1 Table of Contents 1. Executive summary 2. Introduction of the project/ Background information 3 Project Description. 4 Site Analysis 5. Planning Brief. 6 Proposed Infrastructure 7. Rehabilitation and Resettlement (R & R) Plan. 8. Project Schedule & Cost Estimates 9. Analysis of Proposal (Final Recommendations). PRE FEASIBILITY REPORT Of COROMANDEL LIMESTONE MINE (AREA: 602.137 Ha – Non Forest Land) Chilamkur villge, Yerraguntla Mandal, YSR Kadapa District, Andhra Pradesh. For INCREASE OF LIME STONE PRODUCTION FROM 2.00 to 5.00 MTPA (CAPTIVE LIMESTONE MINE) of THE INDIA CEMENTS LIMITED Prepared By B.S. ENVI-TECH (P) LTD., Secunderabad – 500 017
Transcript
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Table of Contents
1. Executive summary2. Introduction of the project/ Background information3 Project Description.4 Site Analysis5. Planning Brief.6 Proposed Infrastructure7. Rehabilitation and Resettlement (R & R) Plan.8. Project Schedule & Cost Estimates9. Analysis of Proposal (Final Recommendations).
PRE FEASIBILITY REPORT
Of
COROMANDEL LIMESTONE MINE(AREA: 602.137 Ha – Non Forest Land)
INCREASE OF LIME STONE PRODUCTIONFROM 2.00 to 5.00 MTPA
(CAPTIVE LIMESTONE MINE)
of
THE INDIA CEMENTS LIMITED
Prepared By
B.S. ENVI-TECH (P) LTD.,Secunderabad – 500 017
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CHAPTER – 1 EXECUTIVE SUMMARY
1. EXECUTIVE SUMMARY
THE INDIA CEMENTS LIMITED., (ICL), is operating a Cement Plantof 1.485 Million Tonnes Per Annum(MTPA) Clinker capacity atChilamkur villge,Yerraguntla Mandal, YSR Kadapa District,Andhra Pradesh.The company is having a total installed capacity of 17 million tonnesof cement production in the country, having Clinkerisation Units inTamilNadu, Andhra Pradesh,Telangana & Rajasthan with grindingunits in Maharastra & Chennai.
The plant at Chilamkur was commissioned in 1984.. The rawmaterial requirement to the cement plant is being met from theCaptive mines located adjacent to the mines in Chilamkur village overan extent of 602.137 Ha. The company is producing OrdinaryPortland Cement (OPC) and Portland Pozzolona Cement (PPC) .
ICL proposes to increase the Clinker production from 1.485 to 3.485MTPA by installation of new Unit.
Limestone requirement for Cement Plant expansion will also be metfrom Coromandel Limestone mine for which ICL had long backexecuted the lease with Government of Andhra Pradesh. The mine isalready in operation.
Captive Mining Lease comprises of North (about 260 Ha) and Southblock (about 342 Ha). A railway track exists between these twoblocks. Further, a village road divides the North block into two(eastern and western sides of the road). Statutory safety zones aremaintained along these infrastructures in accordance with'Regulations' and guidelines.
PRESENT PROPOSAL
Present proposal pertains to Limestone mine of ICL. ICL possessesmining lease extending over an area of 602.137 Ha falling in thejurisdiction of Chilamkur village, Yerraguntla Mandal, AnantapurDistrict Andhra Pradesh. This lease is named as “COROMANDELLIMESTONE MINE”.
ICL proposes to increase the limestone production from 2.0 to 5.0MTPA. The expansion of the existing mine is required to cater thelimestone requirement of the interlinked cement plant expansion.
The mineable reserves are estimated as 276.06 million tonnes.Mechanized method of mining is adopted. The limestone produced iscrushed and transported to cement plant by conveyor.
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A total quantity of 0.50 million cum of top soil is estimated to begenerated from the mining activity which will be used forafforestation.
The present water requirement is 110 m3/day and additional Waterrequirement for the proposed expansion is 220 m3/day sourced frommine pit storm water storage.
Power requirement is mainly for lighting in the mine area, Time officeand Garage-cum-Workshop and is met from grid.
Present manpower is 73 persons to carry out the mining operations.Additionally 10 persons will be employed for expansion. Existing fleetof mining machinery will be upgraded for higher productioncapability.
The capital Cost of expansion is estimated at Rs. 35 crores.
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CHAPTER – 2 INTRODUCTION OF THE PROJECT / BACKGROUNDINFORMATION
2.0 INTRODUCTION OF THE PROJECT / BACKGROUNDINFORMATION
i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. INCASE OF MINING PROJECT, A COPY OF MINING LEASE /LETTER OF INTENT SHOULD BE GIVEN.
PROJECT: ICL proposes to increase the limestone production from2.0 to 5.0 MTPA in Chilamkur Limestone mine located at Chilamkurvillage, Yerraguntla Mandal, YSR Kadapa District, Andhra Pradesh.
ICL has earlier obtained an integrated Environmental Clearance (EC)vide Letter J-11011/513/2007-IA(II)(I) dated 30-11-2007 for 2.0MTPA of Limestone production.
The present proposal is for obtaining Environmental Clearance forincrease of limestone production from 2.0 to 5.0 MTPA from Ministryof Environment and Forests & Climate Change (MoEF & CC) under1(a) category of EIA notification SO 1533 dated 14th Sep. 2006 andsubsequent amendments.
A copy of the mining lease letter is enclosed as Exhibit – 1
PROJECT PROPONENT
THE INDIA CEMENTS LIMITED., (ICL), is operating a cement plantof 1.485 MTPA Clinker capacity at Chilamkur village, YerraguntlaMandal, YSR Kadapa District, Andhra Pradesh.
Exploitation of limestone in this leasehold commenced on01.10.1982. The raw material requirement to the cement plant isbeing met from the Captive mines located adjacent to the factory inChilamkur village. The company is producing the three brands ofCements Viz Ordinary Portland Cement (OPC) and Pozzolona PortlandCement (PPC)
ICL proposes to increase the Clinker production from 1.485 to 3.485MTPA and Cement Production from 1.65 MTPA to 5.0 MTPA byinstallation of new Unit.PRESENT PROPOSAL
Present proposal pertains to existing Limestone mine of ICL. ICLpossesses a mining lease extending over an area of 602.137Ha fallingin the jurisdiction of Chilamkur village, Yerraguntla Mandal, YSRKadapa District Andhra Pradesh. ICL proposes to increase thelimestone production from 2.0 to 5.0 MTPA. The expansion of the
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existing mine is required to cater the limestone requirement of theinterlinked cement plant.
ii. BRIEF DESCRIPTION OF NATURE OF THE PROJECT
The limestone mine is spread over 602.137Ha with mineral reservesof about 276.06 Million Tonnes is located at Chilamkur village,Yerraguntla Mandal, YSR Kadapa District, Andhra Pradesh.
The mining of the deposit is worked by deep hole drilling & blastingwith fully mechanized open cast mining method. The benches are7.00 to 8.00m in height. The limestone is loaded into 35T dumpersand transported to crusher and then to cement plant throughconveyor for its captive use.
A total quantity of 16.00 million cum of top soil is estimated to begenerated at the end of mine life, from the mining activity which willbe used for afforestation and part backfilling mined out pit to theextent of 332 Ha, out of total excavated pit area of 561 Ha.
Soil cover is underlain by massive / bedded dark / light greycoloured limestone followed by purple shale at depth. At the end ofthe life of this mine, three pits will be formed, North Pit on the eastside of village road over an extent of about 216 hectares area, NorthPit on the west of village road over an extent of 20 hectares area andSouth Pit over an extent of 325 hectares area i.e. total over an extentof 561 hectares area. These pits would be partly backfilled i.e. about217 hectares area in South Pit with average soil thickness of 5 metresand 115 hectares area in North Pits, North-West Pit being completelybackfilled while North-East Pit backfilled with average soil thicknessof 5 metres.
All efforts would be made to re-handle the existing surface dumpsand utilize the same for backfilling of the excavated pits during FinalMine Closure period. Mine pit conversion into water reservoir over121 hectares in North pit and 108 hectares excavated area in Southpit respectively, i.e. total about 229 hectares excavated area would beundertaken. Ultimate pit slope would be maintained at 450. It isestimated that by the end of life of the mine, 16.00 million cubicmetres soil would be removed for exploitation of underlying limestoneformation.
After decommissioning mining activities, an area of 332 Ha of thepartly backfilled area and about 40 Ha of the lease including the 12Ha area of 7.50m boundary band will be developed under greenbelt.
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iii. NEED FOR THE PROJECT AND ITS IMPORTANCE TO THECOUNTRY AND OR REGION.
With the demand for cement in the region ICL proposes to enhancesthe cement production by establishing one more kiln accordingly thelimestone production capacity needs to be enhanced.
DEMAND – SUPPLY GAP
Limestone is the main raw material for cement production; thedemand is always there with that of cement. Moreover, the subjectmine produces good grade limestone leading to conservation ofmineral resources.
The cement market has growth due to the central governmentliberalization policies and new schemes for housing, road projects.Cement demand growth is anticipated to be about 11% increasemainly through road projects & Housing Projects.
Continuous demand for exports to South-East Asian countries alongwith the increased requirement of the domestic sector has been leadall the cement manufacturers in the country to plan for increasedcapacities.
iv. IMPORTS VS INDIGENOUS PRODUCTION.
The limestone produced from ICL is meant for the captiveconsumption in the cement plant.
v. EXPORT POSSIBILITYNo export of limestone are proposed.
vi. DOMESTIC / EXPORT MARKETS
The limestone produced from Coromandel Limestone mine is meantfor the captive consumption in the cement plant.
vii. EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TOTHE PROJECT.
Present manpower is 73 persons to carry out the mining operations.The employment for the proposed expansion will be 20 more.
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CHAPTER – 3 PROJECT DESCRIPTION
3.0 PROJECT DESCRIPTION
i. Type of project including interlinked and interdependentprojects, if any.
It is an opencast mining project. Interlinked with the cement plant.The project is for increase of limestone production capacity from 2.0to 5.0 MTPA from Coromandel Limestone mine spreading over anarea of 602.137Ha. with about mineral reserves of 276.06 Million willlast for 55 years. The limestone produced from the mine is of goodgrade limestone and is directly utilized for the cement production.
Status of the interlinked/interdependent projects:-
It is categorized as Category ‘A’ Project under Schedule 1(a), hence itnecessitates obtaining Environment Clearance from Ministry ofEnvironment and Forest & Climate Change (MoEF & CC).
ii.Location (map showing general location, specific location, andproject boundary & project site layout) with coordinates.
The mining lease area comprising 602.137ha is situated atChilamkur village, Yerraguntla Mandal, YSR Kadapa District,Andhra Pradesh.
The COROMANDEL LIMESTONE MINE is located at ChilamkurVillages, Yerraguntla Mandal, Y.S.R. Kadapa district of AndhraPradesh. Fig-1 shows the location map of the Plant site. This Plantsite falls between 1) 14° 38' 51.0''N - 14° 40' 31.1''N, 2) 78° 27'55.4''E- 78° 29' 40.4''E, North latitude and East longitude with anaverage altitude of 175 m above msl. The area is covered in theSurvey of India Toposheet nos. 57 J/6, [1:50000 scale]
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Fig – 2 shows the Key Map of the Mine site.
The area is well connected by road and rail. National Highway - NH-18connecting Kadapa – Kurnool is at 28.0 km in Eastern direction to the Minesite.
State Highway - SH-28 connecting Bellary – Nellore is at 0.2 km inSouthern direction to the Mine site. Nearest Railway line connectingTadpatri to Y.S.R Kadapa of South Central Railway line is Passing ThroughThe Mine Site. Nearest Railway station is Kalamala RS is Adjacent to themine site. Major Railway station is Yerraguntla which is at a distance of 5.3km in ESE to the Mine site.
Penneru River is at a distance of 7.2 km in NE direction and Pageru River –6.9 km SE direction to the mine site. Pedda Vanka adjacent to the minesite, Y.S.R Kadapa is the nearest town/city distance of 38.0 km in SE to theMine site.
Nearest Settlements: Chilamakur – 0.6 km – S, Niduzuvvi – 1.3 km – ESE
And Sunnapurallapalle – 2.2 km – WNW
Nearest Reserved Forests are Niduzuvvi RF – 2.1 km – S, Kosinepalle RF-3.4 km- WNW
Rajeev Gandhi national park is located at 9.5 km in NE direction.
Fig - 3 shows the 10 km radius of the study area around Mine site.
Table-1.1 gives the salient features of the Mine site
Village, Mandal, District, State Chilamkur Village, Yerraguntla Mandal,Y.S.R.Kadapa district of Andhra Pradesh
Maximum Temperature oC 48Minimum Temperature oC 14Relative Humidity, % 25-77Annual rainfall, mm 648Topography PlainSoil Type ClayeyDistrict Head Quarters YSR Kadapa – 38.0 km - SENearest IMD Station KURNOOL – 132.0 km – NNW
Nearest Waterbodies
Penneru River – 7.2 km – NEPageru River – 6.9 km - SEPedda Vanka- AdjacentPenneru River –Third order Stream - 1.2 km – NNW
Details of alternate sites considered and the basis of selectingthe proposed site, particularly the environmental considerationsgone into should be highlighted.
No alternate sites were considered as the project is mineral specific.
i. Size or magnitude of operation.
Mine area is about 602.137ha. The proposal is expansion oflimestone production from 2.0 to 5.0 MTPA.
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ii. Project description with process details (a schematic diagram/flow chart showing the project layout , components of theproject etc. should be given)
ICL is adopting opencast mechanized mining which involves deepdrilling and blasting for breaking the rock, hydraulic excavators tohandle the broken material and loading into 35 T dumpers fortransporting the ROM material to crusher.
Drilling operations are presently conducted with 150 mm dia of AtlasCapco BVB-25-10 model drills with compressor of 550 Cfm.Hydraulic excavators with bucket capacity of 3.3m3 are deployed toload the blasted limestone into Dumpers. The blasted/ excavatedlimestone is sent to crusher and then to cement plant throughconveyor.
The maximum depth of the limestone deposit is 36 m. Four bencheswere developed. Mining will not intersect ground water .
DRILLING
The drilling of holes is done by using 150 mm drill.
BLASTING
Blasting is done using cap sensitive explosives (class-2) as boosterand ammonium nitrate (ANFO) is used in the ratio of 20:80. Noneldetonators are utilized to control ground vibrations and fly rock.ICL is adopting the following blasting parameters in the mine.
Loading is carried out by hydraulic excavators of 3.3 cum bucketcapacity.
HAULING/TRANSPORT
The limestone is loaded into 35T dumpers and transported to crusherand then to the cement plant (through conveyor) for its captive use.
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v) Raw material required along with estimated quantity, likelysource, marketing area of final product/s, mode of transport ofraw material and finished product.
No raw material is required.
vi) Resource optimization / recycling and reuse envisaged in theproject, if any, should be briefly outlined.
A total quantity of 16.00 million cu.m of top soil is estimated to begenerated from the mining activity and will be used for afforestation.
vii) Availability of water its source, energy /power requirement
The present water requirement is 90 m3/day and additional Waterrequirement for the proposed expansion is 220 m3/day to be sourcedfrom storm/rain water stored in mine pit. Mining will not intersectthe water table.
Power requirement is mainly for lighting in the mine area, Time officeand Garage-cum-Workshop and is met from grid.
viii. Quantity of wastes to be generated (liquid and solid) and schemefor their management / disposal.
A total quantity of 16.00 million Cu.m of top soil is estimated to begenerated from the mining activity at the end of mine life. Waste/subgrade material are not anticipated, if any generated in smallquantities will be absorbed completely in the R.O.M. material.
ix. Schematic representations of the feasibility drawing which giveinformation of EIA purpose.
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CHAPTER – 4 SITE ANALYSIS
4.0 Site Analysis
i. Connectivity.
The mine area under reference extends over an area of 602.137Hain Chilamakur Village, Yerraguntla Mandal, Y.S.R.Kadapa district ofAndhra Pradesh.
The area is well connected by road and rail. National Highway - NH-18connecting Kadapa – Kurnool is at 28.0 km in Eastern direction to the Minesite.
State Highway - SH-28 connecting Bellary – Nellore is at 0.2 km inSouthern direction to the Mine site. Nearest Railway line connectingTadpatri to Kadapa of South Central Railway line is Passing Through TheMine Site. Nearest Railway station is Kalamala RS is Adjacent to the minesite. Major Railway station is Yerraguntla which is at a distance of 5.3 kmin ESE to the Mine site.
ii. Land form, land use and land ownership.
Total area of 602.137Ha is owned by ICL.
Topography:
The mining lease area is a near flat terrain with a maximum altitudeof 176 m above MSL and a minimum of 170 m above MSL. No majorstreams or river exists in the mining lease area. The drainage patternis of dendritic type.
Surface plan of the Mining lease area is enclosed as Fig – 4.
The Mining will be continued for 55 more years @ 5.0 million tonnesof limestone per year. The land use pattern is furnished in thefollowing table.
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LANDUSE PATTERN OF THE MINE AREA (Ha)S.NO LANDUSE CURRENT STATUS END LIFE OF
MINE1 Area of Excavation 110 Ha 561 Ha2 Roads/Built up area 5.56 Ha -3 7.5 m barrier zone 12.5 Ha -4 Plantation/ Afforestation 12 Ha 41.137 Ha5 Non Mineral Bearing Area 12 Ha -
Undisturbed area 450.077 -Total 602.137 602.137
* Afforestation area includes 7.5m barrier zone and Non mineral bearing area.
At the end of mining operations, about 229.00 Ha of mined-out areawill be developed into water reservoir. An area of 332 Ha will bedeveloped under greenbelt which includes 7.5 m safety barrier zoneand non - mineral bearing zone and backfilled parts of the mine.
iii Existing land use pattern (agriculture, non-agriculture, forest,water bodies (including area under CRZ), shortest distances fromthe periphery of the project to periphery of the forests, nationalpark, wild life sanctuary, eco sensitive areas, water bodies(distance from the HFL of the river), CRZ, in case of notifiedindustrial area, a copy of the Gazette notification should begiven.
Total area of 602.137Ha is owned by ICLRajiv Gandhi National Park is located at 9.5 km in NE direction. .
The Reserved Forests located in 10km radius of the Mining Lease areNiduzuvvi RF – 2.1 km – S and Kosinepalle RF- 3.4 km- WNW
iv. Existing infrastructure.
None
v. Soil classification
The top soil is covered in the entire mining lease area with varyingthickness (from 3m to 5m).
vi. Climatic data from secondary sources
The tropical climate of the region is manifested in hot and humidsummer, moderately monsoon and mild winter seasons. May is
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the hottest month in the year. The maximum temperature duringthe day time was recorded as 480C and December the coldest withthe temperature as low as 140C. The months of December,January & February are considered to have pleasant climate.
vii. Social infrastructure available.
ICL has constructed a full-fledged colony in upwind directionconsisting of 296 houses for the benefit of employees. The Colonycan accommodate the additional requirement for the newemployees.
All the necessary infrastructure facilities such as School,Dispensary, Park and Playground, Temple, Commercial Complex,etc., are provided in the colony.
A full-fledged water supply and drainage system is already inplace and the wastewater generated from the colony is beingtreated in the sewage treatment plant (STP) to meet thestandards. The treated sewage is used for greenbelt developmentwithin Cement plant complex.
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CHAPTER – 5 PLANINIG BRIEF
5.0 Planning Brief
i. Planning concept (type of industries, facilities,transportation etc.) Town and country planning / developmentauthority classification.
The subjected mine is the captive limestone mine of ICL IndustriesLimited at Chilamkur village, Yerraguntla Mandal, YSR KadapaDistrict, Andhra Pradesh.with extent of 602.137Ha. The proposal isfor increase of limestone production from 2.0 to 5.0 MTPA.
ii. Population projection
Present manpower is 73 persons to carry out the mining operations.The employment for the proposed expansion will be 20 persons more
iii. Land use planning (breakup along with greenbelt etc.,)
During the life of the mine, about 229.00 Ha of mined-out area willbe developed into water reservoir. An area of 332.00 ha will bedeveloped under greenbelt which includes 7.5 m safety barrier zoneand non - mineral bearing zone and backfilled parts of the mine pit.
iv. Assessment of infrastructure demand (physical & social )
Total employment will be 56 after this expansion, there will beindirect employment to many more people, in the form of contractualjobs, business opportunities, service facilities etc. This will enhancethe economic status of the area.
Apart from the jobs, the company is providing medical andeducational facilities to the employees which are availed by the peoplein nearby villages.
v. Amenities / Facilities.
All the necessary infrastructure facilities such as School, Dispensary,Park and Playground, Temple, Commercial Complex, etc., areprovided in the colony.
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CHAPTER – 6 PROPOSED INFRASTRUCTURE
i. Industrial area (processing area)
No processing is involved.
The mine will be operated by means of opencast fully mechanisedmethod of mining which includes deep drilling and blasting, loadingthe broken material by heavy machinery like hydraulic excavatorsand tippers for transporting the limestone to crusher at cement plant.
ii. Residential area (non-processing area)
No residential area is proposed at mine.
iii. Green belt.
An area of 332.00 ha will be developed under greenbelt in the partlybackfilled mine pit and the 12 Ha area under 7.5 m safety barrierzone will be afforested. Further, non - mineral bearing zone andbackfilled parts of the mine pit too will be vegetated.
iv. Social infrastructure.
The mining activity carried out in the area rather has a positive socio-economic impact upon the nearby human settlement as indirectemployment potential is created due to mining and allied activities inthe area. Apart from these, the company promotes health andeducation awareness in the area time to time by organizing healthand education camps.
v. Connectivity (traffic and transportation road / rail / metro /water ways etc.,)
The area is well connected by road and rail. National Highway - NH-18connecting Kadapa – Kurnool is at 28.0 km in Eastern direction to the Minesite.
State Highway - SH-28 connecting Bellary – Nellore is at 0.2 km inSouthern direction to the Mine site. Nearest Railway line connectingTadpatri to Y.S.R Kadapa of South Central Railway line is Passing ThroughThe Mine Site. Nearest Railway station is Kalamala RS is Adjacent to themine site. Major Railway station is Erraguntla which is at a distance of 5.3km in ESE to the Mine site.
vi. Drinking water management (source & supply of water)
Water requirement for the mine after expansion is about 220 m3/dayand is sourced from Mine pit.
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vii. Sewerage system
Domestic waste water from mines office is treated in septic tankfollowed by soak pit.
viii. Industrial waste management
Not Applicable
ix. Solid waste management.
No waste generated from the mine.
A total quantity of 16.00 million cu.m of top soil is estimated to begenerated from the mining activity by the end of Mine life which willbe used for afforestation.
x. Power requirement & supply / source.
The power required for illumination is met from grid.
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CHAPTER – 7
6.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
i. Policy to be adopted (central / state) in respect of the projectaffected persons including home oustees, land oustees andlandless labourers (a brief out line to be given).
Total area of 602.137Ha is already owned by ICL.
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CHAPTER – 8 PROJECT SCHEDULE & COST ESTIMATES
8.0 Project schedule & Cost Estimates
i. Likely date of start of construction and likely date ofcompletion (time schedule for the project to be given).
Enhanced production will be commenced after obtaining EC,CFE, CFO and all other regulatory clearances. Life of the mine @5.0 million tonnes per annum for the mineral reserve of 276.06million tonnes would be 55 years.
ii. Estimated project cost along with analysis in terms ofeconomic viability of the project.
The estimated project cost for increase of limestone productionwill be about Rs. 35 Crores.
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CHAPTER – 9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
9.0 Analysis of proposal (Final Recommendations)
i. Financial and social benefits with special emphasis on thebenefit to the local people including tribal population, if any, inthe area.
Economic development of the region depends largely upon the natureof activities undertaken in the surrounding region. Corporatedevelopment invariably contributes towards acceleration of theprocess of socio-economic upliftment of the rural society by meansof employment, health & study programme, medical camps etc.,
Employment: Preference is given for locals for employment based onqualifications & requirement.
Medical facilities: Medical facilities are provided for employee as wellas people of nearby villages.
Educational facilities: Basic educational and vocational facilities areprovided for the children of employees as well as nearby villages.
Infrastructure facilities: Approach roads is developed at par withmine roads.
