application/form-1 project feasibility report...ensyscon, chennai-78. adequate air pollution control...

Dalmia Cement (Bharat) Limited

Proposed Modernisation & Expansion of DCBL Ariyalur Cement Plant

Production of

Existing Addition on Expansion

Cumulative Percentage Increase

Clinker 2.00 MTPA 0.21 MTPA

(with Modernisation and Upgradations)

2.21 MTPA 10.50%

Cement 3.00 MTPA

1.00 MTPA (with addition of 1.00 MTPA Cement Mill &

Cement Silo)

4.00 MTPA 33.33%

Village-Govindapuram, Taluk & District-Ariyalur, Tamil Nadu

Earlier EC Reference

MoEFCC F. No. J-11011/751/2007-IA II (I) dated 19.06.2008

EC under EIA Notification 2006 -Application to Determine TOR

Schedule Sl. No. 3(b); Category ‘A’

Application/Form-1 Project Feasibility Report

December 2018

EIA Consultant

Ensyscon Enviro Solutions (QCI-NABET Sl. No. 383)

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

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

DCBL Proposed Modernisation & Expansion of Ariyalur Cement Plant, Ariyalur Taluk & District, TN

Ensyscon, Chennai-78.

Dalmia Cement (Bharat) Limited Proposed Modernisation & Expansion of DCBL Ariyalur Cement Plant

Project Feasibility Report (As per MoEF Guidelines vide Circular No. J-11013/41/2006-IA.II(I) dated 30.12.2010)

1.0 Executive Summary

M/s. Dalmia Cement (Bharat) Limited (DCBL) have Cement Plants at Dalmiapuram & Ariyalur in Tamil

Nadu, Kadapa in Andhra Pradesh, Belgaum in Karnataka and Cement Units across Northeast & Eastern

Regions. DCBL’s Cement manufacturing capacity is now about 31 Million Tonnes per Annum (MTPA).

DCBL has obtained the Environment Clearance (EC) from the Ministry of Environment, Forest and

Climate Change (MoEFCC) vide its Letter F. No. J-11011/751/2007-IA II (I) dated 19.06.2008 for the

Ariyalur Cement Plant (Clinker 2.0 MTPA @ 6,090 TPD) and Cement (3.0 MTPA @ 9,100 TPD) along with a

Captive Thermal Power Plant of 27.0 MW in an extent of 112.06 Ha (out of 204.78 Ha/506 Acres) falling in

Survey Nos. 218/5A2, 218/5A5, 219/1A1, 219/1A2, etc. of Govindapuram Village, Taluk & District

Ariyalur in Tamil Nadu State. Guest House and O&M Colony are established in the area earmarked for

the Township.

Ariyalur Cement Plant is located at a distance of 35 km in northeast direction from Dalmiapuram Cement

Plant. The Cement Despatch from these two Cement Plants is fulfilling about 55%-60% of the local

demand of Tamil Nadu and balance 40%-45% is marketed in other States of India.

The limestone requirement of both the Cement Plants is being met from the Captive Limestone Mines

(combined Limestone production of 7.05 MTPA) in Ariyalur & Trichy Regions viz. Kallakudi &

Kovandakurichi (KLK-KVK) Mines, Periyathirukonam (PTK) Limestone Mines and amalgamated

Periyanagalur, Aminabad & Khairulabad (PNR Group) Limestone Mines. Production Enhancement of

these Captive Mines are proposed and prior EC Applications are being submitted to the Authorities.

The Plant & Mines operations are in compliance with the conditions stipulated in the Environmental

Clearances awarded by MoEFCC and Consent Orders issued by TNPCB. The Monitoring Cell of

MoEFCC, South Eastern Zone, Chennai has issued the Certified EC Conditions Compliance Report for the

Plant vide Letter F. No. EP/ 12.1/831/TN/0464 dated 28.03.2018. DCBL has complied with all conditions

stipulated in the EC.The Unit has not received any Notice under Section 5 of the Environment (Protection)

Act, 1986 or Show Cause Notices from TNPCB under Air and Water Acts. There is no litigation against the

Project.

About 112.06 Ha (276.91 Acres) is utilized for the Cement & Captive Power Plants. About 38.10 Ha (34%

Coverage) is under Green Belt with about 66,773 Trees predominantly of local species with 96% Survival

Rate.



There are 626 Direct Employees (533 in Cement Plant and 93 in Power Plant) and 165 Indirect

Employees in DCBL Ariyalur Plant. The total Water Demand of the Complex is 1,400 cu.m/day fresh

water and 200 cu.m/day treated effluent, thus, a total of 1,600 cu.m/day. Existing fresh water demand of

1,400 cu.m/day is met from the permitted borewells (5 Nos.) within the Plant premises. Renewal of NOC

for a drawl of 1,620 cu.m/day from the permitted Borewells has been issued by the Chief Engineer,

WRD/PWD, Chennai vide Lr. No. OT9/G-3/300/2018/Renewal of NOC/Trichy/2017 dated 10.09.2018.

The Cement Plant generates about 40 cu.m/day Domestic Sewage, CPP generates 1.8 cu.m/day

Sewage and the Colony & Guest House generates 298.2 cu.m/day Sewage. Thus, the Complex

generates about 340 cu.m/day Domestic Sewage in total. While, the Domestic Sewage from the Cement

Plant, CPP and Guest House are treated in a Combined Sewage Treatment Plant (STP) of 200 cu.m/day

capacity, the Sewage from O&M Colony are treated in 3 Septic Tanks followed by Dispersion Trenches.

The Treated Sewage of 160 cu.m/day from the STP is utilized for Green Belt Maintenance (120

cu.m/day) and Dust Control Measures (40 cu.m/day). Thus, ‘Zero Effluent Discharge’ is practiced at the

Complex.

STP Sludge of 10 TPD is used as manure. Oily Sludge is utilized in Co-processing in the Kiln and Spent

Oil @ 47.5 KL/Annum is being sold to the Authorised Recyclers for further recycling. Refractory Bricks of

600 Tons/Annum is sold to the Brick Manufacturers. From CPP, generated Fly Ash @ 54 TPD is

pneumatically transported to the Cement Plant and utilized for PPC manufacturing and the Bottom Ash

@ 10 TPD is utilized in the Cement Plant.

The existing power requirement is 23 MW. The source of power is Captive Power Plant (27.0 MW) and

also through TANGEDCO Grid (10.1 MW).

DCBL Ariyalur Cement Plant is located inbetween 11o10’21”-11o11’17” Latitude & 79o05’45”-79o06’42” E

Longitude (Survey of India Topo Sheet No. 58 M/4).2). There is no environmental issues about the site.

There is no National Park, Wild Life Sanctuary, Biosphere Reserve, Hot Spot, Historical Monument exist

within 10 km radius area. Kallankurichi Kaliyuga Varadharaja Perumal Temple is at 3.4 km in SE

direction from the Plant. There are 6 Reserved Forests (RFs) from 9.0-15 km distance from the Plant. A

seasonal nallah Kallar River originates near the Plant area at 1.0 km distance in the east. Seasonal

Marudaiyar River drains the Region which flows at 7.4 km distance from the Plant in the south.

DCBL has proposed the Modernisation & Upgradation of Ariyalur Cement Plant with State-of-Art

Technology viz. improvement of the existing Pyro Processing Systems, modernization of the machineries

and also Pollution Control Measures upgradation to achieve PM emission <30 mg/Nm3 and other

Pollutant Levels within the stipulated Norms. With the proposed Modifications, increase in the clinker

production will be about 6500 TPD, equivalent to 2.21 MTPA per annum. With the enhanced clinker

capacity (2.21 MTPA), the Cement production capacity will be enhanced from existing 3.0 MTPA to 4.0 MTPA.

The Modernisation and Expansion activities are proposed within the existing Plant Premises, with no

additional land and no major Construction for the additional Clinker and Cement Production.



Adequate Air Pollution Control Measures (APC) measures to control PM emissions are provided in the

Cement Plant viz. Electrostatic Precipitators to Clinker Cooler & Boilers, Bag House to Raw Mill/Kiln,

Coal Mill, Cement Mill, etc. to control PM emission <30 mg/Nm3. The dust collected from Bag

House/Filters, etc. are totally recycled in the process for cement manufacturing. Bag House is proposed

for the additional Cement Mill also to control PM emission <30 mg/Nm3.

Existing water demand is 1,400 cu.m/day and is met from permitted borewells within the Plant premises.

The additional water demand of 200 cu.m/day will also be met from the permitted source only and within

the permitted 1,620 cu.m/day.

No change in the Quantity of Solid Wastes Generation, Storage and its Disposal due to the proposal.

The Modernisation and Expansion activities are proposed within the existing Plant Premises with no

additional land and no major Construction for the additional Clinker and Cement Production. As per the

Environmental Impact Assessment Notification SO 1533 (E) dt. 14.09.2006, all Cement Plants with >1.0

MTPA capacity have been kept at Sl. No. 3 (b) under Category ‘A’ for the Environmental Clearance from

the Ministry of Environment, Forest and Climate Change (MoEFCC). Accordingly, Form-1, Feasibility

Report and other required Documents are submitted to the Ministry to determine TOR for the EIA Study.

***



2.0 Introduction of the Project 2.1 Project Proponent

M/s. Dalmia Cement (Bharat) Limited (DCBL) have Cement Plants at Dalmiapuram & Ariyalur in Tamil

Nadu, Kadapa in Andhra Pradesh, Belgaum in Karnataka and Cement Units across Northeast & Eastern

Regions. DCBL’s Cement manufacturing capacity is now about 31 Million Tonnes per Annum (MTPA).

DCBL is operating its Ariyalur Cement Plant, a green field Cement Plant, of 2.00 MTPA Clinker and 3.00

MTPA Cement manufacturing capacity along with 27 MW CPP in an extent of 112.06 Ha (out of 204.78

Ha/506 Acres) falling in Survey Nos. 218/5A2, 218/5A5, 219/1A1, 219/1A2, etc. of Govindapuram Village,

Taluk & District Ariyalur in Tamil Nadu State (Fig. 1.1). Guest House and O&M Colony are established in

the area earmarked for the Township.

Ariyalur Cement Plant is located at a distance of 35 km in northeast direction from Dalmiapuram Cement

Plant. The Cement Despatch from these two Cement Plants is fulfilling about 55%-60% of the local

demand of Tamil Nadu and balance 40%-45% is marketed in others States of India.

The limestone requirement of both the Cement Plants is being met from the Captive Limestone Mines

(combined Limestone production of 7.05 MTPA) in Ariyalur & Trichy Regions viz. Kallakudi &

Kovandakurichi (KLK-KVK) Mines, Periyathirukonam (PTK) Limestone Mines and amalgamated

Periyanagalur, Aminabad & Khairulabad (PNR Group) Limestone Mines (Regional Map as Plate I).

Production Enhancement of these Captive Mines are proposed and prior EC Applications are being

submitted to the Authorities.

Dalmiapuram & Ariyalur Cement Plants and the Captive Mines are headed by the Executive Director who

is also deal with the environmental issues and EC compliances. DCBL has the well laid down

Environmental Policy approved by its Board of Directors. The Integrated Policy of DCBL commits the

compliance to all applicable legal requirements. DCBL has the standard operating process or procedures

to bring into focus of any deviation/violation of environmental or any other norms or conditions. Any non-

compliance/violations of environmental norms and the corrective actions taken will be reported by the

Executive Director to the Managing Director and the Board of Directors of DCBL. The communication

address is as follows : The Executive Director & Unit Head, Dalmia Cement Bharat Limited, Dalmiapuram, Lalgudi Taluk,

Tiruchirapalli District, Tamil Nadu-621 651.

Telephone Nos. : 04329 –235123 Fax : 04329 – 235111 Telegraph : DALMIACMNT e-mail : [email protected]



Plate : I Location of Dalmia Cement Plants and Mines in Ariyalur Regional Map



DCBL has obtained ISO:9001 Certification and ISO:14001 Certification from DNV-GL in 2011. Recognizing

DCBL as Centre of Excellence for transfer of technology, World Bank and Danish International

Development Agency (DANIDA) Team sponsored a Regional Training Centre at Dalmiapuram to cater the

needs of South Indian Cement Industries since 1991.

2.2 Identification of the Project 2.2.1 DCBL Ariyalur Cement Plant

Cement Plant : Ariyalur Cement Plant was commissioned during the Year 2009-10. The Plant is having

a single Kiln with a five stage Preheater and inline Calciner, with an installed capacity of 2.0 MTPA

clinker and 3.0 MTPA Cement. It manufactures ordinary Portland cement (OPC-43 Grade and OPC-53

Grade) and Portland Pozzolana Cement as per demand though consented for 20% OPC and 80% PPC

productions.

Captive Power Plant : Conventional Rankine Steam Cycle Plant has been adopted. Atmospheric

fluidised bed combustion (AFBC) 125 TPH Boiler is installed. Captive Power generation is 27 MW. ESP

and a stack of 81 m height are provided to control PM emission <50 mg/Nm3. Trade effluents viz. Boiler

Blowdowns, Cooling Tower Blowdowns and RO/DM Plant Rejects generated in the CPP are neutralized

in a Neutralisation Tank and used for water spraying in the Cement Plant.

Captive Limestone Mines : The Captive Limestone Mines of DCBL in Trichy and Ariyalur Regions and

their contribution to Limestone Demand of the Plants are given in Table 2.1.

Table : 2.1 DCBL Captive Limestone Mines

Mine Group Extent, Ha Consented Production

Capacity, MTPA

Percentage of

Supply

Kallakudi & Kovandakurichi – Local Mines Group (5 Leases) 191.265 2.95 45%

Periyanagalur, Aminabad & Khairulabad Mines (PNR Group) (3 Leases) 167.605 1.90 30%

Periyathirukonam Mines (PTK Group; 2 Leases) 106.070 2.20 25%

Total 464.940 7.05 100%

Environmental Clearance : DCBL has obtained the Environment Clearance (EC) from the Ministry of

Environment, Forest and Climate Change (MoEFCC) vide its Letter F. No. J-11011/751/2007-IA II (I)

dated 19.06.2008 for the Ariyalur Cement Plant (Clinker 2.0 MTPA @ 6,090 TPD) and Cement (3.0 MTPA @

9,100 TPD) along with a Captive Thermal Power Plant of 27.0 MW (Doc-1).

Consent Orders : Initial Consents to Establish (CTEs) and Consents to Operate (CTOs) Orders were

granted by the Tamil Nadu Pollution Control Board (TNPCB) which are periodically renewed by the

Board. Existing CTOs of Cement Plant are 1808112162606 (Water Act) and 1808212162606 (Air Act)

dated 14.12.2018 with validity upto 31.03.2019 (Doc-2). Existing CTOs of CPP are 1808112162330

(Water Act) and 1808212162330 (Air Act) dated 14.12.2018 with validity upto 31.03.2019.



Plate : II Dalmia Ariyalur Cement Plant and its Environs



2.2.2 Compliances to Statutory Clearances

The Plant & Mines operations are in compliance with the conditions stipulated in the Environmental

Clearances awarded by MoEFCC and Consent Orders issued by TNPCB.

The maximum production of Clinker was 1.18 MTPA during 2014-15 and Cement was 1.53 MTPA during

2017-18 and there is no violation in the Production Quantity.

Certified Compliance to EC Conditions : The Monitoring Cell of MoEFCC, South Eastern Zone,

Chennai has issued the Certified EC Conditions Compliance Report for the Plant vide Letter F. No. EP/

12.1/831/TN/0464 dated 28.03.2018 (Doc-3). DCBL has complied with all conditions stipulated in the EC.

The Unit has not received any Notice under Section 5 of the Environment (Protection) Act, 1986 or Show

Cause Notices from TNPCB under Air and Water Acts. There is no litigation against the Project.

CREP Compliance : A series of industry specific guidelines are formulated in the Charter on Corporate

Responsibility for Environmental Protection (CREP) and action points are also enlisted for the Cement

Industry. DCBL Plant activities are in compliance with the CREP Guidelines (Table 2.2).

Table : 2.2 Compliance to CREP Guidelines

No. Action Points in CREP Compliance Status 1 Implementation of standards in non-

complying units. Air Pollution Control Equipments are installed in order to meet the emission norms of <30 mg/Nm3.

2 Plants in critically polluted or urban area (5 km distance outside urban boundary) will meet 100 mg/Nm3 SPM emission and continue working to reduce the emission of particulate matter to 50 mg/ Nm3.

The Cement Plant is being operated for PM emission Norm of <30 mg/Nm3.

3 The new cement kilns to be accorded NOC/EC for complying 50 mg/Nm3

emission limit.

The PM emissions from the Plant is within the emission norm of <30 mg/Nm3.

4 CPCB will evolve load based standards by June 2004.

The Load based emission is computed to be less than 0.125 kg/ tonne of Clinker.

5 CPCB and NCBM will evolve SO2 and NOx emission standards by June 2004.

The emissions levels of NOx and SO2 are well within the standards proposed by CPCB.

6 Control fugitive emissions from all the raw material and products storage and transfer points by December 2003. The feasibility for the control of fugitive emissions from limestone and coal storage areas will be decided by the NTF. The NTF shall submit its recommendations within three months.

The fugitive emission are controlled by following measures : v Raw meal, Clinker, Cement and dry fly ash are stored in

RCC Silos with bag filters. v Covered sheds are provided for Raw materials storage like

crushed limestone, Imported Coal, petcoke, Lignite, Wet Fly ash and Gypsum

v Cement packing rotors/machines are equipped with dust extraction system with adequate ventilation.

v All transfer points are fully closed and fugitives controlled by water spraying or extraction to Bag filters.

v All raw material handling area are covered with RCC pavement and road sweeping is being carried out using sweeping machines.

7 CPCB, NCBM, BIS and oil refineries will jointly prepare the policy on use of pet coke as fuel by July 2003.

Petcoke is used as Fuel in Kiln apart from Imported coal and Lignite.



No. Action Points in CREP Compliance Status 8 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.

The Continuous Emission and Effluent monitoring systems are installed and readings are connected to TNPCB CARE AIR Centre & CPCB Server through online.

9 Tripping in Kiln ESP to be minimized by July 2003.

Tripping of ESP is minimized by taking all the necessary precautions and interlocking system with fan main drive is provided.

10 Industries will submit the target date to enhance utilization of waste materials.

Installed Alternative fuel feeding system to utilize Hazardous/Non-Hazardous waste material in the Cement Kiln. Currently we are co-processing Tyre chips, Plastic waste, Resin, Solid Waste Mix, Tannery ETP sludge and Textile ETP Sludge in Cement kiln by getting necessary authorization from TNPCB. Every year, quantity of co-processing in kiln is being intimated to TNPCB and CPCB. Co-processing emission monitoring also been carried out with NABL accredited labs half yearly.

11 NCBM will carryout a study on hazardous waste utilization in cement kiln by December 2003.

Hazardous and non-hazardous waste is being co-processed in the cement kiln.

12 Cement industry will carry out feasibility study and submit target date to CPCB for cogeneration of power by July 2003.

Entire cooler hot gas is being used to dry raw materials in vertical raw mill as well as in vertical cement mill.

2.2.3 Awards - Ariyalur Plant Ariyalur Cement Plant has been certified under IMS system such as OSHAS 18001:2007, ISO

14001:2015, ISO 50001:2011 & ISO 9001:2015 Standards. Ariyalur Cement Plant has bagged many

National & State Awards for Safety, Environmental and Energy Conservation Measures as detailed below:

v Green Award for 2014 instituted by Government of Tamil Nadu.

v National Energy conservation award form Ministry of Power for FY 2012 & 2013.

v Consecutive seven years Excellent Energy Efficient Unit in National Energy Management award by

CII.

v Sustenance award in 5s from CII- Southern Region in 2017& 2018

v Sustenance award in 5s from ABK AOTS DOSOKAI-Tamil Nadu Chapter in 2017

v First place for Best Safety Practice organized by Government of Tamil Nadu in 2017

v Best Energy Efficient unit in the National Energy management award organized by CII in 2017& 2018

v Winners in Excellence in Operations & Excellence in Sustainability organized by Manufacturing

Today in 2017

v First place for Best Electrical Energy & Best Environment Excellence organized by NCCBM in 2017

v 5 Star rating for EHS best practices (continuous 3 years) & 2nd place in overall manufacturing

category from CII-SR-2017 and 1st Place in Cement Sector from CII in 2018.

v Role Model Company Award for the 5S Practices through 6 pillars concept from ABK AOTS

DOSOKAI-Tamil Nadu Chapter in 2018.

v Winner of Prashansa Patra Safety Award from NSC-India for best safety practices in 2018

v SGA award for Energy Efficiency from BEE in 2018

v Gold Award for Energy Efficiency Award and Environment Excellence Award organized by Apex

India Foundation in 2018.

v Winners in Excellence in Sustainability by Manufacturing Today in 2018.

v Champian Award from NSC, Tamil Nadu chapter for best Safety Practices.



2.2.4 Existing Land Use



Rate. The Land Use details are as follows :

Cement Plant Builtup Area : 46.01 Ha Power Plant Builtup Area : 3.90 Ha O&M Colony & Guest House : 4.19 Ha Green Belt Area : 38.10 Ha (coverage is 34.00%) Solid Waste Management Area : 0.70 Ha Roads & Truck Parking Area : 7.66 Ha Vacant Area within the Plant : 11.50 Ha ---------------- Plant Area, now : 112.06 Ha Unutilised & prop. Rly. Siding : 92.72 Ha ---------------- Total : 204.78 Ha ----------------

The existing Plant Layout is given as Plate III.

2.3 Existing Process

Well established Dry Process utilizing the Precalciner Technology along with the technological advances

in the area of grinding has been incorporated. The raw materials used in Clinker manufacturing are

Limestone and Fire Clay. Available Indian coal/Lignite or Imported coal from Indonesia and South Africa

are being used in the process. For Clinker manufacturing, Petcoke is also used.

Limestone excavated from the Captive Mines is being crushed to the required size and being sent to

stacker / reclaimer by means of Belt conveyor. In order to obtain better quality of Kiln feed the limestone

of various grades are mixed in the stacker. Limestone along with other ingredients is being mixed in

suitable proportions and is sent to Raw Mill where the raw material is ground to the required size. The

powdered Raw Meal is stored in the Raw Meal silo. Belt bucket elevator is used to feed the raw material

to Preheater cyclones / Precalciner. The calcined material from the Preheater enters the Kiln and is

subjected to physical and chemical changes to form the Clinker.

Evaporation and preheating remove moisture and raise the temperature of the raw mix preparatory to

calcining. Calcining takes place at 800-900 oC and breaks the calcium carbonate down into calcium oxide

and carbon dioxide which is evolved in the process. Kiln temperatures in the burning zone range from

1350-1450 oC. The hot molten Clinker is allowed to pass through a modern high efficient Clinker Cooler

to cool it down to 150 oC. Cooled Clinker is then stored in Clinker Silo. Clinker is then ground along with

Gypsum and Fly Ash in a Cement Mill to produce various grades of Cement. The ground cement is

conveyed to Cement Silos for storage of different types of cement from where it is extracted and packed

in HDPE & Paper bags by Rotary Packers or through bulkers and finally dispatched to the Market.

Cement Manufacturing Process Flow Chart is given as Plate IV. The raw materials, source, mode of

transportation, storage, etc. are given in Table 2.3.



Plate : IV Process Flow Chart



Table : 2.3 Raw & Finished Materials and Storage Facilities

Sl. No. Raw Material Source

Max. Demand,

MTPA

Mode of Transportation Storage Facilities

1 Limestone

Captive Limestone

mines in Trichy &

Ariyalur District

3.780 From crusher by closed conveyors to plant

Stacker Reclaimer

40,000 cu.m capacity

2 Fire Clay Local Market 0.100 Covered 20 Ton truck by road

Linear Stock Pile of 5,000 Tons

3 Wet Fly Ash Mettur Thermal

Power plant 0.085 Covered 20 Ton

truck by road Linear Stock Pile of 5,000 Tons

4 Lignite Neyveli Lignite

Corporation (NLC) 0.340 Covered 20 Ton

truck by road Linear Stock Pile

5 Petcoke

Local Refinery or

Imports from USA/

SA/ Indonesia etc.

0.204 Covered 40 Ton browsers by road


6 Coal

Local Coal Mines or

Imports from USA/

SA/ Indonesia

0.272 Covered 20 Ton trucks by road


7

Synthetic and

Chemical

Gypsum

IL&FS & Greenstar

Fertilizers,

Thoothukudi

0.119 Covered 20 Ton truck by road


8 Fly ash

NLC, IL&FS, North

Chennai Thermal

Power Station

0.850 20/40 Tons Bowsers RCC Silo; 2,000 Tons

9 Clinker - 2.000 - RCC Silo 47,500 Tons

10 Cement - 3.000 By Road RCC Silos 2x7,500 Tons

11 CPP : Lignite NLC 0.153 Covered 20 Ton trucks by road Linear Stock Pile

12 CPP : Coal

Local Coal Mines or

Imports from USA/

SA/ Indonesia 0.119 Covered 20 Ton

trucks by road Linear Stock Piles of 2x5,000 Tons



2.4 Existing EMP Measures

Air Pollution Control Measures : The Cement Plant is being operated for PM emission <30 mg/Nm3.

Online Stack Monitoring Systems are provided to all main Stacks viz. Kiln/Raw Mill, Coal Mill, Cooler and

Cement Mill in the Cement Plant & Boiler Stack in CPP to monitor PM & gaseous emissions (SO2 and

NOX) at Kiln/Raw Mill & CPP Boiler Stacks and the real time emission data are being transmitted to CARE

Air Centre of TNPCB & CPCB. Necessary interlocking facilities are provided in the pollution control

equipments. Two numbers Continuous Ambient Air Quality Monitoring Stations (CAAQMS) are installed at

the Plant in Upwind & Downwind directions for PM2.5, PM10, SOx & NOx and the data are being

transmitted to CPCB and CARE Air Centre of TNPCB.

Periodical environmental monitoring are being carried out and the monitored data are being submitted to

TNPCB (monthly) and to MoEFCC Regional Office, Chennai (Six Monthly). In addition, TNPCB is

carrying out the Survey periodically and the Report of Analysis (ROA) reveals that the environmental

parameters in the Plant vicinity were in compliance with the stipulated norms.

Water Demand : There are 626 Direct Employees (533 in Cement Plant and 93 in Power Plant) and 165

Indirect Employees in DCBL Ariyalur Plant.

The Cement Plant water demand for Equipment Cooling is 900 cu.m/day. Fresh Water of 700 cu.m/day

and treated Effluent of 200 cu.m/day from CPP are utilized for equipment cooling in the Cement Plant.

CPP requires fresh water to the tune of 300 cu.m/day for DM/RO Plants in supply to Boiler Makeup (60

cu.m/day) and Cooling Tower Makeup (60 cu.m/day).

Fresh water to the tune of 48 cu.m/day is required for Domestic Consumption in the Cement Plant, 2

cu.m/day in the CPP and another 350 cu.m/day is required for the Guest House and O&M Colony. Thus,

400 cu.m/day fresh water is required for Domestic Consumption in the Complex.

The total Water Demand of the Complex is 1,400 cu.m/day fresh water and 200 cu.m/day treated

effluent, thus, a total of 1,600 cu.m/day.

Ground Water Board NOC : Existing fresh water demand of 1,400 cu.m/day is met from the permitted

borewells (5 Nos.) within the Plant premises. Renewal of NOC for a drawl of 1,620 cu.m/day from the

permitted Borewells has been issued by the Chief Engineer, WRD/PWD, Chennai vide Lr. No. OT9/G-

3/300/2018/Renewal of NOC/Trichy/2017 dated 10.09.2018 (Doc-4).

Wastewaters Generation Treatment & Disposal : There is no trade effluent generation from the

Cement Plant. CPP Generates about 180 cu.m/day trade effluents from RO/DM Plants and about 20

cu.m/day as Boiler and Cooling Tower Blowdowns. Thus, the total 200 cu.m/day effluents from CPP is

treated in a Neutralisation Pit (6.0x7.5x2.5 m size) and the Treated Effluent of 200 cu.m/day is pumped to

the Cement Plant for bed formation.

The Cement Plant generates about 40 cu.m/day Domestic Sewage, CPP generates 1.8 cu.m/day

Sewage and the Guest House and O&M Colony generates 298.2 cu.m/day Sewage. Thus, the Complex

generates about 340 cu.m/day Domestic Sewage in total.



While, the Domestic Sewage from the Cement Plant, CPP and Guest House are treated in a Combined

Sewage Treatment Plant (STP) of 200 cu.m/day capacity, the Sewage Guest House and O&M Colony are

treated in 3 Septic Tanks followed by Dispersion Trenches.

The Treated Sewage of 160 cu.m/day from the STP is utilized for Green Belt Maintenance (120

cu.m/day) and Dust Control Measures (40 cu.m/day). Thus, ‘Zero Effluent Discharge’ is practiced at the

Complex.

Solid Wastes : STP Sludge of 10 TPD is used as manure. Oily Sludge is utilized in Co-processing in the

Kiln and Spent Oil @ 47.5 KL/Annum is being sold to the Authorised Recyclers for further recycling.

Refractory Bricks of 600 Tons/Annum is sold to the Brick Manufacturers.

From CPP, generated Fly Ash @ 54 TPD is pneumatically transported to the Cement Plant and utilized

for PPC manufacturing and the Bottom Ash @ 10 TPD is utilized in Cement Plant.

2.5 Power Demand

The existing power requirement is 23 MW. The source of power is Captive Power Plant (27.0 MW) and

also through TANGEDCO Grid (10.1 MW).

2.6 Fuel Demand

The Cement Plant will be utilizing Furnace Oil for Kiln’s initial firing. Petcoke is used as fuel in the Kiln.

Also, Coal and Lignite are used as fuel for both Cement &Power Plants. HSD is used as fuel for Standby

DG sets of 3x625 KVA in CPP. The quantity required are :

v Petcoke for Kiln : 600 TPD

v Coal for both Plants (Imported) : 1150 TPD

v Lignite for both Plants : 1450 TPD

v Furnace Oil for Kiln initial firing (1x25 KL Tank) : 15 KL

v HSD for DG Sets, etc. (1x20 KL & 1x30 KL Tanks) : 3 KL/day

2.7 Existing Project Cost

The existing Project Cost and EMB Budgets are given in Table 2.4.

Table : 2.4 Project Cost & EMP Budget

Sl. No. Component Cement Plant CPP Total

1 Project Cost, Rs. Crores 1151.87 166.92 1318.79

2 EMP Capital Cost, Rs. Crores 20.83 5.21 26.04

3 EMP Operating Cost, Rs. Crores/Annum 4.85 0.45 5.30



2.8 Need for the Proposal

DCBL has proposed the Modernisation & Upgradation of Ariyalur Cement Plant with State-of-Art

Technology viz. improvement of the existing Pyro Processing Systems, modernization of the machineries

and also Pollution Control Measures upgradation to achieve PM emission <30 mg/Nm3 and other

Pollutant Levels within the stipulated Norms.

2.9 The Proposal

With the proposed Modifications, increase in the clinker production will be about 6500 TPD, equivalent to

2.21 MTPA per annum. With the enhanced clinker capacity (2.21 MTPA), the Cement production capacity

will be enhanced from existing 3.0 MTPA to 4.0 MTPA. For the Cement grinding, an additional Cement Mill

of 1.00 MTPA capacity will be added (Table 2.5). The proposed Modifications and Upgardations are listed

in Table 2.6.

Proposed Layout is given as Fig. 2.1.

Table : 2.5 Existing & Proposed Production

Production of Existing Addition on Expansion Cumulative Percentage Increase

Clinker 2.00 MTPA

0.21 MTPA

(with Modernisation and

Upgradations)

2.21 MTPA 10.50%

Cement 3.00 MTPA

1.00 MTPA

(with addition of 1.00 MTPA Cement Mill & Cement Silo)

4.00 MTPA 33.33%

Table : 2.6 Proposed Modifications & Upgradations

Sl. No.

Proposed Modifications & Upgradations

Proposed Activities Result Cost Involved, Rs. Lakhs

1 Kiln riser duct

Modification

Riser duct area would be increased from 4.58 to 5.7 m2. By this modification the Riser duct velocity shall reduce from 32 to 26 m/sec and kiln inlet O2 will increase by 1.0%, which results in Preheater fan speed reduction by 1% & reduction in kiln inlet coating formation

Increases Clinker output by 100 TPD

12.00

2 Velocity optimization in Kiln coal pumping line

Kiln coal pumping line size shall be from 250 to 200 mm and by this we can able to maintain the velocity as 28 m/sec by inturn reducing

Results in reduction of specific heat consumption by 1 Kcal/Kg clinker

5.50



Sl. No.

Proposed Modifications & Upgradations Proposed Activities Result

Cost Involved, Rs. Lakhs

blower volume from 5100 to 4650 m3/ hr with help of VFD.

3 Cooler Vent Fan cone up-gradation

By increasing the clinker production, the clinker temperature will get raised to 195 Deg C. To increase the cooler fan volume, cooler vent fan cone to be modified.

By this modification, the fan volume would increase by 30,000m3/hr and the Clinker temperature will get reduced by 20 Deg C.

3.20

4 Conversion of Raw meal Silo feed Elevator

From DOL to VFD Increase the Raw Mill output from 375 to 450 TPH

16.00

5 Conversion of CA Fan & HAG blower motor

From DOL to VFD - 20.00

6 RVRM classifier annular gap reduction

- Mill output increase by 25 TPH

8.00

7 Raw Mill Fan GRR modification

- - 33.00

8 Cooler Vent Fan Upgradation

- - 116.00

9 Kiln feed elevator Upgradation

- - 124.00

10 Cooler Up-gradation ( Static Part)

- - 200.00

11 High efficiency Preheater Fan Upgradation

- - 60.00

12 Pyro- jet Burner Optimization

As compared to Duoflux burner, Pyro-jet burner is having the features of low primary air consumption, thereby reduction in Specific heat consumption by 5 Kcal/ kg clinker as well as reduction in free lime content in clinker.

Primary air volume increased from 4000 to 7500 m3/Hr by installation of high volume PD Blower. With the above measures, clinker production increased to 5800 TPD

-

13 Additional cement mill with silo’s

- - 10,000.00

14 Storage Shed for Green fuels

- - 84.95

15 Coal & Additive Truck Tippler Up gradation

- - 184.56

16 Truck Parking yard - - 427.94

17 Kiln Outlet Seal - - 37.23

18 Stores Open yard shed - - 53.96

19 5th Hopper for additives usage in cement mill

- - 168.81

20 Flooring & HEMM shed - - 75.62

Total 11,630.77

For additional 1.0 MTPA Cement grinding, raw materials required with additional 0.21 MTPA Clinker (max.

demand) are : Gypsum - 0.006 MTPA; Fly Ash : 0.040 MTPA & Slag : 0.65 MTPA.



Some additional improvements which results in increased clinker production are as follows:

v First 3 compartments, higher MFR size change and increased the Cooler Recuperation efficiency by

1%.

v Increase the kiln burner flame momentum up to 3000 % m/sec by increasing PA Fan speed 110 %.

v Increase the Kiln speed from 5.5 to 5.75 RPM.

v Change the PC Coal set point from PC outlet temp to 5thcyclone outlet temperature and increase the

PC outlet temp to 930 Deg C.

v Cooler First 3 Fans speed increased to 110%.

v Provide more number of Air Blasters and Poking holes to avoid the coating formation in kiln inlet and

Cooler.

v Burner position lowered by 100mm to reduce the volatility.

v Blending Silo Extraction Problem was solved by changing the Gates “from V-type to U-type” and

modified Double aeration system instead of Single aeration system.

v Raw meal residue maintaining 15% on 90 mic.

v Coal residue maintaining below 1% on 90 mic.

v Additional water spray nozzles provided in cooler.

v VFD installed in PC Coal Pfister to reduce the RPM.

The Machinery details on Modernisation are given in Table 2.7.

Table : 2.7 Proposed Machineries Capacity

Section Equipment type Make Installed capacity

Capacity on Modernisation

Crusher Two stage MMD 1200 TPH 1200 TPH

Raw mill VRM (Vertical Roller Mill) PFEIFFER MPS

5000 B 400 TPH 450 TPH

Kiln & preheater 5 stage, single string with ILC

(inline calciner) Flsmidth 5800 TPD 6500 TPD

Clinker Cooler SF Cross bar cooler Flsmidth 5800 TPD 6500 TPD

Coal Mill VRM PFEIFFER MPS

2800 BK 40 TPH 40 TPH

Cement Mill VRM PFEIFFER MPS 5600 BC

300 TPH 400 TPH

Packer Roto packer EEL 3x240 16 spouts

3x240 16 spouts

2.10 Proposal Benefits

Environmental Benefits : Optimisation of Process, Modernisation of existing Technology and

Upgradation of existing Machineries so as to increase the Clinker Production without any major

Construction and major Equipments additionally.

Financial Benefits : The Unit can enhance the Plant’s productivity within the existing Infrastructures.

Social Benefits : There will be a positive impact due to the proposal by improved local and regional

economy.



3.0 Project Description 3.1 Type of Project


additional land and, no major Construction for the additional Clinker and Cement Production. As per the

Environmental Impact Assessment Notification SO 1533 (E) dt. 14.09.2006, all Cement Plants with >1.0

MTPA capacity have been kept at Sl. No. 3 (b) under Category ‘A’ for the Environmental Clearance from

the Ministry of Environment, Forest and Climate Change (MoEFCC). Accordingly, Form-1, Feasibility

Report and other required Documents are submitted to the Ministry to determine TOR for the EIA Study.

3.2 Location & Environmental Setting

DCBL Ariyalur Cement Plant is located inbetween 11o10’21”-11o11’17” Latitude & 79o05’45”-79o06’42” E

Longitude (Survey of India Topo Sheet No. 58 M/4; Fig. 1.2). DCBL Cement Plant location in High

Resolution Satellite Imagery is given as Plate IV.

There is no environmental issues about the site. There is no National Park, Wild Life Sanctuary, Biosphere

Reserve, Hot Spot, Historical Monument exist within 10 km radius area (Fig. 1.3). Kallankurichi Kaliyuga

Varadharaja Perumal Temple is at 3.4 km in SE direction from the Plant. There are 6 Reserved Forests

(RFs) from 9.0-15 km distance from the Plant as detailed below :

v Vannankurichi RF- 9.0 km-East

v Manageri RF-12.2 km-East v Kunnam RF, 12.0 km, Northwest v Vilangudi RF-13.0 km-Southeast v Sedalavadi RF, 13.3 km-Northeast v Chittali RF, 14.4 km, Northwest

A seasonal nallah Kallar River originates near the Plant area at 1.0 km distance in the east. Seasonal

Marudaiyar River drains the Region which flows at 7.4 km distance from the Plant in the south.

Vanchiyam odai flows in the west (@ 4.6 km) and joins Marudaiyar River. Another seasonal Anaivari

Odai flows in the north @ 12.7 km and joins Vellar River in the northeast.

The State Highway (SH) 139 Ariyalur-Sendurai-Jayamkondam Road runs adjacent to the Plant Area.

Ariyalur Bypass (3.2 km in SW), NH-136 Ariyalur-Perambalur Section (4.3 km in SW), NH-81 (Trichy-

Chidambaram Section (9.7 km in SE) and SH-143 (4.2 km in W) are the major roads in the Plant Area.

Southern Railway BG Line connecting Chennai-Ariyalur-Trichy-Madurai-Kanniyakumari runs at 1.4 km in

the west and Ariyalur Station is at 3.7 km in SW direction.

Trichy Airport is at 60 km in SW and Chennai Airport is at 230 km in NE. Karaikkal Port (88 km in SE),

Cuddalore Port (94 km in NE) and Chennai Port (247 km in NE) are the nearby Ports. Taluk & District

Head Quarter Ariyalur is at 3.7 km southwest from the Plant. Nallambathai hamlet of Govindapuram

village is located at a distance of 0.3 km in north and Govindapuram is at 1.6 km in west..



3.3 Alternative Sites

The Modernisation and Expansion activities are proposed within the existing Industry premises and

therefore, no alternate site has been considered.

3.4 Size/Magnitude of Operation

With the proposed Modifications and Upgradations, Clinker production will be 2.21 MTPA and Cement

production (OPC/PPC/PSC) will be 4.0 MTPA. For the Cement grinding, an additional Cement Mill of 1.0

MTPA capacity will be established. Additional 4 MW power will be required for proposed cement mill

circuit and the existing Sources are adequate to meet the power demand.

3.5 EMP Measures

Air : Adequate Air Pollution Control Measures (APC) measures to control PM emissions are provided in

the Cement Plant viz. Electrostatic Precipitators to Clinker Cooler & Boilers, Bag House to Raw Mill/Kiln,

Coal Mill, Cement Mill, etc. to control PM emission <30 mg/Nm3. The dust collected from Bag

House/Filters, etc. are totally recycled in the process for cement manufacturing. Bag House is proposed

for the additional Cement Mill also to control PM emission <30 mg/Nm3.

Water : Existing water demand is 1,400 cu.m/day and is met from permitted borewells within the Plant

premises. The additional water demand of 200 cu.m/day will also be met from the permitted source only

and within the permitted 1,620 cu.m/day.

Solid Wastes : No change in the Quantity of Solid Wastes Generation, Storage and its Disposal due to

the proposal.

4.0 Site Setting & Analysis 4.1 Connectivity

The Plant is well connected by road & rail modes. The Plant is accessible from the adjacent State

Highway SH-139 connecting Ariyalur-Sendurai and Jayamkondam. Southern Railway BG Line runs

parallel to the site at a distance of 1.4 km in the west. The nearest Airport is Trichy at a distance of 60 km

in the southwest.

4.2 Land Form

The Plant Area is predominantly dry, barren flat terrain and covered with red soil. Fallow land occupies

45.85% and Dry cropland occupies 34.16% of the Study Area. Water body occupies about 2.09% and

Built-up land occupies about 5.2% of the study area (Fig. 3.2).



4.3 Existing Infrastructure

Other than Dalmia Cement Tamaraikulam Plant, there are five other Cement Plants in the Region viz.

RCL Govindapuram Plant (5.0 MTPA; 0.2 km in SW), TN State Govt. owned TANCEM near Kallankurichi

(0.6 MTPA; 2.6 km in south), Ultratech Plant at Reddippalaiyam (1.2 MTPA; 10.3 km in the southeast),

Chettinad Cement Kilapaluvur Plant (5.5 MTPA; 12.8 km in the south-southwest) and. Jeppiar Cement

Cement Plant (0.3 MTPA) in Kilamattur at 4.5 km distance in the west. These Cement Plants and others

have a Limestone Mines in the Region.

4.4 Soil Classification

The soils in the study area are classified into 5 types. They are Deep moderately drained calcareous

cracking clay soil, Very deep imperfectly drained cracking clayey soil, Very deep moderately well drained

calcareous cracking soil, Very deep well drained clayey soils, Very deep well drained loamy soils.

4.5 Climatic Data from Secondary Source

Sub-tropical climate prevails over the study area. The nearest IMD station is Trichy Airport. The

temperature is maximum during March to May and it drops from June onwards. The maximum

temperature ranges from 40 °C to 44 °C and minimum temperature from 18 °C to 27 °C. The salient

features of climatic data are :

Annual average temperature : 29.4 °C Annual average maximum temperature : 36.0 °C Annual average minimum temperature : 24.4 °C Annual average humidity : 62.9 % Annual average visibility : 5.5 km Annual average wind speed : 13.4 kmph No. of rainy days : 79 Total days with thunderstorm : 36 No. of days with fog : 5

Trichy District receives rainfall both in Southwest and Northeast Monsoons with rainfall ranging from 730

mm to 900 mm.

The nearest raingauge station is located at Ariyalur. The 70 years normal annual rainfall in the area is

around 1096 mm. The North East Monsoon contributes major amount of rainfall, which is about 50 % of

the rainfall, and the remaining rainfall occurs during Southwest and Transitional period. The season wise

and monthly normal rainfall for the Ariyalur station is furnished below :

Rain gauge station Jan – May (Transitional Period)

June – Sep (South West Monsoon)

Oct – Dec (North East Monsoon)

Annual Normal

Ariyalur 199 379 518 1096

Winds are generally of low to moderate speed during most of the months except during northeast

monsoon, which creates cyclonic weather and brings rainfall aided with strong winds. The predominant

wind direction is from W/NE/NNW directions. The average wind speed is 6.7 km per hour. During the



months of May-June the maximum temperature reaches up to 44 oC. and during the December-January

the lowest temperature reaches up to 20 o C. The mean relative humidity measured is 61.2%. The sky is

generally clear or occasionally partly clouded except the NE Monsoon Periods.

4.6 Social Infrastructure Available

All the villages in the study area have the basic educational & medical facilities, transport, phone

connection, post and telegraph, Banking services and market facilities. Drinking water facilities are

available almost in all villages in the study area. Wells and hand pumps are the major source of drinking

water. Primary and Middle Schools are available in almost all villages whereas Senior secondary

schools, Training school and adult literacy centres are available in some of the villages. However, college

education is available only at nearby Ariyalur, Trichy, etc. Public water supply and Power supply are

available in most of the villages. There are good approach roads in the form of panchayat roads and

State Highways passing through the study area and bus transportation is there to almost all villages. The

villages situated on the main road have marketing facilities for their day to day requirements.

5.0 Planning Brief 5.1 Planning Concept & Amenities/Facilities


additional land and no major Construction for the additional Clinker and Cement Production. Existing

Infrastrutures in the Cement Plant are adequate for the Proposal.

5.2 Land Use Planning

There is no major change in Land Use Pattern of the Plant other than the additional Cement Mill.

6.0 Proposed Infrastructure 6.1 Industrial Area



Rate. The Modernisation and Expansion activities are proposed within the existing Plant Premises with

no additional land and no major Construction.

6.2 Residential Area

No Township exists other than Guest House and O&M Colony in the Plant. The Township with recreation

facility will be constructed.



6.3 Social Infrastructure

DCBL CSR Committee exists as per the provisions notified by the Ministry of Corporate Affairs on

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

CSR activities will be covered and Reported (& also displayed in the Company website) :

v Eradicating extreme hunger and poverty.

v Promotion of education & vocational skills.

v Ensuring environmental sustainability.

v Contribution to the Prime Minister's National Relief Fund or any other fund set up by the Central

Government or the State Governments for socioeconomic development and relief.

7.0 Rehabilitation & Resettlement (R&R) Plan

The Project does not involve any R&R and thus no R&R Plan is envisaged.

8.0 Project Schedule & EMP Budget 8.1 Project Schedule

Project will be completed in about 24 months on approval of statutory clearances.

8.2 Project Cost

The Modernisation Proposal Project Cost is Rs.116.37 Crores. An EMP Budget of Rs.3.35 Crores is

earmarked additionally for the Proposal with an Operating Cost of Rs.1.23 Crores per Annum. A budget

of 1% of the Project Cost will be allotted as CER Budget.

9.0 Analysis of Proposal 9.1 Financial & Social Benefits

Financial Benefits : The Unit can enhance the Plant’s productivity within the existing Infrastructures.

Social Benefits : There will be a positive impact due to the proposal by improved local and regional

economy.

***