M/s RAJAT CEMENTS PVT. LTD.

EXECUTIVE SUMMARY

1.0 Preamble
M/s Rajat Cement (P) Ltd. (Mini Cement Plant) is located at Village Sardarpur
Tahsil Sardarpur Dist. Dhar Madhya Pradesh on Badnawar Road. The plant is
based on Vertical Shaft Kiln Technology. The plant was installed in 1986 in the
name of M/s Vallabh Cement Pvt. Ltd.; M/s Rajat Cements Pvt. Ltd. had
purchased the plant in 2003 from Govt. of Madhya Pradesh and started
production from year 2005 at the capacity of 16500 MTPA. The present
capacity of the plant is 16,500 MTPA. Due to increase in market demand
company is going to expand production capacity from 16,500 MTPA to 66000
TPA at the same premises, The capacity enhancement shall be done by
installing three kiln (VSK) of 50 ton each in the existing Premises.

The total estimated project cost will be around 141 lakhs. In order to assess the
likely impacts arising out of the proposed expansion and as per the TOR
issued by the SEAC, Bhopal, the Company had appointed M/s Green
Environmental Technology Bhopal to undertake the Rapid Environmental
Impact Assessment (REIA) study for the various environmental components
which may be cause affect on environment. To assess the impact arising out of
the proposed activity and to prepare a detailed environmental management
plan (EMP) to minimize those adverse impacts.
1.1 Project Proponents:
The directors of the Company are:

S. No. Name of Directors

1. Mrs Kalpana Jain
2. Mr. Jinendra Jain

1.2 Additional Terms of Reference

1) The study area shall be 10 km radius from the project site.

2) Air quality monitoring stations are four in consideration of wind directions.
The location shall be selected keeping in view the nearby habitation as well as
the predominant wind direction.

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3) All sources of the water and likely impact of the proposed construction on
the nearby surface and groundwater sources shall be elaborated.
4) The wildlife parks or Sanctuaries and the wildlife habitats and corridor
(lion movement), if any, within the 10 km from the site in question.
5) Existing landuse pattern, likely changes, impacts on the landuse of the
nearby areas, etc.
6) Existing ecological system and the impacts on ecological aspects due to the
proposed project.
7) Likely generation of the all kind of wastes, its management including
handling and disposal.

1.3 Scope of EIA

Project Description
1. Detailed description of the project site.
2. Raw materials requirement and manufacturing process Details.
3. Land use pattern within10 Km radius of the project site
Environmental pollution and control measures
Air Pollution
1. Sources of fugitive dust emission and control measures.
2. Point sources of Air pollutants and control measures.
Water and Wastewater
1. Water requirement and Source of water supply.
2. Domestic effluent generation, treatment and disposal.

Hazardous Wastes Management

1. Sources and Quantities of Hazardous wastes.
2. Handling, storage and disposal of hazardous wastes.
Environmental Impact Assessment:
1. Ambient air quality monitoring
2. Modeling indicating the likely impact on ambient air quality due to
proposed activities.

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

Environmental Management Plan:

1. Air pollution control measures.
2. Water harvesting systems.
3. Risk assessment and detailed safety control measures to mitigate the risk
and hazards.
4. Occupation health and safety measures.
5. Socio economic development activities.
6. Green belt development plan.
7. Control measures for Noise pollution

1.4 Details of Project Setting:

S.No. Particulars Details

1. Longitude 22034’41”N
2. Latitude 74068’32” E
3. Mean Sea Label 286 AMSL
4 Site Village Sardarpur
5 Khasra No. 286,287,288,289,290 ( Total land -3.2 ha)
5. Nearest City Dhar -35 km
6. Nearest Railway Station Indore at 95 km
7. Nearest Airport Indore located at about 94 km from the
Plant by road
8. Nearest Highway Indore Ahmedabad at 1.0 km
9. Nearest Village Sardarpur Village 1.5 km
10. Hills / Valley Plane Area
11. Ecological Sensitive No national parks and sanctuary.
Zone

1.5 Air Environment

The location of the proposed unit is in the Sardarpur in Dhar Dist. The
ambient air quality monitoring was carried out at 4 numbers of stations with
in 10 km radius of the proposed unit site. Each station was monitored for a
period of 24 hours. The ambient air quality monitoring was carried out over

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duration of three months in the winter season of the year 2009-2010. The
details of the monitoring stations are presented in the following table.
Location of Ambient Air Quality Monitoring Station
S.No Locations Direction from Site Approx.
Distance
from Site

1 Existing Cement Plant Factory gate 0.00

2 Sardarpur Village SE 1.5 km
3 Badvely Village NE 2.3 km
4. Pasodia Village NW 3.4 km

Conclusion of Ambient Air Quality Data

Location Parameter Min Max 98 Avg.
Percentile
A-01 SPM 142 265 256 198
RPM 54 93 71.3 63.4
NOx 11.2 23.6 18.4 16.2
SO2 9.1 18.6 13.7 12.5

A-02 SPM 112 209 169 136

RPM 45 79 68 62
NOx 9.5 24.2 18.3 16.3
SO2 8.9 16.3 11.2 11.2

A-03 SPM 124 198 164 149

RPM 51 85 78 65
NOx 11.3 21.3 18.2 16.2
SO2 9.8 14.5 12.3 12.1

A-04 SPM 91 188 163 147

RPM 58 91 87 82
NOx 11.5 22.6 21.4 18.2
SO2 9.6 15.2 13.3 12.3

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1.6 Noise Environment

Noise Environment may cause an adverse effect on human being and
associated Environment including land, structures, domestic animals, wild
life and natural Ecological systems. Hence, noise survey was carried in and
around the project site. Equivalent noise levels were measured using a
precision noise level meter, at residential areas, schools, hospitals, bus-stands
and commercial centers etc. A total of 5 locations were covered within the 10
Km radial distance.

1.7 Water Environment

Information on water resources was collected during the study period. 3
water samples were collected from various locations within the 10 Km radial
distance. The parameters of prime importance were selected under physical,
chemical (inorganic and organic) and heavy metal groups. As the process
does not generate any effluents waste water characterization has not been
done.

1.8 Land Environment

For land environment studies 2 villages were selected to understand the
physicochemicals and biological properties of the soil. The major soils of this
area may be categorized into Red soils comprising heavy loams. Physico-
chemical properties of soils (Texture, infiltration, Cation Exchange Capacity,
organic matter and moisture), soil biological parameters studied for impact
Identification. In this area, soil is predominantly Red Soil in nature. The
moisture content is generally higher in all areas. The porosity (water holding
capacity in soil) is generally high. On the basis of chemical properties, soil is
slightly alkaline in nature with pH ranging between 6.24 to 8.9

1.9 Socio-Economic Environment

Baseline data for socio-economic and cultural environment is important in
conducting EIA studies. Any developmental activity will bring about changes

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

in socio-economic pattern. Data on demographic pattern, population

characteristics, employment, income, mortality rate, health status, land use
pattern, energy and fuel consumption, and transport and recreation facilities
were collected from neighboring villages. All the fore said environmental
parameters will be used for identification, prediction and evaluation of
significant impacts. Using the baseline data prediction of impacts of the
project has been undertaken.

1.10 Agricultural status

Agricultural practice is one of the important characteristic to be studied and
this greatly depends on the land use pattern in the study terrain. The farmers
in this area are taking even two and more crops from there fields.
Major crops of the study area are:

Important Crops

1. Wheat
2. Jowar
3. Macaa

Important Pulses

1. Chana
2. Udad

Important Tilhan

1. Soyabeen
2. Groundnut

Beside these, other important crops of the area are: Gram, Garlic, Onion,
Potato, Tomato, Bhindi, Mustard.

1.11 Project Description

M/s Rajat Cements Pvt. Ltd. had purchased the plant in 2003 from Govt. of
Madhya Pradesh and started production from year 2005 at the capacity of
16500 MTPA. The present capacity of the plant is 16,500 MTPA. Due to

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

increase in market demand company is going to expand production capacity

from 16,500 MTPA to 66000 TPA at the same premises, The capacity
enhancement shall be done by installing three kiln (VSK) of 50 ton each in the
same premises, without acquiring additional land. The location map are
shown in the figure 1.1

Mini cement plants are categories in the Notification of Central Excise Deprt.
Govt. of India. The Copy of Notification is enclosed with report. As per the
this Notification the mini cement plants can produce cement up to 1,09,500
tonnes in year.

We will install three more kiln of 50 TPD each to achieve the cement
production upto 6600 TPA

1.12 Utilities
Power
The total connected load is 630 KVA which is under HT limits. Proposed
power shall be obtained from MPSEB. However, One D.G sets of 500 KVA is
also proposed to be installed in the scheme as a stand by to the MPSEB
connection

Water
Total water requirement will be around 15 KLD for cooling & administrative
purposes. It will be met by bore well within the project site.
Water Balance
Items Existing Proposed

Process / cooling 10 KLD 20.0 KLD

Domestic 3.0 KLD 5.0 KLD

Others 2.0 KLD 2.0 KLD

Total 15.0 KLD 27.0 KLD

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

• Source – Own Borewell & from outside by tankers

Total Land Available : 3.2 ha.

Existing Constructed Area :
Proposed Construction
For plantation and
Greenbelt development
Open land
0.5 ha.
: 0.5 ha.
: 1.2 ha.
: 1.0 ha.

1.13 Capacity
S. No. Product Installed Capacity Proposed
Capacity
1. Cement 16500 TPA 66000 TPA

Technology: VSK (vertical Shaft Kiln)

1.14 Process Description:

Rajat Cements is proposing to manufacture 66,000 TPA (200 TPD) Ordinary
Portland Cement in the existing plant premises with VSK Technology by
installing three more kilns of 50 TPD each.

1.15 Raw Materials

The quantity of raw material used for producing 200 TPD cement are as
follows:

S. No. Name of material Existing capacity Proposed Capacity

1. Lime Stone 65 MT 260 MT
2. Coke Breeze 7 MT 28 MT
3. Clay 4 MT 16 MT
4. Gypsum 4 MT 16 MT

1.16 Manufacturing Process of Product

Lime-stone and clay are received from mines in lump from lime-stone lumps
are crushed in jaw-crusher average size of 20 mm.

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

Lime-stone, clay, coke as per raw mix ratio will fed to ball mill. All blended
material is ground to a finesse of 170 meshes in raw mill grinding section and
conveyed through screw conveyer/elevator to silos pneumatically operated.
Batches of raw meal are mixed and samples are draw any deficit mixed meal
is discharged to a storage silo. Material from storage silo is conveyed an
elevator to the hopper of nodulizer. Nodules are made by adding water and
deeded directly into VSK through rotary distributor. Clinker is formed and
discharge through VSK is controlled through fully automatic central control
system. Clinker is crushed and storage at under ground (open) storage for
aeration (if any) desired.
Clinker is fed in the crusher for reduction in size crushed. Clinker and
gypsum are fed continuously to a ball mill to get ordinary Portland cement.
Finish good will be packed directly in HDPE bags. The process flow chart is
given in figure.

1.17 Stages of Manufacturing Process

1) Crushing Section
2) Storage and proportioning Section
3) Raw meal Grinding Section
4) Homonizing Section
5) Nodulization
6) VSK Section
7) Cement mill Section
8) Packing Section
1.18 Main object of Mini-Cement Plant Technology

1. To bring it within the financial access of smaller entrepreneurs.

2. Increased employment opportunities in rural and backward areas.
3. Realization of quicker returns of capital investment due to low
gestation period.
4. Exploitation of smaller lime-stone deposits.

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

5. Catering the Cement requirement of local near by areas.

6. Low capital investment per tonne of installed capacity.
7. Reduction of multy-handlling and intermediaries between the
producing and consuming points.
8. Contribution to uplifting the local economy and development.
9. Contribution to the national wealth as a whole.
10. No need of heavy structures/infra-structure.
This establishes the need of mini-cement plant with capacity of 100 multiple
to be installed throughout the entire length and breadth of the company.

1.19 Advantages of VSK Technology

1) Low fuel consumption
2) Low capital investment
3) Wider flexibility in respect of raw-materials
4) Compact in design
5) Low maintenance
6) Simplified operation
7) Better life of refractory lining
8) Elimination of alkalies through flue gases
9) No separate cooler is required
10) No drying and crusher required for the fuel
11) Kiln can be restated instantaneously after
12) Can be fabricated indigenously
13) Low carpet area required
14) Semi skilled personnel is required
15) More Job opportunity
16) To exploit small pockets of lime stone deposit.
17) To cater need for the areas economically remote.
1.20 Salient Features

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

Incorporating secondary crusher optimizes raw material crushing

mainly Limestone.

Introducing energy efficient Ball Mill System for reducing Power
consumption.

Better Kiln design to prevent radiation losses.

Improved Rotary grate design for smooth and trouble free operation.

Preference to Bucket elevator in place of high power consuming Air
lifts.

The manufacturing process basically comprises of the following operations.

Crushing of limestone and other raw materials to size of minus

20mm.

Proportioning of raw mix and fuel based on raw mix design.

Grinding of raw mix to a fineness of 90% passing 170 meshes.

Blending of ground raw mix to a desired level.

Preparation of nodules by addition of water to raw meal in a pan
type noduliser.

Calcimining, sintering, burning and cooling in vertical shaft kiln.

Packing the cement in bags.

1.21 Description of Air Quality Monitoring Stations

The ambient air quality concerning the study area of 10 km around site as
center point forms the baseline information. The study area represents mostly
rural environment. The various sources of air pollution in the study zone are
industrial emissions, and vehicular traffic. The major air pollutants released
into the atmosphere from the industries are SPM, RSPM, SO2, and NOx.

1.22 Conclusion:
M/s Rajat Cements Pvt. Ltd strongly believes in the concept of eco friendly
industrialization as per standards prescribed by the State and Central

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M/s RAJAT CEMENTS PVT. LTD. EXECUTIVE SUMMARY

Pollution Control Boards. Apart from eco -friendly operations, various socio
economic development activities will be undertaken to bring about overall
socio economic improvements in the areas.
As the project is located in tribal area and there is no other industrial activity
in nearby area and a large number of local villagers are getting employment
form the factory therefore, the project may be accorded environmental
clearance for expansion.

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