Pallakkapalayam Limestone Mine The India...

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Pallakkapalayam Limestone Mine The India Cements Limited

PRE FEASIBILITY REPORT

CONTENTS Executive Summary Section

No Particulates Page

No. 1. INTRODUCTION 4 1.1 Identification of Project Proponent 4 1.2 Identification of Project and project Proponent 4 1.3 Brief description of nature of the project 4 1.3.1 Need for the project and its importance to the country and or region 4 1.3.2 Imports/Exports 5 1.3.3 Export possibility 5 1.3.4 Employment Generation due to the project 5

2 PROJECT DESCRIPTION 6 2.1 Type of Project including interlinked and interdependent

projects, if any 6

2.2 Location Details 6 2.3 Details of alternate sites considered 11 2.4 Size or magnitude of operation 11 2.5 Project description with process details 11 2.5.1 Proposed mining method 11 2.6 Raw material required along with estimated quantity 13 2.7 Resource optimization/recycling and reuse envisaged in the project 13 2.7.1 Afforestation Programme 13 2.8 Post Mining reclamation and land use pattern 13

3 SITE ANALYSIS 16 3.1 Plant Location 16

4 PLANNING BRIEF 18 5 PROPOSED INFRASTRUCTURE 18 6 UTILITIES 18 7 WASTE MANAGEMENT 18 7.1 Liquid Effluents 18 7.2 Air Pollution 18 7.3 Solid waste 19 7.4 Rehabilitation and Resettlement (R&R) Plan 19

8 PROJECT SCHEDULE & COST ESTIMATES 19 8.1 Estimated project cost along with analysis in terms of economic

viability of the project 19

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LIST OF TABLE

Table 1 ‐ 1 Man Power Requirement 5

Table 2 ‐ 1 Environmental Setting 6

Table 2 ‐ 2 Afforestation Programme 13

Table 2 ‐ 3 Water Requirements 14

Table 2 ‐ 4 Dump Yard Details 14

Table 3 ‐ 1 Land use pattern 16

Table 6 ‐ 1 List of Machineries 18

Table 7 ‐ 1 Dump Yard Details 19

LIST OF FIGURES Figure 2 ‐ 1 Location Plan of the Mine Lease Area 7 Figure 2 ‐ 2 Location Map of the Project Site 8 Figure 2 ‐ 3 Topo Map of the Project Site 9 Figure 2 ‐ 4 Key Plan of the Project Site 10 Figure 3 ‐ 1 Land Use Map of the Project Site 17

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Executive Summary

S. No. Particulars Details

1 Name of the project

Pallakkapalayam Limestone Mine (G.O. No. 100) by M/s. The India Cements Limited

2 Project Proponent M/s India Cements Limited, Sankari Plant. Sankari West P.O, Salem – 637 303. Ph: 04283 – 240 387

3 Village Pallakkapalayam

4 Tehsil Tiruchengode 5 District Namakkal 6 State Tamilnadu 7 Topography Between Latitude N 11º 27’ 52.7” & Longitude E 77º

47’ and Latitude Latitude N 11º 27’ 46” & Longitude E 77 º 46’ 59”

8 Topo Sheet No. 58 E/14 & 58 E/15 9 Elevation 300 m above MSL 10 Mining Lease Area 1.60.5 Ha 11 11. Production capacity 0.015 MTPA 12 12. Extent of mechanization Fully Mechanized Opencast Mining 13 13. Bench Height Height – 3 m to 10 m 14 14. Depth of Mining 29 m 15 15. Life of Mining 8 years 16 16. Water Requirement &

source 42 KLD from Rain water harvesting pits

17 17. Man Power Requirement 10 18 18. Project Cost Rs. 3.22 Lakhs 19 19. Site Services Facilities like office, canteen, first aid centre,

etc are available. The existing facilities such as roads, building and water supply etc will be suitably utilized.

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1. INTRODUCTION

1.1 Identification of Project Proponent

M/s. The India Cements Ltd was established in 1946 and the first plant was setup at Sankarnagar in Tamilnadu in 1949. Since then it has grown in stature to 10 plants spread over Tamilnadu, Andhra Pradesh and Rajasthan. The capacities have reached 15.50 MTPA. Company Highlights 1. The Company is the largest producer of cement in South India. 2. The Company's plants are well spread with three in Tamilnadu and four in Andhra Pradesh which cater to all major markets in South India and Maharashtra. 3. The Company is the market leader with a market share of 28% in the South. It aims to achieve a 35% market share in the near future. The Company has access to huge limestone resources and plans to expand capacity by de‐bottle necking and optimization of existing plants as well as by acquisitions. 4. The Company has a strong distribution network with over 10,0 stockists of whom 25% are dedicated. 5. The Company has well established brands ‐ Sankar Super Power, Coromandel Super Power and Raasi Super Power. 6. Regional offices in all southern states and Maharashtra and offices / representative in every district. 1.2 Identification of Project and project Proponent Pallakkapalayam Limestone Mine is one of the captive mines of M/s. The India Cements Limited ‐ Cement Plant located at Survey No: 95/3 Pallakapalayam Village, Tiruchengode Taluk, Namakkal District, Tamilnadu. The mine is in operation since 1981. The first GO No 595 was granted for mining limestone from this mine for the period of 20 years. The lease was expired on 16.04.1997.The Lease was renewed vide GO.No.100 dt 09.10.2003 for next 20 years and the lease expiry date is 15.04.2017. The scheme of mining was approved by Regional Controller of Mines, Chennai vide letter No: TN/NMK/LST/MS‐1092.MDS dt. 22.07.2014 and the scheme was valid upto 15.04.2017. 1.3 Brief description of nature of the project The proposed project for limestone mine spread over an area of 1.60.5 Hectares with production capacity of 0.015 Million Tons per Annum limestone. The method of mining is mechanized open cast method. Mining operations include drilling, blasting, sorting, loading and transportation of limestone and reject stone. The waste and interstitial rejection will be transported to waste dumps. The limestone is supplied to the cement plant located at Sankari West, Salem district belong to the same owner M/s.The India Cements Limited. 1.3.1 Need for the project and its importance to the country and or region

Cement industry is one of the main beneficiaries of the infrastructure boom. While on the one hand several big and small cement companies are actively considering expansion plans in anticipation of further growth in demand for cement, on the other, a phase of acquisitions and mergers among the existing players is also going on. In India, the south consumes maximum of

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30% followed by East at 17%, North at 19%, central at 16%, and West 18%. Also, there is an increase in the consumption of PPC cement from 48% to 50%. Weaker sections housing, construction of public toilets, schools in rural area apart from several private and public infrastructure projects will also give tremendous boost to the cement consumption in the state. Most importantly, irrigation projects, worth nearly Rs 1‐ lakh crore, will trigger unprecedented demand for the next 5‐7 years. As per the industry sources, demand has mainly come from the construction sector with the three main cities in the South ‐ Bangalore, Chennai and Hyderabad ‐ witnessing hectic construction activity, be it for the information technology sector, shopping malls or integrated townships. The growth in demand has prompted many cement industries to consider expanding their capacities, both in present locations and in Greenfield locations. The chemical characteristics of limestone extracted from this mine do not warrant any mineral beneficiation, since the quality of limestone produced from this mine is suitable for cement. To meet the limestone requirement of the plant, ICL has applied for renewal of lease for the subject mine, and it is aimed to produce 0.015 MTPA of limestone from this mine.

Demand ‐ Supply Gap

Since Limestone is the main raw material for cement production, the demand is always there with that of cement. Moreover, the subject mine produces good grade limestone leading to conservation of mineral resources. The cement market has growth due to the central government liberalization policies and new schemes for housing, road projects. Cement demand growth is anticipated to be about 11% increase mainly through road projects & Housing Projects. Continuous demand for exports to China and other South‐East Asian countries along with the increased requirement of the domestic sector has been lead all the cement manufacturers in the country to plan for increased capacities. The proposed requirement of limestone for the cement plant is 3900 Tonnes per day approximately. From this mine, around 50 Tonnes per day supplied to the plant and the balance quantity is catered from the other mining leases located nearby the plant.

1.3.2 Imports/Exports Limestone is used for captive use only. There is no import & export of lime stone. 1.3.3 Export possibility

No export business are taken in this Project 1.3.4 Employment Generation due to the project

Around 10 employees will be engaged in the mines and required manpower for mining operation is given in Table 1 – 1.

Table 1 ‐ 1 Man Power Requirement

S. No. Category No. of person

1 Mines Manager 1

2 Asst. Manager 1

3 Foremen 1

4 Mate cum Blaster 1

5 Skilled Manpower 6

Total 10

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2. PROJECT DESCRIPTION

2.1 Type of Project including interlinked and interdependent projects, if

any: Mining of limestone by drilling, blasting, loading & transported to nearby cement plant. There is no interlinked project is proposed along with this proposal. 2.2 Location Details The mine lease area is covered under Survey of India (SOI) Topo sheet No: 58 E/14 and 58 E/15 and between the boundary pillars ‐ A of Latitude N 11º 27’ 52.7” & Longitude E 77º 47’ 1”and boundary pillars ‐ B of Latitude N 11º 27’ 46” & Longitude E 77 º 46’ 59”. The nearest village hamlet is Ayeegoundapalayam at a distance of 0.5 km in NW direction from the mine area and Pallakkapalayam village located at a distance of 1.0 km in South direction. The NH‐47 is at a distance of 1.0 km in South direction. Nearest town is Sankari at a distance of 9.25 km in E direction, Railway station is Sankari Durg at a distance of 9.5 Km in ESE direction. Cauvery River is at a distance of 7.2 km in NW direction. Suriyamalai Reserve forest is at a distance of 4.5 km in NE direction. There are no national parks, wildlife sanctuaries and critically polluted areas within 10 km radius of the area. The environmental setting of the project site is given in Table ‐ 2.1.

TABLE 2 ‐ 1 ENVIRONMETNAL SETTING

Description Details

Site Location Pallakkapalayam Village, Tiruchengode Taluk, Namakkal District.

Survey Nos 95/3 SOI Toposheet 58 E/14 & 58 E/15 Nearest City Erode ‐ 14 Km, SSW Nearest Highway National Highway 47 – 1.0 km, S Nearest Railway Junction Sankari Durg Railway Station – 9.5 km, ESE

Erode Junction – 16.5 km, SSW Nearest Airport Coimbatore International Airport – 94 km, WSW Nearest Water Bodies/River/Sea

Cauvery River‐ 7.2 km, NW

Archaeologically important places

None within 15 km radius

National parks / Wildlife Sanctuaries

None within 15 km radius

Reserved / Protected Forests Suryamalai Reserve Forests ‐ 4.5 km, NE Seismicity Zone II Defense Installations None within 15 km radius

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Figure 2 ‐ 1 Location Plan of the Mine Lease Area

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Figure 2 ‐ 4 Key Plan of the Project Site

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2.3 Details of alternate sites considered No alternative sites considered, the proposal is mining project and it is site specific. 2.4 Size or magnitude of operation Extent of the mining lease area is 1.60.5 hectares. It is proposed to recover the Lime stone highest production of 0.015 Million TPA by mechanized open cast method. 2.5 Project description with process details Mining of limestone is a project which includes drilling, blasting, loading and transporting of material to nearby cement plant belong to M/s The India Cements Limited and dumping the reject stones within the lease hold area.

Drilling‐‐‐‐‐‐ blasting‐‐‐‐‐‐ loading‐‐‐‐‐‐ Transportation 2.5.1 Proposed mining method

The height of the benches are varied from 6 meters to 10 meters due to variation in thickness mechanised opencast mining with controlled blasting, loading & transporting is being carried out in this mine. The same activities will be continued in the ensuing mining scheme. The lists of machineries are depicted in table no 15. Schedule hours = 8 hours Available hours = 6.5 hours Utilisation hours = 6 hours Availability = Available hours / Schedule hours 6.5 = ----- x 100 8 = 81.25 % Net utilisation = Utilised hours / Schedule hours 6 = ----- x 100 8 = 75 %

Availability = 81.25 % Net utilisation = 75 %

Calculation for requirement of mining machineries

To mine 50 tonnes of limestone and 150 tonnes of reject material per day, the machinery calculations are shown as below: No of Working Shift - 1 shift /day Drilling To generate 200 tonnes of blasted material, the required drilling meterage is Burden X Spacing X Depth X Tonnage Factor = 200 Tonnes

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1 X1X Depth X 2.5 = 200 Depth = 200/ (1 X1X 2.5) = 80 meters The meterage to be drilled = 80 meters Hours required to drill 80 meters at the rate of 20 meters / hour = 4 hours Shifts per day = 1 shift Tractor compressor 50 meters per day = 1 No. Secondary breaking Hours required to handle 200 Ts. Material at the rate of 25 Ts/hour = 8 hours Shifts required to handle 200 Ts. /day = 1 shift Secondary Breaker required = 1 No. (EX 210 Excavator with Atlas Copco Breaker MB1200) Loading Reject loading (PC 200) Hours required to handle 150 Ts. of material at the rate of 25 Ts/hour =6 hours Shifts required to handle 150 Ts/day = 1 shift Limestone loading (JD 315) Hours required to handle 50 Ts. of ROM material at the rate of 25 Ts/hour= 2 hours Shifts required to handle 50 Ts/day = 1 shift Transportation To transport ROM from mines to crusher and Development face to waste dump yard Tippers (25 Ts.) will be used. Mines to crusher Haul distance from Mines to crusher = 16 Kms (both ways) Cycle time for one trip (actual) =60 minutes. (Hauling, unloading, waiting, positioning)

Loading time =25minutes Matching factor =Cycle time +1 Loading time =60+1 Required no. of tippers = 1

No. of tippers required for limestone = 1

Mines to dump yard Development face Haul distance from Development face to Waste yard= 3 Kms (both ways) Cycle time for one trip (by experience) =30 minutes. (Hauling, unloading, waiting, positioning)

Loading time =9 minutes Matching factor =Cycle time +1 Loading time =30 +1

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2 Required no. of tippers = 2

No. of tippers required for development = 2

Blasting Primary drilling is done by the TAMROCK DRILLING Machines of 32 mm dia with a spacing of 1 m and a burden of 1 m for drilling 6 m holes and the material is blasted by using slurry explosives. For carrying out blasting, we will be keeping the bench height at 5m. Powder factor will be around 5 Ts per kg of explosives. 2.6 Raw material required along with estimated quantity No raw material is required; project is for mining of limestone. The extracted lime stone shall be sent to the cement plant through Taurus tippers. 2.7 Resource optimization/recycling and reuse envisaged in the project

The waste materials such as Calc gneiss, Biotite gneiss and Pegmatite to be removed will be around 0.26 million tons till the end of mine life and it will be dumped in the refilling area of western side of the pit. The precautionary measures like afforestation in dumps, periodical stabilization etc will be carried out in phased manner. 2.7.1 Afforestation Programme

During the next 9 year period about 200 trees will be planted within the lease area over an extent of 0.105 Ha. The afforestation programme is given below,

Table 2 ‐ 2 Afforestation Programme

Sl. No Year Location Name of the

species Area (Ha)

No. of trees to be planted

1 2017-2022 Western side of lease area

Pungan, Teak and Neem 0.055 100

2.8 Post Mining reclamation and land use pattern The limestone deposit is a metamorphic formation and dipping towards eastern side. The refilling is proposed in the western side of the pit. About 0.47 Hectare area will be refilled to maintain safe bench height in the ensuing scheme period. i) Availability of water its source:

Water requirement for the project is mainly for maintaining the green belt and also for sprinkling on the haulage roads to mitigate dust emissions. Total water required for the mine is met from Rain water collected in the pit and for domestic purpose from ground water/tankers from nearby villages.

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Table 2 ‐ 3 Water requirements

S. No Water Usage Quantity KL/day

1 For water sprinkling on mine haulage roads 20 2 For wet drilling 5 3 Domestic 2 4 Green Belt 15

Total 42 The ground water table is at a depth of 100 m from the surface level. Since there are no toxic elements present in the mining area there is no possibility of contamination of water. The rainwater collected inside the pit is being pumped out for domestic purpose as well as for agricultural purpose. Electricity: It is a fully mechanized mine, all machineries are diesel operated and power required for office and etc will be drawn from Tamil Nadu Electricity board.

ii) Quantity of wastes to be generated and scheme for their Management /

disposal The waste material of 0.24 million Tonnes to be removed during this Proposed scheme period will be dumped in the refilling area of western side of the pit of the Mining lease Area. The Table – 2.4 shows Details of the dump yard for end of mine life is depicted as below:

Table 2 ‐ 4 Dump Yard Details

Dump No.

Location Max. Height (in meters)

Extent (hec.)

Quantity (Million. Ts)

1 Refilling towards South in the western side 27 0.47 0.25

The Limestone deposit is intricate in nature. To segregate limestone from interstitial mineral reject, one JD315 loader is engaged especially for sorting the limestone from the broken stones and rejects will be handled separately and dumped in the dump yard. So there is no chance of limestone mixing with the waste material.

iii) Schematic representations of the feasibility drawing which give information

of EIA Purpose

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3. SITE ANALYSIS 3.1 Plant Location The mine lease area is covered under Survey of India (SOI) Topo sheet No: 58 E/14 and 58 E/15 and between the boundary pillars ‐ A of Latitude N 11º 27’ 52.7” & Longitude E 77º 47’ 1”and boundary pillars ‐ B of Latitude N 11º 27’ 46” & Longitude E 77 º 46’ 59”. The nearest village hamlet is Ayeegoundapalayam at a distance of 0.5 km in NW direction from the mine area and Pallakkapalayam village located at a distance of 1.0 km in South direction. The NH‐47 is at a distance of 1.0 km in South direction. Nearest town is Sankari at a distance of 9.25 km in E direction, Railway station is Sankari Durg at a distance of 9.5 Km in ESE direction. Cauvery River is at a distance of 7.2 km in NW direction. Suriyamalai Reserve forest is at a distance of 4.5 km in NE direction. There are no national parks, wildlife sanctuaries and critically polluted areas within 10 km radius of the area.

Table 3 ‐ 1 Land use pattern

Sl. No Activities As on

01.04.2014

At the end of scheme period

At the end of mine life

1 Area under mining 1.50.0 1.50.0 1.03.0 2 Storage for top soil - - - 3 Overburden/dump

(Refilled) - - 0.47.0 4 Mineral storage - - - 5 Infrastructure workshop,

Administration building - - - 6 Road - - - 7 Railways - - - 8 Green belt - 0.05.5 0.10.5 9 Tailing pond - - -

10 Effluent treatment plant - - - 11 Mineral separation plant - - - 12 Town ship - - -

Sub Total 1.50.0 1.55.5 1.60.5 13 Other details- Non –mining

area (to be specified) 0.10.5 0.05.0 - Grand total 1.60.5 1.60.5 1.60.5

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Figure 3 ‐ 1 Land Use Map of the Project Site

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4. PLANNING BRIEF Year wise excavation of Limestone, interstitial reject are given below Excavation programme for life of the mine.

The limestone reserve as on 01.04.2017 will be 0.11 million tonnes as per UNFC norms. The production for the ensuing scheme period is 0.075 million Ts. The remaining reserve will be 0.035 million tonnes. At the rate of production of 0.015 million tonnes per year after the scheme period the reserves will last for 3 years. (0.035/0.015 = 3 years) The total anticipated life of the mine will be 5+ 3 = 8 years ie. upto 2025. 5. PROPOSED INFRASTRUCTURE

Infrastructure facilities are in the form of office, store room, first aid room, drinking water tank are already provided in the mine. The buildings are semi‐permanent nature and there will not be any problem in dismantling them during the closure of mine. The mine roads are also semi‐permanent nature and hence will not be any impact after the closure of mine. 6. UTILITIES

The list of machineries proposed to deploy in Pallakkapalayam limestone mine is given as below:

Table 6 ‐ 1 List of Machineries

SI. No EQUIPMENT POWER (HP) UNITS Drilling

1 Tamrock Drill Machine 92 1 Breaking

2 Ex 210 190 1 Loading

3 PC 200 128 1 4 TATA JD 315 back hoe 95 1

Levelling 5 Dozer 178 1

Transport 6 Tipper 25 Ts 3

7. WASTE MANAGEMENT

7.1 Liquid Effluents Domestic effluent sent to septic tank followed by soak pit. 7.2 Air Pollution Periodically air samples are collected and tested in the laboratory. Control measures like suppression of dust by water sprinkling and developing green belt along the periphery of the pit are carried out for controlling the dust. While drilling wet drilling will be carried out.

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7.3 Solid waste Solid waste is reject material only and they will be dumped in the refilling area of western side of the pit of the lease area for end of mine life time.

Table 7 ‐ 1 Dump Yard Details

Dump No. Location No. of

Terrace Height of

each terrace Angle of repose Lx W x H Extent

(hec.) Quantity

(Million. Ts)

1 Refilling towards South 1 27 37 150X32X27 0.47 0.26

7.4 Rehabilitation and Resettlement (R&R) Plan No rehabilitation is occurred, it is an existing mine lease. 8. PROJECT SCHEDULE & COST ESTIMATES Infrastructure facilities are in the form of office, store room, first aid room, drinking water tank are already provided in the mine. The mine roads are also developed as semi-permanent nature. No major construction activity involves. 8.1 Estimated project cost along with analysis in terms of economic viability

of the project The estimated cost of the project is approximately Rs. 3.32 Lakhs as all the machineries deployed in this mine will be from the adjoining lease hold area belong to our company.

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