PRE FEASIBILITY REPORT For EXPANSION OF CEMENT...

PRE FEASIBILITY REPORT

For

EXPANSION OF CEMENT PLANT

With

INCREASE OF PRODUCTION CLINKER: 1.5 to 4.0 Million Tonnes per Annum CEMENT: 2.0 to 4.6 Million Tonnes per Annum

& INCREASE OF WASTE HEAT RECOVERY

POWER PLANT: 10 MW to 20 MW

By

PENNA CEMENT INDUSTRIES LTD., Boyareddypalli Village, Yadiki Mandal, Anantapur

District, Andhra Pradesh.

Table of Contents

1. Executive Summary 03

2. Introduction Of The Project/ Background Information 06

3. Project Description 10

4. Site Analysis 17

5. Planning Brief 25

6. Proposed infrastructure 26

7. Rehabilitation and resettlement (R & R) Plan 29

8. Project schedule & Cost Estimates 30

9. Analysis of proposal (Final Recommendations) 31

Figure

Table-1 Salient features of project

Table-2 Land breakup

Figure

Figure-1 Location Map

Figure-2 Key Map

Figure-3 Topographical Map

Figure-4 Cement Plant Layout

Annexures

Annexure – I Copy of MoEF Clearance

1. EXECUTIVE SUMMARY

PENNA CEMENT INDUSTRIES LTD (PCIL)

Penna Cement is one of the largest privately held cement companies in

India, with an installed cement capacity of 7 Million Tonnes Per

Annum.

Founded in 1991, Penna Cement has established itself as one of the

most trusted cement brands, with significant footprints in southern

and western India. Our clientele ranges from small house owners to

established real estate developers and from various state governments

to global construction majors.

Over the last two decades, PCIL had grown organically by developing

in-house expertise and capabilities, across the entire value chain in

the cement industry. All PCIL cement plants are equipped with state-

of-the-art technology, enabling the company to deliver the superior

quality products.

PENNA CEMENT INDUSTRIES LTD (PCIL) is operating a Cement

Plant with a Clinker production capacity of 1.5 Million Tonnes Per

Annum (MTPA) at Boyareddypalli Village, Yadiki Mandal, Anantapur


Penna Cement manufactures a wide range of cement including

Ordinary Portland Cement (OPC 53 grade and 43 grade), Portland

Pozzolana Cement (PPC), Portland Slag Cement (PSC).

The limestone requirement of the cement plant is met from Gudipadu

Limestone mine located at Gudipadu, Yadiki Mandal, Anantapur


PCIL received Environmental Clearance vide MOEF letter no. J-

11011/351/2006-IA-II(1) dt 18-05-2007 (Annexure-I)

The current status of various units of PCIL along with installed

production capacities are given below:

OVERVIEW OF PRODUCTION CAPACITIES OF PCIL

Installed capacity MTPA

1 Clinker Production Capacity 1.50

2 Cement Production Capacity 2.00

3 Captive Limestone Mining 2.30

PCIL has obtained CFE and operating 10 MW Waste Heat Recovery

power plant from APPCB and project in under installation stage. PCIL

now proposes to increase clinker production capacity from 1.50 to 4.0

MTPA and cement production from 2.00 to 4.6 MTPA by enhancing

the Unit-I production capacity from 1.5 to 1.65 MTPA and by

installing a new line of 2.35 MTPA. With increase of clinker production

capacity, the limestone requirement increases from 2.30 to 5.30

MTPA.

PCIL proposes to meet the additional limestone requirement from

same captive limestone mining lease. The mining lease extends over

an area of 392.62 Ha., in Gudipadu, Yadiki Mandal, Anantapur


The present proposal pertains to obtaining environmental clearance

for expansion of the cement plant as per the following table:

PRODUCTION CAPACITY (MTPA)

Unit

Present approved Capacity as per

MoEF EC (MTPA)

Capacity after proposed expansion (MTPA)

Clinker Cement Clinker Cement

Cement Plant

Unit –I 1.5 2.0 1.65 2.0

Unit –II (new unit)

- - 2.35 2.6

Total 1.5 2.0 4.00 4.6

Waste Heat Recovery based Power Plant,

MW 10 20

PCIL complex is located in an area of 60 Ha. The new unit will be

located within the existing cement plant complex as shown in the Lay

out plan.

PCIL cement plant is supported by their captive Limestone mines to

meet the additional limestone requirement of proposed expansion. The

production capacity of limestone mines will be augmented. The

proposal is being submitted to MoEF separately for necessary

environmental clearance.

The present water requirement of the plant is 930 m3/day and is

sourced from borewells & mine pit within the plant site. Additional

Water requirement for the proposal is 500 m3/day which will be met

from mines pit.

The project is based on Clinkerization factor of 1.50 on Raw Meal

basis with specific heat consumption of 740 Kcal/ kg clinker.

There is no wild life sanctuary, national park, eco-sensitive area

within the 10 km radius of the project site.

For transporting cement from the cement plant to the market and

obtaining raw materials like coal, gypsum and other additives, well

connected road and railway siding is available.

No additional quarter’s construction is proposed.

No solid waste generation from the plant. Only Wastewater generated

is only from domestic activities at cement plant and residential colony.

A full-fledged sewage treatment plant (STP) is in operation designed

for a maximum load of 250 m3/day. Treated domestic wastewater is

100% reused for greenbelt development within PCIL cement plant

complex.

Greenbelt is maintained in about 33 % of the total area.

The peak power consumption in the PCIL Cement plant complex

including mine is 25 MW. Power requirement is met from grid. An

additional power of 15 MW is required for the proposed expansion

project. Totaling 40 MW. Internal Power generation from WHR will be

20MW. There will not be any additional power requirement.

Plant is expected to be commissioned in 18 months from date of

commencement of construction

Total capital Investment Cost is Rs. 800 crores.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. IN

CASE OF MINING PROJECT, A COPY OF MINING LEASE / LETTER

OF INTENT SHOULD BE GIVEN.

PENNA CEMENT INDUSTRIES LTD (PCIL) is operating a Cement

Plant with a Clinker production capacity of 1.5 Million Tonnes Per

Annum (MTPA) & 10MW WHR Power Plant at Boyareddypalli Village,

Yadiki Mandal, Anantapur District, Andhra Pradesh.

PCIL present installed capacity of cement plant is 1.5 million tonnes

per annum (MTPA) of clinker and 2.0 MTPA of cement & 10MW WHR

Power Plant. PCIL is manufacturing Ordinary Portland Cement (OPC),

and Portland Pozzolana Cement (PPC).

To meet the increasing demand of cement, both in the domestic and

international markets, PCIL is proposes to increase production of

clinker capacity to 4.0 MTPA and cement production to 4.6 MTPA &

20MW Power.

ii) Brief description of nature of the project

The project is cement plant with present clinker production of 1.5

MTPA and cement of 2.0 MTPA. The proposal is for increase of clinker

production to 4.0 MTPA and cement production capacity to 4.6 MTPA

& 20MW Power.

iii) Need for the project and its importance to the country and or

region.

The cement market has growth potential due to the central

government liberalization policies and new schemes for housing, road

projects. Cement demand growth is anticipated to be about 9 to 10%

increase mainly through road projects (Golden Quadrilateral), Housing

Projects (1.3 million houses in rural & 0.7 million in urban areas).

Continuous demand for exports to China and other South-East Asian

countries along with the increased requirement of the domestic sector

have led all the cement manufacturers in the country to plan for

increased capacities.

So with a view to capture growing opportunity demand, the

management PCIL wants to take up the section wise capacity

balancing and optimization. The proposed expansion will enable the

company to maximize its profitability by optimum utilization of

technology, manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficient

equipment, fuel, financial charges and other fixed overheads on

account of large scale economics due to higher volume of production

and sales.

It would also enable the company to withstand against the

considerable competitive pressure from large-scale units in the

country and also to create wider brand loyalty for the product.

The increase of production within the existing plant is based on the

following considerations

Proximity of the site to captive limestone mines and abundant

availability of reserves.

Market demand

Availability of land – no further land is proposed to be acquired

Availability of existing infrastructure.

Demand – supply Gap

Cement demand in India is expected to increase due to government’s

push for large infrastructure projects, leading to 45 million tonnes of

cement needed in the next three to four years1.

India's cement demand is expected to reach 550-600 Million Tonnes

Per Annum (MTPA) by 2025. The housing sector is the biggest demand

driver of cement, accounting for about 67 per cent of the total

consumption in India. The other major consumers of cement include

infrastructure at 13 per cent, commercial construction at 11 per cent

and industrial construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56

million tonnes (MT) capacity over the next three years. The cement

capacity in India may register a growth of eight per cent by next year

end to 395 MT from the current level of 366 MT. It may increase

further to 421 MT by the end of 2017. The country's per capita

consumption stands at around 190 kg.

The Indian cement industry is dominated by a few companies. The top

20 cement companies account for almost 70 per cent of the total

cement production of the country. A total of 188 large cement plants

together account for 97 per cent of the total installed capacity in the

country, with 365 small plants account for the rest. Of these large

cement plants, 77 are located in the states of Andhra Pradesh,

Rajasthan and Tamil Nadu & Telangana

v) Imports Vs. Indigenous production

India is self sufficient to meet the demands of the market with the

GDP projected at 10 % in the coming decades and in view of the

infrastructure.

The end product being cement, the importance of the project is

detailed below with respect to cement demand.

India is self sufficient to meet the demands of the market with the

GDP projected at 10% in the coming decades and in view of the

infrastructure.

vi) Export possibility

No export of cement outside the country is planned.

vii) Domestic / export markets

The expansion of cement plant will meet the domestic markets

demand.

viii) Employment generation (direct and indirect) due to the

project.

100 additional employees are required.

3. PROJECT DESCRIPTION

i. Type of project including interlinked and interdependent

projects, if any

The present proposal is setting up new kiln and by enhancing the

present kiln production capacity, within existing Cement Plant area of

PCIL located at Boyareddypalli Village, Yadiki Mandal, Anantapur

District, Andhra Pradesh in area of 60 Ha.

To meet the limestone requirement of Cement Plant after proposed

project, the existing mines’ production will be enhanced.

ii. Location (map showing general location, specific location, and

project boundary & project site layout) with co-ordinates.

The Cement plant is located near Boyirredipalli Village, Yadiki Mandal,

Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The site

falls between A) 15° 3'35.20"N- 77°56'52.51"E B) 15° 3'51.44"N-

77°56'52.03"E C) 15° 3'52.10"N- 77°57'12.06"E D) 15° 3'35.82"N-

77°57'12.55"E North latitude and East Longitude with an average

altitude of 276m above MSL. The area falls within Survey of India

Toposheet no. 57/E/16 [1:50000 scale].

Fig-1 shows the location map of the Plant Site.

Nearest railway line connecting Rayalacheruvu - Tadipatri of South

Central Railway line is located at a distance of 11.1 km to WSW

direction from the site. Key map showing the location of various

features around the Plant site is shows in Fig – 2. Tadipatri is major

town is located at a distance of 17.8 km in SSE direction.

The National Highway (NH-44) connecting Dhone - Gooty is located at

a distance of about 29.5 km in WNW direction. The State Highway

(SH-57) connecting Bellary– Nellore is located at a distance of about

3.0 km in Southern direction.

The nearest railway station is located at Tadipatri which is 17.7 km in

SSE direction.

A N D H R A P R A D E S H

L O C A T IO N M A P

C h it to o r

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7

7

A N A N T A P U R D IS T R IC T

P L A N T S IT E

N o te :- N o t to S c a le

N

L E G E N D

R A IL W A Y T R A C K

R IV E R

R O A D

D IS T R IC T B O U N D A R Y

M A JO R R O A D

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D IS T R IC T H E A D Q U A R T E R

T O W N

N A T IO N A L H IG H W A Y

P C IL P L A N T S IT E

7

T E M P L E

F IG - 1

2 k m10

S E C U N D E R A B A D

P re p a re d b y

T IT L E :

C L IE N T :

K E Y M A P

S C A L E

M /s . P E N N A C E M E N T IN D U S T R IE S L T D .,

C E M E N T P L A N T

N

P R O JE C T :

B o y ire d d y p a lli V illa g e , Y a d ik i M a n d a l, A n a n th a p u r D is tr ic t , A n d h ra P ra d e sh

C h in ta la y a p a lli

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K u r la p a lli

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3 9 6

3 6 9

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G u d ip a d u

C O L O N Y


1 .1 k m

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S E T T L E M E N T S

S P O T H E IG H T S

S T R E A M S / T A N K S

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D IS T R IC T B O U N D A R Y

3 9 6

C O L O N Y


F IG - 2

Penneru River – 11.4 km – S and Maruna Vagu – 8.9 km – WSW are

the nearest waterbodies in the 10 km radius of the plant site.

Yadiki RF is the Nearest Forests at a distance of 8.4 km in WNW

dirsction. The Nearest Airport from the Plant site is Kadapa Airport –

106.1 km – SE

Due to availability of rich limestone deposits, major cement plants,

which are located within 10 km are BMM Cements Limited – 3.0 km –

ENE and Ultratech Cement – 7.5 km – SE

There are no national parks/wild life sanctuaries/eco sensitive zones

within 10 km radius of the cement plant and mine sites.

Fig-3 shows the 10 km radius around Cement plant. Salient features

of the plant site are given in Table-1.

TABLE – 1

SALIENT FEATURES OF THE CEMENT PLANT

Feature Details

Altitude 276 m above msl

Longitude Latitude

A) 15° 3'35.20"N- 77°56'52.51"E B) 15° 3'51.44"N- 77°56'52.03"E C) 15° 3'52.10"N- 77°57'12.06"E D) 15° 3'35.82"N- 77°57'12.55"E

Village, Tehsil, District, State

Boyirredipalli Village, Yadiki Mandal, Tadipatri Taluka, Ananthapur District of Andhra Pradesh.

Annual rainfall 725 mm

Nearest water bodies Penneru River – 11.4 km – S Maruna Vagu – 8.9 km - WSW

Nearest Highway The National Highway (NH-44) connecting Dhone – Gooty-29.5km-WNW The State Highway (SH-57) connecting Bellary– Nellore - 3.0 km in Southern direction.

Nearest Railway station Tadipatri RS - 17.7 km - SSE

Inter State Boundary Andhra Pradesh – Karnataka – 85.5km - W

Nearest Industries BMM Cements Limited – 3.0 km – ENE Ultratech Cement – 7.5 km - SE

District Head Quarter Ananthapur – 55.9 km - SW

Nearest Town Tadipatri – 17.8 km – SSE direction.

Nearest Air port Kadapa Airport – 106.1 km – SE Tirupati ( Renigunta ) Airport – 236 .0km - SE

Nearest Forest Yadiki RF - 8.4 km - WNW

Nearest Wild life Sanctuaries

None within 10 km Radius

* All distances mentioned in the above table are aerial distances.

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iii. Details of alternate sites considered and the basis of selecting

the proposed site, particularly the environmental considerations

gone into should be highlighted.

As the expansion is proposed in the existing premises, no alternate

site considered or proposed for the proposed project

iv. Size or magnitude of operation

With the proposed expansion, the clinker production will be 4.0 MTPA

and Cement at 4.6 MTPA & 20MW Power from WHR.

PCIL is manufacturing blended cement. viz., Ordinary Portland

cement (OPC)) and Portland Pozzolana Cement (PPC)/ Portland Slag

Cement.

Manufacturing Process:

Limestone Mining: Mechanized mining of lime stone is done by deep

hole drilling, nonel blasting, excavation and hauling. The blasted lime

stone of size less than 1000mm will be transported to lime stone

crusher for crushing.

Limestone Crushing: A single Rotor Impact Crusher is installed to

reduce limestone size from 1000 mm to 75mm.

Stacking & Reclaiming: The crushed lime stone is stacked

longitudinally with stacker as per the required quality given by Quality

Control Dept. The capacity of stock pile is 60000 T. After forming the

stockpile, the reclaimation will be started. The total process of

stacking and reclaiming is called chevron method.

Raw material grinding: Blended lime stone will be reclaimed and will

be filled into raw material hopper in the Vertical Roller Mill (VRM)

section. Laterite, Iron Ore and corrective limestone will be filled into

hoppers. All the materials with the required ratio are conveyed

through the weigh feeders and belt conveyors to Vertical Roller Mill,

where grinding takes place.

VRM with inbuilt system of separator will grind the raw materials 75

mm size to 18% R on 90 micron size. The product called raw meal is

collected in cyclones and RABH and transported through air slides

and bucket elevator and stored in blending Silo.

Coal Crushing & Grinding: Raw Coal unloaded from open trucks by

wagon tippler through rakes to yard and transported by Belt

Conveyors to crusher where the size is reduced from 100mm to 25

mm and conveyed to raw coal hopper through conveyor belts. Vertical

roller mill (VRM) pulverizes raw coal to fine coal with fineness of 10%

R on 90 microns, which is collected in Bag Filter. The fine coal is

further conveyed mechanically to fine coal bins and transported to

kiln and calciner pneumatically (through FK pumps) for firing.

Pyro-Processing: This system consists of Rotary Kiln with 5 stage

Pre-heater and In-line Calciner. Raw meal from Silos is conveyed

through pre-heater. Fine coal is fired through burner pipe into kiln

and into pre-calciner. The material is 90 to 92 % calcined before

entering into kiln and balance calcination, Pre burning and sintering

takes place in the kiln for ensuring complete chemical reactions.

Clinker formed is cooled in grate coolers with high pressure fans. The

clinker after cooling is transported mechanically to clinker storage

tanks.

Cement Grinding: Clinker from clinker storage tank is conveyed to

clinker hopper. Gypsum is filled into gypsum hopper. Closed Circuit

Tube Mill with dynamic separator grinds clinker and gypsum in a

ratio of 95:5 respectively. The product, called Ordinary Portland

cement (OPC) is conveyed mechanically to cement storage silos.

Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectively

are ground in the Ball Mill to make Portland Pozzolana Cement (PPC),

Portland slag cement (PSC) & Portland Pozzolana Cement (PPC) which

is conveyed mechanically to cement storage silos.

Cement Packing: Electronic Packers (12 spout- double discharge)

automatically fill the PP bags or paper bags of 50 Kg. These bags are

loaded to the trucks through belt conveyors and loaders/Rail

The Plant is well automated and operated form Central Control Room

and Control system is based on PLC.

Quality Control: All the raw materials, in- process and products are

carried out by means of XRF and XRD of PAN Analytical. The

preventive measures are taken to ensure the consistent and best

quality is achieved. Material testing is undertaken on calibrated

instruments for both Physical and Chemical parameters all the time.

The people involved in this stream are highly qualified and

experienced and quality conscious. The product is well accepted in the

market and customers like Readymix concrete, Industries and

Builders prefer our product very well.

Process Control: The plant operation through Automation is

equipped with Expert Control Systems (ECS), comprising the SDR

system. PIDs with closed loops systems are intact and PLC is in

advanced modern system. Fuzzy logic from FLS is also adopted for

smooth and consistent operation of the plant. The process parameter

is designed by the experts and is operated by qualified and

experienced engineers. The deviations are minimized and the

tolerances are limited. This is resulting in achieving the productivity in

terms of best quality, optimal production and energy conservation

(thermal as well as electrical).

vi. Raw material required along with estimated quantity, likely

source, marketing area of final products, mode of transport of raw

material and finished product.

The raw material required for production of clinker is Limestone, Iron

ore, Bauxite and Coal. Available limestone reserves of existing mines.

The requirement of raw material per annum on an average for the

production clinker and cement as mentioned above is presented in

below table.

RAW MATERIAL REQUIREMENT (MTPA)

PRESENT EXPANSION Source

Limestone 2.3 5.30 Captive mines

Iron ore 0.02 0.05 Bellary / Hospet

Laterite 0.08 0.18 Veldurty, Rajahmundry

Gypsum 0.10 0.23

SPIC and Sterlite Industries,

Tuticorin, EID Pary India

Ltd., Chennai & Coramandel

Fertilizers Ltd., Vizag

Coal 0.26 0.56

Singareni Collieries Company

Ltd/ Imported Coal/Petcoke

from USA

Slag 0.50 1.14 Jindal Steel and SJK Steel

Ash

requirement

for PPC

0.10 0.23

Rayalaseema Thermal Power

Station and Jindal Power

Plant, AP Genco , Power Plant

, Nellore

For obtaining raw materials like coal, gypsum, additives and

transporting cement from the cement plant to the market well

connected roads & rails are available. The National Highway (NH-44)

connecting Dhone – Gooty is located at a distance of about 29.5 km in

WNW direction.

vii. Resource optimization / recycling and reuse envisaged in the

project, if any, should be briefly outlined.

Available limestone reserves of existing mines which cater to limestone

needs of Cement Plant

Limestone from the mine is blended to arrive at the proper feedable

quality (subjected to the receipt of quality of coal) and supplied to

Cement plant for optimum utilization of resources.

Cooling water circuit is close circuited, thereby ensuring no generation

of wastewater. The process, selected envisages re-cycling all the

material collected in the pollution control equipment whereby

ensuring no generation of solid waste.

viii. Availability of water its source, energy / power requirement

Water

Water is required for cooling, dust suppression, sanitary facilities and

gardening. The present water requirement of the plant is 930 m3/day

and is sourced from borewells within the plant site. Additional Water

requirement for the proposal is 500 m3/day. The source of water is

borewell/mine pit.

Power


including mine is 25 MW. Total power requirement for the PCIL

cement plant complex is met from Grid. Additional power required is

about 15 MW and it also is sourced from grid and WHR Power Plant.

ix. Quantity of waste to be generated (liquid and solid) and

scheme for their management / disposal.

In cement plant water is used for cooling, gas conditioning and raw

material addition at various stages. This water is totally absorbed in

the process or will be subjected to evaporation and hence no

wastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plant

and residential colony. A full-fledged sewage treatment plant (STP) is

in operation designed for a maximum load of 250 m3/day. Treated

domestic wastewater is 100% reused for greenbelt development within

PCIL cement plant complex.

No solid waste will be generated from the cement plant. The dust

collected in the pollution control devices is being 100% recycled back

to the process.

x. Schematic representations of the feasibility drawing which give

information of EIA purpose.

4. SITE ANALYSIS

i. Connectivity

The Cement plant is located near Boyareddypalli Village, Kamalapadu

Panchayath Yadiki Mandal, Anantapur District, Andhra Pradesh.

The area is well connected by road and rail. The National Highway

(NH-44) connecting Dhone – Gooty is located at a distance of about

29.5 km in WNW direction. The nearest railway station is located at

Tadipatri which is 17.7 km in SSE direction.

ii. Land form, land use and land ownership.

Break-up of present land use of existing cement plant is given in

Table-2 and PCIL cement plant layout is shown in Fig-4. No

additional land acquisition will be required for proposed new line.

TABLE-2

LAND AVAILABILITY

S.No.

Area (ha.)

Before expansion

After expansion

1 Plant area and roads 25 30

2 Colony with infrastructure 8 9.6

3 Parking area 5 1

4 Greenbelt 16 19.4

5 Vacant Land 6 -

Total 60 60

iii. Topography (along with map)

The existing PCIL Cement plant site is located at an elevation of 268 m

above MSL.

The Cement plant is located near Boyirredipalli Village, Yadiki Mandal,

Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The site

falls between A) 15°3'35.20"N- 77°56'52.51"E B) 15°3'51.44"N-

77°56'52.03"E C) 15°3'52.10"N- 77°57'12.06"E D) 15°3'35.82"N-

77°57'12.55"E North latitude and East Longitude with an average

altitude of 276m above MSL. The area falls within Survey of India

Toposheet no. 57/E/16 [1:50000 scale].

FIG – 4

PLANT LAYOUT

EX

IST

ING

PO

WE

R=

54

33

1 H

P

PR

OP

OS

ED

PO

WE

R=

12

HP

TO

TA

L P

OW

ER

= 5

43

43

HP

Nearest railway line connecting Rayalacheruvu - Tadipatri of South

Eastern Railway line is located at a distance of 11.1 km to WSW

direction from the site. Tadipatri is major town is located at a distance

of 18.1 km in SSE direction.

The area is well connected by road and rail. The National Highway

(NH-44) connecting Dhone – Gooty is located at a distance of about

29.5 km in WNW direction. The nearest railway station is located at

Tadipatri which is 17.7 km in SSE direction.

Penneru River – 11.4 km – S and Maruna Vagu – 8.9 km – WSW are

the nearest waterbodies in the 10 km radius of the plant site.

Yadiki RF is the Nearest Forests at a distance of 8.4 km in WNW

dirsction. The Nearest Airport from the Plant site is Kadapa Airport –

106.1 km – SE

Due to availability of rich limestone deposits, major cement plants,

which are located within 10 km are BMM Cements Limited – 3.0 km –

ENE and Ultratech Cement – 7.5 km – SE

There are no national parks/wild life sanctuaries/eco sensitive zones

within 10 km radius of the cement plant and mine sites.

iv. Existing land use pattern (agriculture, non-agriculture, forest,

water bodies (including area under CRZ), shortest distances from

the periphery of the project to periphery of the forests, national

park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ, in case of notified

industrial area, a copy of the Gazette notification should be

given.

The existing cement plant is located in Boyareddypalli Village. No

additional land will be required for proposed expansion project.

There are no national parks or wildlife sanctuary within 10 km of

the subject plant area.

No ecologically sensitive area such as tropical forests, biosphere

reserves, important lakes or coastal area rich in coral formation

fall within 10 km of the plant area.

There are no sensitive places of notified archaeological, historical

or tourist importance within 10 km from the plant area.

v. Existing Infrastructure



connected road/rail is available.

vi. Soil Classification

The proposed new line will be located in existing plant area. No

additional land will be required for proposed new line.

Soil in the area is found to be clayey in texture with clay percentage in

the range 40 - 70%.

vii. Climate data from secondary sources

The tropical climate of the region is manifested in hot and humid

summer, moderately monsoon and mild winter seasons. May is the

hottest month in the year. The maximum temperature during the day

time was recorded as 45.6 0C and December the coldest with the

temperature during the day time falling down to about 34.40C. The

night temperature in winter can be as low as 6.70C. The months of

December, January & February are considered to have pleasant

climate.

viii. Social infrastructure available

A well-equipped Occupational Health center is provided at colony,

which has full time male and lady medical officers assisted, by

compounders and nurses. Necessary free medicines and medical aid is

available for the company employees.

A good canteen is provided for the benefit of the employees. The

canteen serves tea & snacks at subsidized rates to the employees.

Adequate number of shelters with fans, drinking water etc. for taking

food and rest are provided for the benefit of the employees.

Safe hygienic drinking water is provided at the plant. Drinking water

facility is available near rest shelters.

A full-fledged Training hall is available in the PCIL cement plant

complex. The training to workmen is provided on basics as well as for

refreshers.

The employees are provided with well-designed houses having

electricity and water connections.

For the education facility of employee’s children School is provided at

our colony.

5. PLANNING BRIEF

i. Planning concept (type of industries, facilities, transportation

etc) town and country planning / development authority

classification.

This is expansion project of existing cement plant within the present

PCIL cement plant complex. Additional civil structures will be required

for proposed unit.

ii. Population projection

The total manpower at the existing plant is 550. 100 additional

manpower is required.

Apart from the jobs, the company provided medical and educational

facilities to the employees which were availed by the people around

the plant. Adequate recreational facilities for the staff of the company

and the local people were created.

iii. Land use planning (breakup along with greenbelt etc.,)

This is expansion project of existing cement plant. The present land

use pattern of the existing PCIL cement plant complex is given in

Table-2. No additional land will be required for proposed expansion

project

iv. Assessment of infrastructure demand (physical & social)

Few additional housing facility will be created within the existing

colony.

v. Amenities / Facilities

All infrastructure facilities such as education, health facilities and

other social facilities are adequate at district headquarter which site

makes the region adequate in amenities.

6. PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

The following are the major equipment proposed under the new

production line

Main Machinery

Item Type Capacity

Limestone

Crusher

Single stage

impactor type

Crusher

900 tph

Limestone

Stacker

Luffing Boom Type

Stacker 900 tph

Limestone

Reclaimer

Bridge Type

Reclaimer 500 tph

Raw Material

Grinding VRM 380 TPH

Coal Grinding Vertical Roller Mill 45 TPH

Preheater /

Calciner

Single String 5 Stage Preheater with

Inline Precalciner - 5000 TPD

Kiln Rotary Kiln - 3000 tpd

Clinker Cooler Grate Cooler – 3000 tpd

Cement

Grinding

Ball Mill with

Roller press as pre

grinder

200 TPH

Packing Plant Rotary Packer 100 tph

Main Storages

Item Type Capacity

Limestone Stock

pile

Longitudinal

Stockpile 2x 30000 t

Chemical

gypsum

Stockpile

Closed stockpile 3000 t

Raw Meal Silo RCC 10000 t

Fly Ash Silo RCC 2000 MT

Clinker Silo RCC 40000 MT

Cement Silo RCC 2 X 8000 t

ii. Residential area (non-processing area)

Residential colony is located nearer to the plant. The Waste water

from colony and plant is treated in the Sewage Treatment Plant.

iii. Greenbelt

PCIL has already developed greenbelt in an area of 16 ha in and

around the PCIL cement plant complex. PCIL is taking up more area(4

Ha)under greenbelt development programme.

iv. Social infrastructure

PCIL has well defined CSR policy to Carryout social development and

welfare measures in the surrounding villages. Under CSR activity

PCIL will initiate community development projects, in the fields of

health, education and environmental preservation, in the study area

around the plant as is done in their existing units.

v. Connectivity (traffic and transportation road/rail/metro/water

ways etc)



connected roads are available. The National Highway (NH-7) Dhone –

Gooty is located at a distance of about 29.5 km in WNW direction.

vi. Drinking water management (source & supply of water)

existing cement plant is having safe drinking water facility. RO water

is supply to all the employee and contract workmen & surrounding

villages.

vii. Sewerage System

Existing STP will be utilized for treatment of domestic wastewater after

expansion of project.

viii. Industrial waste management

The production of cement will be based on completely dry process;

hence no process waste water will be generated from the plant. Also

the cooling water will be through a closed circuit system. The only

waste water generated will be domestic waste water from residential

township and the same will be treated in STP and used for green belt

development.

Hazardous wastes like spent oil from construction equipment, DG sets

etc., generated in small quantities during construction and

operational phase would be appropriately stored & handled and

properly disposed off in accordance with the provisions of the

Hazardous Waste Management Rules, 2010.

ix. Solid waste Management

No solid waste is generated from the cement plant. The dust collected

in the pollution control devices is being 100% recycled back to the

process.

x. Power requirement & Supply/Source.


including mine is 25 MW. Total power requirement for the PCIL

cement plant complex is met from grid. An additional power of 15 MW

is required for the proposed expansion project.

7. REHABILITATION AND RESETTLEMENT (R&R) PLAN

The new Unit is coming up in the existing complex owned by PCIL and

the R&R does not arise.

8. PROJECT SCHEDULE & COST ESTIMATES

The project is expected to be completed in a period of 18 months from

the date of receipt of all the approvals from statutory authorities. The

estimated cost of the project is Rs. 800 crores.

9. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)

The capital cost, for the proposed production enhancement project,

works out to Rs. 800 crores. Financial institutions will be funding the

project.

Growth of infrastructure, Irrigation and housing scenario

automatically drives the increased requirement of Cement in the

market. Based on the growing demand in the South East region of the

country for Cement over the next 10 years, the proximity of the project

location to this market is an advantage with respect reduction in

freight of cement to these markets. The financial viability also show a

good Rate of return from the project. Considering the above PCIL is

planning to go ahead with the project, once it gets all the statutory

approvals for this enhancement project.

PRE FEASIBILITY REPORT For EXPANSION OF CEMENT...

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