Presentedby PV Krishnaiah Yadav GM (Works) - QCFI...

Sustainable MiningPresented by

PV Krishnaiah YadavGM (Works)

Penna Cement Industries Limited

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Presented by

PV Krishnaiah YadavGM (Works)

Talaricheruvu Unit -1994 Ganeshpahad Unit - 2002

PENNA CEMENT PLANTS

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Tandur Unit - 2010Boyareddypalli Unit -2008

PENNA BRANDS

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OPC PSCPPC

SUSTAINABLESUSTAINABLEMININGMINING

DRILLING

LOADING &TRANSPORTATION

DUMPMANAGEMENT

CSRACTIVITIES BLASTING

SUSTAINABLESUSTAINABLEMININGMINING LOADING &

TRANSPORTATION

CRUSHINGENVIRONMENT

WATERMANAGEMENT

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MINING LEASE DETAILSKorumanupalli Limestone Mines

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MINING LEASE DETAILSKorumanupalli Limestone Mines

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Name of the Mining Lease / ML No.Korumanipalli Limestone Mine-205.212Ha3575/R4—4/2001

Name of the Lessee Address

M/s Penna Cement Industries Limited,Lakshmi Nivas, PLOT-705, Road No-3,Banjara Hills, Hyderabad,Telangana State-500034.

Phone & Email Ph:[email protected]

LEASE AREA DETAILS

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Ph:[email protected]

Mine code (for ML) 38APR11115

IBM Registration Number(under rule 45 of MCDR, 1988) IBM/1099/2001

Mineral Limestone

Total Lease Area (ha)Break up of area:Forest Land (ha)Private Land (ha)Revenue land (ha) (Govt. Land)Others, if any

205.212 Ha00.00 Ha167.70 Ha37.51 Ha0.00 HaL

Talaricheruvu Works

Lease period (valid up to) 28.01.2054

Resources as on 01.04.2015(beginning of the year under report) 30.89 Million Tonnes

Method of Mining Opencast Mining

LEASE AREA DETAILSContd…

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Method of Mining Opencast Mining

Name and contact details of all the membersof Sustainable Development Unit (SDU)

PV Krishnaiah Yadav – GM (Works)Ph :9440906826K. Ramakrishna Reddy-AGMPh :9492131960K. Ramanjaneya Reddy-AGMPh :9440906980Ch.Jayakrishna – ManagerPh :9490263372

Talaricheruvu Works

S.NoType of land use

(in ha)

As perapproved

Mining plan

Area utilisationat the

beginning of RY

Additional areaoperated during

the year

Cumulativeat the end of

RY

1 Mining 38.766 27.00 3.50 30.50

UTILISATION OF LEASE AREA

8

2 OB/waste dump 0 0 0 0

3Top soilpreservation

0.25 0 0 0

4 Area reclaimed 0 0 0 0

5 Others (Greenbelt) 5.00 ha 2.62 1.03 3.65

Talaricheruvu Works

STATUTORY COMPLIANCES

S.No DETAILS REMARKS

1Date of Approval of Mining Plan/Validupto/valid Quantity

AP/KNL/MS/Lst-257-SZ/66,dt:02.01.2013,2012-13 to 2016-171,03,53,201 Tonnes

2.

SPCB Approvals

(i) Consent to Establish

(ii) Consent to Operate

APPCB/KNL/443/CFE/HO/2007-1698dated: 26.10.2007APPCB/KNL/443/CFO & HWA/HO/2014 -710 DATED: 04.12.14

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2.

SPCB Approvals

(i) Consent to Establish

(ii) Consent to Operate

APPCB/KNL/443/CFE/HO/2007-1698dated: 26.10.2007APPCB/KNL/443/CFO & HWA/HO/2014 -710 DATED: 04.12.14

3. Forest Clearance, Letter No. and details NA

4 Violations pointed out by IBMTotal no. of violations pointed out –0Violations complied with -0

5Violations pointed out by DMG, DGMS,MoEF&CC and CPCB/SCPB.

Total no. of violations pointed out –2Violations complied with - complied

Talaricheruvu Works

SPENDING TOWRDS SDF

S.No PARTICULARS DETAILS

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Constitution of SDU (SustainableDevelopment Unit) at Mine level - team ofMine management comprising of Technical,Financial, CSR, HRD, Environment heads forensuring implementation of SDF principles.

PV Krishnaiah Yadav - GM (Works)M Subba Reddy – Sr.DGM (P&P)P Ramprasad - Sr. DGM (Mech.)M Dayakar Reddy -Sr. DGM (Accounts)K Ramakrishna Reddy - AGM (Mines)G Ravinder Reddy - AGM (E&I)B Prabhakar Reddy – Sr.Manager (HR)B Karunakar Reddy - AM (Civil)

Total expenditure incurred forimplementation of SDF at minelevel includingEnvironment Protection,CSR & other welfare activities inperipheral area

10

2

Total expenditure incurred forimplementation of SDF at minelevel includingEnvironment Protection,CSR & other welfare activities inperipheral area

Total Expenditurefor SDF

implementation (a)

Rs. 65.11 Lakhs

10% of Royalty(b)

Rs 78.76 Lakhs

% ofUtilisation(a/b *100)

82.66%

3CSR spending at the mine level inReporting Year (as per CompaniesAct, 2013 or otherwise)

Committed:65 Lakhs

Utilised:57.27 Lakhs

Talaricheruvu Works

Korumanipalli Mines -TLC Chanakya Mines -GPD

PENNA MINES

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Ogipur Mines-TNDGudipadu Mines -BRP

Talaricheruvu Works

PENNA MINES

KORUMANUPALLILIMESTONE MINES - TLC

Lease area : 205.212 HaLease period upto : 28.01.2054Reserves as on 01.04.2015 : 30.89 Million Tonnes

CHANAKYA CEMENTLIMESTONE MINES - GPD


12 Talaricheruvu Works

GUDIPADULIMESTONE MINES - BRP


OGIPURLIMESTONE MINES - TND


ZERO WASTE MINING

KORUMANUPALLILIMESTONE MINES - TLC

A thin layer of Black cotton soil is available which isscrapping and using for Green belt development. No overburden.

No waste generation during Mining.


BC soil in between the outcrop is available and using forGreen belt development. No over burden.




BC soil in between the outcrop is available and using forGreen belt development. No over burden.


GUDIPADULIMESTONE MINES - BRP

0.3 to 0.5mts layer of black cotton soil is using for green beltdevelopment. No over burden.


OGIPURLIMESTONE MINES - TND

A very thin layer of Black cotton soil is available which cannot be separated. No over burden.


DUMP MANAGEMENT

Where waste is generated during Mining it should be dumped systematicallyand the dump should be stabilized. Dump should be in such a way that, not toerode due to rains /whether to protect the environment form the mining activityand also for sustainability. So that dump area can be utilized for vegetation.


COCO COIR MATTINGR&R PLAN

MINERAL CONSERVATION

Flaggy Limestone on top of the depositand Clay band intrusion in second benchwhich are in the deposit are usingdirectly by proper blending in theStacker - Reclaimer with suitable ratiofeedable to the Raw mill

CLAY BAND

Korumanipalli Mines -TLC


High silica material of 8Mtrs thick band ontop bench (20 to 24% silica) is blendingwith high grade of 2nd and 3rd benchesand using the mineral judiciously.Siliceous Lst

Chanakya Mines -GPD

MINERAL CONSERVATION

There is a high silica band of thicknessabout 12 mts in between the thickness ofthe deposite and separated the benchformation. No stocking of this material.Since Mine is developed for full depth wecould able to blend with the other top &bottom benches and using.

Gudipadu Mines -BRP

Siliceous Lst


This mine started in the year 2010 and notdeveloped fully. A very thin layer of Blackcotton soil is available which can not beseparated in mining and using in the processand very good in buranbility. Explorationhas been done further depths and high silicamaterial is there in 4th and 5th benches whichwill be blended with the top high gradebenches and mineral will be conserved.

Ogipur Mines - TND

Siliceous Lst in bottombenches

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Bench Height Proposed – 9 to 10 MtrsActual maximum bench height– 8 to 9.5 Mtrs

Bench WidthProposed – Widest machine+2 Mtrs

Actual minimum bench width15 Mtrs

General Housekeeping in Mineworkings

Very good house keeping is maintaining

MINING OPERATIONKorumanipalli Mines -TLC

Talaricheruvu Works17

MINES PRODUCTION in Tonnes

800000

1000000

1200000

1400000

1600000

1800000

2011-12

2012-13

2013-14

Talaricheruvu Works

0

200000

400000

600000

800000

TLC GPD BRP TND

2013-14

2014-15

2015-16

MINING OPERATIONS

Where the lead from the mine to plant is same of 6 kms by providing the highercapacity crusher and belt conveyor transportation from crusher to plant to restrictthe movement of Dumpers the cost of mining will come down to almost 50%. Thisis practically getting the advantage in our own Mine in Gudipadu - BRP

To sustain the Korumanipalli Mines at TLC we are switching over to highercapacity in-pit mobile crusher and belt conveyor transportation system fromcrusher to the plant to reduce the cost and for good environment


To sustain the Ogipur mines at TND we are going for Pipe conveyor system it isunder commissioning stage of length 5 kms supplied by M/s Flsmidth fromcrusher to the plant to reduce the cost and for pollution free environment

The following are the main focus points:To avoid secondary blastingTo improve the Loading & Transportation efficiencyTo reduce the cost of MiningTo minimise the CO2 emissions

DOWN HILL CONVEYOR 5 Kms

Gudipadu Limestone Mines to plant Stacker


PIPE CONVEYOR 5 Kms

Ogipur Limestone Mines to plant by Pipe conveyor – 5 kms


Pipe conveyor under construction

Equipped with track mounted and operators cabin

Auto idle, emergency stop, battery cutoff switch

Inbuilt wet drilling arrangement

Auto drill rod changing arrangement

Auto idle, emergency stop, battery cutoff switch

Talaricheruvu Works

Drill holes are plugging

Using optimum spacing and burden

Training is giving to the employees on specific subject,required PPE provided and PME conducted

Explosive & Ammonium nitrate are stored in licensedGodown and transported to blast site in licensed Van

Non electrical delay detonators are using for controlledBlasting and for good fragmentation

Optimum charging will be done for controlled blasting

Talaricheruvu Works

Induced ground vibrations are measured

Optimum charging will be done for controlled blasting


Blasting will be done at definite timings conductedand siren & sentries are arranged

Safety hand rails, anti skid pads, baffle plate, turboguard, fire protection system and Centralized autolubrication system

AC Cabin and swing lock arrangement provided

Talaricheruvu Works

Auto idling and emergency cutoff are provided

Muck pile wetting arrangement made before loading


Dust proof cabin, fire fighting equipment, emergencysteering, steering lock arrangement are provided

Audio visual alarms, Rear view camera and blind spotmirrors and Tail end protection are provided


Talaricheruvu Works


One way traffic with CC roads from pit mouth tocrusher and with in the Mine water sprinklingarrangement made for avoid fugitive emission


Provided jet water sprinklers in dump hopper tosuppress the dust and three sides closed shed provided

Water spray in crusher and bag filters are provided tosuppress and collect the dust in crushing operation

Covered the belt conveyors and transfer points andalso bag filters provided in transfer points

Talaricheruvu Works

Covered the belt conveyors and transfer points andalso bag filters provided in transfer points


Emergency stop and Emergency siren provided

ENVIRONMENT MANAGEMENT

To maintain the good environment in and around the Mines and plants green belt isdeveloped

Water spray arrangements has arranged to sprinkle along the Mines haul roads tominimise the fugitive emission and CC roads with one way traffic

Wet drilling arrangement with in built water injection system provided

Muck pile wetting arrangement to suppress the dust at loading point

Closed shed for dump hopper and water spray nozzles in the crusher hopper providedto suppress the dust during Dumper unloading

Bag filters and water spray arrangements are made in crusher and transfer points tocollect and suppress the dust

Ambient Monitoring is doing by third party certification in addition to that installation ofpermanent stations


To maintain the good environment in and around the Mines and plants green belt isdeveloped

Water spray arrangements has arranged to sprinkle along the Mines haul roads tominimise the fugitive emission and CC roads with one way traffic

Wet drilling arrangement with in built water injection system provided

Muck pile wetting arrangement to suppress the dust at loading point

Closed shed for dump hopper and water spray nozzles in the crusher hopper providedto suppress the dust during Dumper unloading

Bag filters and water spray arrangements are made in crusher and transfer points tocollect and suppress the dust

Ambient Monitoring is doing by third party certification in addition to that installation ofpermanent stations


YEAR TOTALPLANTS

1992-95 70001995-00 170002000-05 146212005-10 56562010-11 9422011-12 564

YEAR TOTALPLANTS

2002-05 15950

2005-10 7441

2010-11 2713

2011-12 2098

YEAR TOTALPLANTS

2008-09 585

2009-10 17352010-11 3335

2011-12 4695

2012-13 6050

2013-14 4500

YEAR TOTALPLANTS

2010-11 1500

2011-12 1700

2012-13 1800

2013-14 2450


2011-12 5642012-13 4402013-14 14652014-15 22652015-16 3084

TOTAL 53037

TLC GPD

2012-13 3089

2013-14 3827

2014-15 9595

2015-16 5144

TOTAL 52018

2013-14 4500

2014-15 5000

2015-16 3120

2016-17 3200

TOTAL 32220

BRP

2013-14 2450

2014-15 1400

2015-16 7500

TOTAL 16150

TND

GREEN BELT DEVELOPMENT -TLC

Talaricheruvu Works

GREEN BELT DEVELOPMENT-TLC

GREEN BELT DEVELOPMENT -TLC

Talaricheruvu Works

GREEN BELT DEVELOPMENT-GPD

Talaricheruvu Works

GREEN BELT DEVELOPMENT-BRP

Talaricheruvu Works

GREEN BELT DEVELOPMENT-TND

Talaricheruvu Works



ENVIRONMENT MONITORINGAMBIENT AIR QUALITY


WATER MANAGEMENT

Garland drains provided along the periphery of the pit. A big water sump is created inlower bench of the Mine to collect the catchment water and also for settling thesuspended solids. The same water is using for the requirement of plant operations, greenbelt development and dust suppression in Mines

Check dam is constructed during very initial stage of the plant with an intention toimprove the water table nearby lands, which has given good effective result to all thefarmers nearby our mines and enjoying the facility with good crops.

Washing ramp with oil skimming tanks constructed for vehicular washing to separate theoil and grease traps

STP is constructed for the domestic usage water and after filtering the same water isgardening

Water quality is monitoring with the third party certification


Garland drains provided along the periphery of the pit. A big water sump is created inlower bench of the Mine to collect the catchment water and also for settling thesuspended solids. The same water is using for the requirement of plant operations, greenbelt development and dust suppression in Mines

Check dam is constructed during very initial stage of the plant with an intention toimprove the water table nearby lands, which has given good effective result to all thefarmers nearby our mines and enjoying the facility with good crops.

Washing ramp with oil skimming tanks constructed for vehicular washing to separate theoil and grease traps

STP is constructed for the domestic usage water and after filtering the same water isgardening

Water quality is monitoring with the third party certification

WATER MANAGEMENT

MINE SUMP

CHECK DAM


STPSERVICE RAMP &OIL SKIMMING TANKS

ENVIRONMENT MONITORINGWATER QUALITY



NOISE LEVEL

Controlled Blastings are conducting to avoid high noise levels and fly rock as well asground vibration

Avoid secondary blasting which create very high noise and air over pressure and where notpossible to avoid, it should be minimized

Dust proof cabin and PPE are provided to operators who are exposing to high noise levels

Acoustic and shed covered crushers, generators and compressors for minimise the noiselevels

Good maintenance of equipment to minimise the noise generation

Noise levels are monitoring with the party certification


Controlled Blastings are conducting to avoid high noise levels and fly rock as well asground vibration

Avoid secondary blasting which create very high noise and air over pressure and where notpossible to avoid, it should be minimized

Dust proof cabin and PPE are provided to operators who are exposing to high noise levels

Acoustic and shed covered crushers, generators and compressors for minimise the noiselevels

Good maintenance of equipment to minimise the noise generation

Noise levels are monitoring with the party certification


AC CABIN AC CABIN


CRUSHER SHED

AC CABIN

ENVIRONMENT MONITORING

NOISE LEVEL


WELFARE & SOCIO - ECONOMIC DEVELOPMENTPROGRAMS FOR LOCAL COMMUNITIES- TLC

DETAILS OF DEVELOPMENTDETAILS OF EXPENDITURE NO. OF

BENEFICIARIESPROPOSED ACTUALSUPPORT FOR DRINKING WATER & AGRICULTURE

Water storage tanks, drinking water supply facility& irrigation support to agriculture

Exp. Rs. 21 Lacks Rs. 13 Lacks 1800

SUPPORT TO HEALTH & MEDICAL SERVICES

Preventive measures for mitigation of mine relatedhealth problems Promotion of Hygiene andsanitation public health initiatives

Exp. Rs. 1.6 LacksRs. 1.4Lacks

2000

42

Preventive measures for mitigation of mine relatedhealth problems Promotion of Hygiene andsanitation public health initiatives

Exp. Rs. 1.6 LacksRs. 1.4Lacks

2000

SUPPORT TO SKILL DEVELOPMENT & EDUCATION

Skill development & Vocational Trainingprogrammes for local communities

Exp. Rs. 475 Lacks Rs. 60 LacksStarting the college forconcrete tech. 120 studentsper year benefited

Promotion of Literacy & Education Exp. Rs. 48 Lacks Rs.45 Lacks 400 students apart fromemployees children in TLC

SUPPORT TO TRANSPORTATION SERVICES & INFRASTRUCTURE

Improvement of Road connectivity and Publictransport and other infrastructure facilitates

Exp. Rs. 16 Lacks Rs. 15 Lacks 300

Talaricheruvu Works

Reclamation & Rehabilitation

Reclamation is doing where the mineral is exhausted as per theRule 23(B) of MCDR 1988 of Progressive Mine Closure Plan.Since the waste generation is not there leaving the deeper levelsas water body where mineral is exhausted and plantation is doingalong the completed benches and mine boundary. To improve theflora and fauna.


Reclamation is doing where the mineral is exhausted as per theRule 23(B) of MCDR 1988 of Progressive Mine Closure Plan.Since the waste generation is not there leaving the deeper levelsas water body where mineral is exhausted and plantation is doingalong the completed benches and mine boundary. To improve theflora and fauna.

Exemplary work by small players as well

CSR activities extending to near by villages about 24 villages in remote area

Cement for housing, community centre & Temples

CC Roads for the village approaches

Drinking water supply with RO systems and permanent arrangements

All-furnished Schools with free education

Hospitals - free treatment, medicine, ambulance, health camps, sanitationmeasures

Institute for concrete technology with free boarding & stipend

In addition to that, community development by constructing temples, Churchand Dharga etc in surrounding villages

Talaricheruvu Works

Exemplary work by small players as well

CSR activities extending to near by villages about 24 villages in remote area

Cement for housing, community centre & Temples

CC Roads for the village approaches

Drinking water supply with RO systems and permanent arrangements

All-furnished Schools with free education

Hospitals - free treatment, medicine, ambulance, health camps, sanitationmeasures

Institute for concrete technology with free boarding & stipend

In addition to that, community development by constructing temples, Churchand Dharga etc in surrounding villages

CSR ACTIVITIES

YEAR Amount inRs.

2004 16000002007 61200002008 424000

2009 180000

2011 1075000

2012 648000

YEAR Amount inRs.

2009-10 355000

2010-11 439700

2011-12 1328150

2012-13 1817500

YEAR Amount inRs.

2010-11 200000

2011-12 230000

2012-13 13125000

2013-14 1548000

YEAR Amount inRs.

2008 580000

2009 790000

2010 672000

2011 1865000

2012 657609

The below amounts excluding running of schools with about 75 Lakhs per annum


2012 648000

2013 147000

2014 874000

2015 2864000

2016 1750000

TOTAL 1,59,64,000

TLC GPD

2013-14 235000

2014-15 487000

2015-16 851000

TOTAL 55,13,350

BRP

2013-14 1548000

2014-15 1476000

2015-16 1507000

TOTAL 1,80,86,000

TND

2013 3676734

2014 429671

2015 8323995

2016 2340356

TOTAL 1,93,35,365

PENNA SCHOOL DE-SILTING OF POND

Talaricheruvu Works

Talaricheruvu Works

Talaricheruvu Unit Ganeshpahad Unit

Boyareddypalli Unit

Talaricheruvu Works

Penna Management Systems

QMS (ISO 9001:2008) – Certificate No : 9910012073dt : 26/10/2010 Validity 25/10/2016

EMS (ISO 14001:2004) – Certificate No : IND15.579U/Edt : 26/6/2015 Validity 25/06/2018

49

EMS (ISO 14001:2004) – Certificate No : IND15.579U/Edt : 26/6/2015 Validity 25/06/2018

We are in the process of IMS (QMS, EMS & OHSAS)(Integrated Management System)

Talaricheruvu Works

Principle 1 Integrate sustainable development considerations within the corporatedecision making

Principle 2 Conduct business with ethical practices and sound systems ofcorporate governance

Principle 3 Implement risk management strategies based on valid data and sound science

Principle 4 Seek continual improvement in health and safety performance

Talaricheruvu Works

Principle 5 Seek continual improvement of our environment performance based on aprecautionary approach

Principle 6 Uphold fundamental human rights and respect cultures, customs and values indealings with employee and others who are affected by our activities

Principle 7 Contribute to conservation of biodiversity and integral approaches to landuse planning and management

Principle 8 Facilitate and encourage responsible use, reuse and recovery of minesmaterials including associated natural resources

Principle 9 Contribute to the social, economic and institutional development of thecommunities in which we operate

Employee HSE &community well being

Regional development

SustainableSustainableMiningMining

Emission monitoringsystems and controltechniques

51

Ecological stewardship

Sustainable practices leads to profitability & competiveness

Environmental andsocietal innovations arethe “right thing to do”

Water Management

SustainableSustainableMiningMining

Talaricheruvu Works

Talaricheruvu Works

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Presentedby PV Krishnaiah Yadav GM (Works) - QCFI...

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