retaining rock wall, not less than 1 meter wide and about 1.5 to 2 meter in height, all along the toe of the dump would be constructed to arrest the washed fines and rolling boulders. The top of dump as well as slope surface would be vegetated by hydro-seeding technique or use of pre-seeded geo-textile mats, if so required for stability. This would prevent erosion as well as dust generation. The individual dump 27


terrace slope will be around 35o equal to angle of repose of the material while the overall ultimate slope of dumps will not exceed 28o.

Top soil, wherever encountered will be temporarily stacked in separate stock for plantation. The year wise details of proposed development are given in Table 2.2. Table 2.2: Details of Proposed Yearwise Development Works-Western Block Year I(2009-10) I(2009-10)

Location Development Details S10o -N30o / E80o-E100o Preparation of road to Kashlog village S80o -S60o / W30o -W10o Preparation of haul roads up to 1300 MRL in Southern portion and alteration of existing haul roads within the working area, construction of retaining and parapet walls. II(2010-11) S80o -S70o / W10o -0o Preparation of ramp /haul road to 1290 mrl bench and alteration of existing haul roads within the working area, construction of retaining and parapet walls. III(2011-12) S95o -S0o / W10o-E80o Face development at 1280 mrl bench and preparation of ramp /haul road to 1290 mrl bench and preparation of approach road from office to 1320 mrl bench, construction of retaining and parapet walls. IV(2012-13) S95o -N30o / W10o -E80o Preparation / alteration of ramp / haul road to 1270 mrl bench and alteration of existing haul roads within the working area, construction of retaining and parapet walls . V(2013-14) 0o -N30o / E20o -E85o Face development at 1410 mrl bench and construction of 2 check dams / filters and alteration of existing haul roads within the working area, construction of retaining and parapet walls.

2.7.4.2

Eastern (Mangu) Block

New crusher will be installed in the footwall area of the Eastern Block in the region E1470/S1220. Further a new overland belt conveyor (OLBC) shall be installed by 2011 from proposed new crusher to existing crusher in the Western Block and from Western Block to the Suli/Rauri site. A new road of about 4.5 kms length would be constructed from existing Karara-Kashlog road to top of the hill via proposed crusher near Chola village. The 2 kms long road from top of the hill to proposed crusher would serve the purpose of the haul road. This road would have connectivity of feeding roads from 1730 to 1690 MRL benches during the initial development period of first two years. Further, 1730 MRL bench would be chopped off and face would be developed at 1720. About 28


50000 tonnes of limestone obtained during developmental works would be kept at two stocks/dumps over 1720 and 1710 MRLs. Developmental work would also be undertaken over 1700 MRL bench in the eastern direction and it would be kept ready for exploitation. Further, faces from 1720 to 1690 MRL benches would be ready by the end of second year of development. Drains would be prepared towards hill side along haul road to avoid accumulation of water. Roads would be given 10 slope towards drainage to avoid accumulation of water. Benches would be given 10 slope away from the faces towards road drainage. Further, check dams and check filters would be constructed over seasonal nallahs on the virgin slopes. A separate area west of proposed limestone workings (E18-E20 / S12-S15) has been earmarked for shale mining for third and fourth year of production. The proposed haul road to crusher would be linked to this area during second year. Apart from this, site office, dormitory, HSD pump and workshop would also be constructed near to proposed crusher during first two years. In general, the roads would be prepared maintaining a gradient not steeper than 1 in 16 except for ramps, where the maximum gradient would be 1 in 10. Appropriate bunding / toe walls would be made towards valley side of the roads and plantation would be resorted to. The stockpiled quantity of 50,000 tonnes of development period would be used for trial runs of crusher and will be sent to the plant from third year onwards. Top soil, wherever encountered will be temporarily stacked as separate stock for plantation near proposed plantation areas. Year wise details of proposed development are given in Table 2.3

.

Table 2.3: Details of Proposed Yearwise Development Works-Eastern Block Year I(2009-10)

Location Development details S150o -S85o / Preparation of road from Karara-Kashlog road to proposed crusher E107.5o -E225o site II(2010-11) S165o -S105o / E175o Preparation of haul road from crusher site to 1730 , 1720 , 1700 mrl -E255o levels, face and working space development at 1730 , 1720 , 1700 mrls for production and creation of 50,000 tonnes limestone stock. Preparation of approach road to shale mining area. Construction of 4 check dams III(2011-12) S145o -S115o / E200o Preparation of haul road up to 1690 mrl level , face development at -E255o 1690 mrl and construction of 4 check dams / filters o IV(2012-13) S150 -S115o / E190o Preparation of haul road / ramp up to 1680, 1670, 1660 MRL -E265o benches. face development at 1680 to 1660 mrl benches and construction of 5 check dams / filters V(2013-14) S150o -S107.5o / Preparation of haul road / ramp up to 1650 mrl bench. face development at 1650 mrl bench and construction of 6 check dams / E175o -E265o filters 29


Year-wise production proposed for the next five years: The present capacity of the Suli Cement unit is 2.6 MTPA clinkerisation. The Rauri unit is envisaged to produce about 0.9 million tonnes of clinker during first year of scheme period and therefore, the total plant capacity considered for first year is 3.5 million tonnes of clinker while for second to fifth years period is @ 5.2 MTPA. Accordingly, the total raw material requirement from the captive mine for the two units would be 7.6 MTPA from second year onwards.

Limestone is characterized by a Lime Saturation Factor (LSF) varying between 80 and 150 and sometimes even higher while shale and shaly limestone has LSF from 3 to 80. The general requirement of LSF from the mine is around 108 - 110. Therefore, limestone around 88 to 90% and shale /shaly limestone in the range of 10 to 12% is regularly blended at mine face and material is dispatched to crusher for onwards conveying to stockpile in the cement plant. Considering above blending pattern, the production levels as per the Table 2.4 have been planned for the next five years period. Table 2.4: Planned Production for Next Five Years (In Million Tonnes) Year

I II III IV V Total

Western(Kashlog) Block Limestone 4.60 6.84 5.04 4.14 3.42 24.04

Shale 0.51 0.76 0.56 0.46 0.38 2.67

Eastern(Mangu) Block Limestone 0.00 0.00 1.80 2.70 3.42 7.92

Shale 0.00 0.00 0.20 0.30 0.38 0.88

Total Total Shale Limestone 4.60 6.84 6.84 6.84 6.84 31.96

0.51 0.76 0.76 0.76 0.76 3.55

It has been planned to raise 90% of total limestone production by controlled blasting and 10% through primary rock breaking in the Western Block. Similarly, it is envisaged to raise 70% of total limestone production by controlled blasting and 30% through primary rock breaking in the Eastern Block. Preliminary studies are also underway for considering utilization of Hydraulic Cutting Head as an attachment for hydraulic excavator and to use Terrain Leveler for limestone raising in the peripheral areas of the lease. The entire planned shale would directly be raised by an excavator.

30


Considering 300 mine working days in a year, the planned maximum production is 12000 TPD from a Block once the Eastern Block is fully developed. Hence, a maximum of 10800 TPD of Limestone and 1200 TPD of Shale from an individual Block and 21600 TPD of Limestone and 2400 TPD of Shale from the entire lease would be raised during next five years period. However, during second year entire production would be achieved from Kashlog Block. The bench-wise details of proposed production from the two areas are described below: Western (Kashlog) Block (Details of next 5 year plan) First Year: As discussed above, a total of 5.11 million tonnes of limestone and shale would be raised during the year. The planned limestone and shale production would comprise a tonnage of 46 and 5.1 lakhs respectively. Limestone and shale would be raised both from northern and southern sub-blocks. In the northern block , benches namely 1470 , 1460 and 1430 MRL would be worked apart from some shale workings over 1480 MRL bench. The face alignment for the benches would be initially E-W with advancement in the NE direction and it would gradually change to N-S with advancement in the eastern direction. Similarly, in the southern sub-block, the face alignment for the benches would be E-W while the advancement in the north and south directions. Mainly benches from 1380 to 1300 MRL benches would be operated in the southern sub-block. Total of 49.70 ha area would have been opened by the end of first year. 1.58 ha reclaimed area as per suggestions would be worked and 3.48 ha area would have been reclaimed and used for afforestation purposes by the end of the year. It has been envisaged to raise 90% of the limestone production through controlled blasting while 10% would be raised through primary breaker.

Second Year: As discussed earlier, a total of 7.6 million tonnes of limestone and shale would be raised during the year. The planned limestone and shale production would comprise a tonnage of 68.4 and 7.6 lakhs respectively. Limestone would be raised both from northern and southern sub-blocks while shale would be mainly produced from northern sub-block occurring in-between two limestone bands. In the northern block benches namely 1450, 1420 and 1410 would be worked apart from some shale workings over 1470 MRL bench. The face alignment for the benches would be initially E-W with 31


advancement in the NE direction and it would gradually change to N-S with advancement in the eastern direction. Similarly, in the southern sub-block, the face alignment for the benches would be E-W while the advancement in the north in south directions. Mainly 1370 to 1290 MRL benches would be operated in the southern subblock. Total of 56.27 ha area would have been opened by the end of second year. 1.71 ha reclaimed area would be worked and 2.70 ha area would have been reclaimed and used for afforestation purposes by the end of the year. It has been envisaged to raise 90% of the limestone production through controlled blasting while 10% would be raised through primary breaker.

Third Year: As discussed earlier, a total of 5.6 million tonnes of limestone and shale would be raised during the year. The planned limestone and shale production would comprise a tonnage of 50.4 and 5.6 lakhs respectively. Limestone would be raised both from northern and southern sub-blocks while shale would be mainly produced from northern sub-block occurring in-between two limestone bands. In the northern sub-block benches namely 1450 and 1440 would be worked apart from some shale working over 1460 MRL bench. The face alignment for the benches would be initially E-W with advancement in the NE direction and it would gradually change to N-S with advancement in the eastern direction. Similarly, in the southern sub-block, the face alignment for the benches would be E-W while the advancement in the north and south directions. Mainly 1360 to 1280 MRL benches would be operated in the southern subblock. Total of 60.01 ha area would have been opened up and 3.41 ha area would have been reclaimed and used for afforestation purposes by the end of third year. It has been envisaged to raise 90% of the limestone production through controlled blasting while 10% would be raised through primary breaker.

Fourth Year: A total of 4.4 million tonnes of limestone and shale would be raised during the year. The planned limestone and shale production would comprise a tonnage of 39.6 and 4.6 lakhs respectively. In the northern sub-block benches namely 1440 to 1420 would be worked apart from some shale working over 1460 MRL bench. The face alignment for the benches would be initially E-W with advancement in the NE direction and it would gradually change to N-S with advancement in the eastern direction. 32


Similarly, in the southern sub-block, the face alignment for the benches would be E-W while the advancement in the north and south directions. Mainly 1340, 1300 and 1280 MRL benches would be operated in the southern sub-block. Total of 61.16 ha area would have been opened up and 4.56 ha area would have been reclaimed and used for afforestation purposes by the end of fourth year. As being practiced, it has been envisaged to raise 90% of the limestone production through controlled blasting while 10% would be raised through primary breaker. Fifth Year: A total of 3.8 million tonnes of limestone and shale would be raised during the year. The planned limestone and shale production would comprise a tonnage of 34.2 and 3.8 lakhs respectively. The limestone production would be achieved from 1420 to 1410 MRL benches in the northern portion and 1290 to 1270 MRL benches in southern portion apart from some shale production over 1460 MRL bench .

The face

advancement of benches would be from north to north-east to eastern direction. Total of 63.78 ha area would have been opened up and 5.34 ha area would have been reclaimed and used for afforestation purposes by the end of fifth year. As being practiced, it has been envisaged to raise 90% of the limestone production through controlled blasting while 10% would be raised through primary breaker. Eastern (Mangu) Block: (Details of next 5 year plan) First & Second Year: As discussed above, no production would be undertaken during first two years in this block. The 50000 tonnes of material raised during the developmental activities would be kept in two dumps over 1720 to 1700 MRL benches and would be sent to crusher during third year. 4.8 ha area would be opened up for development of infra-structural facilities like haul road, crusher, office, workshop etc. and 0.7 ha will be opened up for development of initial benches.190 tonnes of top soil would be generated and would be stocked on temporary basis for vegetation in the lease and surrounding areas. A total of 5.5 ha area would have been opened during developmental works. Third Year : The limestone production would be achieved from 1720 to 1690 MRL benches at two locations over Band-1 and Band-2. Band-1 developed over 1690 MRL 33


bench would produce 0.54 lakh tonnes of limestone while Band-2 developed from 1720 to 1690 MRL benches would produce about 17.46 lakh tonnes of limestone. The intercalated shale area between two limestone bands would provide .32 lakh tonnes of shale while 1.68 lakh tonnes of shale would be raised from 1670 to 1630 MRL benches of separate shale mining area. A total of 18 lakh tonnes of limestone and 2 lakh tonnes of shale would be sent to crusher during the year. This will comprise .50 lakh tonnes of limestone obtained during developmental activities from 1730 and 1720 MRL benches and stocked during first two years. 70 % of the limestone would be raised by controlled blasting while 30% would be raised through breaker. Entire shale would be directly raised by an excavator. 758 tonnes of top soil would be generated and would be stocked on temporary basis for vegetation in the lease and surrounding areas. A total of 12.3 ha area would have been opened up by the end of third year. Fourth Year: The limestone production would be achieved from 1690 to 1660 MRL benches at two locations over Band-1 and Band-2. Band-1 developed from over 1680 to 1660 MRL benches would produce 11.58 lakh tonnes of limestone while Band-2 developed from 1690 to 1680 MRL benches would produce about 15.42 lakh tonnes of limestone. The intercalated shale area between two limestone Bands would provide .96 lakh tonnes of shale while 2.04 lakh tonnes of shale would be raised from 1630 to 1620 MRL benches of separate shale mining area. A total of 27 lakh tonnes of limestone and 3 lakh tonnes of shale would be raised during the year. 70% of the limestone would be raised by controlled blasting while 30% would be raised through breaker .Entire shale would be directly raised by an excavator. 1086 tonnes of top soil would be generated and would be stocked on temporary basis for vegetation in the lease and surrounding areas. A total of 19.9 ha area would have been opened up by the end of fourth year.

Fifth Year: The limestone production would be achieved from 1680 to 1650 MRL benches at two locations over Band-1 and Band-2. Band-1 developed from over 1660 to 1650 MRL benches would produce 5.27 lakh tonnes of limestone while Band-2 developed from 1680 to 1650 MRL benches would produce about 28.93 lakh tonnes of limestone. The intercalated shale area between two limestone bands would provide 2.92 lakh tonnes of shale while .88 lakh tonnes of shale would be raised from 1660 MRL 34


bench developed in foot-wall area of Band-2. A total of 34.2 lakh tonnes of limestone and 3.8 lakh tonnes of shale would be raised during the year. 70% of the limestone would be raised by controlled blasting while 30% would be raised through breaker or hydraulic cutting head. Entire shale would be directly raised by an excavator. A total of 26.2 ha area would have been opened up by the end of fifth year. Table 2.5: Co-Ordinates of Proposed Workings – Eastern Block Year I&II

III

IV

V

2.7.5

Bench (MRL) 1730 1720 1700 1720 1710 1700 1690 1670 TO 1630 1690 1680 1670 1660 1630 1620 1680 1670 1660 1650

Northing(x100m) S14-S12.8 S14-S12.5 S13.3-S12.8 S14-S12.5 S14.2-S12.4 S14.6-S12 S14.2-S11.7 S14.8-S12.5 S14.8-S12.8 S14.6-S11.3 S13.5-S11.4 S14-S11.8 S14.8-S12.5 S14.8-S12.5 S14.8-S13.6 S15.6-S11.3 S15.8-S12 SS14.2-S10.7

Easting(x100m) E19.7-E20.6 E19.6-E21.6 E24-E25.2 E19.6-E21.6 E19.5-E21.7 E19.3-E22 E20-E25.6 E18-20 E19-E21.6 E19.2-E26 E22.2-E26.2 E23.2-E26.3 E18-20 E18-20 E18.7-E20.3 E17.8-E22.5 E17.8-E26.4 E20.8-E25.7

Drilling & Blasting

Drilling in the present mines is fully related to the production requirement. There is 1 No. of Hydraulic drill machine & these can drill holes up to 36 meters vertically of 150 mm diameter. Blasting operations are carried out in a controlled manner to minimize fly rock generation for safety of civil structures, machines and nearby habitation and agricultural fields. Due care is taken to keep the ground vibrations and air blast levels to the lowest possible limits to avoid any adverse impacts on the surrounding environment.

The

blasting parameters like spacing, burden, depth, sub-grade, charge per hole, delay pattern, firing pattern etc. have been established as per the guidance and advice from concerned experts of Universities/Research Institutes viz. IBM , CMRI , etc .The operations are carried out under the supervision of Assistant Manager (Mines), well 35


versed with technique to ensure quality and safety in the work. The non electric shock tube initiating system like EXEL & Noiseless Trunkline Delay (NTD) and Ikon (Digital Electronic System) are regularly used for safety and to reduce noise levels. In this system of blasting, the detonating cord in the hole is replaced with a non electric/electronic detonator. During firing of the blast, the explosive charge

is

initiated at the bottom of the hole and this ensures that most of the explosive energy is used in actually breaking the rock, thus reducing the fly rock considerably. In NONEL system, on the surface of the hole, the delay between different holes is provided by non electric connectors ensuring correct firing as per the blast design. The process reduces the maximum instantaneous charge per delay which finally reduces the vibration levels.

ground

The 10m deep blast hole comprises bottom, column charge and

stemming zone. The common distribution ratio is 0.4% booster and 99.6% column charge (ANFO) having a stemming column of 4 to 5 meters.

The i-kon™ Digital Energy Control System consists of two way programmable digital Detonators and control equipment (i-kon™ Logger and Blaster). The Logger is used during hook-up to assign the delay sequence and perform testing functions. The Logger reads and stores the unique Detonator Identification Number (DetID) and required delay time. The Blaster is used to conduct final system tests, blast programming and firing.

i-kon™ Detonators are fully programmable and have on board digital timing circuits and energy storage enabling them to function independently once the fire signal has been sent. Lead wires of ikon detonator end in an easy to use hinged connector. A connecting harness consists of twin twist copper wire used to hookup the Detonators using hinged connectors. The harness is connected to a Logger to enable delay assignment and testing during hookup.

As each Detonator is connected, the i-kon™ Logger checks Detonator functionality, reads the DetID and then writes along with the delay time to its memory. The user is able to edit the assigned delay times stored in the Logger upon review of the delay list. 200 Detonators can be logged to a single Logger in delay increments of 1 millisecond (ms)

36


from 0 to 15000 ms. Any delay can be assigned to any detonator, regardless of order on harness.

Once hook-up is complete, or at any time during logging, the system may be fully tested by using the Logger test menu. This causes the Logger to communicate with every detonator individually and determine its’ status. If errors are detected the Logger will display these in a meaningful way along with comprehenside help information. Current leakage is continuously monitored during logging and can be measured using the ‘Measure Leakage’ facility. To fire the blast, the Logger is placed at a safe position from the blast and connected to the Blaster via a firing line. The Blaster communicates with the Detonators via the Loggers. Blasters are protected by a digital key to prevent use by unauthorized personnel. i-kon™ Blasters are available in two sizes. Blaster 400 can fire 400 Detonators on 2 Loggers and Blaster 1600 can fire 1600 Detonators on 8 Loggers.

The i-kon™ Digital Energy Control System complies with the principle of ‘Inherent Safety’. This means the i-kon™ Logger, used at the blast hole, is unable to fire Detonators even if the Logger develops faults. This is ensured because Loggers are unable to produce more than 5 volts r.m.s and the proven, tested No-Fire voltage of every Detonator is above 10.5 volts. In addition, the Logger does not contain any circuitry or programming capable of generating program, arm and fire signals. i-kon™ Detonators have protection structures in the electronic circuitry, which give a high level of protection against stray currents, over-voltage, static and electromagnetic radiation.

The i-kon™ Detonator will directly initiate detonator sensitive packaged explosives and Primex™ boosters. The steel lead wire of ikon detonators is extremely robust, however if the insulation is cut or split, moisture may cause earth leakage problems causing testing and communication errors with the i-kon™ System. Excessive force should not be applied to the lead wires.

Main advantages of electronic detonators: There are three main characteristics of electronic detonators which make them different from pyrotechnic delay detonators: 37


a. Accuracy b. Programmability c. Testability

Fly rock is controlled by constant monitoring with Minimate (Seismograph) through study of the peak particle velocity at different distances in all the three axes. The blast pattern and charging is modified accordingly. The saw dust up to 10-12% by weight is mixed with ANFO to reduce the bulk density of column. This helps to reduce consumption of ANFO as well as ground vibration levels.

A well-trained crew under the direct supervision of a Blasting Engineer is carried out in day-to-day blasting operations. Commonly used boosters are powergel-boost of M/s ICI and emul-boost of M/s IDL. Each cartridge weighs 125gms. Except in adverse weather conditions and hole condition prilled ANFO explosives is used as column charge in noncartridge form. The non-electric shock tube initiating system viz. EXEL & NTD (NoiselessTrunkline Delay) are in regular use. It has resulted in maintaining the highest safety standard and simultaneously decreases the noise level and ground vibrations. We have three Nos. MINIMATE Model DS-567 for use of monitoring ground vibration and air blast. These instruments are imported from INSTANTEL, Canada. Based on the results from records of these instruments further modification in blasting parameters is being done from time to time. Secondary blasting in the mines has been totally eliminated by the use of Hydraulic Rock Breaker.

The present 25 tonnes capacity magazine is sufficient to supply the explosive sand even for new enhanced capacity of 2.6 Million Tonne. During the course of mining in the peripheral areas to avoid rolling of limestone boulders towards the slope and also to adopt safe mine practices, the introduction of primary rock breaker with backhoe combination has been enormously successful. Today, about 10% of material is disintegrated by this method. The rock breaker is able to break the limestone continuously and at the same time backhoe enables removal of broken material by pulling up towards the benches. The raised material is loaded into dumpers through a wheel loader or excavator. The inner / central portions of the sub-blocks are being 38


worked adopting controlled blasting techniques. Further, secondary blasting was completely eliminated by using hydraulic rock breaker (Fig 2.6) for primary breaking at critical places in the mine like peripheral edges. Hydraulic Cutting Head as an attachment for hydraulic excavator is used. This practically eliminates noise generated through rock breakers and is very helpful for edge removal Studies are underway for utilization of Terrain Leveler for limestone raising specially in the peripheral areas for further restricting blasting. The process helps in avoiding

the common problems of

fly rock and noise associated with the secondary blasting. All the mined material is supplied to plant. No waste rock occurs in between the limestone which may require formation of dumps. Top soil is manually collected and stacked in the soil yard and later used for afforestation purpose.

Figure 2.7: Hydraulic Rock Breaker 39


2.7.6

Transportation of Limestone and Shale

The transportation of material from the working area to the crusher is undertaken by 50 tons capacity dumpers. The existing capacity of OLBC is 900 TPH. For 2009 and 2010 the existing OLBC is upgraded to 1200 TPH. Limestone to Rauri plant for first 2 years will be fed from Kashlog block by working three shifts. Temporarily a crusher is being installed, near the existing crusher. A crusher will be installed at Mangu block to meet the requirement of the plant at Rauri. The bigger boulders are crushed to smaller boulders of size ranges 50mm-70mm. The crushed material is proposed to be conveyed to the plant via Kashlog block by an Over Land Belt Conveyor (OLBC) system. The OLBC from Mangu to present crusher and another OLBC Line-II from present Crusher to new plant site is proposed.

2.7.7

Mining Equipment

It is envisaged to produce 85% limestone production through drilling and blasting and 15% by deploying Hydraulic Rock Breakers mounted on PC-650/PC-1250 machine for primary breaking. In this context, earlier during the year 2001, HM-2500 primary rock breaker was successfully introduced at the mine while HB-5800 primary breaker was introduced in 2007. The Hydraulic Rock Breaker is mainly utilized in peripheral areas of the mine to avoid rolling down of material down the slope along with backhoe combination. The same technique would be continued during the coming years. As per the ongoing practice, benches of 10m height will continue to be adopted for the two Blocks considering safety and productivity of the machines. Adequate bench width (minimum 30 m) and working space for easy machine movement would be maintained. Bench \ Face slope during working time would be 80 degrees to vertical while when the benches are leftover during closure stage , it will range between 35 to 50 degree in the Western Block and 35 to 70 degrees in the Eastern Block . Overall, pit slope would be below 45 degrees in the two Blocks.

The haul roads would be prepared maintaining a gradient not steeper than 1 in 16 except for ramps, where the maximum gradient would be 1 in 10. Appropriate bunding / 40


toe / parapet walls would be made towards valley side of the roads and plantation would be undertaken. It is proposed to procure HB-7000 hammer mounted on PC-1250 excavator for removal of edges and primary breaking. It will give an average production of around 150-200 tonnes per hour. Hence one number of Breaker mounted on PC-1250 machine has been considered for eastern block. One no. hydraulic cutting drum (EARKAT Cutter) ER5500 which can be mounted on PC1250 is also proposed for edge working. The Hydraulic Cutting Head is a complimentary tool to close the gap between excavator and breaker/ripper. This equipment would help to further reduce limestone production through drilling and blasting. Proposed Dozer and Rock Breaker mounted on PC-200 excavator would be used for developmental works and secondary boulder breaking.

Figure 2.8 : Working of Backhoe and Dumper Terrain Levelers: Preliminary studies are also underway for considering utilization of Terrain Leveler for limestone raising specially in the peripheral areas for restricting 41


blasting. Terrain Leveler produces the mineral in one pass without the need for primary crushing. The high end 99.8 tonne weight and 600 HP model can cut an area up to 3.7 meters wide and 69 cm deep in a single pass. The greater penetration is achieved through the use of rotary power headshaft motor and a splined headshaft employing a top-down cutting system. It also eliminates the need of large loaders and dumpers. The material generated through this machine can be transported through standard tippers. If successful, this equipment may help to further reduce limestone production through drilling and blasting.

Table 2.6

List of Mining Equipment

Machine

Specification

Capacity

No. of Machines 01

Performance

PC-650-3 Excavator (BEML make)

410

4.5m3

400 TPH

B-35 Rear dump truck (BEML make)

455

35 tons

100 TPH

07

150 TPH

01

30 TPH

01

100 TPH

01

D-355 ripper Dozer (BEML) PC-220-3, Hydraulic rock breaker(HM960) PC-650-3 Hydraulic backhoe-cumbreaker (HM-2500) EX-600-V(Tata Hitachi),Rock Breaker(HB-5800) PC600-LC,KOMATSU Excavator PC-1250-7,KOMATSU Excavator HD-465-7,KOMATSU Dumper ROC L8,Drill M/C Motor Grader, Volvo, G710B Vibratory Soil Compactor,L&T,1107D

3

410

15m 160 bar pressure 180 bar pressure

148 410 370

4.0 m3

120 TPH

01

384 651 715

4.0m3 6.5m3 50T

300 TPH 600 TPH 190 TPH

01 01 04

450

-

30 MT/H

01

179

-

-

01

112

-

-

01

Table 2.7 List of Miscellaneous Mining Equipment Machine Specification / Capacity

No. of Machines

Water Sprinkler

10 KL

1

HSD Tanker

12 KL

1

Maintenance Van

-

1

Ambulance Van

-

1

Service Van & Jeep

-

2

Explosive Van

-

1

14T

1

Crane

42


Table 2.8 List of Proposed Additional Mining Equipment (Expansion) Machine

Specification

PC-1250-7,KOMATSU 651 Excavator HD-465-7,KOMATSU 715 Dumper Motor Grader, Volvo, 179 G710B Vibratory Soil 112 Compactor,L&T,1107D HD275A Dozer ROC L8,Drill M/C 450 Hydraulic Cutting Drum Dia.-910 mm Drum(Eraket ER 5500) Drum Width-1600mm PC-200-3, Hydraulic rock breaker(HB 1700) PC-1250,With HB-7000 Rock Breaker

Capacity

Performance

No. of Machines

6.5m3

600 TPH

02

50T

160 TPH

06

-

-

01

-

-

01

-

30MTH

01 01

-

-

01

50 TPH

01

150 TPH

01

Table 2.9 List of Additional Miscellaneous Equipment - Expansion Machine Specification / Capacity No. of Machines Water Sprinkler HSD Tanker Maintenance Van Ambulance Van Service Van Jeep Explosive Van Crane

2.7.8

10 KL 12 KL -

14T

1 1 1 1 1 2 1 1

Water for Limestone Mines Expansion

The water demand for the existing plant, staff colony and mines is met through common water system. Total water demand for the existing Suli Plant and existing Limestone mines is 1200 KLD. Permission to draw 1200 KLD of water from Pazeena Kund is available with ACL (obtained from Irrigation and Public Health Department, Government of Himachal Pradesh). The water demand of existing mines is 100 KLD, for drinking and dust suppression purpose. Additional 50 KLD water will be required during the expansion of mines for dust suppression purpose. This water will be met from the rainwater storage reservoir developed inside the ML area. 43


2.7.9

Power Supply

At the mines office and workshop, required electrical power has been drawn from power line of State Electricity Board. The power line has been extended from plant area for the Western Block. This line would also be further extended to meet the demand of Eastern Block. Power supply of additional 1 MW for the expansion shall be arranged from State Electricity Board. DG Set of 500 KVA will be used in case of power failure. 2.7.10

Employment

The detail of available manpower is as follows. 1. Highly skilled (Mines Manager, Maintenance Managers: Asst Managers / Engineers) 2. Skilled (Operator, Mechanics, Clerks) : 3. Un-skilled (Helpers / Mazdoors) :

24 62 24

Additional 110 manpower will be deployed for working the Eastern Block during expansion.

2.7.11

Infrastructure

Mines Office: A permanent office for the mines staff and a dormitory has been constructed in the Western Block. First aid station, canteen, drinking water and W.C. facilities, rest shelter have also been provided near existing crusher besides some facilities in the operating area. Similar facilities other than dormitory will also be created in the proposed new office in the Eastern Block. Restroom for truck and dumper drivers shall be provided at the ground floor of mines office.

Workshop: A full fledged workshop and store has been constructed near mines office in the Western Block besides creating the facility of a mobile maintenance van. A workshop on a relatively smaller scale has been envisaged near the proposed crusher in the Eastern Block. All the required tool and tackles would be provided to attend routine maintenance / break down jobs. Essential spares for repair works will be housed in a separate room within the workshop and these spares will be supplied from the existing 44


centralized store located in the Western Block. The existing centralized stores at Darlaghat and Western Block will maintain the inventory and supply necessary spares to the workshop in the Eastern Block. An additional mobile maintenance van has also been envisaged for the Eastern Block.

Training Centre: A Vocational Training Centre (as per statutory requirements) is functioning at the main mines office located in the Western Block, wherein workers are imparted basic and refresher training with necessary training aids etc. The workers of the Eastern Block would also be imparted training at this Centre.

Diesel Supply: High speed diesel for HEMM is supplied deploying a diesel tanker from the Pump located near Mines office in Western Block. An additional HSD Tanker would be utilized for supplying fuel to the machinery of Eastern Block. For night working purpose, mobile light towers have also been put to use besides fixed installations. Similar pattern has been envisaged for the Eastern Block to ensure proper lighting.

2.8 Description of Mitigation Measures - Mining

2.8.1

Movement of HEMM on Haul Road

The movement of traffic on haul roads would be the cause of fugitive air emissions. In order to control the fugitive emissions, water sprinklers shall be provided so that the ambient air quality shall remain under the norms specified under pollution control laws. Base data for ambient air quality have been collected and discussed in the separate chapter. Furthermore, the ambient air quality shall be monitored regularly as per the monitoring plan provided in another chapter. Mining activity is already under progress for the cement plant (at village Suli) in the western block of the mining lease area for which water sprinklers have been provided.

2.8.2

Drilling of Holes for Blasting

Drilling is carried out by deploying 150 mm dia. drill (Atlas Copco ROC L8) equipped with in-built arrangement of water sprinkling for dust suppression and separate dust 45


extraction system and this arrangement makes operations practically dust free. The use of explosives for blasting is restricted to limestone only. Shale is soft and weathered and thus it is excavated directly by excavator or backhoe.

Figure 2.9 - 150 mm Drill Machine

Figure 2.10 - 150 mm dia. Hole for Blasting

46


2.8.3

Blasting

Blasting process involves slackening of big blocks of rocks/ore from the mines. This operation generates maximum dust, which results in the increase of SPM concentration. It also contributes to emissions of certain gases (Oxides of Nitrogen and Ammonia) due to the use of explosives like ANFO and Nitroglycerin.

The size of the dust particles emitted into the atmosphere plays a major role in deciding the distance to which they may be transported. Particles of larger size fall fairly rapidly and closer to their source, because of gravitational settling. However, the aerosols because of their small size may be held in suspension for years in the atmosphere and may be transported on a global scale. Eventually, these smaller particles are collected in raindrops and fall on Earth. The composition of these particles largely depends on the composition of the ore being processed.

The continuous ambient air quality monitoring of the area reveals that the smaller particles are also within the prescribed limits. Blasting operations are carried out in a controlled manner to minimize fly rock generation for safety of civil structures, machines and nearby habitation and agricultural fields. Due care is taken to keep the ground vibrations and air blast levels to the lowest possible limits to avoid any adverse impacts on the surrounding environment, as per the advice from concerned experts of Universities/Research Institutes viz. IBM , CMRI , etc. The non electric shock tube initiating system like EXEL & Noiseless Trunkline Delay (NTD) and Ikon (Digital Electronic System) are regularly used for safety and to reduce noise levels.

Fly rock is controlled by constant monitoring with Minimate (Seismograph) through study of the peak particle velocity at different distances in all the three axes. The blast pattern and charging is modified accordingly. The saw dust up to 10-12% by weight is mixed with ANFO to reduce the bulk density of column. This helps to reduce consumption of ANFO as well as ground vibration levels.

47


2.8.4 Crushing

The crusher house will be completely enclosed. To arrest the particulate matters generated from the existing limestone crushing plant, baghouse has been provided. Similarly, the emissions shall be channelized (from crushers, screens and transfer points) and a well designed baghouse shall be provided. Water sprinkling arrangement (fixed type with sensor) will be provided at the dumper unloading hopper of the crusher.

2.8.5 Over Land Belt Conveyor (OLBC)

The limestone produced is transported within the mining area for crushing using dumpers and thereafter the same is transported using OLBC from mining area to cement plant. A new crusher shall be installed in the foot wall area of the Easter Block (by 2011) and further a new parallel OLBC shall be installed from new crusher to the existing crusher in the Western Block by 2011. The OLBC will eliminate the use dumpers to transport the mined material to cement plant.

To mitigate the fugitive air emissions, the existing OLBC is fully covered and there is no scope has been left for particles to be air born. The new OLBC shall be covered in the similar manner to protect the area from the air emissions.

2.8.6

Noise

About 100-120 (at approximately 25 m distance from source) dB(A) noise is generated during the blasting but the exposure is not continuous. Ear plugs shall be provided to workers. Noise level from the machinery ranges between 90dB(A) to 100dB(A) (1 m away from source) and this also does not give continuous exposure to workers. About 90 – 95 dB(A) noise is generated from the crushing plant. 8 hours exposure at 90 dB(A) is allowed. Noise level shall be monitored regularly as done for the present mining activity including regular monitoring of vibrations.

48


2.8.7

Solid Waste

The mining method shall not generate any overburden, sandstone, rocks, debris, etc Shale shall be used in the cement making. Top soil shall be excavated and properly used for greenbelt development (given in Table 4.7, Chapter 4). Used batteries will be given back to dealer during the purchase of new batteries under byback arrangement. Domestic garbage will be segregated. Recyclable materials will be sold to kabadis. Organic matter will be composted and used as manure.

2.8.8

Wastewater

No waste water is generated from the mining process except domestic effluent from the site which is sent to septic tanks and spent oil and lubricants from workshop. Oil water separator tank will be constructed in workshop premises. Used oil, spent oil and lubricants will be collected and disposed off to the authorized vendors.

2.8.9 •

Safe Mine Practices

Retaining toe walls and check dams are constructed to restrict rolling of boulders towards the slope areas. Check dams / filters are also constructed to control the surface runoff water carrying silt during monsoon season.

•

Secondary blasting has been replaced by the introduction of primary rock breaker with backhoe combination. This has also been found successful for mining of Shale and at the loose edges. About 15% limestone/ shale is excavated by using rock breaker with backhoe combination. All the mined material is supplied to plant. The top soil is manually collected and temporarily stacked in the soil yard and used for afforestation purposes.

•

Considerable quantity of blasting explosives are saved due to this in addition to reduction of emissions which otherwise bound to be generated by virtue of blasting 49


Figure 2.11 – Rock Breaker

Figure 2.12 - Backhoe for Excavation of Limestone 50


•

Every effort is and would be made to maintain scenic beauty of the surroundings. A planned restoration of area surrounding the mines is being taken up and implemented and would continue the same in future.

•

Bench slopes were dressed using backhoe, dozer and rock breaker and a gentle gradient of about 25 to 30 degrees is maintained. Slope stabilization works in the form of physical and biological reclamation of mined slopes are also done.

•

The area comes under the seismic zone V and highly vulnerable to earthquakes. Every step has been/ shall be taken for the existing mining area while designing the site office, check dams for rollover boulders, slope protection by geo jute cover technology for the protection. Slopes are also protected from soil erosion. Figure-2.10 shows benches in mining area.

Figure-2.13 - Benches of Mining Area and Haul Road 51


•

The mine lease area is not affected by the surrounding catchment basin as it is located on the hilly terrain and on the contrary, it discharges the rainwater into its peripheral valleys.

•

About 225 ha area would be available for reclamation and rehabilitation at the end of the deposit life Part of land shall be converted to natural jungles, water bodies, plantation etc.

•

Road gradient shall not be steeper than 1:16.

•

Drains shall be laid along the haul road towards hill side to avoid accumulation of water and damage to haul roads.

•

Check dam / check filters shall be provided over seasonal nallahs.

•

Variety of species shall be used for enhancement of survival rate of the plants. Top soil shall be stacked and utilized for plantation.

•

No aquifer exists in the mining lease area. Ground water level is below 1200 m MRL.

Therefore, no interception of groundwater will occur while undergoing

mining of minerals. •

Large sized buckets shall be used to reduce the fugitive emissions during loading of limestone in dumpers.

52


2.9

Clinkerisation Process

The dry process comprises short rotary kiln with a cyclone pre-heater and a pre-calciner. 6 Stage Preheater will be used to save on fuel consumption. Vertical mill for grinding raw materials and vertical mill for grinding coal has been considered. The process flow diagram of clinker making is shown in Figure 2.14.

Dry process plants with 6-stage preheaters have a specific fuel consumption of 700-730 kcal/kg of clinker. The pyroprocessing section requires approximately 20-25 unit /ton of clinker. The specific power consumption is given below: Serial No.

Section

Kwh/T Clinker

1

Crushing and Conveying of raw materials

4.0

2

Raw material grinding

21.0

3

Coal grinding

2.5

4

Pyroprocessing

20.0

5

Miscellaneous

2.5

6

Sub-Total

50.0

7

Colony lighting and Bulk Loading

2.0

Total

52.0

The plant will be designed to incorporate the latest in technology and machinery to obtain optimum results with the minimum input costs in terms of energy, manpower, and with minimum environmental pollution. The plant will be sized for a rated capacity of 8400 tonnes per day, or 2.6 Million Tonnes per annum (MTPA) capacity of clinker.

The major equipments of the plant e.g. Raw Mill, Kiln, Coal Mill, Cooler have margin in the capacity to produce 8400 TPD clinker. Precalciner, Preheater Fans, T.A. Duct with design margin and little enhancement shall be able to support 8400 TPD of clinker. i. ii. iii. iv. v. vi.

Rated Capacity of Clinker (i.e. 2.6 Million Tonnes per annum) Design Margin Conversion ratio raw meal/clinker Quality of coal Specific fuel consumption Specific power consumption

: 8400 TPD : 10% :1:1.48 : 4500-5000 kcal/kg : 710 kcal/kg clinker : 52 KWH per Ton of clinker 53


Storage of Raw Materials: Clinker will be stored in closed clinker silo / stock pile, gypsum will be stored in covered shed, coal will be stored in covered sheds and water will be sprayed surface. Design of Raw Mix: Stipulations regarding the various moduli required for Quality & Process Control (QPC) will be maintained. In the calcinations process, almost all the coal ash is absorbed in the clinker. Therefore, the lower the specific fuel consumption, lower will be the ash absorption. For dry process kilns with 6 stage preheater and pre calciner, the specific fuel consumption would be around 710 Kcal/Kg. The calorific value of coal from the South Eastern Coal Fields, from where coal will be brought, can be taken as 4500 Kcal/Kg. and ash content around 28-30%. On this basis, ash absorbed in clinker would be about 4 - 5%. The raw mix composition would be adjusted to allow for this absorption of ash.

Corrective Materials: The geological investigation shows that shale found in the area surrounding the deposit is suitable as the correcting material and is being used presently. Approximately 1% of shale and 1.6% of iron oxide (mill scales) and 0.6% Red Ochre is needed to be added to obtain a suitable raw mix.

Composition of Raw Mix: A typical chemical analysis of the raw mix is given below: Al2O3

LOI

SiO2

35.30

13.40 2.75

Fe2O3 CaO 2.40

MgO

43.55 1.00

Na2O

K2O

LSF

SM

AM

0.10

0.70

103

2.60

1.15

Additives like shale and iron ore would need to be added to the limestone to prepare a raw mix of suitable composition, for making clinker. Shale of suitable quality is available in the Mines. The preliminary raw mix design would comprise of the following: Lime Stone Shale Iron Ore Red Ochre

: : : :

96.8% 1.0% 1.6% 0.6%

54


Transport of Raw Coal, Clinker and Additives: Raw Coal will be transported from South Eastern Coal Mines to Ropar by rail and from Ropar to Rauri by road. Clinker will be transported to ACL’s various grinding units by road. Iron oxide will be transported from Ropar and Red-ochre from Rajasthan by road.

Material Handling Inside the Plant & Mines: The layout has been designed to achieve energy conservation. The systems requiring high-energy consumption such as Pneumatic Pumps are avoided wherever possible.

Mechanized material handling

systems, like belt conveyors, elevators, airsides etc., will be used to the maximum. Brief description of the major machinery units is given in the following paragraphs.

1. Raw Mill: It is proposed to install a vertical roller mill for grinding limestone to a fineness of 2% residue on 212 µ. Considering the moisture in the limestone and the properties of limestone, this type of mill will be the most suitable. It is also energy efficient. A roller mill is simple in installation and operation. The Company has adequate operational experience of operating the vertical roller mills, and has found them to be very dependable. The hot gas for drying raw materials in the roller mill will be drawn from the preheater exhaust gases.

Dust Collector for Kiln and Raw Mill: It is proposed to install a Pulse Jet Bag filter as common dust collector for the raw mill & kiln system. In normal operation, the exhaust gases from the kiln and preheater will be taken into the bag house via the raw mill. When the raw mill is not working, the kiln exhaust gases will go directly to the bag filter.

2. Blending System: It is proposed to install a continuous blending system consisting of on 22,800 T capacity storage silo. The continuous blending system will be integrated with the kiln feed system, so that a continuously metered raw meal could be fed to the kiln at the desired rate. The emphasis will be on maintaining the accuracy both in terms of quality and the rate of feed.

3. A. Pyroprocessing Section: It is proposed to install a 6-stage preheater with precalciner for obtaining maximum fuel economy. The latest design of preheater with a 55


minimum pressure drop will be installed to save energy. The preheater fan will have a variable speed drive. The fans used will have efficiencies higher than 80%, to conserve energy. The precalciner will be of a design suitable for firing high ash coal with low calorific value.

Adequate attention will be paid to retention time and the degree of

calculation achieved. Normally, 60% of the fuel will be fired in the precalciner. The kiln will have three supports and will have seals of the latest designs, for ensuring fuel efficiency. The kiln drive will be a variable speed motor. The kiln will be designed in such manner that hazardous or non hazardous wastes with some calorific value could be used long with coal. The clinker cooler will be a latest generation grate cooler designed to cool clinker to a temperature at which it can be handled conveniently. The cooler will be designed to achieve maximum heat recuperation. The exhaust gases would be vented through an Electro-static precipitator, to restrict the dust emission.

3. B. Coprocessing of Hazardous Wastes in Kiln: Coprocessing of hazardous waste will be provided in the kiln. Coprocessing refers to use of waste materials (alternate fuel and raw materials - AFR) in kiln to recover energy and material. Due to high temperature and long residence time in cement kilns, all type of wastes are effectively disposed without any harmful effects. ACL is an associate company of Hoilcim, which has endorsed the global AFR policy. Continous emission monitoring system, waste specific feeding arrangement and waste processing platforms at different locations has been considered as sub-unit to this facility. ACL have successfully installed co-processing facility like using ETP sludge and cream wastes of Colgate-Palmolive Ltd, using food grade gelatin waste of Ranbaxy Laboratories.

4. Crushing, Storing and Feeding into Coal Mill: Coal will be received by rail, in rake loads, at the railhead at Ropar. It will be transported in trucks to the plant site. It is proposed to have a 21 days stock in the plant. In the plant, coal received in trucks will be crushed and stacked in a stockpile with pre blending facilities, with the help of existing coal stacker/reclaimer system. Pre blending is considered necessary for coal also, to minimize the fluctuations in the quality of coal, and thereby to feed the kiln with coal of a uniform quality, to maintain optimum operating conditions.

56


5. Coal Mill: It is proposed to install a vertical coal mill for supplying pulverized coal to kiln and precalciner. Inert hot preheater gases shall be utilized to dry wet coal during grinding from initial moisture of 10-12% to final moisture of 1 to 2%.The dust collector in the mill system will be designed to have explosion flaps to safeguard against any possible explosions/ built up pressures. Provision will also be kept for extinguishing fires if they occur. Two silos will be provided to store pulverized coal. A coal firing system with metering facilities for coal will be installed for firing coal in the kiln and in the precalciner. A standby will be provided in the coal conveying system. 6. Clinker Transport: It is proposed to transport clinker by deep pan conveyor to a clinker storage silo of adequate capacity with proper extraction facility. 7. Clinker Bulk Loading: It is proposed to install 6 nos. truck bulk loaders of 250 tph capacity each, for bulk transportation of clinker to grinding units.

The process flow chart of clinker making, showing location of various units and stacks is shown in Figure 2.14.

Performance Norms: The project has been designed so as to ensure that the performance norms mentioned below are achieved: Energy consumption Fuel Efficiency Environmental Control

: 52 kwh/t clinker : 710 kcal/kg clinker : below 50mg/Nm3 in clean air dust emission

Electrical & Automation Systems i).

Receiving power by extra high voltage (EHV) transmission from the State Electricity Board.

ii).

Distributing this power to the various sections of the plant for numerous drives of machinery with metering system.

iii).

Standby captive DG Power.

iv).

Electrical Drives & their control gear, Energy conservation measuring.

v).

Earthing & Lightening protection and lighting systems.

vi).

Automation & Instrumentation.

vii).

Instrumentation & Controls.

viii).

Telecommunication. 57


Figure 2.14 Process Flow Chart of Clinker Making, Showing Location of Various Units and Stacks 58


2.9.1

Water for Cement Plant

The water demand for the existing plant, staff colony and mines is met through common water system. Total water demand for the existing Suli Plant and existing Limestone mines is 1200 KLD. Permission to draw 1200 KLD of water from Pazeena Kund is available with ACL (obtained from Irrigation and Public Health Department, Government of Himachal Pradesh). The water demand of Rauri Plant (considering the existing and expansion activities) is 500 KLD. This water will be met from the groundwater, for which necessary approval from Ground Water Authority and permission from Local Body has been obtained.

2.9.2

Power Requirement:

The requirement will be 30 MW with a contract demand of 24 MVA. It will be taken from state grid. Two new transformers of 28 / 32 MVA, 220 /6.6 KV will be installed in the switchyard at Rauri Project site. 4 x 6 MW DG sets will be installed to meet the power requirement during emergency. Lighting: All the plant buildings and roads inside the plants have been considered for provision of lighting. The level of illumination has been kept as per BIS standards. The fixtures have been selected to avoid scatter and glare. Sensors have been considered for automatic ighting. It has been considered that lighting does not affect the ecology. Earthing: All the equipment shall be provided with Earthing & Lightening protection, entirely in conformity with Indian Electricity Rules, IS 304 & IS 2309

2.9.3

Automation & Instrumentation:

Automation and Instrumentation have been considered to protect the equipment to control the process variables and to provide safety to the working personnel. The automation system shall also help to achieve process optimization and shall carry out technical audit, besides helping to produce consistently well guilty of clinker. The equipment shall be modular in concept to permit system enhancement without any

59


difficulty. It shall also be provided with self-diagnostic facilities, to reduce the incidence of forced outage and increase plant availability. The automation system is divided into: a) b) c) 2.9.4

Sequence Control of drives Measuring of closed loop control Data logging and information processing and retrieval Instrumentation and Control:

Electronic Weighing Raw Material Composition Control: Analysis by X-Ray spectrometer. Pyroprocessing: Sensors for temperature, pressure, draughts and gas analysis. CCTV to give the operator inside view of the kiln.

2.9.5

Civil Structures

For the purpose of seismic design of plant structures, the considerations will generally be as per ISI: 893-1975. The proposed plant site lies in Seismic Zone-V. As the proposed plant site is on a moderately level terrain, leveling & grading of the area would be required to be done to some extent and has been allowed for in the estimates. The plinth level of various structures would generally be kept at about 200mm above the surrounding ground level to prevent surface water from entering the operational areas. There could be terracing of the plant sections according to the natural slopes available and the feasibility from the point of view of material handling.

Roads: Paved roads inside the plant shall be made as shown in the proposed layout. New exit road shall be provided for trucks to move out of the plant and meet the State Highway – 88. The exist traffic will avoid Darlaghat town and crossing.

Sewerage: Toilet blocks within the plant area provided as per the functional requirements shall be connected to septic tanks and soak pits. Presently about 150 KLD of water is received form the colony, which is treated in the Sewage Water Reclamation Plant (SWRP) of 250 KLD capacity. Due to expansion in plant and colony about 50-100 KLD of sewage is expected. The existing SWRP is adequate to take care of additional 60


load. All the sewage lines shall be of stoneware/cast iron pipes and shall be laid at adequate slopes for attaining self-cleaning velocities.

Structures in the Plant & Non-Plant Building: The design and construction of plant structures have to primarily meet the load data conditions and the functional requirement of various equipment. Due care will be taken of maintenance, erection requirements and storage facilities. The buildings and structures, housing heavy equipment and subjected to heavy shock loads, will be designed in RCC framed construction.

The use of

structural steel shall be limited to walkways of tall structures, such as Preheater Towers, grinding mills where flexibility for stage wise construction is involved. GI corrugated sheets shall do the cladding for all buildings or brick/rubble masonry wall as may be dictated by the functional requirements.

Non-plants structures like administrative

building, canteen, laboratory, engineering office, workshop, will be designed and constructed as per standard norms.

Residential Colony: It is proposed to expand the existing residential colony to meet the additional housing requirement of the staff.

2.9.6

Manpower

Total manpower requirement is 344, as per following break-up. - Management Grade Employees : 117 - Wage Board Employees : 121 - Casual Labour : 106 Casual labour mentioned above shall be deployed for carrying out the activities of unloading coal, iron ore etc. from trucks. On an average around 2000 to 2500 work force of skilled and unskilled men are required during the construction of the plant. . 2.9.7

Pollution Mitigation Measures

1. Air Pollution Control: Following systems will be installed.

61


S. No.

Location

Air Pollution Control System

01

Stockpiles

Covered. Water sprinkling network

02

Raw Mill Hoppers

Bag Filter

03

Raw mill & Kiln system

Glass Bag House

04

Blending Silo / Kiln feed

Bag Filter

05

Clinker Cooler

ESP

06

Clinker Storage

Bag Filter

07

Coal Mill System

Bag House

08

Truck Bulk Loading Machines

Bag Filter

09

Transfer Points

Bag Filter

All the units have been designed to satisfy the following World Bank Standard as suggested in the Pollution Prevention and Abatement Handbook (Effective July 1998)

Pollutant

Emission Standard

Particulate Matter (In stack gases under full-load conditions) Nitrogen oxides

50 mg/Nm3

2.9.7.1

600 mg/Nm3

Fugitive Dust Emission Control Measures: •

• • • • •

Designing the production system so as to generate minimum dust and arrest the dust at its source (bag house with suction and ducting system proposed at transfer points, silos, clinker storage, truck loading machine (bulk), raw mill hoppers and blending siols. Minimizing the number of material transfer points and maintaining optimum height of fall of materials. Providing high efficiency pulsejet bag filters at material transfer points including mill feed hoppers. Covering the belt conveyors including walkways. Providing concrete roads inside the plant. Regular cleaning of plant work areas and road using vacuum cleaners. Greenery and greenbelt development inside plant premises.

In addition to above water spraying through permanently mounted water sprinklers for the suppression of fugitive dust during raw material unloading / handling sections will be done. Stockpiles will be kept under covered shed. The dust emission from stockpiles viz. crushed raw material stock pile (viz. limestone, ore, etc) shall be controlled by providing water spray system. For control of fugitive particulate emissions, ventilation systems 62


should be used in conjunction with hoods and enclosures covering transfer points and conveyors. Drop distances should be minimized by the use of adjustable conveyors.

2.

Water Pollution Control Measures: There will be no waste water generation from

the dry process. Anciliary sources of liquid effluents generation from the plant are as follows: i) ii) iii) iv) i)

Waste water generated from cooling tower blowdown. Waste water generated plant toilets and washrooms Waste water generated from laboratory & workshop Waste water generated in colony Storm water run-off from stockpiles yard

The domestic effluent shall be treated in the existing Sewage Water Reclamation Plant (250 KLD capacity). The reclaimed water from SWRP will be used for gardening. Plant water will be reused for dust suppression. Spent oil and lubricants will be collected in drums and sold to authorized reprocessors. Sedimentation basin with oil trap will be provided in storm water drain. No wastewater will be discharged outside the plant premises.

3. Solid Wastes Management: The dry process doesn’t generate any solid waste. Soiled cotton wastes will be burnt in the kiln. Garbage (80 kg food waste and 130 kg plastic, paper, packaging material, etc) will be collected in containerized system and sorted out for recyclable metrials, inert and biodedradable materials. Recyclable materials will be sold to kabadis. Inert materials will be used as landfill. Organic wastes will be composted.

4. Noise Pollution Control Measures: Noise will be generated from various crushing / grinding of raw materials & coal and also from transporting machineries. Low noise equipment will be procured. All work will be done inside shed. Appropriate noise reduction measures will be provided. Greenbelt and greenery will also attenuate the noise to considerable extent. Regular maintenance of the equipment will help in reducing these noise levels. Further, ear plugs shall be provided to the workers to protect from high noise exposure in the area where noise level exceeds 85 – 90 dB (A).

63


CHAPTER 3 : DESCRIPTION OF THE ENVIRONMENT 3.1

Study Area, Period and Methodology

The study area comprises 10 km area around the Rauri Plant and Kashlog mines. Table 3.1 Components, Study Area, Study Period and Methodology of EIA Environmental Components Meteorology

Monitoring Location Roof top of Guest House; above stack release level.

Monitoring Period

Methodology

Winter Season (1st Dec 2008 – 28th February 2009) & Summer Season (April to June 2011)

Met station was established at colony near plant site. Wind speed and direction, humidity, and temperature were recorded on hourly basis. Long-term historical met data was obtained from IMD.

Ambient Quality

Impacted and non-impacted location due to the air emission from the plant and mines

Winter Season (1st December 2008 –28th February 2009) & Summer Season (April to June 2011)

AAQ monitoring was done at 10 locations by following the CPCB methods. SPM, PM2.5, PM10, SO2 and NO2 levels were determined. Sampling locations were established at site, villages around site at various upwind and downwind directions.

Noise Quality

Locations covering all area category

Winter Season (15th January to 30th January 2009) & Summer Season (10 - 15th May 2011)

Noise level monitoring was done at 10 locations at various area categories using integrated sound level meter. Measurements were taken by following the CPCB procedure.

Surface & groundwater quality

Upstream and downstream of streams and ground water of nearby villages.

Winter Season (25th - 30th January 2009) & Summer Season (20 & 25th May 2011)

Five samples of surface water and 8 samples of ground water were collected nd analysed using standard methods (APHA).

Soil Quality

Agriculture fields

Winter Season 3rd February -2009 & Summer Season (28th May 2011)

Six soil samples were collected and analysed for all relevant parameters by following IARI Methods.

Flora & Fauna

Study area

Secondary data

Data collected from Working Plan and checked during field surveys.

Demography and Socioeconomic

Study area

Secondary data

Data was collected from District Statistics Handbook.

Air

64


3.2

Hydrology

The lesser Himalayan history traces back to the late Pre-Cambrian and early Cambrian All along the low Himalayan belt are found the thick argillaceous formations with some quartzite and lime stones, which may be of marine origin. The recent discovery of stromatolitic horizons in the lower Himalayan sections leads evidence to this inference and also suggests a late Pre-Cambrian to Cambrian age. The geological formations of the study area are belonging to the outer Shimla Himalayan’s stratigraphy. The Shimla group is folded as a broad open synform, which is complimentary to the shale antiform to the east. This synform is a patterned after the folded jutogh cliff lying at the topmost tectonic level and also the inner krol cliff. The Shimla group wraps around the shale antiform in the eastern part after going around the Tattapani antiform and Batwara Synform. The western limb of the synform particularly along the thrust contact where it has ridden over the palaeogene bilt, are tightly folded. This is evident in the Basantpur and the kunihar formations and the folds have north-south fold axis confirming to the Darla antiform, which occupies a pivotal place in the apex part of the major synform. The shali orogeni also results in the formation of several divides within the Great Shali Basin. There is an important north-south polarization due to a main east-west divide separating the present Shale Ramgarh from the largi-Deoban (Shimla Himalayan). The divide is rather narrow between the shale and Deonan. There was also sporadic stromatolite growth, which gave rise to the kunihar formation. Classification of Shimla rocks by Pilgrim and West is as follows: Formation Dagshai series Upper Subathu Unconformity Subathu series Unconformity Karol series Karol sand stone

Litholoigcal Description Purple sandstone and clay Purple sandstone and grits

Age Lower Miocene Upper Oligocene

Shale, limestone, carbonaceous bed and late rite

Middle Eocene

Limestone and red shale Sandstone decomposing to sand 65


Infra-Karol beds Balini limestone (=Mundhalis) Balani Conglomerate Unconformity Shali Shimla series Unconformity Jaunsar series

Unconformity Chail Series

Jutogh series

Shaly slates, with bed and lenticeless of quartzitic grit Pale pink magnesian limestone Lower Gondwana Bounder bed, slates with pebbles

Limestone and slate Dark slate, micaceous sandstone Limestone Sub-schistose, slates, micaceous Slate and phyllite, conglomerate Green and gray quartzite Light grey and brown schistose Slates and quartz-schist, talcosic And quartz-schist, talc schist band, gray slate with interbedded limestone. Igneous rock and olivine dolerite Quartzite and schist, thrusted and Banded carbonaceous dolomite, Carbonaceous phyllite, mica-schist

Position uncertain Lower Paleozoic

Purana

Purana

Archaean

The main geological formation of the study area is as follows: 1

Formation Terraces Alluvium

Age Quaternary

2 3

Shivalik Group Sabathu

Pliocene to middle Miocene Middle Eocene to Upper Oligocene

4

Krol

Triassic

5

Infra Krol

Permian

6

Blaini

Upper Carboniferous

7

Sanjauli, Chhaosa Kunihar

Lower Paleozoic

8

Shali and Jutog

Precambrian

1.

Jutog formation: This formation consists of rocks which are oldest in the area.

These rocks rest on younger formation of Shimla Group. The Jutog formation comprises of highly metamorphosed sediments. The original marine sediments have now been altered into compact quartizite schists and gneisses. Black carbonaceous schists 66


constitute a significant part of this formation. Instrusions of granite are present in the extension of these rocks towards the east. 2.

Shali Formation: These occur as a narrow NNW to SSE trending belt bounded

on both the western and eastern sides by faults. This formation consists mainly of calcareous rocks, limestone and dolomite with minor amount of quartzite, shale and siltstone. 3.

Shimla Groups of Rocks: The Shimla slates occur around Domehar, Shangi,

Pandher and Kamlog. The Sjimla slates are dark coloured, with gray blue tints and are made up to micaceous shales, slates, occasional phyllite sandstone with predominant gray wakes. A number of limestone bands occur in the lower horizone of the Shimla slates series. Another band of massive limestone occurs on the ridge at Arki while yet another overlies sandstone and marl on the Gandhal, Majhatu Baraghat ridge. Different recognized formations of this group, found in the Kunihar Division are as follows: A)

Kunihar Formation: This formation is developed near Subathu through

Kakarhatti and Kunihar up to Bamol. It consists of shale siltstone with alternating bands of limestone. It is characterized by general lack of carbonaceous beds and by the occurrence of limestone inter beds with shale and silt stones showing ripple arks. Some lime stone bands show algal structures showing water, near shore condition of deposition. B)

Chhaosa Formation: This formation is well exposed between Danoghat and

Thalog. Its development can also be seen from near Sabathu. The Chhaosa formations are characterized by a thick rhythmic sequence of well bedded shale, silt stone and greywacke. The shales are grey olive green and purple in colour. Bands of quartizite are also present. 4

Blaini Formation: This formation is one of the most important formations of the

Shimla Himalayas because of its significance in fixing the age of the other formation below and above it. This formation is deposited during upper carbonaceous period when there was wide spread glaciations in this part of the globe. Glacial boulder beds, shale and lime stone constitute the different litho units of this formation. 5.

Infra Krol Formation: This formation present in a small part of the area SE of

Delgi. It comprises grayish black carbonaceous shale and siltstone. The Infra Krol has been intricately folded and faulted and shows great variation in the grade of 67


metamorphism. Admixture of Chil and few broad leaved species occur in these formations. 6.

Krol Formation: This formation consists of sandstones, limestone and shale.

Soft slicken sided and crumpled, red and green shale are found above Baran on the Krol hills. Soft white sandstone and shale occur in nala on the road from Chandi to Badlag. Chil is the main vegetation on this formation. 7

Sabathu Formation: Rocks of this formation are exposed in the neighborhood of

Sabathu and the area towards north east of it as linear outcrops, trending NW to SSE. It consists of olive green splintery sales with grey inter bands of limestone. The main crop of this formation consists of Chil. 8

Shiwalic Groups: These are divided into four different stages as described

below: A)

Kundlu Stage:

The name is after the name of village Kundlu. This stage

forms the lower stage of the Shiwalik exposed in the area. This stage occurs in the anticlinal valleys east of Nalagarh town. B)

Nalagarh Stage: Kundlu stage is overlain by Nalagarh stage which comprises of sandstone largely micaceous and forms major features, running north from Nalagarh town. The top zone of this stage consists of maroon clays and buff sandy clays alternating rhythmically with a few fossil fragments in places.

C)

Sutlaj Stage: it overlies the Nalagarh stage and has exposed sandstones in NW of Riwalsar. The massive beds of sandstone upto 16 meters and more in thickness are interbeded with bright clay bands. The sandstone is gray or of light brown colour forming the topmost horizon of the lower.

D)

Middle Shiwalik: These consist of brown to whitish colour sandstones and bright coloured clays. In the east they are cut by the Gambhar Thrust, which has brought older rocks over them. Their western boundary is also affected by a fault in this area.

9.

Terraces and Alluvial Deposits: These are encountered in Doon portion in the south in Kunihar region and on a limited scale all over the tract as flood-plain traces. The alluvial deposits in Kunihar actually start somewhere in the North of Arki town and occur in the lesser Himalayan zone. 68


Hydrogeology: The Hydrogeology map of Solan District, obtained from HP Government Document is given in Figure 3.1.

Figure 3.1 Hydrogeological Map of Solan District 69


Rainfall starts from the end of June and extends till the middle of September with snow fall in the upper reaches above the elevation of 1700 m AMSL. April, May, June, October and November are the driest months. The average annual rainfall in the area is about 1425 mm. Due to its altitudes the climate varies from mild to cold. The typical geographic location of the study area gives rise to variegated climatic zones. The minimum temperature drops down to 30C during winter and summers the maximum temperature touches 400C. The relative humidity varies from 28% to 92% through out the year. The relative humidity is in the higher range between 80 to 90% during rainy season and during the remaining period of nine months the relative humidity varies from 30 to 50%. The study area falls under Seismic Zone V. The topography of the area is highly undulating terrain traversed by hills of height ranging from 480 m to 2360 m. The minimum and maximum elevation occurs in the north east region of the study area. The elevations are indicative of the nature of undulating terrain in the study area. The central part of the study area though presents an undulating topography does not indicate wide variation in the elevation. The average elevation of the plant site is 1550 m AMSL. The orogeny is young and the formations are being affected severely by the denudational agencies. The multi directional stress has affected the formations resulting in intricate structure. The difference in hardness and composition can be contributed to the fact that the ranges are not of definite pattern and of no definite formational wise ranges. The drainage pattern of the area is dendritic in nature and is traversed by gullies which carry the excess water during the rainy season from the source to the lower portions of the hill ranges. The streams in the lower portion of the study area attain the perennial status discharging the water received from the gullies located on the upper reaches. These dry seasonal nallas join the Gyana khud, which ultimately meets the westerly flowing Dhamla khud. The rivers traversing the study area are said to have formed an antecedent drainage since they were in existence before the formation of Himalayas. As the mountains grew the rivers continued to excavate their valleys thus maintained their pre existing course. The drainage of the study area is controlled by River Sutlej. The tributaries of river Sutlej drain the study area in the NW and North of the plant site. The 70


source of water for the existing and the proposed plant is Pazeena khud (Pagoda Khud), an out fall point from the river Sutlej located in the NE at a distance of about 8 Kms. There are sufficient water sources both for drinking and irrigation. The study area is covered by catchments area of Satluj river. Soil is generally sandy loam and soil depth is generally shallow except in areas having good vegetative cover. It is generally dry, shallow and deficient in organic matter. The study area comprises mostly of alluvial deposits of Quaternary age.

Tropical dry deciduous forests, sub-tropical pine and Himalayan moist temperature forests predominate in the study area. The main minerals extracted are limestone, dolomite and gypsum. Stone cutting is also prevalent in the study area. The topography is represented by steeply rising hills and restricts the mobility to defined routes and tracks only. However, the hill ranges are aligned in general in northwest - southeast direction. The topography of the area indicates that the ground water potential is restricted to lower reaches, which are recharged by the perennial surface water sources. However from the topography of the area it is indicated that the occurrence of ground water is restricted only to the plain. The upper reaches to which most of the villages are confined and do not have any indication of aquifer and also any catchment to recharge the aquifer if at all present. The location of bore wells around plant area may have been springs of the past. The depth to water table in this bore wells is in the range of 15 m to 18 m below ground level. However, in the mining area the morphology and the nature of strata give no indication of possible water bearing horizons and hence any mining will not hamper any water source. Very little quantity of stream water is used for agricultural purpose on the low lying areas along the stream. The villagers use tap water supplied through pipelines laid by State Government for drinking purposes. From the above it can be observed that the occurrence of ground water is restricted only to the plain and lower reaches due to the topography. The highly undulating hilly terrain 71


makes the area highly unsuitable for ground water recharge, as the surface flows are very fast and do not have any retention time for the precipitated water to infiltrate into the ground. Thus the ground water occurrence is highly localized. Similarly due to the steep flows the streams in the upper reaches drain away early in to the streams or rivers in the lower reaches or the plains. The stream in the upper reaches are ephemeral in nature as they flow only during the monsoon season only and the streams in the lower reaches and the plains attain perennial status by deriving water drained from the streams of the upper reaches. Extract from hydrogeological report prepared by R.P. Agrawal (former Regional Director, CGWB) of the study area (Rauri clinkerization plant, Suli cement Plant and Kashlog mine) is attached as Annexure-6.

3.3

Meteorology

The plant is located at 1550 m MSL. Meteorological monitoring station has been established on roof top of Guest House of Staff Colony, which is located at 1665 m MSL. Wind speed, wind direction, ambient temperature and relative humidity values were noted on hourly basis. The wind rose diagram for winter season 2008-09 and summer season 2011 is given in Figure 3.2 and 3.3 respectively.

3.3.1

Meteorological Observations

Wind Direction: The predominant wind direction at site during winter season is from east direction. The second most dominant wind direction is from northeast. During summer 2011 the predominant wind direction is from SEE and SE sector. Wind Speed: The average wind speed at site during the monitoring period is observed to be 13.7 kmph (3.8 m/s). The maximum wind speed was found to be 39.6 kmph (11 m/s). During the monitoring period 7.5% time was calm (