PRE FEASIBILITY REPORT For EXPANSION OF CEMENT PLANT...

0

PRE FEASIBILITY REPORT

For

EXPANSION OF CEMENT PLANT

With

INCREASE OF PRODUCTIONCLINKER: 2.00 to 5.00 MTPACEMENT: 3.00 to 6.00 MTPA

By

ORIENT CEMENT LIMITEDItagi & Diggaon villages, Chittapur taluk,

Kalaburagi district, Karnataka.

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Table of Contents

1. Executive Summary

2. Introduction Of The Project/ Background Information

3. Project Description

4. Site Analysis

5. Planning Brief

6. Proposed infrastructure

7. Rehabilitation and resettlement (R & R) Plan

8. Project schedule & Cost Estimates

9. Analysis of proposal (Final Recommendations)

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 Previous Environmental Clearance letter

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1. EXECUTIVE SUMMARY

ORIENT CEMENT LIMITED (OC)is operating a Cement Plant with aClinker production capacity of 2.0 Million Tonnes Per Annum (MTPA)at Itagi & Diggaon villages, Chittapur taluk, Kalaburagi district,Karnataka.

The limestone requirement of the cement plant is met from ChittapurLimestone mine located at Itga & Diggaon villages, Chittapur taluk,Kalaburagi district, Karnataka.

OC received Environmental Clearance for 2.0 MTPA Clinker and 3.0MTPA cement capacity along with a 50 MW Coal based power videMoEF letter no. J-11011/342/2011-IAII(I), dt. 11.3.2013 (Annexure-I)

The current status of various units of OC along with installedproduction capacities are given below:

OVERVIEW OF PRODUCTION CAPACITIES OF OCInstalled capacity

1 Clinker Production Capacity 2.0 MTPA2 Cement Production Capacity 3.0 MTPA3 Captive Limestone Mining 3.0 MTPA4 Power Plant (CPP) 50 MW

OC now proposes to increase clinker production capacity from 2.0 to5.0 MTPA and cement production from 3.0 to 6.0 MTPA by enhancingthe Unit-I production capacity from 2.0 to 2.50 MTPA and byinstalling another 2.5 MTPA new unit i.e., Unit-II. With increase ofclinker production capacity, the limestone requirement also increasesfrom 3.0 to 7.5 MTPA.

OC proposes to meet the above additional limestone requirement byincreasing limestone production from captive limestone mining lease.The mining lease extends over an area of 519 Ha. in Itagi & Diggaonvillages, Chittapur taluk, Kalaburagi district, Karnataka.

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The proposal for increase of Limestone from 3.0 to 7.5 MTPA is beingsubmitted to MoEF & CC separately for necessary environmentalclearance.

The present proposal pertains to obtaining environmental clearancefor expansion of the cement plant as below:

INCREASE OF PRODUCTIONCementPlant

Present approvedCapacity as per MoEF EC

(MTPA)

Capacity after proposedenhancement (MTPA)

Clinker Cement Clinker CementUnit –I 2.0 3.0 2.50 3.00Unit –II - - 2.50 3.00Total 2.00 3.0 5.0 6.0

OC complex is located in an area of 266 Ha. The new unit will belocated within the existing complex. No additional area is required.

The present water requirement of the plant is 3500 m3/day and issourced from reservoir made in the plant premises and water ispumped from Kagina River as per the agreement. Additional Waterrequirement for expansion is 2000 m3/day, taking the total waterconsumption to 5500 m3/day.

There is no wild life sanctuary, national park, eco-sensitive areawithin the 10 km radius of the project site.

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available. Railway siding is under installation.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 500 m3/day. Treateddomestic wastewater is reused for greenbelt development within OCcement plant complex.

The peak power consumption in the OC Cement plant complexincluding mine is 36 MW and is met from Captive Power Plant (CPP).

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An additional power of 36 MW is required for the expansion projectwhich can be met from the Grid power and CPP.

Plant is expected to be commissioned in 24 months from date ofcommencement of construction.

Total capital Investment Cost is Rs. 1354 crores.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. INCASE OF MINING PROJECT, A COPY OF MINING LEASE / LETTEROF INTENT SHOULD BE GIVEN.

OC is operating a Cement Plant with a Clinker production capacity of2.0 Million Tonnes Per Annum (MTPA) at Itagi & Diggaon villages,Chittapur taluk, Kalaburagi district, Karnataka.

ii) Brief description of nature of the project

The project is cement plant with present clinker production of 2.0MTPA and cement of 3.00 MTPA. The proposal is for increase ofclinker production to 5.00 MTPA, cement production capacity to 6.0MTPA. The excess clinker produced in the Plant will be shipped toSplit Grinding location which is outside the state.

iii) Need for the project and its importance to the country and orregion.

The cement market has growth potential due to the centralgovernment liberalization policies and new schemes for housing, roadprojects. Cement demand growth is anticipated to be about 9 to 10%increase mainly through road projects (Golden Quadrilateral), HousingProjects (1.3 million houses in rural & 0.7 million in urban areas).Continuous demand for exports to China and other South-East Asiancountries along with the increased requirement of the domestic sectorhave led all the cement manufacturers in the country to plan forincreased capacities.

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So with a view to capture growing opportunity demand, themanagement OC wants to take up the section wise capacity balancingand optimization. The proposed expansion will enable the company tomaximize its profitability by optimum utilization of technology,manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficientequipment, fuel, financial charges and other fixed overheads onaccount of large scale economics due to higher volume of productionand sales.

It would also enable the company to withstand against theconsiderable competitive pressure from large-scale units in thecountry and also to create wider brand loyalty for the product.

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

• Proximity of the site to captive limestone mines and abundantavailability of reserves.

• Market demand• Availability of land – no further land is proposed to be acquired• Availability of existing infrastructure.

iv) Imports Vs. Indigenous production

India is self sufficient to meet the demands of the market with theGDP projected at 10 % in the coming decades and in view of theinfrastructure.

The end product being cement, the importance of the project isdetailed below with respect to cement demand.

India is self sufficient to meet the demands of the market with theGDP projected at 10% in the coming decades and in view of theinfrastructure development being planned.

vi) Export possibility

No export of cement outside the country is planned.

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vii) Domestic / export markets

The expansion of cement plant will meet the domestic marketsdemand.

viii) Employment generation (direct and indirect) due to theproject.

Present manpower is 346. Under expansion, additional manpower of143 will be employed.

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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 thepresent kiln production capacity, within existing Cement Plant area ofOC located at Itagi & Diggaon villages, Chittapur taluk, Kalaburagidistrict, Karnataka in area of 266 Ha.

To meet the limestone requirement of Cement Plant after proposedexpansion, the existing mine production will be enhanced.

ii. Location (map showing general location, specific location, andproject boundary & project site layout) with co-ordinates.

The Cement plant is located near Itga & Diggaon villages, Chittapurtaluk, Kalaburagi district, Karnataka.

The Project site falls in the jurisdiction of Itagi, Mogla & Diggaon villagesof Chittapur taluk, Kalaburagi District of Karnataka. The geo coordinatesof the plant site are given:

170 5’ 45.24” – 170 7’ 5.54” N Latitude770 7’ 23.64” – 770 8’ 13.11” E Longitude

The project area is covered in Survey of India Topo sheet No. 56G/4(Scale : 1:50000).

Fig-1 shows the location map of the project site on 1:10,00,000 scale.

Kagna River is located at a distance of 6.9 km in N with respect to minesite and 6.2 km in NW with respect to the Plant site. Benithora River isat a distance of 7.9 km in N to the mine site and 10.7 km in NNE to theplant site.

Chittapur is the nearest town to the project site and is at a distance of 5km in Western direction to the mine site and 3.5 km in Western directionto the plant site. Kalaburagi is the major city which is at a distance of 36km in NW to the mine site and 37 km in WNW to the plant site.

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FIG - 1

INDIAKARNATAKA

KANNADUTTAR

DEVANGERE

CHAMRAJNAGARMYSORE

MANDYA

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CHIKMANGALUR

KANNADDAKSHIN

SHIMOGA

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TUMKUR KOLAR

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KOPPAL

BIJAPUR

RAICHUR

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LEGEND

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RIVER

ROAD

DISTRICT BOUNDARY

STATE HIGHWAY

TALUK HEADQUARTER

DISTRICT HEADQUARTER

TOWN

STREAMS

NATIONAL HIGHWAY

TOURIST PLACE

63&13

MINE SITE

Bengaluru(Bangalore)

LOCATION MAP

KALABURAGI

PLANT SITE

PLANT SITEMINE SITE

TUMKURCHITRADURGA

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Fig- 2 shows the Key Map of the proposed project site on 1;50,000scale

The area is well connected by road network. National highway NH-218 connecting Homnabad, Kalaburagi, Jevargi, etc. can beapproached at Firozabad (via Shahabad) covering an approximatedistance of around 33 km. Kalaburagi can be approached by two statehighways SH-19 & SH-10 which are at a distance of about 50 km &20 km respectively.

Chittapur is the nearest Broad gauge (BG) railway station of SouthCentral Railway is adjacent to the Mine site and 3.5 km in Westerndirection to the plant site. Nearest major rail junction is at Wadi at 20km.

There is an abandoned railway track at Chittapur railway stationtowards the plant site. The plant site is located at 4-5 km from thetermination point of this track. Construction of rail line into plant isbeing constructed.

The industries existing within 10 km radius are :

RajaShree Cement Plant, Malkhed - 2.4 km South India Cement, Malkhed - 2.4 km

The nearest airport is Hyderabad at 220 km. New domestic airport isalso proposed at a distance of 12 km from Kalaburgi on Kalaburgi –Sedam state highway no.10 (SH-10).

The Nearest Airport from the Plant site is Hyderabad Airport – 220 km

There are no national parks/wild life sanctuaries/eco sensitive zoneswithin 10 km radius of the cement plant site.

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PROJECT :

TITLE :

SECUNDERABAD

PREPARED BY

KEY MAP

FIG - 2

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ROADS

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449 SPOT HEIGHT

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Itga & Digaon Villages, Chittapur Taluk,ORIENT CEMENT LIMITED

PLANTSITE

MINESITE

PLANT SITE

2.4km

Mogla

Kalaburgi District, Karnataka

1.2km

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Fig-3 shows the 10 km radius around Cement plant. Salient featuresof the plant site are given in Table-1.

TABLE – 1SALIENT FEATURES OF THE PLANT AND MINE SITES

Features W.r.t Plant site

Altitude,m 420-430

Longitude Between 770 7’ 23.64” – 770 8’ 13.11” E

Latitude Between 170 5’ 45.24” – 170 7’ 5.54”N

Village, District, StateNear Itagi & Diggaon Villages, ChittapurTaluk, Kalaburagi District, Karnataka

Topography Plain

Soil Type Black cotton Soil

Nearest RiverKagna River – 6.2 km – NWBenithora R – 10.7 km - NNE

Nearest Highway NH – 218 : 32.8 km - W

Nearest Railway station Chittapur – 3.5 km - W

Nearest IndustriesRajashree Cement – 2.4 km – NESouth India Cement – 2.4 km – NE

Nearest Village Itga – 1.2 km - ENE

Nearest City Kalaburagi – 37 km - WNW

Nearest Air port Shamshabad (Hyderabad) – 133 km – E

Nearest Forest None within 10 km radius

Historical places 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 selectingthe proposed site, particularly the environmental considerationsgone into should be highlighted.

As the expansion is proposed in the existing premises, no alternatesite considered or proposed for the proposed project

iv. Size or magnitude of operation

With the proposed expansion, the clinker production will be 5.00MTPA and Cement at 6.00 MTPA.

Manufacturing Process:

Limestone Mining: Mechanized mining of lime stone is done by deephole drilling, nonel blasting, excavation and hauling. The blasted limestone of size less than 1000mm will be transported to lime stonecrusher for crushing.

Limestone Crushing: A single Rotor Impact Crusher is installed toreduce limestone size from 1000 mm to 75mm.

Stacking & Reclaiming: The crushed lime stone is stackedlongitudinally with stacker as per the required quality given by QualityControl Dept. After forming the stockpile, the reclaimation will bestarted. The total process of stacking and reclaiming is called chevronmethod.

Raw material grinding: Blended lime stone will be reclaimed and willbe filled into raw material hopper in the Vertical Roller Mill (VRM)section. Laterite (out source material) and corrective limestone will befilled into laterite hopper and corrective limestone hopper respectively.All the three materials with the required ratio are conveyed throughthe weigh feeders and belt conveyors to Vertical Roller Mill, wheregrinding takes place.

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VRM within built system of separator will grind the raw materials 75mm size to 15 to 17% on 90 micron size. The product called Raw mealis collected in cyclones and Pulse jet Bag House and transportedthrough air slides and bucket elevator and stored in blending Silo.

Pet Coke Coal Crushing & Grinding: Pet Coke / Raw Coal unloadedfrom open trucks to yard and transported by Belt Conveyors tocrusher where the size is reduced from 300 mm to 50 mm andconveyed to raw coal hopper through conveyor belts. Vertical rollermill (VRM) pulverizes raw coal to fine coal with fineness of 16%R on90 microns, which is collected in Bag Filter. The fine coal is furtherconveyed mechanically to fine coal bins and transported to kiln andcalciner pneumatically (through FK pumps) for firing.

Pyro-Processing: This system consists of Rotary Kiln with 6 stagePre-heater and In-line Calciner. Raw meal from Silos is conveyedthrough pre-heater. Fine coal is fired through burner pipe into kilnand into pre-calciner. The material is 90 to 92 % calcined beforeentering into kiln and balance calcination, Pre burning and sinteringtakes place in the kiln for ensuring completion of chemical reactions.Clinker formed is cooled in Static grate coolers with high pressurefans. The clinker after cooling is transported mechanically to clinkerstorage tanks.

Cement Grinding: Clinker from clinker storage tank is conveyed toclinker hopper. Gypsum is filled into gypsum hopper. Closed CircuitTube Mill with dynamic separator grinds clinker and gypsum in aratio of 95:5 respectively. The product, called Ordinary Portlandcement (OPC) is conveyed mechanically to cement storage silos.

Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectivelyare ground in the Vertical roller Mill to make Portland PozzolanaCement (PPC)/ Portland slag cement (PSC) & Portland PozzolanaCement (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 areloaded to the trucks through belt conveyors and loaders.

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The Plant is well automated and operated form Central Control Roomand Control system is based on PLC.

Quality Control: All the raw materials, in- process and products arecarried out by means of XRF and XRD of PAN Analytical. Thepreventive measures are taken to ensure the consistent and bestquality is achieved. Material testing is undertaken on calibratedinstruments for both Physical and Chemical parameters all the time.The people involved in this stream are highly qualified andexperienced and quality conscious. The product is well accepted in themarket and customers like Readymix concrete, Industries andBuilders prefer our product very well.

Process Control: The plant operation through Siemens Automation isequipped with Expert Control Systems (ECS), comprising the SDRsystem. PIDs with closed loops systems are intact and PLC is inadvanced modern system. Fuzzy logic from FLS is also adopted forsmooth and consistent operation of the plant. The process parameteris designed by the experts and is operated by qualified andexperienced engineers. The deviations are minimized and thetolerances are limited. This is resulting in achieving the productivity interms of best quality, optimal production and energy conservation(thermal as well as electrical).

vi. Raw material required along with estimated quantity, likelysource, marketing area of final products, mode of transport of rawmaterial and finished product.

The raw material required for production of clinker is Limestone, Ironore, Bauxite and Coal. Available limestone reserves of existing mines.The requirement of raw material per annum on an average for theproduction clinker and cement is presented in below table.

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RAW MATERIAL REQUIREMENT (MTPA)

PRESENT ADDITIONAL TOTAL SOURCE Mode ofTransport

Limestone 3.0 4.5 7.5Captivemine

Conveyor

Laterite 0.109 0.164 0.213Vizag orRajamundryWarangal

Road/RailBauxite 0.118 0.178 0.296

Belgaumarea,Karnataka

Feld Spar 0.029 0.044 0.073 Vikarabad

Gypsum 0.150 0.150 0.300

EID ParyIndia Ltd.,Chennai &Coramandel FertilizersLtd., Vizag.

CoalCementPlant

0.300 0.450 0.750SCCL orWCL orMahanandiCPP 0.262 - 0.262

Pet Coke 0.166 0.250 0.416MRPL,Mangalore

Ashrequirementfor PPC

0.590 0.885

1.475 Raichurpower plant& JindalSteel,Bellary

For obtaining raw materials like Petcoke, coal, gypsum, additives andtransporting cement from the cement plant to the market, wellconnected roads are available. Railway siding is under development.

vii. Resource optimization / recycling and reuse envisaged in theproject, if any, should be briefly outlined.

Available limestone reserves of existing mines cater to limestone needsof Cement Plant

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Limestone from the mine is blended to arrive at the proper feedablequality (subjected to the receipt of quality of coal) and supplied toCement plant for optimum utilization of resources.

Cooling water circuit is close circuited, thereby ensuring no generationof wastewater. The process, selected envisages re-cycling all thematerial collected in the pollution control equipment wherebyensuring no generation of solid waste.

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

Water

Water is required for cooling, dust suppression, sanitary facilities andgardening. The present water requirement of the plant is 3500 m3/day(Cement Plant and Power Plant). Additional Water requirement for theproposal is 2000 m3/day. The source of water is Kagina River.

Power

The peak power consumption in the OC Cement plant complexincluding mine is 24 MW. Total power requirement for the OC cementplant complex is met from Captive Power Plant. Additional powerrequired is about 36 MW and it will be sourced from Captive PowerPlant and WHRB. Grid also is accessed, if required.

xi. Quantity of waste to be generated (liquid and solid) andscheme for their management / disposal.

In cement plant water is used for cooling, gas conditioning and rawmaterial addition at various stages. This water is totally absorbed inthe process or will be subjected to evaporation and hence nowastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 500 m3/day. Treateddomestic wastewater is 100% reused for greenbelt development withinOC cement plant and Colony.

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No solid waste will be generated from the cement plant. ash generatedfrom the power plant is used for cement manufacturing. The dustcollected in the pollution control devices is being recycled back to theprocess.

x. Schematic representations of the feasibility drawing which giveinformation of EIA purpose.

4. SITE ANALYSIS

i. Connectivity

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ii. Land form, land use and land ownership.

Break-up of present land use of existing cement plant is given inTable-2 and OC cement plant layout is shown in Fig-4. No additionalland acquisition will be required for proposed new line.

TABLE-2LAND AVAILABILITY (Ha)

S.No. Landuse Before expansion Afterexpansion

1Cement Plant, Power plant,space in between, Roads andParking

100 115

2 Water reservoir 42 42

3Greenbelt 88

(so far developed – 40 Ha)88

4 Substation 14 145 Vacant Land 22 7

Total area of cement plant 266 266

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PROJECT :

TITLE : PLANT LAYOUT

FIG - 4

N

Itga & Digaon Villages, Chittapur Taluk,ORIENT CEMENT LIMITED

Kalaburgi District, Karnataka

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iii. Topography (along with map)

The existing OC Cement plant site is at an elevation of 425 m aboveMSL. The Cement plant is located near Itagi & Diggaon villages,Chittapur taluk, Kalaburagi district, Karnataka.

The Project site falls in the jurisdiction of Itagi, Mogla & Diggaonvillages of Chittapur taluk, Kalaburagi District of Karnataka. The geocoordinates of the plant site are given:

170 5’ 45.24” – 170 7’ 5.54” N Latitude770 7’ 23.64” – 770 8’ 13.11” E Longitude

The project area is covered in Survey of India Topo sheet No. 56G/4(Scale : 1:50000).

Kagna River is located at a distance of 6.9 km in N with respect tomine site and 6.2 km in NW with respect to the Plant site. BenithoraRiver is at a distance of 7.9 km in N to the mine site and 10.7 km inNNE to the plant site.

Chittapur is the nearest town to the project site and is at a distance of5 km in Western direction to the mine site and 3.5 km in Westerndirection to the plant site. Kalaburagi is the major city which is at adistance of 36 km in NW to the mine site and 37 km in WNW to theplant site.



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The industries existing within 10 km radius are :

RajaShree Cement Plant, Malkhed - 2.4 km South India Cement, Malkhed - 2.4 km

The nearest airport is Hyderabad at 220 km. New domestic airport isalso proposed at a distance of 12 km from Kalaburgi on Kalaburgi –Sedam state highway no.10 (SH-10).

The Nearest Airport from the Plant site is Hyderabad Airport – 220km.

iv. Existing land use pattern (agriculture, non-agriculture, forest,water bodies (including area under CRZ), shortest distances fromthe periphery of the project to periphery of the forests, nationalpark, wild life sanctuary, eco sensitive areas, water bodies(distance from the HFL of the river), CRZ, in case of notifiedindustrial area, a copy of the Gazette notification should begiven.

The existing cement plant is located in Itga & Diggaon Villages. Noadditional land will be required for proposed expansion project.

• There are no national parks or wildlife sanctuary within 10 km ofthe subject plant area.

• No ecologically sensitive area such as tropical forests, biospherereserves, important lakes or coastal area rich in coral formationfall within 10 km of the plant area.

• There are no sensitive places of notified archaeological, historicalor tourist importance within 10 km from the plant area.

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v. Existing Infrastructure

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available. And Rail line is nearing completion.

vi. Soil Classification

The proposed new line will be located in existing plant area. Noadditional land will be required for proposed new line.

Soil in the area is found to be Clayey and rock texture with claypercentage in the range 60-65%.

vii. Climate data from secondary sources

The tropical climate of the region is manifested in hot and humidsummer, moderately monsoon and mild winter seasons. May is thehottest month in the year. The maximum temperature during the daytime was recorded as 50 0C and December the coldest with thetemperature falling down to about 140C. The months of December,January & February are considered to have pleasant climate.

viii. Social infrastructure available

A well-equipped Clinic is provided at Factory, which has full medicalofficer assisted, by compounder and nurse. Necessary free medicinesand medical aid is available for the company employees.

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

Adequate number of shelters with fans, drinking water etc. for takingfood and rest are provided for the benefit of the employees.

Safe hygienic drinking water is provided at the plant. Drinking waterfacility is available near rest shelters.

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5. PLANNING BRIEF

i. Planning concept (type of industries, facilities, transportationetc) town and country planning / development authorityclassification.

This is expansion project of existing cement plant within the presentOC cement plant complex. Additional civil structures will be requiredfor proposed unit.

ii. Population projection

The total manpower at the existing plant is 346 and 143 additionalmanpower is required.

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

This is expansion project of existing cement plant. The present landuse pattern of the existing OC 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)

Nil

v. Amenities / Facilities

All infrastructure facilities such as education, health facilities andother social facilities are adequate at district headquarter whichmakes the region adequate in amenities.

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6. PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

Upgradation of existing Unit – I

The production capacity of the existing unit will be enhanced byimplementing the following

• Extending operational hours of Raw mill and Cement Mill• Kiln speed is proposed to be increased by replacing the girth gear,

pinion and the gear box• Cooler area will be extended

Unit – II (New Line)

The following are the major equipment proposed under the newproduction line

MainMachinery

Item Type

Limestone CrusherSingle stage impactor typeCrusher

Limestone Stacker Luffing Boom Type StackerLimestone Reclaimer Bridge Type ReclaimerRaw Material Grinding VRM / Roller PressCoal Grinding Vertical Roller Mill

Preheater / CalcinerSingle String six Stage Preheaterwith Inline Precalciner - 7500tpd

Kiln Rotary Kiln - 7500 tpdClinker Cooler Grate Cooler - 7500 tpd

Cement GrindingBall Mill with Roller press as pregrinder or VRPM

Packing Plant Rotary PackerMain Storages Item Type

Limestone Stock pile Longitudinal StockpileChemical gypsumStockpile

Open stockpile

Raw Meal Silo RCCFly Ash Silo RCCClinker Silo RCCSlagCement Silo RCC

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ii. Residential area (non-processing area)

Residential colony is being located nearer to the plant. The Wastewater from colony and plant is treated in the Sewage Treatment Plant.

iii. Greenbelt

OC has already developed greenbelt in an area of 20 Ha in and aroundthe OC cement plant complex. OC is taking up more area (70 Ha)under greenbelt development programme.

iv. Social infrastructure

OC has well defined CSR policy to Carryout social development andwelfare measures in the surrounding villages. Under CSR activity OCinitiated the following community development projects, in the fieldsof health, education and environmental preservation, in the studyarea around.

I Development Initiatives1 Infrastructure development in the villages.

1.01 Construction of 4.8 kms. approach roads.1.02 Construction of 6 kms. Internal CC roads in villages1.03 Electrification on roads, internal roads and at facilities.1.04 Construction of community centers.

1.05Developing parks, sports complex and recreation centers, library etc. at villages andTehsil.

1.06 Construction of covered box type drainage systems

1.07Creating facilities for safe drinking water (overhead tanks) and its distribution acrossvillage at nodal points.

1.08 Creating facilities for water harvesting at each village to help recharge ground water.

1.09Construction of houses for the poor and back ward classes in collaboration with thegovernment housing schemes (600 houses from 3 - 10th year )

1.1Promotion of storage facilities - promotion of ware housing for storage of pulsesproduced by the farming communities

1.11 Development of Park, recreation center, sports facility and library at Taluka1.12 6 kms. road strengthening for better transport.1.13 Support CHAMP - Bio Medical Waste Management

2 Education

2.01Extension/Construction of school buildings to accommodate higher classes i.e. 9th,10th, 11th and 12th.

2.02Additional facility creation at schools such as labs, sports grounds and facilities,library , etc.

2.03 Creating fund to Introduce scholarship schemes for outstanding students to encourage

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and support them financially.

2.04Allocation of funds to Educate illiterate grown up children and adults- men and womenboth.

2.05 Creating sanitary facilities at schools.2.06 Creating funds for recognizing best teachers based on fixed KPI.

2.07

Training to the teachers on methods of teaching, audio visual aids etc. Training onfinancial literacy, saving habits, road safety, health hygiene, environment and on suchother specialized fields to children.

2.08 Sponsoring educational tours for the children in 10th, 11th and 12th.2.09 Organizing taluk level sports- indoor and outdoor meet every year.2.1 Free coaching for brilliant poor and needy to make them excel2.11 Support for computer education, cultural and music classes.2.12 Support to Kendriya Vidyalaya, Kalaburagi.2.13 Support to Deaf and Dumb School at Kalaburagi.2.14 Support to Blind school at Kalaburagi.

2.15Establishment of smart class room methodology in primary and other schools in 2panchayats and also in Chittapur

2.16 Support to ITIs and Polytechnics in Taluka and Distt.3 Hygiene and sanitation

3.01 Support for individual sanitary latrines for 500 houses.

3.02Audio-Visual Trainings to the villagers on hygiene and sanitation issues through healthworkers.

3.03Infrastructural facilities (like construction of soak pits etc.) for sewage treatment andmanagement.

3.04 Construction of RO plants to provide safe drinking water at each village.3.05 Provision of common washing platforms and safe disposal of detergent water.

4 Health

4.01 Regular health checkup for children in schools and providing necessary support.4.02 Construction of Primary health Units at Itga and Mogla villages.

4.03Periodical health checkups through health camps, immunization and medicinalsupports at villages.

4.04 Supports to Chittapur Health Centre.4.05 Support to the RED CROSS SOCIETY at Kalaburagi4.06 Support to Dist. Hospital.

4.07Health awareness programs (HIV, AIDS, Epidemics, hepatitis, Typhoid for adults - menand women.

4.08Launching ICUs on wheels service with ultra-modern facilities like ECG,EEGRespirator, life savings equipment, biometric monitors, blood transfusion unit etc.

4.09 Effective management of ICU services4.1 Support to the community for chronic diseases.

5 Livelihood Promotion and Capability building

5.1 Agriculture - Popularizing modern composting methods, Vermicomposting,Training of farmers on best practices and updated technologies.Soil and Moisture conservation activities.Nala training, clearance and deepening.Integrated pest management (IPM) training.Construction of elevated compost pits

5.2 Livestock - Promoting Dairy farming activities.

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Establishment of veterinary care center with travis.Water troughs for cattle.Poultry Farming for identified families.

5.3 Community mobilization, Youth capability building and SHG promotionPromotion of Farms producer’s organizations.Formation of self-help groups, training to SHGs on entrepreneurship, Revolving fundsupport to SHGsTraining to SHGs on microfinancing and micro financing activities.Formation of a central federation and support to them so that individual SHGs canunite and have access to wider market.Support for establishing phenyl making plant.Collection of NEEM seeds, Support for making NEEM OIL manufacturing unit, sellingNEEM cake as manure.Support for Candle making activities.Support for establishing sewing and knitting centers- making of hand gloves etc. forplant requirements.Support for pickles, papad and masala making.Training on Heavy earth moving Equipment masons, Carpentry, Form Work, Barbending, Welders, Electricians, Fitters, MTOs, Instrumentation, mobile phone repairs,TV , plumbing and Computers Training to 1000 youths in 10 yrs.Establishment of Livelihood resource center and managementConducting livelihood studies to understand the gaps further to train the farmersFood Processing and Medium sized dal mills

Setting up small and medium enterprises like stone polishing units, food andpackaging units etc.

v. Connectivity (traffic and transportation road/rail/metro/waterways etc)

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected roads are available. Two state highways SH-19 & SH-10which are at a distance of about 50 km & 20 km respectively. Railwaysiding is under development.

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

The existing cement plant is having safe drinking water facility. ROwater is supplied to all the employee and contract workmen.

vii. Sewerage System

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Existing STP will be utilized for treatment of domestic wastewater afterexpansion 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. Alsothe cooling water will be through a closed circuit system. The onlywaste water generated will be domestic waste water from residentialtownship and the same will be treated in STP and used for green beltdevelopment.

Hazardous wastes like spent oil from construction equipment, DG setsetc., generated in small quantities during construction andoperational phase would be appropriately stored & handled andproperly disposed of in accordance with the provisions of theHazardous Waste Management Rules, 2010.

ix. Solid waste Management

No solid waste is generated from the cement plant. ash generated fromthe power plant is utilized for cement manufacturing The dustcollected in the pollution control devices is recycled back to theprocess.

x. Power requirement & Supply/Source.

The present peak power consumption in the OC Cement plantcomplex including mine is 24 MW. Total power requirement for the OCcement plant complex is met from Captive Power Plant. An additionalpower of 36 MW is required for the proposed expansion project. Thetotal power required after expansion is 60 MW. This shall be met withexisting captive power plant.

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7. REHABILITATION AND RESETTLEMENT (R&R) PLAN

The new Unit is coming up in the existing complex owned by OC andthe R&R does not arise.

8. PROJECT SCHEDULE & COST ESTIMATES

The project is expected to be completed in a period of 18 months fromthe date of receipt of all the approvals from statutory authorities. Theestimated cost of the project is Rs. 1354 crores.

9. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)

The capital cost, for the proposed production enhancement project,works out to Rs. 1354 crores. Financial institutions will be fundingthe project.

Growth of infrastructure, Irrigation and housing scenarioautomatically drives the increased requirement of Cement in themarket. Based on the growing demand in the South East region of thecountry for Cement over the next 10 years, the proximity of the projectlocation to this market is an advantage with respect to reduction infreight of cement to these markets. The financial viability also show agood Rate of return from the project. Considering the above OC isplanning to go ahead with the project, once it gets all the statutoryapprovals for this enhancement project.

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Annexure – 1

PRE FEASIBILITY REPORT For EXPANSION OF CEMENT PLANT...

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Transcript of PRE FEASIBILITY REPORT For EXPANSION OF CEMENT PLANT...