4 Project Description

Transcription

1 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 61 4 Project Description 4.1 Motivation for the project Currently demand for cement in the western part of the DRC (estimated to be 1.1 million ton per year and 40% of the DRC s demand) exceeds the supply with existing operations are not able to satisfy the demand. Existing plants are adversely impacted by the age of their equipment and the use of expensive imported heavy fuel oil and kiln feed. Currently cement imports enter the DRC from Zambia in the south, Uganda in the east and at the Port of Matadi in the west. The DRC is placing an emphasis on infrastructure projects and improving sustainability of supply to outer regions. Improved access and penetration, combined with the availability of cement, will mean increased consumption. This in turn will stimulate the construction sector and private investors will then develop commercial and industrial infrastructure centres. This will also stimulate the residential market and private sectors (Shirley, Gaylard; Dec 2012). In addition, opportunities to export cement to the Republic of Congo (Brazzaville) and Angola have also been identified (Shirley, Gaylard; Dec 2012). The proposed Songololo mine has been authorised in terms of DRC legislation and exploitation rights granted. Indications are that the grade of limestone in the area of the proposed project is of good quality for cement manufacture and is conservatively indicated at 56 million tons (measured resource which will adequately support a 3000 tpd kiln line for more than 30 years (Shirley, Gaylard; Dec 2012). This will assist in meeting the cement demand opportunities both in-country and in adjacent markets. It is estimated that a capital investment cost of US$260 million will be required to bring this project into operation. 4.2 Project activities being addressed as part of the current scope Infrastructure required The Songololo Cement Project comprises the following components: A limestone quarry which will be located in the area for which the Barnet Group SPRL has the exploitation rights to mine limestone. This being for the Permanent Quarry Concession No CAMI/CECP/6389/11 ; A cement manufacturing facility outside and adjacent to the north-east section of the Concession area was selected due to its suitable topography and proximity to the quarry and to the RP111 provincial road; A haul road between the quarry and the cement manufacturing facility; A temporary construction camp to house a maximum of 1200 construction workers; A borehole for water provision for the construction camp during the construction phase (A permanent village to house a portion of the quarry and cement plant workers) of the project and for the cement manufacturing facility and permanent village during the operation phase of the project. A permanent village to house a portion of the quarry and cement plant. Additional provision will be made for sourcing surface water. ; A power line between the SNEL Kwilu substation and the cement operation;

2 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 62 Road repairs and maintenance on RP111 for access to Kimpese, Kinshasa and Matadi; Modifications or additional equipment at supplier s facilities to accommodate the proposed project Suppliers will include a sand quarry within a 60 km radius to provide up to 3000 tons of sand per month Location of infrastructure Currently no definitive information is available with regard to the location of the borehole, powerline route (to be developed and applied for by SNEL) and modifications or additional equipment at supplier s facilities Exclusions from the impact assessment and implications Given a lack of information regarding the infrastructure detailed above, this has been excluded from the scope of the current impact assessment. This infrastructure will need to be addressed in separate environmental authorisations by the proponent responsible for its provision or PPC should project financing or in-country legislation compliance be required. However, the major components of this project have been assessed as part of this study and the project associated impacts and cumulative impacts are therefore assumed to be adequately defined and understood Structure of this section of the report The remainder of this chapter of the report has therefore been prepared to report on the following key components: Project phasing and activities proposed during each phase; The limestone quarry; The cement manufacturing facility; Ancillary and supporting infrastructure including: o o o o o o o Road infrastructure; Water supply; Power supply; Telecommunications; Sewage and waste management; Clean and dirty water management; Construction camp Anticipated employment opportunities; The project programme; Project alternatives considered to date. 4.3 Project phasing and activities The project will be undertaken in four phases, namely: Construction phase;

3 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 63 Operation phase; Decommissioning phase; Closure and post closure phase. Activities proposed during each of these phases are detailed below: Construction Phase R111 repair and bridge development Provision of temporary electricity supply using diesel generators Drilling of borehole, groundwater availability establishment and use, as well as additional provision for sourcing surface water Construction of stormwater management facilities and supporting pipeline infrastructure Provision and installation of a sewage packaged plant and use thereof Clearing of vegetation over site for construction camp, cement manufacturing facility site and mine admin offices and associated infrastructure Topsoil stripping and stockpiling as per above Construction of the construction camp Establishment of laydown areas within the cement manufacturing complex and a construction site office Construction of the haul road between the quarry and the cement manufacturing facility Construction of the cement manufacturing facility Construction of the quarry, admin offices and associated quarry infrastructure Permanent electricity supply infrastructure provision and use Construction of water storage facilities and supporting pipelines and use thereof Waste management - infrastructure development and use Construction of a permanent village and use thereof Operation Phase The overall cement manufacturing process during the operational phase can be seen in Figure 4-1 Ongoing road maintenance Water abstraction from borehole and from pit dewatering, and from surface water (river) Stormwater management on site Operation of a package sewage plant Clearing of vegetation over quarry area on a progressive basis Topsoil stripping and stockpiling as per above

4 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 64 Development of haul roads and maintenance of the haul road between quarry and cement manufacturing facility Removal of overburden and stockpiling Drilling and blasting Transportation of limestone from quarry to crushing plant by haul truck Transport of clay and laterite to plant stockpile area by haul truck Progressive backfilling of the quarry area as allowed for in terms of pit design and space requirements Progressive topsoil replacement and re-vegetation in backfilled areas Limestone, laterite and clay crushing (separate facilities) Stockpiling and blending limestone (open stockpiles) Clay, laterite and sand storage in covered store Importation of sand as raw mill feed. Source still to be determined, but will be transported by road. Sand stockpiling Importation of coal as kiln fuel. This will be transported by road from the Port of Matadi Coal stockpiling: open storage area and covered store Raw material proportioning Raw milling: combined drying and grinding Storage of raw meal in silo/s following transportation via enclosed conveyors Coal milling and drying Storage of milled coal in bins Preheating and precalcining Clinker production in the rotary kiln Clinker cooling Storage in the clinker silo. Transported via pan conveyor from the cooler. Importation of gypsum for addition in cement milling. This will be transported by road from the Port of Matadi. Storage of gypsum and limestone for the cement grinding process. The gypsum will be stored in a partly covered store. Proportioning of clinker with gypsum Feed into two ball mills for grinding via enclosed transport Storage of cement. Delivery via airslides and bucket conveyors to cement silos (enclosed transport) Feed into packaging plant via airslides and bucket elevators

5 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 65 Cement packaging and feeding of bagged cement Loading of bulk cement Road transportation of final product either to Kinshasa or to enter other points of consumption Provision of other mining supplies via road network Use of all administration and support facilities Permanent electricity use Water storage facilities and supply pipelines use Waste management - infrastructure use Management and maintenance of cement manufacturing plant, bag filters and electrostatic precipitators. Figure 4-1: Summary of the cement manufacturing process during the operation phase of the project (PPC) Decommissioning Phase Removal of all infrastructure on site in agreement with the local communities. This may include subsurface infrastructure Cover all underground support infrastructure that is to remain in place Removal of building materials or selling of scrap Termination of electrical and water supply to the area (if required in terms of the final land use plan). All electrical supply infrastructure to be removed. Ripping and re-vegetation of haul roads in line with the requirements of the final land use plan as agreed to with the local communities.

6 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 66 Remove bridges, culverts, conduits and restore natural water flow in line with the requirements of the final land use plan. Rehabilitation of backfilled areas and dumps through shaping, replacing of topsoil, ripping of soil and re-vegetation (where required in compliance with the final land use plan). Rehabilitation of contaminated soils where required Profile remaining overburden dumps, cover in topsoil and rehabilitate. Dispose of all hazardous materials as required in terms of local legislation. Dismantle packaged sewage treatment plant and ensure no residual contamination. Closure and post closure phase Post-closure management and monitoring commitments as per the Environmental Management Plan and any associated action plans Further information on the timing of each of these phases is presented in Section 4.9 of this report. 4.4 Mining operation Mine products The proposed mine is a limestone quarry (open pit operation) which will source limestone. The limestone will be supplemented with clay and laterite (both of these making up 8-10% of the raw mix) and sand to produce clinker which will then be milled with gypsum and limestone to produce cement. The clay and laterite will also be quarried on site. Sand and gypsum will be sourced externally Mineral resource and estimated reserves It is anticipated that the following reserves are in place as a minimum in the Concession area: Limestone 56 million tons (measured resource); Clay and laterite sufficient to support the operation. The limestone thickness averages at m with an overburden of an average thickness of 27 m Production rate and life of mine It is currently proposed that clinker production will be targeted at tons of clinker per annum. In order to support this production rate, per annum, the following will need to be mined: Limestone 1, tons Clay and laterite tons With this rate of mining, the expected life of mine is at least 30 years Layout of quarry infrastructure The quarry will be located south west of the plant area. This locality is favourable with regard to limestone tonnage, quality as well as stripping ratio. Mining would commence from the east of the quarry site and progress westwards into the hill.

7 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 67 This proposed limestone deposit has a single band of cement grade limestone. Over burden/ inter burden, interstitial clay and waste rock expected to be generated during the course of mining is likely to comprise about 0.5 times of R.O.M. quantity The mining operations shall be carried out by a mechanised open cast method utilizing heavy earth moving equipment for loading and transportation. To start with the production in the existing mining blocks, slices / benches shall be kept long. To the extent possible, benches shall be kept along dip and advanced along the strike to give a fairly well blended material in each slice. The direction may be varied in due course based on experience gained, to give wider working periphery, longer faces and proper alignment along haul roads.

8 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 68 A proposed pit design is presented in Figure 4-2. It is anticipated that mining will take place to a depth of 70 m. Working benches will be developed with a height of 9.0 m height and m width. Figure 4-2: Proposed pit design (PPC Business Plan, 2012, pg. 25) Mining method and equipment requirements Vegetation clearing, topsoil stripping and stockpiling An excavator, bulldozer, grader and dump truck will be utilised to remove all vegetation on site. Topsoil will then be removed and stockpiled for use in ongoing rehabilitation. Removal of overburden and stockpiling In order to access the limestone deposit, it is necessary to remove the overburden, clay and laterite. This will be undertaken using an excavator in front of the mined face or a mechanical digger and excavator for deeper workings. Initial development activity will involve the removal of overburden (with depth of m) and the provision of haul roads / ramps, opening and development of slices / benches / faces which are essential as a pre-production stage. Excess overburden will be used for haul road maintenance, backfilling, and in the case of the clay in the cement manufacturing process. Overburden and clay will be transported via dumper trucks. Overburden will be stockpiled. Clay and laterite will be analysed and stored in stockpiles from where it will be extracted for blending with the limestone in the cement manufacturing process. Access roads / haul roads from the topmost bench to benches at lower levels shall also be developed gradually. Face management, which is a continuous process, shall be taken into account to secure the shortest (average) lead distance up to the dump yard near the limestone crusher, and also to prevent clustering of dump trucks. Drilling, blasting and secondary blasting Most of the limestone deposit is found in outcrops which therefore allows for horizontal mining. The limestone will be mined in successive layers each with a depth of approximately 5 metres. Blasting will be required for the fragmentation of the limestone material. No blasting is required for the removal of the overburden, clay and laterite, due to the soft nature of this material. Drill holes will be marked out in accordance with short term mine plans in areas stripped of overburden. A modern drill, placed on a mobile platform, controlled by a single operator and equipped with a compressor, and a hydraulic control system will be utilised. The drill will be secured

9 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 69 and then used to drill mm diameter holes, 24 m in depth. These holes will be loaded with explosives and filled with sand. The holes will be placed every 5 m along parallel lines, also spaced 5 m apart. Primary blasting will be undertaken on a fortnightly basis through the detonation of the explosives. It is estimated that g per m 3 of explosives will be used depending on the nature of the rock. Blasted material will then be loaded onto dumper trucks where no secondary blasting is required. Secondary blasting will be required for limestone that is oversized for feed into the crushing plant. This material will therefore be drilled and blasted again making use of g per m 3 of explosives. Intermediary storage areas will be set up in the quarry to facilitate the transferral of the disintegrated blocks towards the larger storage areas developed for this purpose. Explosives will be stored in a designated explosives store at the quarry site. It is estimated that 125 tons per annum of explosives will be required. Transportation of limestone, laterite and clay from quarry to crushing plant by truck After the limestone resource has been fragmented through blasting, it is loaded via front end loaders onto haul trucks (35 to 50 tons capacity) and transported to the crushing plant for further processing, where it will be reduced to minus 75mm in size. This transportation of limestone will take place via the proposed haul road between the quarry and the cement manufacturing facility. Access to this haul road will be restricted Pit dewatering The quarry will be planned with a section of the quarry floor at a lower level to form a sump to collect water, and from which water can be pumped. The water tanker which will operate on each shift for spraying haul roads for dust control will be filled using one of the quarry dewatering pumps Ancillary infrastructure In order to successfully implement the mining operations described above, there are a number of supporting services dedicated to the mining department which are explained below: Haul road from the quarry working area to the limestone crusher; Quarry vehicle garage: situated within the plant area and located near the limestone crusher; 380 volt powerline from the plant to the quarry to provide electric power for dewatering pumps and lighting. Fuel depot: Quarry vehicles will require regular refuelling. A fuel truck in the quarry and bundwalled fuelling station will be provided for this purpose. It is estimated that litres of fuel will be required on an annual basis by the quarry. Mine offices: The quarry offices will be located adjacent to the haul road near the limestone crusher Equipment requirements during construction and operation The following minimum requirements for the mining operation have been identified. The equipment listed will be sufficient for the initial period of two years when the limestone quarried during the quarry development stage shall also be used partly to meet the requirement of the plant: Two hydraulic excavators (4.2 m 3 ); One front end loader;

10 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 70 Two bulldozers; Seven haul trucks (40 tons); One explosives van; One grader; Two hydraulic drill crawlers; One tractor; One ambulance; One mobile service van; One diesel powered centrifugal water pump; One fork lift; One skid steer loader; Two 4x4 light utility vehicles; One diesel bowser; One water bowser; Concurrent rehabilitation Concurrent rehabilitation forms part of PPC s quarry operating philosophy: rehabilitation area targets are set for each quarry each year and the cost makes up part of the ongoing quarry operating cost. Overburden dumps that are not to be utilised for backfilling will be profiled through dozing, grading and terracing; covered in topsoil and revegetated. Further information about the decommissioning and closure activities are detailed in Section 8 of this report Post closure land use The end land use for the area remains to be determined in consultation with surrounding communities. PPC has committed, however to meet the following closure objectives: To render the quarry area safe following mine closure and return it to a state so as to support an alternative land use; To eliminate risks harmful to the health and safety of people; To limit the production and propagation of substances that may harm the receiving environment; To leave the site in a state that is acceptable to the community and suitable for future usage.

11 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Cement manufacturing facility Layout of cement manufacturing facility The proposed layout for the cement manufacturing facility is presented in Figure 4-2. The following main infrastructure will be required: Limestone primary crusher Clay and laterite crusher Area for bulk loading Blending and stockpiling facilities Cement packaging plant Covered store for crushed clay and laterite and sand Coal stockpile (covered) Dispatch area Conveyors and bucket elevators material handling Sand stockpile Substation and electrical reticulation Raw material proportioning station Pumping station water supply Coal crusher Compressed air station Raw meal silos Laboratory 5 stage Preheater and Precalciner Electrical and mechanical repair workshops Rotary kiln Office buildings Clinker grate cooler Canteen Clinker storage silo Sales office Coal grinding plant Refractory store Gypsum and limestone stores for cement milling Store: consumable stocks and equipment spares Gypsum and limestone crusher Diesel generator emergency power Ball mills cement production Stormwater facilities Cement storage silos Ablution facilities Raw water tank Shed for fire tends Waste water treatment facilities Weighbridges Clinic Guard office

12 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Process flow diagram through the cement manufacturing facility The proposed cement manufacturing process is presented in Figure 4-3. Each stage in the process is described in the following sub-sections of this report. Mass balances have been provided wherever this information is available. The following sources (of illustrations) were utilised by PPC to produce the process flow diagrams: Polysius Engineering (page 3) FL Smidth stacker and reclaimer systems (page 3) FL Smidth coal grinding plants (page 4). Figure 4-3: Process flow diagram for the cement manufacturing facility (PPC) Primary crushing Crushing is required for the following materials feeding into the cement manufacturing facility: Limestone from the quarry; Clay and laterite from the quarry; Gypsum (imported via the Port of Matadi) and limestone prior to its introduction into the cement milling process (detailed under raw material storage and cement grinding in this section of the report). Limestone crusher The rock extracted from the limestone quarry is discharged from dump trucks into the crusher feed hopper. The limestone is extracted from the feed hopper and passes through a double rotor impact crusher which reduces the limestone to a maximum size of 75 mm. From the crusher it is fed via two

13 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 73 conveyor belts to one of two longitudinal ton pre-blending stockpiles. While one stockpile is being built, limestone is reclaimed from the second pile as feed to the raw mill plant. The chemical quality of the limestone is monitored by an on-line analyser positioned before the stockpiles. The limestone crusher has a rated capacity of 850 tons per hour. Clay and laterite crushing Clay and laterite will be transported from the quarry by dump truck and stockpiled near the crusher which will be used for both materials. A wheel loader will be used to load either clay or laterite into the crusher feed hopper. Clay and laterite will be extracted from the feed hopper and passed through a roll crusher with a rated capacity of 300 tons per hour. The crushed material (<75mm) will then be transported by belt conveyors and stockpiled in a covered store with capacity for tons of clay and tons of laterite Raw material storage The covered store used for clay and laterite will be used both for raw materials and for coal. Sand for use as a raw material (2 000 tons) will be stored adjacent to the clay and laterite stockpiles. Coal will be stored in two longitudinal blending piles, each with a capacity of tons. It is proposed that sand will be transported to the manufacturing facility from a source within a 60 km radius (still to be decided). It is anticipated that up to 3000 tons per month will be required. Coal will be imported via the Port of Matadi for use as fuel for kiln firing. This will be stockpiled on the factory site in a stockpile of up to tons. A wheel loader will be used to feed coal from this stockpile into the conveying system for transport to the covered blending piles (2 X 5000 tons each). The coal handling equipment includes an impact crusher with a capacity of tons per hour to reduce any oversize coal to a size of <25mm. In addition to the storage of limestone, clay, laterite, sand, and coal; storage for the following raw materials will also be required: Gypsum; Limestone for the cement grinding process. Gypsum is required for addition at the cement grinding process. This will be delivered in 2-ton big bags and stored in a partly covered area. It is estimated that up to 6000 tons will be stored at times, depending on gypsum shipments and deliveries to the plant. In addition to the gypsum, limestone will also be utilised in the cement grinding process. The limestone storage area will have a capacity of 4000 tons, and will be located at the end of the limestone pre-blending stockpiles. The limestone (<75mm) and gypsum (<70mm) are crushed to <25mm in a hammer crusher with a capacity of 100 tons per hour, before being transported by conveyor to the cement mill feed bins Limestone blending Because of the variance in the chemical composition of the limestone there is a need to blend the limestone before it is fed to the raw mill. The Chevron method of stacking will be used. The limestone is piled in thin layers which extend along the total length of the blending bed or stockpile. Stockpiled limestone is recovered as raw mill feed by the reclaiming operation. Optimum blending efficiency is obtained by reclaiming a stockpile end-on in cross-sectional slices. Ideally, each reclaimed slice has an average quality close to that of the overall stockpile average. Reclaimed limestone is conveyed to the limestone feed bin at the raw mill.

14 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Raw mill operation The required raw materials (limestone, clay, laterite and sand) are fed to the mill from feed bins and weigh feeders which enable the raw materials to be correctly proportioned to achieve the required raw meal and kiln feed composition. The corrective materials (clay, laterite, and sand) are moved by wheel loader in the raw material store to the conveyor system which transports these material to the raw mill feed bins. The combined raw materials are fed at a controlled rate into a vertical roller mill (VRM) with a capacity of 270 tons per hour. The mill is used both for drying and grinding of the raw materials. Exhaust gas from the kiln preheater is used to provide the required heat for drying. When the cement plant is commissioned, the raw mill is started before the kiln in order to produce the feed material required for the kiln. As no heat is available from the kiln at this stage, the plant is equipped with a hot gas generator (fired with diesel fuel) to supply the heat for raw material drying. The hot gas generator is not utilised during normal plant operation. After grinding and separation of course particles, the final product is collected in cyclones. The mill product is conveyed to the blending silo by means of air slides and a bucket elevator. The finely milled material from the raw mill (raw meal) is conveyed to a continuous flow silo for blending and storage. The role of the silo is to ensure the homogenisation of the raw meal to produce a kiln feed with consistent composition which, in turn, promotes good quality clinker. The raw meal silo will have a capacity of tons. An hourly sample of the raw meal is collected for analysis in the laboratory, the results of which are used for overall quality control of the raw meal production process. All gas streams vented from the process are de-dusted in bag filters with a dust emission of less than 30 mg/nm 3. A common bag filter system serves the raw mill and kiln Coal mill Milled coal is used as fuel for the kiln and precalciner. Coal from the blending stockpile is conveyed to the raw coal bin at the coal mill plant. The coal mill will utilise hot gas drawn from the preheater exit gas stream to provide heat for drying the coal. The coal mill will operate at a capacity of 24 tons per hour. The fineness of the coal mill product is controlled by a separator which returns oversize material to the mill. The fine coal from the bottom hopper of the bag filter is transported to two fine coal bins by screw conveyors (one for the kiln burner and the other for the precalciner burner). From these two bins, fine coal is conveyed pneumatically to the kiln burner and the calciner burner. Exhaust gas from the coal mill is vented through a bag filter and stack (estimated height of 35 m) which also collects the fine coal. The fine coal product is stored in two bins one for supplying the main kiln burner, and the second for supplying the precalciner. The coal plant design is in line with international safety standards including the provision of explosion flaps for pressure release, and the use of kiln exhaust gas with a low oxygen content which reduces potential fire risk Kiln and clinker production The kiln feed shall be conveyed to the kiln by means of an air slide and bucket elevator. Cement kilns may be fired with solid, liquid, or gaseous fuel. For this operation, pulverised coal will be used as the kiln fuel. The heat in the kiln exit gas stream will be used to preheat the feed material entering the kiln system. This is achieved by installing a cyclone suspension preheater at the feed end of the kiln, consisting of a system of cyclones and ducts in which the raw meal feed to the kiln system is suspended in the gas stream in several stages for effective heat transfer. A fan located after the

15 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 75 preheater is used to draw the gas stream through the preheater. Raw meal extracted from the raw meal silo is weighed, combined with the dust return from the kiln/raw mill bag filter and fed to the five-stage cyclone preheater system with an in-line calciner by means of a bucket elevator. The bucket elevator transporting the kiln feed will have a height of 105 m; the kiln stack will be at a height of about 110 m. The feed system allows for feeding the raw meal into the first cyclone stage at the top of the preheater building. The raw meal moves down the preheater in counter-current flow to the gas stream, and is separated from the gas in each cyclone before entering the next preheating stage. The gas velocity in each duct between the cyclones is sufficient to entrain the raw meal dropping from the cyclone above and to carry it into the next cyclone. Pre heated material from the stage 4 cyclone passes through the precalciner before entering the kiln. The kiln has two firing systems using pulverised coal. In the precalciner, typically 55 65% of the total kiln fuel is used. The precalciner operates at about 900 o C and enables the feed to be 90% calcined before entering the kiln. In the main kiln burner which is located at the discharge end of the kiln, 35 45% of the kiln fuel is used. The burner flame provides the heat required to complete clinker formation in the kiln. The raw meal slowly cascades down the rotating inclined kiln towards the main burner and reaches a temperature of about C in the burning zone where a process called clinkerisation occurs. Tertiary air is drawn from the kiln hood via the tertiary air duct to the precalciner to provide hot air for the combustion of fuel in the precalciner. The exhaust gas from the preheater is cooled by an ambient air bleed where after the gas is de-dusted in a bag filter before venting to the atmosphere. The recovered dust is then returned to the kiln feed. The rated kiln production capacity is 3000 tons of clinker per day Clinker cooling Hot clinker discharged from the kiln at a temperature of o C passes through a grate cooler where it is cooled to o C above ambient temperature. The cooler is fitted with a crusher to reduce any lumps in the clinker. The clinker is cooled by air supplied by several fans which blow air through a moving clinker bed. Air from the cooler is utilised in the kiln process as secondary air for the combustion of fuel in the kiln burner, and as tertiary air for combustion in the precalciner. Clinker is sampled hourly at the cooler discharge chute, below the clinker crusher and taken to the laboratory for testing. Excess air from the cooler is passed through an electrostatic precipitator for the collection of dust before being vented to the atmosphere via a stack (estimated height of 35 m). The electrostatic precipitator will have a dust emission of less than 30 mg/nm Clinker storage Clinker discharging from the end of the grate cooler flows into a steel pan conveyor, which is adequately sized to cater for variations in clinker flow caused by kiln flushes. The pan conveyor transports the clinker to the clinker silo which has a storage capacity of tons. A bag filter is installed on top of the clinker silo to remove dust at the clinker conveyor discharge point Cement grinding Gypsum shall be crushed in a common hammer crusher for gypsum/limestone and the crushed gypsum shall then be conveyed to the cement mill hoppers for feeding to the cement mills. For producing Portland Limestone Cement, (CEM II), crushed limestone from a conical stockpile shall be transported by front end loader to the common dump hopper for gypsum/limestone in the gypsum storage yard and shall be further crushed to a size suitable for ball mill operation.

16 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 76 The crushed limestone shall be transported to the limestone bins in the cement grinding section. A belt conveyor shall be installed to transport the gypsum and limestone to the cement mill bins. The feed bins supply two cement grinding mills (closed circuit ball mills) each with a nominal capacity of 80 tons per hour. The proportioning of the mill feed is determined by utilising weigh feeders below the feed bins. Water injection will be utilised for temperature control in the mills, when required, to prevent overheating of the gypsum. Cement discharged from each mill is transported by bucket elevator and airslide to a dynamic separator. The separator reject stream is returned to each mill via a weigher. The fresh feed to each mill is adjusted to compensate for variations in the separator rejects flow rate. Fine cement carried out of the separator in the gas stream is collected in a bag filter as the final cement product. Cement discharged from the bag filter is transported by airslide and bucket elevator to the cement storage silos. The clean air from the bag filter is vented to atmosphere via a stack. Each mill is equipped with a second bag filter which is used for venting the air drawn through the mill and for collecting the cement dust carried in the air stream. The collected dust is discharged into the mill product conveying system. The bag filters will all have a dust emission rate of less than 30mg/Nm 3. For quality control, an automated sampling system will take cement product samples for analysis and testing at the on-site laboratory. The cement is sampled before reaching the storage silos Cement storage Cement storage will be in silos for each cement type. It is currently proposed that two silos will be provided of 7500 tons each. The plant layout makes provision for the addition of a third silo, of similar capacity. Two cement types will be produced, in conformance with EN-197 standards: CEM I Portland Cement, containing 95% clinker CEM II Portland Limestone Cement, containing 20% limestone Cement packaging and dispatch Cement dispatched will be in two forms: Bagged cement Bulk cement A complete packaging and bulk loading facility is envisaged. Cement will be transferred from the cement silos to the packing plant via airslide and bucket elevator. The packaging plant for bagged cement production will consist of 4 packing units. Each packer has a nominal capacity of 90 tons per hour (1800 bags per hour). The packers are suitable for both paper and polypropylene bags. Bags will be placed on the packer spouts by hand. From the packers the cement bags are transferred by conveyor belt directly on to road transport vehicles. The packaging and loading area will be partially enclosed and make use of a bag filter installed at each packer for dust control. The dispatch facility will consist of 6 loading lanes: two packers will deliver bagged cement to the first three loading lanes, while the remaining two packers will deliver cement to the next three loading lanes. A bulk loading facility will be provided for the loading and dispatch of cement in bulk from below the cement silos. The loading lane will be equipped with a weighbridge and the discharge chute for loading road tankers will be equipped with a manual sampler.

17 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Waste products/residues/emissions All dust collected in dust collection units at each stage of the cement production line are returned to the process: no dust is discarded as waste. Correct and continuous operation of all the dust control equipment will require good management and maintenance. In the process of cement production, as set out above, the raw materials as well as the final product are ground to a fine powder. The grinding, conveying and processing of these materials results in the generation of dust. In order to limit dust emissions into the environment, with an adverse effect on working conditions and on the immediate neighbourhood, the cleaning and ventilation of large volumes of air and gas is required. The plant design includes an adequate number of dust collection units (i.e. bag filters and electrostatic precipitators) to limit particulate emission from dust generation in the cement production process. Bag filters with a dust emission level <30 mg/nm 3 will be installed for the kiln and raw mill, the coal mill, and the cement mills. Bag filters will also be installed at each crusher and at dust generation points in the material transport and conveying systems. For the grate cooler exhaust gas, an electrostatic precipitator with a dust emission level 30 mg/nm 3 will be installed. No residues are anticipated as part of the cement manufacturing process. Further information about waste management on site is presented in Section of this report Ancillary infrastructure In addition, to the infrastructure detailed above and the service infrastructure detailed in Section 4.7 of this report, the following will be required: Compressor system; Water treatment, pumping and reticulation; Firefighting systems; Office administrative buildings including canteen and clinic; Maintenance workshops; Internal roads; Control room and laboratory building; Stores and store yards for machine and equipment spares, kiln refractories, grinding media and heavy equipment; Security fencing and guard house; Ablution facilities Post closure land use The end land use for the area remains to be determined in consultation with surrounding communities. See Section with regard to some of the principles that the PPC hope to attain through the decommissioning and closure process. 4.6 Transportation of raw materials, product and demand Road transportation will be utilised for the import of all raw materials and export of all products from the operation. The following transportation routes will be utilised and have formed the focus of this study: Road transport to and from Kinshasa via the N1 and RP111;

18 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 78 Road transport to and from Port Matadi via the N1 and RP111. The table below is an assessment of the anticipated traffic volumes along these routes: Route Material being transported Quantity and type of vehicle transporting Construction and decommissioning phases Construction camp so transportation not defined RP111 and N1 from Matadi Port Operational phase Local area so road transportation not defined RP111 and N1 to Matadi Port or Kinshasa. Currently anticipated 80% to Kinshasa, but subject to change Personnel It is envisaged that tons or a volume of m 3 of construction materials will be transported to site Personnel Cement tons per day Distance between construction camp and plant limited 155 TEU plus break-bulk (cargo loaded individually, not in containers) Limited and short distances as housed in permanent or local villages 30 tons: flatbed trucks for bagged gypsum (100 per day) RP111 and N1 from Matadi Port Coal 375 tons/day 25 tons: side tippers for coal (15 per day) RP111 and N1 from Matadi Port Will depend on source, but currently anticipated to be RP111 and N1 to Matadi RP111 and N1 from Matadi Port Gypsum 90 tons/day Sand 100 tons/day Cement bags 9 containers per week 30 tons: flatbed trucks for bagged cement (3 per day) tons: rear tippers for sand (4 per day) Flatbed trucks (9 per week) Road repairs and the improvement of two bridges (between the villages of Malanga and Zamba) are proposed for the RP111 route which is approximately an 8 km stretch of road from the N1 to the cement plant site. 4.7 Services and infrastructure provision for this Water supply and storage It is anticipated that water will be sourced from the Lukunga River and will initially be transported by bowers; whereafter a pipeline will be constructed linking the Lukunga River to the plant. Further work is currently underway to determine water requirements, availability and resultant impact on neighbouring communities. Water will be required at the quarry for dust suppression on haul roads. Dewatering of the quarry should provide an adequate supply for this purpose. The water requirement at the cement manufacturing facility will be for: Process water for cooling will be on a recirculation system. Make up water of 20% will be required to cater for evaporation losses. Process water which is used as a spray system in the ball mills for cement milling and in the raw milling restricted roller mill.

19 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page 79 Apart from the above, potable water is required for human consumption and for use in the laboratory. Water is also required for the firefighting hydrant system. The installed water supply capacity for the project is estimated at 1200 m 3 /day. It is currently estimated that the following water requirements need to be met at the cement manufacturing facility: ESTIMATE: PLANT WATER CONSUMPTION No litres/pers litres/day Personal usage Plant staff Truck drivers 200 (peak) Equipment litres/hour Process usage Raw mill (VRM) Average Cement mills Grate cooler Occasional Peak (10000) (40000) Maintenance Make-up Cooling Workshops Washing Power supply Total The following is currently proposed with regard to power supply: A 220 kv powerline will be constructed by PPC in accordance with SNEL specifications and requirements. This will run for approximately 13 km from the Kwilu substation on the Inga- Kinshasa line to the plant site. This has not been addressed as part of this study and will require separate authorisation when further planning has taken place. The incoming substation will be located on the northern boundary of the cement manufacturing site. The substation shall have a loop-in and loop-out arrangement for the 220 kv line and an outgoing transformer feeder for the 24/30 MVA, 220/11 kv transformer. Load centre substations shall be set up in the plant area to step down from 11kV to 380V through suitably rated transformers with an off load tap changer for further distribution in the plant. Internal reticulation will be via 11kV and 380V lines. A back-up diesel generator will be provided at the cement manufacturing facility for emergency power. The construction camp will be powered by a separate diesel generator during the construction phase until electric power is available.

20 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Telecommunications Telecommunication equipment will be installed for this project and will include telephone lines and an antenna which may be attached to the preheater tower, which will be approximately 100 m in height Sewage handling and treatment A sewage package plant will be provided for the operational phase of the project in the cement manufacturing facility area. A separate sewage package plant will be installed to serve the construction camp. This will be installed by an advance team at the start of building the construction camp Waste handling, management and storage There is no formal refuse collection and disposal system in the nearby town of Kimpese. The cement manufacturing facility and quarry will therefore have to operate its own waste disposal site. The design and location of this has as yet not been determined. The plant will require a waste management system to address the following issues. Where possible, recycling should be implemented. Used kiln lining bricks; Used oil and lubricants; Scrap metal; Plant and village domestic waste; Office waste. Provision will be made for domestic waste disposal and for factory waste Stormwater management and storage On site stormwater drainage will be provided and for the open coal stockpile. Stormwater drainage provision has been made in the cement manufacturing facility area. Stormwater currently drains from the north-west corner of the plant site and from the southern boundary. These drainage areas will be maintained. At the open coal stockpile, run-off water will be impounded and coal settled/separated before the water is released Accommodation facilities Accommodation will be provided for the construction staff in a construction camp located adjacent to the RP111 to the east of the plant area. It is anticipated that facilities will need to be provided at the construction camp to house a maximum of 1200 people. The construction camp includes a kitchen and canteen, accommodation and ablution facilities. The preferred location of the permanent village is to the exit of the plant area. It is intended that this will house skilled employees (totalling a maximum of 12). The remaining operational workforce will be housed in the surrounding villages.

21 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Employment requirements during all phases of the project Permanent employees It is anticipated that for the operational phase of the project 259 employees will be on site. This figure includes the General Manager and 7 Heads of Department. It is anticipated that ultimately 254 of these employees will ultimately be local to the area Contractors A Chinese contractor will be appointed for the construction phase of the project. It is anticipated that a maximum of 1200 contractors will be appointed at any one time during the construction phase of the project. 5% of these personnel are anticipated to be local to the project area. The Engineering, Procurement and Construction (EPC) contractor will also have a Project Manager/Construction Manager on site and PPC will have a management team which will include a General Manager and Human Resources and Risk, Mining, Production, Engineering, Quality Assurance and Administration Managers on site during the first year of construction Service providers Employment opportunities associated with the establishment or expansion of the operations of the service providers have not been addressed in this study.

22 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Organisational structure The total manpower requirement for the quarry, plant and administration services is based on requirements for a functional modern plant: Sl. No. Department During Project Stage Additional Manpower required for Plant Operation Total Manpower A Factory Manpower A.1 Administration A.2 Engineering A.3 Mining A.4 Production A.5 Packaging and Logistics A.6 Quality Assurance A.7 Organisational Performance (HR) A.8 Risk A.9 Environmental 1-1 TOTAL.A B. Admin Centre-Kinshasa C. CSI Program Total (A+B+C)

23 SRK Consulting: : PPC Barnet_Framework ESIA and ESMP Page Anticipated project programme The following procedure and timing is proposed for the remainder of the investigations and project implementation: Activity Date of completion Duration Purpose Pre-feasibility study December months To establish whether there are any fatal flaws associated with the project and whether it is viable to proceed into the feasibility stage of the project. Feasibility study November months To inform a decision regarding the project and whether it may proceed or not from a financial perspective. Environmental and Social Impact Assessment complete December months To inform a decision regarding the project and whether it may proceed or not. All in country environmental authorisations to be in place December 2013 To allow mining to proceed Construction phase December months To establish and develop the proposed sites sufficiently for the operation phase of the project Operation phase First half of 2016 > 30 years To implement the project and fulfil the motivation for the Project Closure - decommissioning After 2050 Typically, closure operations will take place over a period of 5 years following cessation of operations at the facilities. To rehabilitate the disturbed environment sufficiently so as to meet the objectives of the closure plan (this will to some extent depend on decisions/agreements reached with the local communities for the use of the land post-closure) Closure postclosure Timeframe to be advised by environmental impacts and monitoring requirements Closure will be planned to limit any post closure activities but some monitoring may be required. To ensure that there are no residual impacts associated with the proposed operation or that there are adequate plans in place for the management of residual impacts.