Integrated Project Cement Plant and Limestone Mines

at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

EXECUTIVE SUMMARY

1.0 PROJECT DESCRIPTION

1.1 INTRODUCTION

M/s. Prism Cement Limited (PCL) is a Public Limited company with its registered office at 306,
Laxmi Niwas Apartment Ameerpeth Hyderabad (A.P.). The company was initially incorporated
under the name of Karan Cement Ltd. in March 1992 under the Indian Companies Act, 1956 as a
joint venture between Raheja Group of Mumbai, F.L. Smidth and Co. Denmark and Industrialization
Fund for Developing Countries, Denmark. The name of the company is subsequently changed to
Prism Cement Limited (PCL) in September 1994. M/s. Prism Cement Limited has successfully set
up and commissioned a 2 million tonnes per annum capacity cement plant at village Mankahari,
Tehsil Rampur Baghelan in Satna District of Madhya Pradesh in the year 1997. Subsequently, the
capacity has been increased to 2.5 million tonnes Clinker per annum.
In addition to this, Prism Cement is setting up second Cement Plant of 3.00 MTPA clinker capacity.
Total requirement of limestone for second Cement Plants will be 4.50 million tonnes per annum.
As per the New EIA Notification dated 14.09.2006 and circular dated 06.02.07, this integrated
project falls in category A Section (3) with 1(a)(3).

1.2 DETAILS OF THE PROJECT AREA

Details Cement Hinouti & Hinouti & Mendhi Limestone Bagahai Limestone
Plant Sijhata Sijhata Mine Mine
Limestone Mine Limestone Mine (117.594 ha) (512.317 ha)
(772.067 ha) (99.416 ha)
Village Mankahari Hinouti & Sijhata Mendhi Bagahai

Tehsil Rampur Baghelan Rampur Baghelan Rampur Baghelan Rampur Baghelan

District Satna Satna Satna Satna
State Madhya Pradesh Madhya Pradesh Madhya Pradesh Madhya Pradesh
Toposheet No. 63 H/2 63 H/2 63 H/2 63 H/2
Latitude 24 34'-24 36' N 24 33'22 - 24 36' 22 N 24 34'08 - 24 33'14 -
24 35' 00 N 24 34' 44 N
Longitude 81 0' - 81 02' E 80 59'24 - 81 01' 47 E 81 01'39 - 81 01'47 -
81 02' 34 E 81 04' 20 E
Elevation 300 mRL 280.33 mRL to 299.86 mRL 289 mRL to 293 mRL 291.44mRL to 324 mRL
Range
Temperature 3.6oC 47.8oC
Relative 25% - 85%
Humidity
Mean Annual 1100 mm
Rainfall
Nearest City Satna (22 km) Satna (21 kms) in the east Satna (25 kms) in the Satna (24 kms) in the
eastern side eastern side

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

Nearest Satna Railway Station (20 Satna on the Jabalpur Allahabad Satna on the Satna on the Jabalpur
Railway km) broad gauge section of West Central Jabalpur Allahabad Allahabad broad gauge
Station Railway(19 km) broad gauge section section of West Central
of West Central Railway (22 km)
Railway (23 km)
Nearest Airport Khajuraho Khajuraho (120 kms west of Satna) Khajuraho (120 kms Khajuraho (120 kms
(120 km) located on DelhiAgra Khajuraho- west of Satna) west of Satna)
Varanasi sector located on Delhi
Agra Khajuraho -
Varanasi sector
Reserved / 1. Jamori Reserve Forest : 1. Khando Jhalawar Reserve Forest 1. Khando Jhalawr 1.Khando Jhalawr
Protected (3.25km NW) (10km SSW) Reserve Forest Reserve Forest (10 km
Forest within 2. Sathari Reserve Forest 2. Jamori Reserve Forest (1.75 km (10km SSW) SSW)
10km radius (3.85 km NNE) WNW) 2. Jamori Reserve 2. Jamori Reserve Forest
(Boundary to 3. Naro Protected Forest 3. Sathari Reserve Forest (adjacent to Forest( 6km WNW) (6km NW)
boundary (6.5km SW the mine NNE) 3. Sathari Reserve 3. Sathari Reserve Forest
distance) 4. Khando Jhalawr 4. Naru Protected Forest(11km SW) Forest (1.5km NNE) (1.5km N)
Reserve Forest (8 km 4.Naru Protected 4. Naru Protected
SSW) Forest(11km SW) Forest(11km SW)
Nearest River Tamas river 2.15 km (NW) Adjacent to the boundary Tamas river : 3.5 km Tamas river : 4 km
(NW of Mendhi) (NW of Bagahai)

1.3 MINING DETAILS

S. Details Hinouti & Sijhata Limestone Mine Mendhi Baghai
No. (772.067 ha & 99.416 ha) Limestone Mine Limestone Mine
(117.594 ha) (512.317 ha)
1. Top Soil 0-3.8m 0 to 3.36m 0 to 2m
2. Method of mining Fully Mechanized Opencast Fully Mechanized Fully Mechanized
Opencast Opencast
3. Lime Stone Bench Height Height: 2-6 m Height: 4.5-6m Height: 3-6 m
and Width Width: > 12 m Width: >12 m Width: >12 m
4. Mineable Reserve 12.519 Million Tonne 7.690 Million 5.186 Million
Tonne Tonne
5. Life of the Mine 14 years 5 years 5 years
6. Ultimate Working Depth 271 mRL 274mRL 277 mRL
7. Generation of O.B. Soil : 6,35,314 MT Soil : 77,560 MT Soil : 6,44,650 MT Soil : 3,13,250 MT
Waste rock : Waste rock : 37,699 MT Waste rock : Waste rock :
1,07,348 MT 1,64,600 MT 3,33,150 MT
8. Height and spread of the Max. height : 4m-4.5m Max. height : 6 m Max. height of
dumps Spread of the dumps : 6.0 ha Spread of the waste rock and
dumps : 1.430 ha soil dump: 6 m
(Soil will be Spread of the soil
stacked dumps : 3.240 ha
temporarily, it will Spread of the
be used for waste rock dumps
backfilling of mined

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

out areas at the : 3.50 ha

end of life mine.) (waste rock
generated in 1st
year will be used
for backfilling of
the mined out
area at the end of
IV and V year.)

1.3.1 Drilling & Blasting

The mining method chosen is the conventional drilling and blasting followed by loading. Drilling will
be done by larger diameter 102 &115 mm drills. The type of explosives proposed is ANFO. Loading
will be done by high bucket capacity (4.0 m3) shovel.

Based on the nature of the limestone deposit, the blast hole parameters proposed are as
follows:
Parameters Hinouti & Sijhata Limestone Mine Mendhi Limestone Mine Baghai Limestone Mine
(772.067 ha & 99.416 ha) (117.594 ha) (512.317 ha)
Diameter of the 102 -115 mm 115 mm 115 mm
drilled Hole
Burden 3.0 M 3.0 m 3.0 M
Spacing 3.5 M 3.5 m 3.5 M
Depth of Hole 4.5 - 6.5 M 4.5 - 6.5 m 4.5 - 6.5 M
Powder Factor 6 T/Kg 6 T/Kg 6 T/Kg
Maximum charge As per permissible limit As per permissible limit As per permissible limit
per delay
Maximum charge As per permissible limit As per permissible limit As per permissible limit
per Hole

1.3.2 Hauling and Transport

For haulage within mining leasehold, tippers are being proposed. Limestone is being transported
from mine head to the crusher plant by tippers only.
1.3.3 Equipment Details
The following equipments are proposed-
Equipment Hinouti & Sijhata Limestone Mine Mendhi Limestone Baghai Limestone Mine
(772.067 ha & 99.416 ha) Mine (117.594 ha) (512.317 ha)

Capacity No. Capacity No. Capacity No.

Excavator 0.91-4.0 cum 4 1-1.5m3 6 1.20 Cum 5

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

Tipper/Dumper 20-40 Ton 12-15 20 - 40Ton 20-30 20 -40Tonnes 15-20

Loader 5.74 Cum. 1
Dozer 1 D 155 1 - 1
Drill 102 mm dia. 1 115 mm dia 2 110 mm dia 1
115 mm dia. 2
Rock Breaker 1500 MPa 2 1500 MPa 1 1500 MPa 1
Compactor - 1 - 1 - 1
Diesel Tanker - 1 - 1 - 1
Water pump - 4 500 Cum / Hr 2 500 Cum / Hr 2
Explosive Van - 1 10 T 1 10 T 1
Water Tanker 10KL 2 10 KL 1 10 KL 1
Maintenance Van - 1 - 1 - 1
Compressor - 3 400 cfm 2 - 1

1.4 BASIC REQUIREMENTS FOR CEMENT PLANT

S.No. Raw material Projected Consumption in tons per day.
1. Lime Stone 13500
2. Iron Ore 104
3. Laterite 22
4. Coal 1700
5. Fly Ash 7124
6. Gypsum 1038

Total water requirement - 2650 m3/day (for Integrated Project)

Power - 48 MW
Manpower - 897 persons
Land requirement - Total plant area : 26.30 ha
Total colony area : 28.34 ha
Total Area : 54.64 ha
1.5 CEMENT MANUFACTURING PROCESS
1. Limestone and Correctives Crushing
2. Limestone Pre-blending
3. Raw Material Drying and Grinding
4. Raw Material Blending and Kiln Feed

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

5. Pyro-Processing
Kiln. Pre-Heater and Pre-calciner (PC)
Kiln Burner
Clinker Cooler
Clinker Transport and Storage
6. Fly Ash Storage and Handling
7. Gypsum Crushing and Storage
8. Cement Grinding
9. Cement Packing and Dispatch
2.0 DESCRIPTION OF THE ENVIRONMENT
2.1 Land use Pattern
Land use Pattern of the Project Area
Area in Village Ownership / Occupancy in ha Tehsil District &
hectares State
772.067 ha Hinouti & Private 764.661 Rampur Satna(M.P.)
(Exisitng Mine) Sijhatta Baghelan
Government 7.406
Total 772.067 ha
117.594 ha Mendhi Private 117.594 ha Rampur Satna(M.P.)
(New Mine) Baghelan
Government Nil
Total 117.594 ha
512.317 ha Bagahai Private 511.246 ha Rampur Satna(M.P.)
(New Mine) Baghelan
Government 1.071 ha
Total 512.317 ha
99.416 ha (New Hinouti & Private 73.059 ha Rampur Satna(M.P.)
Mine) Sijhatta Baghelan
Government 26.357 ha
Total 99.416 ha

Land use Pattern of the Mining Lease Area

Type of land Hinouti & Sijhatta Mendhi Bagahai Hinouti & Sijhatta
Total Area in 772.067 117.594 512.317 99.416
hectares
Irrigated Land 386.208 52.96 351.056 26.575
Un-irrigated Land 73.287 56.428 161.261 15.905

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

Waste Land 312.572 8.206 0.000 56.936

LAND USE PATTERN OF THE AREA

Type of land Mankahari Hinouti Sijhatta Mendhi Bagahai
Village Village Village Village Village

Area in hectares 399.75 ha 730.88 ha 527.11 ha 126.04 ha 691.57 ha

Forest Land 0.00 ha 30.85 ha 0.00 ha 0.00 ha 0.00 ha
Irrrigated Land 22.61 ha 214.96 ha 315.345 ha 53.99 ha 68.08 ha
Unirrigated Land 240.30 ha 292.08 ha 102.399 ha 55.93 ha 327.40 ha
Waste Land 136.84 192.99 109.368 16.12 296.09

2.2 CLIMATIC CONDITION

The different seasons in the area as considered by Meteorological Department are winter (Dec-
Feb), summer (March-May), Monsoon (June-September) Post Monsoon (October-November). The
study period considered as September 2007 to November 2007. The area under study experiences
semi arid to moderate climate. On an average the maximum temperature of the area goes up to
47.8C in summer and goes down to 3.6C in winter. The humidity varies in summer season from
25 to 59%.
2.3 AIR QUALITY MONITORING
Ambient air quality monitoring has been carried out at different stations in the study area on 24
hourly basis for SPM & RSPM and 8 hourly bases for SO2 and NOX. The data for September to
November 2007 are in the ranges given as under:
SPM and RSPM ranges between 90.3 to 157.2 gm/m3, 37.0 to 56.3 gm/m3 respectively. SO2
and NOx ranges between 6.0 to 14.5 gm/m3 and 7.4 to 17.3 g/m3.
2.4 NOISE LEVEL MONITORING
Noise monitoring in the study area at 11 stations shows that the noise level varies in Leq value
ranges from 40 dB (A) to 56 dB (A) in rural areas.
2.5 WATER QUALITY MONITORING
Water samples were collected from 5 locations and the analysis of the samples shows that the
concentration of Total Dissolved Solids (TDS) ranges between 459 mg/l to 499 mg/l, pH varies from
7.1 to 7.7 and Total Hardness varies from 477 mg/l to4 87 mg/l in all ground water samples.
2.6 SOIL QUALITY MONITORING
The soil samples collected from 5 locations and analyzed. The analysis report shows that the pH
value range between 7.09 to 8.02, organic carbon ranges from 0.42 to 0.76 %, soil texture is Sandy
loam and conductivity of the soil samples ranges from 752 to 840 mho/cm.
2.7 BIOLOGICAL ENVIRONMENT

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

FLORA : The observed flora of the region is typically dry deciduous type. The density of the plants
is very low with dominating tree species. The main species of flora found in the region are: Mahua
(Madhuca indica), Peepal (Ficus relegiosa), Mango (Mangifera indica), Tendu (Diospyros
melanoxylon), Amla (Embelica officinalis), Siris (Albizia lebbeck), Amaltas (Cassia fistula), Shisham
(Dalbergia sissoo) etc.
FAUNA : There are no endangered species reported in the study area. The fauna mostly constitute
domesticated animals. The main species of fauna found in the region are: Hare (Lepus nigricollis),
Monkey (Presbytis phayrei), Sambhar (Cervus unicolous), Squirrel (Funambulus planarum), House
Sparrow (Passer domesticus), Common Myna (Acridotheras tristicus) etc.
2.8 SOCIO-ECONOMIC ENVIRONMENT
The study area falls within only one taluka namely Rampur Baghelan of Satna district. The Taluka
area has a total number of 216 villages. The study area has a total number of 58 villages. The total
population in the study area as per 2001 census is 76191. Male fraction of the population is 51.20%
and female fraction of the population is 48.79%. The percentage of Schedule Cast and Schedule
Tribe is 14.19% and 12.25% as per 2001 census record. Number of households in the area is
13861. The literacy rate in the study area is 54.33 %. Total working population is 37.99%.
3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION
MEASURES
3.1.1 Impact on Land Use & Cropping Pattern
Preparatory activities like the use of access roads and construction of storage sheds, etc. being
spread over an area would have no significant impact.
Therefore, the impacts of proposed project on the land use pattern shall be insignificant.
The overall indirect impact on the land use is considered as positive due to adoption of latest
methods of sowing and irrigation as there is likelihood of increase in purchasing power of local
habitants, which could be attributed to the improvement in income.
3.1.2 Air Quality
The sources of air emissions during construction phase will include emissions from vehicles used
for transportation of man and material to the site and from construction equipment. These
emissions are expected to have temporary adverse impact on ambient air quality of surroundings of
the construction site. The key emissions from the cement manufacturing process are emissions to
air of particulate nature, oxides of nitrogen (NOX) and sulphur dioxide (SO2). In the cement industry,
NOX are produced as a direct result of the high temperature flame in the cement kiln. Special type
of burners and addition of lime (CaCO3) are being practiced to control NOX and SOX respectively.
Automobile emissions from trucks movement have not been considered as continuous source of
any significant air pollution.

3.1.3 Water Quality

The wastewater generated during construction phase will be mainly from domestic activities. Since
most of the workers will be from local area, wastewater generated will be minimal. Prism Cement
Limited will develop Sewage Treatment Plant (STP) for handling and treatment of domestic waste
water.

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

No wastewater will be discharged from the mining operation. The wastewater will be generated only
from office toilets, which will be discharged in to soak pit via septic tank. Therefore there will be no
significant impact on either the hydraulic gradient or the flow rates in the wells as well as on the
surface water due to the mining operations in limestone area. Thus no significant impact on water
quality is anticipated.

3.1.4 Solid Waste

Solid waste generated will be taken to waste dump yard. Some metal waste and very small amount
of oil & grease from construction machines which will be generated will betaken to scrap yard
storage area for suitable disposal to scrap dealers and recyclers approved by SPCB.

The other solid waste generation from the proposed Cement plant is mainly dust collected from
various control equipment will be recycled back to the system, results there is no solid waste
generation from the plant.

Solid waste generated from STP is/will be used as manure for green belt development. Therefore,
impact of solid/liquid waste generation will be insignificant.

3.1.5 Noise Level

The general noise level generated from equipment in the proposed project would usually be below
80 Leq dB (A) working area. These noise levels are temporary in nature and its transient
insignificant due to the large distances.

3.1.6 Socio-Economic Conditions

The manpower required for the proposed project will be skilled and unskilled labours generally to be
taken locally. Contract labor is also envisaged for activities like loading, unloading, security etc. in
accordance with prevalent practices. The Managerial and Supervisory category if not available
locally will only impact as influx, but their members will be very small not to affect much adversely to
the local prevailing infrastructure and facility. Generally with installation of plant, there will be
improvement in local infrastructure also. This will have a positive impact on the socio-economic
status of the people. Ultimately economy of the area would improve.

3.1.7 Terrestrial Ecology

Available land to be utilized for proposed project is free from trees, shrubs and herbs and no
vegetation will need to be cleared. Therefore, impact of the proposed project is anticipated to be
insignificant on terrestrial ecology of the area.

4.0 ENVIRONMENTAL MONITORING PROGRAMME

S. No. Description
1 AIR
Ambient air monitoring (24 hourly samples), twice a week continuously.
Parameters : SPM, SO2, NOX & RSPM

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

2 Meteorological parameters at hourly duration simultaneously at one air monitoring station.

Parameters : Wind speed, direction, Relative humidity, Temperature ,
Cloudiness, Rainfall etc.

3 WATER
Water /effluents from various locations (surface and ground water samples) in core and
buffer zone (10 km radius)
Parameters : water/effluents : tested for physical and chemical and biological parameters
as well as according to applicable standards
4 SOIL
Once in a week at various locations in core and buffer zone.
5 NOISE
Once in a week at various locations in core and buffer zone.

5.0 ENVIRONMENT MANAGEMENT PLAN

5.1 Air Pollution Control
The emission of SO2 & NOX may be due to use of diesel operated excavator / Loader / dumper /
Truck etc due to the mining activities. The emissions are estimated to be far below permissible
limits. Not much increase is envisaged. The better maintenance of equipment will help to reduce
such emissions.
Dust is released in drilling, blasting, excavation and loading.
Dust suppression is being done by sprinkling of water. Drill machines having inbuilt bag filters for
dust collection and water injection system is deployed for drilling.
The major sources of pollution are particulate matter from different sections of cement plant. The
emissions of particulate matters from all the stacks will be limited to below 50 mg/Nm3.
The emission of SO2 may also be accounted due to use of coal as fuel in the cement plant. Better
maintenance and installation of proper pollution control equipment like Bag Houses, Bag filters and
ESP help in reducing such emissions.
5.2 NOISE MITIGATION
Exposure of high noise level to workers for long duration may lead to certain occupational diseases.
To mitigate the high noise level, following steps should be adopted.
v Walls and ceilings of the concerned buildings are lined with sound absorbing materials.
v Properly insulated enclosures are provided to machineries producing high noise.
v Noise attenuating devices like earplugs and earmuffs are provided to the workers exposed
to high noise level.
v Regular monitoring of noise level will be carried out and corrective measures in concerned
machinery should be adopted accordingly.

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

v Green belt has been developed in an area, which will greatly help in reducing noise levels
in PCL plant area.
v Silencers have also been provided in the areas generating high noise.
5.3 WATER MANAGEMENT
There is no generation of wastewater from the present operations of the cement plant. The
domestic effluent generated from the colony, will be treated in Sewage Treatment Plant (STP) and
will be reused 100% for plantation / gardening purpose within the plant and colony.
Therefore there will be no wastewater discharge on land either from plant or from the colony.
5.4 SOLID WASTE MANAGEMENT
Entire overburden / waste rock generated during the course of mining will be used for backfilling of
the mined out area. As the OB is not sufficient to reclaim the entire mined out area so a part of the
excavated pit will be developed a water reservoir.
The only solid waste generated will be the sewage sludge from STP, which will be used as manure
for green belt development within the premises.
5.5 SOCIO-ECONOMIC MANAGEMENT

In general, socio-economic environment will have positive impact due to the project in the area. In
order to improve the socio-economic conditions of the people of the area, a detailed programme for
development of the area has been framed. The salient features of the programme are as follows.

i. A well-laid plan for employment of the local people has been prepared by giving priority to
those villagers, whose land falls in the project area, including the water dam constructed to
meet the requirement of this plant project.

ii. Social welfare programme like provision of medical facilities educational facilities, water supply,
recreational amenities for the employees as well as for nearby villagers.

iii. Supplementing Govt. efforts in health monitoring camps, social welfare and various awareness
programmes among the rural population.

iv. Medical facilities will be made available for health checkup of employees as well as villagers.

v. Local people will be taken into confidence in all activities to redress their grievances, if any,
and to meet their aspirations.

5.6 GREENBELT DEVELOPMENT AND PLANTATION PROGRAMME

A thick green belt all along the roads, colony, mines and plant will be developed under afforestation
program.
Details No. of Area of Plantation
Plants (hectares)
Cement Plant + Colony Area
19000 19.12 ha
Hinouti & Sijhata Limestone Mine (772.067 ha) and 99.416 ha) 6000 6.0 ha

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 Integrated Project Cement Plant and Limestone Mines
at Tehsil Rampur Baghelan, District Satna (Madhya Pradesh) Executive Summary

Mendhi Limestone Mine (117.594 ha) 15000 15 ha

Bagahai Limestone Mine (512.317 ha) 11000 11.28 ha

6.0 CONCLUSION
As discussed, it is safe to say that the project is not likely to cause any significant impact on the
ecology of the area, as adequate preventive measures will be adopted to contain the various
pollutants within permissible limits. Green belt development around the area would also be taken
up an effective pollution mitigative technique, as well as to serve as biological indicators for the
pollutants released from the premises of PCL. Cost of the project is Rs. 1000 Crores and cost for
the Environmental Management Plan is Rs. 115 Crores.

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