M/s. HIMALAYAHEIGHT CEMENT PVT....

PRE-FEASIBILITY REPORT

On

Proposed Cement Grinding Unit for 0.14 MTPA GreenField Portland Pozzolana Cement ( PPC )At-Kurari, Durgauti, Bhabua District, Bihar.

OF

M/s. HIMALAYAHEIGHT CEMENT PVT. LTD.

Prepared by:- SEPTEMBER-2014

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

TABLE OF CONTENT

Sl.No. PARTICULARS PAGE No.

CHAPTER-1 EXECUTIVE SUMMARY

1.0 Introduction 2

2.0 Identification of Project & Project Proponent 2

3.0 Project description 3

4.0 Site Analysis 5

5.0 Planning Brief 6

6.0 Proposed Infrastructure 7

7.0 Rehabilitation & Resettlement(R&R) Plan 7

8.0 Project Schedule & Cost Estimates 7

9.0 Analysis of Proposal 8

CHAPTER-02 INTRODUCTION

2.1 Identification of Project & Project Proponent 9

2.2 Brief Description of nature of the Project 10

2.3 Need of the Project & its importance to the country andor Region 10

2.4 Supply-Demand Gap 10

2.5 Export Possibility 11

2.6 Employment Generation(Direct& Indirect) due to the Project 11

CHAPTER-03 PROJECT DESCRIPTION

3.1 Type of Project 13

3.2 Location 13

3.3 Site Selection 17

3.4 Technology Selection 17

3.5 Project description 23

3.6 Raw Materials Requirements 26

3.7 Resource Optimization/Recycling & Reuse envisaged in the Project 28

3.8 Water & Power Requirement 29

3.9 Quantity of waste to be generated(Liquid& Solid) & Scheme for their

Management/ Disposal

30

3.10 Schematic Representations of the Feasibility Drawing Which Give Information of 33

EIA Purpose

CHAPTER-04 SITE ANALYSIS

4.1 General 35

4.2 Connectivity 35

4.3 Existing Land use Pattern 35

4.4 Existing Infrastructure 35

4.5 Climate Data 35

CHAPTER-05 PLANNING BRIEF

5.1 Planning Concept 36

5.2 Population Projection 36

5.3 Amenities & Facilities 36

CHAPTER_-06 PROPOSED INFRASTRUCTURE

6.1 Industrial Area 40

6.2 Residential Area 40

6.3 Green Belt 40

6.4 Social infrastructure 40

6.5 Connectivity 41

6.6 Drinking water Management 41

6.7 Sewerage System 41

6.8 Solid Waste management 42

CHAPTER-07 REHABILITATION & RESETTLEMENT(R&R) PLAN

7.1 Rehabilitation & Resettlement(R&R) Plan 43

CHAPTER-08 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule 44

8.2 Project Cost 46

CHAPTER-09 ANALYSIS OF PROPOSAL

9.1 Financial & Social Benefits 48

9.2 Other Benefits 48

LIST OF TABLES

Sl. No. PARTICULARS PAGE No.

1.0 Raw Materials Requirement & Source 4

1.1 Water Requirement 5

1.2 Land Use Breakup 6

1.3 Project Cost Breakup 7

2.0 Market Potential-Cement Consumption Forecast(MT) 11

3.0 Land Use Breakup 16

3.1 Raw Materials Requirement & Product Mix 27

3.2 Raw Materials Requirement & Source 27

3.3(a) Raw Material Analysis of Clinker 28

3.3(b) Raw Material Analysis of Gypsum 28

3.3(c) Raw Material Analysis of Fly Ash 28

3.4 Water Requirement 29

3.5 Source of Air Pollution & Control measures 31

3.6 Solid Waste Generation & Management 32

8.0 Project Cost 46

8.1 Cost of Pollution Control Measures 47

LIST OF FIGURES

Sl. No. PARTICULARS PAGE NO.

3.0 Plant Location 14

3.1 TOPO Map(10 Km Radius) 15

3.2 Plant Layout 17

3.3 Process Flow Diagram 23

3.4 Material Balance 26

3.5 Water balance 29

3.6 Schematic Representation 34

6.0 Rain Water Harvesting Diagram 42

Visiontek Consultancy Services Pvt. Ltd,Bhubaneswar

M/s HimalayaHeight Cement Pvt. Ltd.Pre- Feasibility Report for Proposed Cement Grinding Unit of 0.14 MTPA Greenfield PortlandPozzolana Cement (PPC) At-Kudari, Durgauti, Bhabua District, Bihar.

Page 1

CHAPTER – 01

EXECUTIVE SUMMARY

1 Name of the Project Proposed 0.14 MTPA Greenfield Portland PozzolonaCement (PPC) grinding project at Kudari, Durgauti,Bhabua District, Bihar.M/s HimalayaHeight Cement Private Ltd.

2 S.No. in the Schedule Activity 3(b)

3 Registered Office M/s HimalayaHeight Cement Pvt. Ltd.723, Bharuli-4, Bharauli, Tehsil-Ballia, Ballia-221713,U.P.

4 Name of the Promoters Mr. Rambabu VermaAt- Village BharauliP.O.-BharauliDist - Ballia-277501Uttar Pradesh

5 Present Business Cement Grinding

6 Area of Plant 3.10 Acres

7 Topo Sheet No 63 O/7, 63 O/8, 63 O/11, 63 O/12

8 LatitudeLongitude

250 12’ 59.16” N830 26’ 52.88” E

9 Proposed Capacity 0.14 MTPA Portland Pozzolana Cement (PPC)

10 Cost of the Project 805.00 Lakhs

11 Man Power Requirement 60 Peoples

12 Water Requirement 8 m³/Day Will be sourced from Bore well.

13 Power Requirement 1000 KW, Will be met from Bihar State Electricity Board

14 Nearest Railway Station/Airport along with distance inKms.

Karmnasha at 3.0 KM NW & Dhaniachha at 4.5 km NE.Lal Bahadur Sastri International Airport, Varanasi at 64Km N.

15 Nearest Town, City, DistrictHead quarters along withdistance in Kms

Nearest Town- Mohania 18.3 Km ENearest City- Chandauli 18.7 Km NWDistrict Headquarter- Bhabua -24 Km SE

16 Villag Panchayats,ZillaParishad,Municipalcorporation, Local telephonenos. to be given) body(complete postaladdresses with telephoneno.s to be given)

Village Panchayat : Dhadahad Panchayat -3 km EZilla Parishad : Bhabua-24.8km SE



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1.0 INTRODUCTION

Bihar Cement Industry is on a roll, driven by a booming housing & industrial sector, the

demand for cement has increased substantially. In particular within a short span of time the

industrial sector has shown tremendous growth and the infrastructure has to meet the pace

to provide better facilities and services.

Since the entire market of Bihar is a predominately PPC user, it shall not be difficult for any

cement industry to market the cement within the state of Bihar as well as to neighboring

state of Uttar Pradesh. Further, numbers of Industries like power plants, housing in urban &

rural sectors and infrastructural projects are coming up in Bihar where the consumption of

cement will be in huge quantity. Hence, the marketing of cement produced locally will be in

better position than the cement plant presently marketing Cement produced outside Bihar.

In this aspect demand and supply of cement plays crucial role to realize and sustain the

growth. After identifying the cement market potential in Bihar and specific area, the growth

/ cement demand & supply gap further widens and hence the scope for cement market

potential. The cement demand & supply statistics indicates that the supply is not meeting

the current demand and there is scope for further 50% more addition than the prevailing

scenario.

To cater this wide gap of cement demand & supply, it is intended as a quick think to set up a

cement grinding unit in the fast growing industrial location at Bhabua. In addition to this, it is

also intended to make use of the available by-product (disposable) resources such as fly ash

in abundant quantity from the nearby Power industry.

Blended cement manufacturing has become the need of the day to meet the present market

trend and also to save ecosystem. PPC Cement is produced by addition of 25% fly ash by

feeding to the mill inlet /separator. It is foreseen to produce blended cement with addition

of 45-50% fly ash with appropriate method of fly ash feeding & mixing arrangements to

achieve consistent quality.

2.0 Identification of Project and Project Proponent

M/s HimalayaHeight Cement Pvt. Ltd intends to install a 0.14 MTPA Cement Grinding Units

to produce Portland Pozzolana Cement(PPC) at - Kudari, Durgauti, District- Bhabua, Bihar to

cater to the demand of Western Utter Pradesh, with focus on essentially within the state of

Bihar and secondary market North West of Utter Pradesh.



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M/s HimalayaHeight Cement Private Limited has proposed to purchase main raw materials

like,

Clinker: K.J.S Cement, Maihar Birla cement, Satna, M.P. Shree cement, Rajasthan

Fly Ash: Hindalco - Renukoot, NTPC- Anapara, U.P. and

Gypsum: Paradeep Chemical -Odisha, Druk Sapair Corporation, Bhutan.

2.1 Demand - Supply Gap

The Indian cement sector is expected to witness positive growth in the coming years, with

demand set to increase at a CAGR of more than 8 per cent in the period FY 2013-14 to FY

2015-16, according to the latest report titled ‘Indian Cement Industry Outlook 2016’ by

market research consulting firm RNCOS. The target markets are those of essentially within

the state of Bihar and secondary market North West Region. The current scenario of the

markets is presented below:

Bihar:

The current annual demand for cement in Bihar is about 10 MTPA. This is projected to

increase to 12 MTPA by FY 2015.

2.2 Employment Generation

Employment potential of the proposed project is given below:

The manpower requirement for the operation of the plant will be about 60 including

Administration staff & Managerial staff.

Plus additional jobs generated by local business in the supply of raw materials, finished

products and services.

3.0 PROJCET DESCRIPTION

The proposed project is 0.14 MTPA Cement Grinding Unit to produce Portland Pozzolana

Cement (PPC) using Ball Mill technology.

3.1 Location

The proposed site is located at - Kurari, Durgauti, District- Bhabua, Bihar. The Latitude and

Longitude are 25ᵒ 12’ 59.16” n and 83ᵒ 26’ 52.88” E respectively.

3.2 Site Selection

The total project land area required for the proposed project is 3.10 acres. The selection of

Grinding Unit location has been based on the following considerations.



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Access to high growth domestic cement markets and future industrial and

infrastructure development.

Availability of land, road and fly ash as waste of nearby Power plant.

Availability of Infrastructure facilities.

No other alternate site is considered for the project.

3.3 Technology Selection

The technical concept of the plant has been developed keeping in view the state-of-art

technology in size reduction & communition as well as an effective control on the level of

pollution for the PPC grinding unit at Bhabua in Bihar. The Ball Mill technology has been

selected for manufacturing of PPC. For production of Portland Pozzolona Cement (PPC),

inter-grinding of fly ash with clinker and gypsum is being proposed.

3.4 Project Process Details

Following are the steps involved in production process:

1. Raw material receiving

2. Raw material storage

3. Raw material feeding

4. Clinker Grinding Mill

5. Cement Storage

6. Cement Packing and Dispatching

3.5 Raw Material Requirement

Following are the inputs along with source and mode of transport.

Table 1.0 Raw Materials Requirement & Source

SL Material Source Transportation mode

Total R.MRequirement(PPC) in TPA

1 ClinkerK.J.S Cement, MaiharBirla cement, Satna, M.P. ShreeCement, Rajasthan.

Road/Rail 98,000

2 Flyash Hindalco, Renukoot, NTPC, Anapara,U.P. Road 36,400

3 Gypsum Paradeep Chemical, Odisha,Druk Sapair Corporation, Bhutan. Road/Rail/Ship 5,600



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3.6 Water Requirement

Water requirement for the project is as follows:

Table 1.1 Water Requirements

Sl.

No.Description Total water Requirement

(m3/day)

1 Process Requirement Nil

2 Greenbelt & Dust Suppression 5.0

4 Domestic & Misc 3.0

TOTAL 8.0

3.7 Power Requirement

The total power demand of the plant is expected to be about 1000 KW and the requirement

will be met from BSEB from 33 KV substation located at Karmnasha at 3.5 Km from the site.

3.8 Waste Generation and Management

The cement grinding plant will not generate any solid waste or liquid effluents and will be

fully equipped to handle its domestic sewage. The plant will not have any gaseous emissions.

All air emissions of the plant through stacks will be through the most efficient pollution

control equipment and will not have any adverse impact on the land or marine environment.

The plant systems will be designed to keep stack emissions to levels well below the

stipulated norm of 50 mg / m3.

4.0 SITE ANALYSIS

4.1 Connectivity

The proposed site is well connected to roads & rails networks. The site is at about 18.3 km

away from nearest town Mohania. Plant is about 1.6 km from NH-2, 9.5 Km from NH-97.

Nearest railway station Karmanasha R.S is at 3.0 Km NW & Dhaniachha at 4.5 km NE away

from the site. Nearest airport is at Varanasi, at about 64 Km N from the proposed project

site. Nearest River is Karmanasha River at about 4.9 Km from the proposed site.

4.2 Topography and Existing Land use Pattern

The topography of the land is generally flat and well suited for development of industrial

projects. Land of the proposed project is barren Land. Plant is not coming under the dense



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forest category land. This area does not form part of any National Park, Wild Life Sanctuary

and Natural/Biosphere reserve.

4.3 Climate Data

May month is usually the hottest with daily maximum of 45 ⁰C and mean daily on yearly

basis is 34⁰C. December is the coldest month with mean daily minimum of 10 degree Celsius.

Average annual rainfall is 1164 mm.

5.0 PLANNING BRIEF

5.1 Planning Concept

Technical Concept: This technical concept indicates the plant capacity, size and type of main

machinery, storages, design of systems, plant layout, flow sheets etc. It covers process,

mechanical, electrical, instrumentation and civil engineering aspects. The concept has

considered quality, pollution control, operation, maintenance and utility services.

Process Control, Instrumentation and Automation: Integrated & Distributed

Microprocessor based, Control & Instrumentation system has been considered for effective

control of various process variables.

Human Resources: Human Resource is the most valuable asset in any industry. The

accelerating pace of technology advancement and fierce competition in the market has led

to the increasing importance of human resources. Continuous skill updation of the existing

human resources and generating new talents in consonance with the needs of the industry

are vital for the progress of the industry.

5.2 Land Use Planning

The total land use for the project area is about 3.10 Acres which has already been identified

and acquired and will be converted from agricultural land to Industrial Land.

Table 1.2 Land Use Break-up

SL. No Description Area in Acres1 Plant Built up 1.50

2 Auxiliary Plant facilities 0.12

3 Raw material & finished products area 0.16

4 Road & administrative building 0.12

5 Green Belt (33%) 1.10

6 Truck Parking 0.10

TOTAL 3.10



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6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial and Residential Area

The setting up of the grinding mill and packing plant, their auxiliary equipment, clinker and

cement storage areas, electrical power receiving substation, administrative buildings and

provision for future expansion is envisaged.

6.2 Green Belt

A greenbelt development plan will be prepared and implemented along with the project.

Total green belt area shall be of 1.10 Acres (34.1% of total area). The main objective of the

greenbelt is to provide a barrier between the plant and the surrounding areas.

6.3 Others

A garland drain around the plant is envisaged to collect surface run-off during rainy

season.

Drinking water facilities will be provided for employees.

Existing road and rail network will be utilized for raw material and final products

transportation. However existing road network will be strengthened.

7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN

The proposed project site is a barren land where no human habitation exists. Therefore,

there is no chance of any displacement of persons from their land and hence Rehabilitation

and Resettlement Policy is not applicable for the proposed project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Project Schedule

The total project implementation schedule is 16 months from the date of approval and all

other statutory clearances from the State / Central Government.

The external agencies such as consultant, machinery suppliers, contractors of civil

construction and equipment will be selected carefully well in advance. An effective project

team has been formulated with an experienced Project Manager as its leader.

8.2 Project Cost

A broad break-up of the indicative estimate of the Project cost is provided below:



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Table 1.3 Project Cost Break-Up

SL Description Rs. in Lakhs

1 Land & Land Development 5.00

2 Building & Civil construction 80.00

3Plant & Machinery, Electrical installation

& other fixed assets620.00

4 Pre-operative & preliminary expenses 25.00

5 Working Capital 75.00

Total 805.00

9.0 ANALYSIS OF PROPOSAL

The benefits of the proposed unit are follows,

Improving and building road network in the adjoining villages.

Strengthening Local School buildings for education.

Social awareness programme to improve sanitation, hygiene, HIV Prevention

Program etc.

The manpower requirement for the operation of the plant will be about 60

including Administration staff and Managerial staff.

Plus additional jobs generation by local business in the supply of raw materials,

finished products and services.

Development of the local area in terms of an enlarged market will provide the

farmers with a good outlet of their agricultural products to enjoy the price effect,

which is likely to be strong enough to offset the impending local inflations through

real-balance effect.

Thus, the proposed project will usher in social and economic upliftment of the persons

living in the vicinity of the Project i.e. of society at large.



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CHAPTER – 02

INTRODUCTION

2.1 Identification of Project and Project Proponent

M/s HimalayaHeight Cement Private Limited is proposing to establish a Cement Grinding

Unit of 0.14 MTPA at- Village Kurari, Durgauti, District- Bhabua, Bihar. In the recent years

the Bihar state has shown tremendous growth in terms of overall socio economic as well as

in the manufacturing sectors. To sustain the growth rate and as well to move further with

great pace it is taking steps to develop the infra structure, housing sector etc.

In the wake of increased construction activity under the liberated region, the cement

sector has been marked by bullish trends in term of off-take. In Bihar, there has been a

sudden spurt in demand of construction materials as a large number of industries have

been developed in nearby areas. Many infrastructure projects have also been undertaken

by the Govt. to boost the growth process. The statistical facts indicate that the demand for

the cement is very much increased but there is short fall of supply in this region. The

promoters of HHCPL have identified this shortage of Cement supply and are interested to

balance the situation and utilise as an investment opportunity.

The prospect in the proposed project is very much encouraging and attractive by the

investor friendly environment in the state of Bihar.

A brief account of Management:

The company head quarter is in Bihar, as a part of its domestic capacity generation plans,

HimalayaHeight Cement Pvt. Ltd. proposed to set up a state of the art and most modern

Grinding unit named to be located in Bihar, having a capacity of 0.14 MTPA of Portland

Pozzolana Cement (PPC) per annum to cater to the demand of India, with focus on Bihar &

nearby areas.

Shri Gowri Sankar Varma , age 60, has 25 years Cement trading experience, ,

Ram Babu Varma, age 33, has 10 years experience in cement trading &

manufacturing.

Sham Babu verma, age 28, has 8 years experience in cement trading industry,

Ghanshyam Babu verma, age 25, has 7 years experience in cement trading.



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2.2 Brief Description of Nature of the project

It is proposed to produce Portland pozzolana cement in the plant. The plant will have the

flexibility to produce this type of cement, according to market requirements.

The plant will have capability to dispatch cement in 50 kg bags as well as in bulk tankers.

The packing plant will be equipped with a Double nozzle packing machine together with its

auxiliaries.

2.3 Need of the Project and its Importance to the Country and/or Region

The cement industry forms the backbone of infrastructure development in any country. In

India, the cement sector has been growing steadily. It is evident that states like Jharkhand,

Madhya Pradesh, Bihar, Odisha, Chhattisgarh and West Bengal need huge investments in

the infrastructure sector. There is a high demand of PPC in the market of Bihar and it shall

not be difficult for HHCPL to market the cement within the state of Bihar as well as in

neighboring state of Utter Pradesh. Further, numbers of Industries like power plants,

housing in urban & rural sectors and infrastructural projects are coming up in Bihar and

neighboring states where the consumption of cement will be in huge quantity. Hence,

marketing of cement produced locally will be in better than the cement presently being

marketed produced outside Bihar. Thus, this is the appropriate time to create capacity in

order to meet the growth in demand for cement in future. Hence the Company will not

have any difficulty in selling its product in the Market. The cement market is booming day

by day. There is a huge demand and supply gap in the region. So, the promoters have

decided to set up the proposed Cement Grinding Plant of 0.14 MTPA Capacity.

2.4 Demand – Supply Gap

The Indian Economy is expected to grow at about 7.5% - 9% p.a. for the next few years.

Government of India proposes to invest around USD 475 billion on infrastructure sector in

the next five years. With the large infrastructure projects like roads, irrigation projects and

special economic zones in the pipeline, increasing growth in the construction activity of

industries and households, the outlay on infrastructure shall be phenomenal. Cement is

the key ingredient for all infrastructure projects. Consequently, the demand for cement is

expected to grow at about 10% -11% until 2015-16. The National Statistical Department

expects that the cement consumption in India shall increase up to 300 Million Tons by

2012, while the cement capacity was about 225 Million Tons in FY 2010.



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India is the world's second largest producer of cement with total capacity of 224 million

tonnes (MT) as on April 30, 2010, according to the Cement Manufacturer’s Association.

Moreover, the government's continued thrust on infrastructure will help the key building

material to maintain an annual growth of 10-11 per cent in 2010-11.

Table 2.0 Market Potential – Cement Consumption Forecast (Million Tons)

Year Cement Consumption Consumption growth y-o-y

2010-11 224.50 10.15%

2011-12 246.95 10.61%

2012-13 271.60 10.68%

2013-14 300.68 10.50%

2014-15 330.45 10.41%

2015-16 382.50 11.56%

The market potential in this region is very much evident that there is big gap in the

demand and supply of Cement. Establishing a Cement grinding Unit can be a quick win

solution to meet the immediate demand.

The target markets are those of essentially within the state of Bihar and secondary market

North West-Utter Pradesh. The current scenario of the markets is presented below:

Bihar:

The current annual demand for cement in Bihar is about 10 MTPA. This is projected toincrease to 12 MTPA by FY 2015.

The primary markets of interest for HimalayaHeight Cements Private Limited are

essentially within the State of Bihar and Secondary market North West-Utter Pradesh.

2.5 Export Possibility

The primary markets of interest for HimalayaHeight Cements Private Limited are

essentially within the State of Bihar and Secondary market North west-Utter Pradesh.

However, export possibility maybe explored in future if required.

2.6 Employment Generation (Direct and Indirect) Due to the Project

Employment potential of the proposed project is given below:


Administration staff and Managerial staff.



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The manpower requirement has been planned keeping in view the following:

Smooth & efficient running of the plant with optimum manpower.

Capacity utilization with optimum energy consumption.

Effective coordination

Rational distribution of responsibilities

The organizational development would be started from the project phase itself as those

involved with the project would also be trained for operations.



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CHAPTER - 3

PROJECT DESCRIPTION

3.1 Type of Project

The Proposed Project of 0.14 MTPA Cement grinding Unit at Bhabua is a new plant. The

Cement grinding Unit will have a state of the art Ball mill. The proposed grinding mill will

have the capability of producing all the two types of cement, both in inter grinding mode

as also capable of grinding the various raw materials separately. A blending plant will also

be provided for proportioning and mixing to produce the desired quality of cement. The

plant will also be equipped with the most efficient auxiliary sub systems, material handling

facilities and pollution control equipment

3.2 Location

The location for the plant is at Kurari, Durgauti, District- Bhabua, Bihar. Anticipating the

future relevant growth in domestic and social it is proposed to realize the proposed plant

in this location.

The proposed site falls under the Survey of India Toposheet No. 63 O/8 and the buffer zone

falls under the Survey of India Toposheet 63 O/7,63 O/8,63 O/11 and 63 O/12.The Latitude

and Longitude of the proposed site is 250 12’ 59.16” N and 830 26’ 52.88” E respectively.

3.2.1 Plant Location

The proposed site is located at - Kurari,Durgauti, District- Bhabua, Bihar. The Latitude and

Longitude are 25ᵒ 12’ 59.16” n and 83ᵒ 26’ 52.88” E respectively.



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Fig. 3.0-Plant Location



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Fig. 3.1- TOPO MAP (Buffer Zone-10Km radius)



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3.2.2 Land Requirement

The requirement of total land including Green Belt is 3.10 Acres, details given in Table

below. The land has been already identified & acquired.

Table 3.0 Land- Use Breakup for the Project

Sl. No. Description Area in Acres

1. Plant Built up 1.50

2. Auxiliary Plant facilities 0.12

3. Raw material & finished products area 0.16

4. Road & administrative building 0.12

5. Green Belt (33%) 1.10

6. Truck Parking 0.10

TOTAL 3.10

3.2.3 Plant Layout

The layout of the plant when developed will have the following features.

1. Process departments will be consolidated into comprehensive production units

requiring short conveying distances and elevations and lengths of gas ducts.

2. The major utilities and service facilities will be centrally located in respect to points

of high consumption.

3. Sufficient space will be provided for ease of operation and maintenance.

4. The lengths of power cables will be minimized by suitably locating load distribution

centres in respect of process departments.

5. Outward movements of materials from customers/suppliers will be segregated from

internal plant traffic.

6. Sufficient space for storage of raw materials.

7. Adequate green belt.

8. Provision for future expansion.


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Fig. 3.2- Plant Layout



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3.3 Site Selection

Selection of the grinding unit site had been done with due consideration to the availability of

the land & raw materials, approach road and access from the nearest National highway /

district road.

Factors influencing the site selection can be broadly categorized as:

Availability of power & water.

Scope for expansion.

Availability of Transport & Communication.

Nearness to market.

Vicinity of social infrastructural facilities such as market center, educational institution,

local transport, entertainment centers, medical facilities, etc.

3.4 Technology Selection

3.4.1 Inter-grinding and separate grinding

Blended cements have been produced for decades in many countries, including India, and in

recent years, a renewed interest in the production of such cements has been observed all

over the world. There are many reasons for this, with one of the main reasons being that the

production of blended cements results in a lower overall production cost, a fact that has

been strongly accentuated with the increase in fuel and power prices. The ability to have a

partial substitution of clinker with replacement materials also results in an overall increased

plant capacity without a large capital investment in terms of additional clinker production.

Blended cements can have some advantages over pure Portland cement in end use

properties such as lower heat development during hardening and an improved durability of

the final concrete structures. Finally, saving of natural resources, utilization of industrial by-

products and reduction of CO2 emissions are important contemporary issues favoring

production of blended cements.

There are a variety of solutions for the grinding of clinker replacement materials, whether by

separate grinding or by inter-grinding into blended cement. In making the selection, one

must consider not only the initial investment cost and the production cost, but also the

simplicity of the operation, maintenance issues, drying requirements, etc.

Blended cement is a mixture of separately ground or inter ground cement clinker, gypsum

and mineral admixture(s). The mineral admixture(s), clinker replacement materials, will

typically be one or more of the following material.



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• Fly Ash (PFA)

The properties of those materials vary a lot as far as reactivity (i.e. clinker replacement

potential), grindability, granulometry, humidity and abrasiveness is concerned.

Fly Ash (PFA)

Fly ash (or Pulverized Fuel Ash - PFA) is an artificial pozzolanic material with a reactivity

similar to the reactivity of natural pozzolana. Hence, practical clinker replacements are

normally below 40% with 20-30% as a typical range. The particles of PFA are mostly

spherical, with a small fraction being hollow. The fineness of PFA usually varies between 200

and 350 m2/kg (Blaine), (45 μm residues of 10-40%), which means that it has a fineness

similar to that of Portland cement. Therefore PFA is often introduced into blended cement

with little or no grinding at all. If grinding is performed it will first result in crushing of the

hollow and porous particles. A subsequent further grinding of the dense glassy material will

result in high energy consumption.

PFA is usually available as a dry powder suitable for pneumatic transportation. A comparison

of the two methods of making fly ash cement – combined grinding and separate grinding–

indicates that the most favorable ratio between cement strength achieved and the

corresponding grinding energy spent, is obtained with combined grinding. A partial

combined grinding is implemented in the way that the PFA is introduced to the separator,

irrespective of the type of grinding circuit, and only the coarse particles are returned to the

mill for further grinding. Those particles and agglomerates are then reduced in size and the

reactivity is improved.

Therefore, the PPC will be produced by inter-grinding fly ash with clinker and gypsum andblended.

3.4.2 Mill systems for grinding of blended cements and clinker replacement materials

As grinding of blended cement became more common, a large number ball mills were

brought into operation for these applications. A main issue that then needed to be

addressed was how to dry the wet mill feed materials before grinding. Other mill types like

roller presses and especially the vertical roller mill are much more suitable for grinding and

drying of materials with considerable moisture content. Mill circuits with these types of mills

are today often designed and installed specifically for grinding such materials. Further, the

roller mills in comparison to a ball mill system offer much lower specific energy

consumption.



Page 20

Ball mill

As stated previously most existing types of ball mills designed for grinding Portland cement

are not particularly suited for drying wet materials like, say many of the clinker replacement

materials. However, the ability to dry the feed materials can be increased significantly if a

hot gas generator is included in the mill circuit and the mill is provided with a drying

compartment. An example of such a mill is one that has only one grinding compartment,

which is typical for slag grinding applications, as the raw slag is fine enough to be ground

with relatively small grinding balls. Further, the flow of hot drying gas through the mill is

facilitated without an intermediate diaphragm in the mill. However, for inter-grinding of

blended cement with clinker and lower moisture content in the mill feed material; a two-

compartment mill will usually be more suitable.

A ball mill offers a very well proven and sturdy technology for grinding of blended cements

and slag. However, the ball mill has its limitations as regards drying of the wet clinker

replacement materials, and further it has higher energy consumption, consequently, other

types of mills are becoming increasingly more common for grinding of these types of

materials.

High pressure Grinding Rolls (HPGR)

It is a well-known fact that high-pressure grinding rolls or roller presses are much more

efficient in the grinding process than ball mills. For every 1 kWh/t that the HPGR contributes

to the grinding circuit, the ball mill power is reduced by approximately 2kWh/t or even

more, dependent on the type of material to be ground. Maximizing the work done by the

HPGR, results in a more efficient overall grinding process. In order to increase the amount of

work done by a HPGR, it is necessary to recycle a portion of the pressed material back to the

press for further grinding. A large number of roller presses have been introduced for various

applications, including grinding of blended cement. However, slag in particular is an ideal

material for grinding in a roller press. The glassy and thus brittle structure of the slag makes

grinding under high pressure very efficient. Further, with a suitable amount of moisture

present slag forms a very stable grinding bed that allows a higher circulation of material back

to the press without the associated operational instability as compared to clinker grinding. In

many applications of a roller press for slag grinding at least a partial drying of the raw slag is

required to attain moisture content in the feed material that will provide adequate

operating conditions for the roller press. Obviously the facilities for drying of the slag will

usually add to the complexity of the installation.



Page 21

The various suppliers of grinding equipment offer a variety of grinding systems designed for

a larger utilization of the roller press than can be achieved in a pregrinding arrangement.

Such systems, often named semi-finish systems, hybrid systems combi-grinding etc,

comprise a roller press, a ball mill, drying facilities and a separator arrangement that can be

combined in a multitude of arrangements. In particular the design of the separator

arrangement is specific for the individual suppliers. Whichever separator arrangement is

applied they all have the ability to disagglomerate the product from the roller press and

separate it in a course fraction recirculated to the press and a finer fraction for the ball mill

and/or the fines separator. With the fines removed from the coarse material recirculated

back to the roller press the operation is stabilized, resulting in a significant reduction in the

overall circuit power.

In the extreme the ball mill can actually be eliminated – this is described as finish grinding in

the roller press but separate slag drying facilities are required in this arrangement as good

control of moisture is required for stable operation Finish grinding operation results in very

large savings in the specific energy consumption of the grinding system. One of the

drawbacks to this type of system is the fact that the slag produced will have a very steep

particle size distribution, which may not be optimum in terms of the effects of the setting

time and the water requirements in concrete.

The maintenance of a roller press is much more critical than that required by a ball mill.

Wear of the grinding rollers needs continuous repairs. This maintenance is more expensive

and requires a higher degree of sophistication and labour than a ball mill, if only for the

reason that a roller press system comprises more equipment of a higher complexity than a

ball mill circuit.

As grinding of blended cement and slag became more common, a large number ball mills

were brought into operation for these applications. A main issue that then needed to be

addressed was how to dry the wet mill feed materials before grinding. Other mill types like

roller presses and especially the vertical roller mill are much more suitable for grinding and

drying of materials with considerable moisture content. Mill circuits with these types of mills

are today often designed and installed specifically for grinding such materials. Further, the

roller mills in comparison to a ball mill system offer much lower specific energy

consumption.



Page 22

Conclusion:

Today there is a fairly wide range of mill arrangements available for grinding the various

types of clinker replacement materials. All the systems described have been in the market

for several years and with proper adjustments to the operational parameters or adjustments

to the arrangement, each is capable of producing a product that satisfies the market’s

requirements to end product quality.

A ball mill and a vertical roller mill offer a simple plant arrangement, while

arrangements with a roller press generally are somewhat more complicated with

more equipment, which in many cases comprises a separate drying installation.

A ball mill represents sturdy and well proven technology and it is easy to maintain.

The roller press and the vertical roller mill are more complicated machines and

maintenance work requires more skill. The maintenance costs may also be higher for

the more complicated machines, to some extent depending on the materials

ground.

The specific energy consumption for a ball mill system is significantly higher than for

systems with roller presses or vertical roller mills. The high energy consumption of

the ball mill is actually the most decisive disadvantage of this technology.

The vertical roller mill is the most versatile of the three grinding machines. Separate

drying facilities are not required and it is easy to change from one product type to

another product with practically no transition periods between products.

Generally the ball mill system offers the lowest plant installation cost, including the

costs for civil works. The total cost for a vertical roller mill installation is usually

somewhat higher, and the cost for an installation with roller press will in most cases

be the highest. However, the relative costs of the systems will obviously depend on

specific plant arrangements and in particular on regional variations of costs for civil

works.

Today the ball mill offers a very well proven and sturdy technology for grinding of blended

cements and slag. However, the ball mill has its limitations as regards drying of the wet

clinker replacement materials, and further it has higher energy consumption consequently. 3

nos. of Ball mills will be used for this process with capacity of 150 TPD each.

The Ball Mill technology has been selected for the Project. 3 nos. of Ball mills will be used for

this process with capacity of 150 TPD each.



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Fig. 3.3-PROCESS FLOW DIAGRAM

3.5 Project Description

The Portland pozzolana cement will be produced by either, intergrinding of clinker along with

gypsum and flyash in certain proportions in a Ball mill or grinding the clinker, gypsum and

flyash separately and then thoroughly blending them in certain proportions in the ball mill.

Three hoppers are considered; one for storage of clinker, one for gypsum and the other one

for additives. The grinding circuit is connected with a high efficiency ball mill. The final

product from mill will be conveyed to cement silo by means of bucket elevator.

3.5.1 Raw material receiving

The plant will have an installed cement grinding and packing capacity of 0.14 million tonnes

per annum. The main raw material clinker requirement will be met from K.J.S Cement,

Maihar Birla cement, Satna, M.P. Shree cement, Rajasthan manufacturing Plants. The clinker

will be stored in a covered condition while it awaits transportation to site.The additives raw



Page 24

materials gypsum requirement will be met from the nearby source Paradeep chemical,

Odisha, Druk Sapair corporation, Bhutan. The raw material receiving & handling system will

be adequately equipped with pollution control equipment.

3.5.2 Raw material Storage

The raw materials, clinker, gypsum and additives will be stored in their respective

designated areas inside the plant. Adequate storage capacity, depending upon quantitative

consumption requirements, availability, transport lead times and seasonality will be

provided inside the plant.

3.5.3 Raw material Feeding

A belt conveyor will run along the length of the storage areas on which will be placed steel

hoppers for feeding the belt. The raw materials will be fed by a pay loader into the hoppers

to feed the material onto the belt.

The belt conveyor will run to the mill hoppers so as to discharge the material into the mill

hoppers. The mill section will have four individual hoppers one each for clinker, gypsum and

additive, the storage capacities of each to be decided based on process requirements.

The belt conveyor will discharge the respective raw material into the individual mill

intermediate and storage hoppers. All these hoppers will be enclosed and each will be de-

dusted, separately, with high efficiency bags type dust filters.

Each of these hoppers will have a rod type gate for extraction through which the raw

material will be fed onto a belt type weigh feeders for proportioning and controlling feed to

the grinding mill. The individual weigh feeders containing the proportioned and controlled

amount of material will discharge onto a common belt conveyor, which will discharge the

material into the mill inlet box for grinding. All the transfer points will be de-dusted, with

high efficiency bag type dust filters.

3.5.4 Clinker Grinding Mill

The clinker, gypsum and fly ash, will be either ground separately or inter ground in a ball

mill, to produce the desired type of cement.

Cement from the mill will be fed to a new generation, high efficiency Air separator. The air

separator will classify the coarse material and the same will be returned to the mill for

further grinding. The air separator will be provided with a set of high efficiency cyclones and

a bag filter in series, into which the fines will be carried with the air stream, which will collect



Page 25

the finished product cement. The air from the cement mill will be de-dusted in a bag filter

before being vented out.

The finished product cement from the mill will be transported by a series of air slides and

belt bucket elevator to the cement storage silos.

All the material transfer points and process venting will be de-dusted, with high efficiency

bags type dust filters.

3.5.5 Cement Storage

Once the production of Cement is complete, the finished product is transferred using bucket

elevators and conveyors to storage silos for dispatch. Most of the Portland cement is

transported in bulk by railway, truck, or barge, or in 50 kg multi walled paper bags. Once the

cement leaves the plant, distribution terminals are sometimes used as an intermediary

holding location prior to customer distribution. The same types of conveyor systems used at

the plant are used to load cement at distribution terminals.

Two nos.of silos of capacity 500 Tons each are considered for storage of Cement. The

cement can be extracted from the silos through an extraction system and metering devices.

The extracted cement will be conveyed to the Packing machine through Bucket Elevator.

Each silo will have two discharge points, one for cement extraction to the Packing (Bagging)

plant and the other for dispatch of cement in bulk.

3.5.7 Cement Packing

Single nozzle packing is considered and the cement bags will be loaded into the Truck /

Wagons through belt conveyors and loading stations.

There will be arrangements made in the lay out for bulk loading of cement directly into the

truck tankers from the silos and hoppers. This will facilitate the reduction of packaging cost

for bulk and industrial customers.



Page 26

Fig. 3.4- MATERIAL BALANCE (for Manufacture of PPC)

Plant and Machinery Source

All plant and machinery will be sourced through globally reputed and proven suppliers

having vast experience of supply of various equipments required for the Cement Industry. All

equipment will incorporate the latest state of the art design and technology, eco friendly

and will conform to global standards of workmanship.

Taking into account, reliability of equipment and matching capacities between the different

sections of the plant, the type of equipment/ installation system and the departmental

capacities at the plant, have been arrived at.

3.6 Raw Materials Requirements

The clinker for the plant will be sourced from the neighboring clinker manufacturing Plants.

The plant will have adequate storage facilities for clinker. The clinker will be stored in a

covered condition while it awaits transportation to site.

The additives raw materials Gypsum requirement will be met from the nearby source K.J.S

Cement, Maihar Birla cement, Satna, M.P. Shree cement, Rajasthan. and Fly ash from

Hindalco, Renukoot, NTPC, Anapara, U.P.The required facilities for unloading of bulkers and

trucks and storage of fly ash will be provided at the plant. The gypsum required for the

production of the various types of cement will be sourced from Paradeep chemical, Odisha,



Page 27

Druk Sapair Corporation, Bhutan.

The Cement grinding plant will have a state of the art Ball mill. The proposed grinding mill

will have the capability of producing PPC grade of grinding the various raw materials

separately. A blending plant will be provided for proportioning and mixing to produce the

desired quality of cement. The plant will also be equipped with the most efficient auxiliary

sub systems, material handling facilities and pollution control equipment.

The plant will have capability to dispatch cement in 50 kg bags as well as in bulk in tankers.

The packing plant will be equipped with packing machine having a capacity of 1 x 20 TPH,

along with semi mechanized Loading machines, together with its auxiliaries.

All other infrastructure facilities, required for operation and maintenance of the plant will be

set up along with main plant and equipment. The cement produced will be sold mainly in

Bihar. And secondary market will be in the North- East Region of U.P.

The raw material requirement for the proposed plant has been worked out for a production

of 0.14 million tonnes per annum. However the requirement of various raw materials may

change from time to time. The quantitative requirement and sources of various raw

materials, generally, will be as follows:

Table 3.1- Raw Material Requirement and Product Mix

Sl.No Raw MaterialFor PPC(0.14 MTPA)

Raw Material Mixin %

Requirement TPA

1 Clinker 70 98,0002 Fly ash 26 36,4003 Gypsum 4 5,600

Total 100 1,40,000

Table3.2- Raw Material Requirement & Source

SL.No Material Source Transportatio

n mode

Total R.MRequirement (PPC)

in TPA

1 ClinkerK.J.S Cement, MaiharBirla cement, Satna, M.P. Shreecement, Rajasthan.

Road/Rail 98,000

2 Flyash Hindalco, Renukoot, NTPC,Anapara, U.P. Road 36,400

3 Gypsum Paradeep chemical, Odisha,Druk Sapair corporation, Bhutan. Road/Rail/Ship 5,600



Page 28

3.6.1 Raw Material Analysis

Table 3.3(a) Raw Material Analysis of Clinker

MATERIAL CHEMICAL COMPOSITION, %

ClinkerLOI SiO2 Al2O3 Fe2O3 CaO MgO SO3 K2O Na2O TiO2 Mn2O3 P2O5 Cl

0.27 23.8 5.6 1.9 65 2 0.33 0.74 0.09 0.18 0.03 0.05 0.01

Table 3.3(b) Raw Material Analysis Gypsum


GypsumLOI SiO

2Al

2O

3Fe

2O

3 CaO MgO SO3

P2O

5 Cr2O3 Purity

18.09 1.79 1.01 0.62 30.97 0.6 44.86 0.80 0.01 94.36

Table 3.3(c) Raw Material Analysis Fly Ash


Fly AshLOI SiO

2Al

2O

3Fe

2O

3 CaO MgO SO3

Na2O Total Chlorides

0.17 65.29 24.96 4.99 4.05 0.28 0.12 0.13 0.01

3.7 Resource Optimization/Recycling and Reuse Envisaged In the Project

a. Fire Protection Facilities: In order to combat any occurrence of fire in plant premises

the following tire protection facilities have been envisaged for the various units of

the plant.

b. Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc

will be provided with adequate number of portable fire extinguishers to be used as

first aid fire appliances. The distribution and election of extinguishers will be done in

accordance with the requirement of IS: 2130-92.

c. Hydrant System: Internal hydrants will be provided at suitable locations and at

different levels inside the major plant units. Yard hydrants will be provided normally

along the road and in the close vicinity of the units to meet the additional

requirement of water for existing fire.



Page 29

d. Automatic Fire Detection System: Unattended and vulnerable electrical premises like

electrical control rooms, cable tunnels, MCC. Transformer rooms, switch gear rooms, etc.

will be provided with automatic fire detection and alarm systems.

3.8 Water and Power Requirement

3.8.1 Water Requirement

The total water requirement of the plant is estimated to be 8 m3/day as per details givenbelow.

Table 3.4- Water Requirement

Sl. No. Description Total water Requirement(m3/day)




TOTAL 8.0

Water requirement for the proposed Cement grinding Plant will be sourced from bore well.

There will be no Process effluents from the plant as no water is required in process. The

domestic effluents will be treated in septic tank and routed to soak pit. The recycled water

from settling tank will be consumed for green belt development and gardening inside the

plant.

Fig.3.5- Water Balance



Page 29












TOTAL 8.0





plant.




Page 29












TOTAL 8.0





plant.




Page 30

3.8.2 Power Requirement

The total power demand of the plant is expected to be about 1000 KW and the requirement

will be met from BSEB from 33 KV substation located at Karmnasha at 3.5 Km from the site..

3.8.2.1 Electrical System

Earthing:

Adequate provision of sub-station earthing and earthing of high and low voltage equipment

are considered for the safety of operating personnel as well as for proper system operation

as per requirements of Indian Electricity Rules and IS : 3043.

Illumination

An efficient illumination scheme for inside and outside buildings shall be provided. Sufficient

number of lighting boards and distribution boards has been considered for lighting of

various locations of the plant.

Fire detection and alarm system for electrical buildings

For detection of fires in electrical buildings, Ionisation type dual chamber/ dual source

smoke detectors will be used where incipient fires are likely, e.g. in cable cellars, switchgear

rooms, control rooms etc. Fixed temperature cum rate of rise type heat detectors will be

installed in transformer rooms, battery rooms, etc.

Multi-zone type fire alarm panels will be installed in the electrical buildings. The fire

detectors will be wired in zones. On detection of fire/ fault in any zone, audio-visual alarm

will be sounded in control panel and also by electronic hookers fixed in various locations in

the electrical buildings. The alarm shall also be sounded at the central position.

3.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their

Management/Disposal

3.9.1 Air Quality Environment & Management

Air Environment – Mitigation Measures



Page 31

Table 3.5- Source of Air Pollution and Control Measures

Sl.No. SOURCES POLLUTANTS MITIGATIVE MEASURES

MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT)1. Transfer Points Fugitive Dust All transfer points will be fully enclosed with provision

for access doors. Spillages will be periodicallyremoved. Air borne dust at all transfer points will beextracted through dust extraction system to the bagfilters.

2. Air Slides Dust All the air slides will be closed type and will beconnected to dust extraction system i.e. bag Filter.

3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it will beconnected to Bag Filter.

4. Weigh feederdischarge

Fugitive Dust The weigh feeder vents will be connected to bagfilters.

GRINDING SECTION1 Ball Mill Section Dust The vent of cement mill will be connected to reversible

jet bag house and mill ventilation.2 Air Separator Dust The air separator in the grinding section separates the

oversize particle from the required product sizes. Theair separator will be connected to bag filter to arrestthe fugitive dust emission and recover the product.

3 Air slides Dust All the air slides will be closed type and will beconnected to dust extraction system i.e. Bag Filter.

CEMENT STORAGE1. Air slides Dust The air slides will be of closed type and will be

connected to Bag Filter.2. Vents of silo Dust The vents of the cement silos will be connected to bag

filter.CEMENT PACKING & DISPATCH SECTION1. Double Nozzle

PackerDust • The packing machine will be equipped with dust

extraction arrangement such that the packingoperation is performed under negative pressure.The dust will be captured in bag filters.

• Adequate ventilation for the packing hall will beprovided for venting out suspended particulatesthereby ensuring dust free work environment.

• The spilled cement from the packing machine willbe collected properly and sent for recycling.

2. Loading to trucks Dust From Packing Section finished product will be takenthrough belt conveyor. From belt conveyor throughtruck loader, it will be loaded in trucks.

ROADS1. Internal Roads Fugitive Dust • The internal roads will be made of Concrete/ Black

topped.• Manual sweeping/vacuum sweeping will be carried

out regularly followed by water sprinkling.



Page 32

Pollution Monitoring Equipment:

On line dust monitors

Off line dust emission monitoring kit.

3.9.2 Waste Water Generation & Management

Process water is required only for cooling purposes and hence no waste water will be

generated from the plant.

Wastewater generation will be mainly due to the sanitary wastewater generated due to

domestic uses. There will be ‘zero discharge’ from the proposed plant and there will not be

any contamination of surface water bodies or ground water due to effluent discharges.

3.9.3 Waste Generation and Management

The cement grinding plant will not generate any solid waste or liquid effluents and will be

fully equipped to handle its domestic sewage.

The plant will not have any gaseous emissions. All air emissions of the plant through stacks

will be through the most efficient pollution control equipments and will not have any

adverse impact on the land or marine environment. The plant systems will be designed to

keep stack emissions to levels well below the stipulated norm of 50 mg / m3.

3.9.4 Solid Waste Generation and Utilization

No hazardous waste will be generated either in the process or pollution control facilities.

Dust collected from air pollution control equipment will be 100% recycled in the process and

there will be no solid wastes in the plant. All domestic waste will be routed to septic tank

and then to soak pit.

Waste oil in small quantities will be generated from gear box and other machineries and will

be disposed off to authorized recyclers registered with Pollution Control Board.

Table 3.6-Solid Waste Generation & Management

Sl.No. SOURCE OF GENERATION QUANTITY IN TPA MANAGEMENT PLAN

1 Dust from APC Devices 70.0 Will be completely reused inthe process.

2 Used Oil / Lubricants 60.0 Litres Will be sold to authorizedRe-processors.

3 Garbage / food waste fromcanteen & guest house 0.10

Will be made vermi-composting and will be used asmanure for green beltdevelopment.



Page 33

3.9.5 Noise Levels

The noise generation from the Clinker Grinding plant can be broadly categorized into two

type’s viz. Area and Point sources. All the equipment used can be categorized as point

sources and the vehicular traffic movement can be treated as area source. All the equipment

is designed to comply with the International Norms, Rules and Stipulations on not exceed 75

dB (A).

All these noise generating equipment will be within the buildings and the presence of

workers at these equipment is either not required or Intermittent. People required for

intermittent work near high noise generating equipment will be provided with earplugs and

their working hours in these areas will be regulated.

The noise levels at the periphery of the plant will be well within the stipulated norms of

noise pollution.

3.9.6 Green Belt Development


Total green belt area shall be of 1.10 Acres (33% of total area). The main objective of the

greenbelt is to provide a barrier between the plant and the surrounding areas. The greenbelt

helps to capture the fugitive emissions and to attenuate the noise generated in the plant

apart from improving the aesthetics of the plant site.

The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the

effects of emissions from the plant. The treated effluents from the plants will be utilized for

the greenbelt development.

The landscaping of the plant will be carried out. Roads for vehicular movement will be paved

and adequate mitigation measures will be provided to prevent fugitive emissions.

3.10 Schematic Representations of the Feasibility Drawing Which Give Information of EIAPurpose.



Page 34

Fig.3.6- Schematic Representation



Page 35

CHAPTER-04SITE ANALYSIS

4.1 General

The proposed site is well connected to roads & rails networks. The site is at about 18.3 km

away from nearest town Mohania. Plant is about 1.6 km from NH-2, 9.5 Km from NH-97.

Nearest railway station Karmanasha R.S is at 3.0 Km NW & Dhaniachha at 4.5 km NE away

from the site. Nearest airport is at Varanasi, at about 64 Km N from the proposed project site.

Nearest River is Karmanasha River at about 4.9 Km from the proposed site.

4.2 Connectivity4.2.1 Road

The plant site is located about 1.6 Km distance from NH-2 through a metallic road of 0.55

Km.

4.2.3 Rail Linkage

Karmnasha at 3.0 KM NW & Dhaniachha at 4.5 km NE railway station will be the serving

station for the proposed plant.

4.2.4 Topography

The topography of the land is generally flat and well suited for development of industrial

projects. The Mean Elevation of the site is 75m above the MSL. There are no ecologically

sensitive zones nearby forests within 10 km from the plant site.

4.2 Existing Land Use Pattern

Land of the proposed project is barren Land. Plant is not coming under the dense forest

category land. This area does not form part of any National Park, Wild Life Sanctuary and

Natural/Biosphere reserve.

4.3 Existing Infrastructure

Proposed plant site is barren land and devoid of any buildings and vegetation. The site has

all required facilities i.e. water, housing, power, hospital etc.

4.4 Climate Data: Temperature

May month is usually the hottest with daily maximum of 45 ⁰C and mean daily on yearly

basis is 34⁰C. December is the coldest month with mean daily minimum of 10 degree Celsius.

Rainfall

More than 75 percent of the annual rainfall occurs during monsoon in the period from June

to October. Average annual rainfall is 1164 mm.



Page 36

CHAPTER - 5

PLANNING BRIEF

5.1 Planning Concept

Setting up of Cement Grinding Unit will be provided with following facilities

Transportation facility will be provided to the executives.

Medical facilities will be provided for the emergency.

Drinking water and electricity facilities will be provided.

Greenbelt will be developed in and around the plant.

Canteen will be provided with all facilities.

Separate sanitary facilities will be provided for workers and company employees.

However, no residential colony/township is envisaged for employees because in local areas

all the infrastructure facilities are available and maximum employees will be recruited from

these areas.

5.2 Population Projection

With the set up of proposed project infrastructure and social development will

simultaneously takes place. Project will contribute for rising up of the population as it

created job opportunities and economic upliftment of the area. Plant activities will also

boost the ancillary industries, business and market establishments. The whole set will invite

both skilled and unskilled from outside. This will result in increase in the population density

due to industry.

5.3 Amenities and Facilities

5.3.1 Water System

Water system for the Cement Grinding Unit shall comprise the following:

Drinking water system

Fire water system

Dust suppression system

A brief detail of these system along with details regarding water requirement, source of

water, re-circulating system etc. are described in the following paragraphs.

Drinking and sanitary water system:

Drinking and sanitary water requirement for the plant will be met from bore well.



Page 37

Fire water system:

The emergency water pipelines will be led throughout for fire fighting. These fire fighting

pipelines will be connected to the emergency water storage tank. In addition to the fire

fighting pipelines, additional fire hydrants/extinguisher would also be provided at suitable

locations.

Dust suppression system:

The dust suppression will be carried out by sprinkling water on the raw material stockpiles

etc. Dust suppression will be accomplished by cooling water from time to time.

Distribution pipe work:

In general mild steel pipes are being considered for re-circulating water piping. Mainly

buried pipes are considered except for shop internal pipes and the pipe work shall comprise

all necessary valves, fittings, hydrants etc.

5.3.2 Fuel Oil & Gas System

FO will be used as fuel for DG sets which will be sourced from local petroleum supplier. No

other combustion process is involved in the whole production process.

5.3.3 Dust Extraction System

Dust extraction system will be provided at material transfer points. The generated dust

during material transfer in various conveyors will be collected in bag filters and the collected

dust will be disposed at suitable locations. The bag filters will consist of suction hoods, duct

work, fans, bag filters, filter cleaning devices by compressed air, bag houses etc. It is

proposed that the dust from the dust silo below the bag filter hopper shall be collected in

closed trucks through rubber hose connected below the discharge gate of the dust silo.

5.3.4 Communication

Public Address System with paging and party facility for CCR operator to contact the field

operator and vice versa has been considered in order to facilitate plant operations in

quickest possible time.

The plant shall be equipped with all modern communication facilities such as telephone

(landline & mobile), tealeaf, STD, ISD and Internet etc.



Page 38

5.3.5 Auxiliary Facilities

Repair Shop Facilities

Repair shop will be provided in proposed plant area to serve the repair and maintenance

requirement of various equipment and facilities. Repair facilities for maintenance of

mechanical & electrical equipment and instruments have been included as mentioned

hereunder.

1. One hydraulic press 5. One induction heater

2. One pedestal drilling machine 6. Two welding machine

3. One bench grinder 7. Measuring equipment / tools

4. Electrical and instrument repair facilities 8. Belt vulcanizing unit

Fire Fighting System

Many working area in the proposed plant have hazardous and fire prone environment. To

protect the working personnel, equipment and machineries, fire fighting measures have

been planned for the proposed plant.

In order to control any situation of fire in plant premises the following fire protection

facilities have been envisaged for the various units of the plant.

Portable fire extinguishers

Hydrant system

Automatic fire detection system

Automatic extinguishing system

Ventilation, Air Conditioning & De-dusting System

Pressurized ventilation system has been provided for MCC room and exhaust ventilation for

battery room and transformer rooms. Natural ventilation has been envisaged for the plant /

concentrator building through louvers.

Air conditioning of control room has been provided by split type air conditioner / window

type air conditioner with air cooled condenser, refrigerant compressor and other

accessories.

De – dusting system for all material transfer points prior to addition of water, will consist of

pulse jet type bag filter, centrifugal fan, dust holding bunkers and other accessories. Dust



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suppression system will be provided for the stockpiles. Water will be sprinkled on the

stockpiles to suppress the fugitive dust generated during stacking and reclaiming operations.

Ancillary Buildings

There will be a main gatehouse, which will accommodate time office, security office,

guardroom etc. Beside this, there will be works office located near the production shops.

This building will accommodate the Plant offices, commercial, personnel, finance and other

administration offices. A canteen building will be provided inside the plant in a suitable a

location.

Machinery stores

A store building needs to be constructed for storing tools, spare parts, consumables, etc.

Open area is to be earmarked for storing machinery and construction materials during

project activity.

5.3.6 Other Requirements

Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks to be provided at

all suitable locations in the plant for ease of maintenance and operation.

First aid

A first aid centre shall be provided in the plant premises near production shop. Provision will

be made for regular health checkup for all plant employees by specialist doctor in regular

interval.

Weigh bridge

The plant shall be equipped with a 30 t capacity electronic weigh bridge with printer facility,

which takes care of incoming and outgoing material.

Parking

Adequate parking space shall be provided in the plant premises for the parking of the

vehicles.

Welfare

The proposed plant shall be furnished with necessary welfare measures like rest room,

Canteen, bath room, and a First Aid trained staff for immediate requirements. Also shall be

tied up with local Hospitals/clinic for Health care and Medical requirements



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CHAPTER – 06PROPOSED INFRASTRUCTURE

6.1 Industrial Area

The setting up of the grinding mill and packing plant, their auxiliary equipment, clinker and

cement storage areas, electrical power receiving substation and administrative buildings will

require about 3.10 acres of land.

6.2 Residential Area

The area around the site is under development with reasonably good communication

facilities. Other social infrastructure like Housing, Schooling and Medical facilities are all

available nearby and will be available when the plant becomes operational. Hence, no

residential colony is envisaged for employees.

6.3 Green Belt


Total green belt area shall be of 1.10 Acres (33% of total area). The main objective of the

greenbelt is to provide a barrier between the plant and the surrounding areas.

Comprehensive greenbelt / plantation program will be undertaken in and around the

project. The species selection will depend upon crown shape, surface of bark and leaves,

flower, color, capacity of growth in the wide variations of ecological conditions etc. A

mixture of soil should be prepared by mixing commercial fertilizer, cow dung, BHC powder in

the topsoil.

6.4 Social Infrastructure

M/s HimalayaHeight Cement Private Limited will commence a lot of infrastructure

developmental works in the periphery area. Some glimpses of the developmental activities

are presented below:


Strengthening School buildings for education.

Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program.



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6.5 Connectivity

Proposed project is well connected to NH-2, NH-97 by road and has good rail network.

Existing road and rail network will be utilized for raw material and final products

transportation. However, existing road network, if required will be strengthen.

6.6 Drinking Water Management

Drinking water facilities will be provided for employees as well as nearby villagers. A fresh

water tank will be constructed for this drinking purpose.

6.7 Sewerage System

A garland drain around the plant is envisaged to collect surface run-off during rainy season.

Internal drainage system will be constructed to collect domestic and industrial effluent.

6.7.1 Run-off Management

The rain water collected from the roof of buildings will be channelized through drains

around the buildings and will be recharged into the ground by providing recharging pits.

Overflow, if any, will be discharged to the nearby plant drainage. Also one rain water

collection pond has been considered in the layout. All the plant storm water drains will be

routed to the rain water collection pond and overflow, if any, from the pond will be

discharged to any existing natural outfall outside the plant area. The rain water collection

pond will be unlined.

A Rain Water Harvesting Pond has been contemplated to act as collection basin for

rainwater. The collected water will be 100% reused in the raw water reservoir in dry season.

The pond will be located at the lowest area of the plant so that it can effectively collect all

the rainwater by gravity. The Tank shall be earthen. The pond will be lined at the bottom and

sides with two layers of HDPE lining of appropriate thickness to prevent percolation of the

harvested rainwater in to the ground. Figure below depicts schematically the proposed

rainwater harvesting scheme for the proposed plant. The Rain Water Harvesting Pond is

depicted below:



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Garland drain will be provided around raw material stock pile area. The run-off collected

from these areas will be treated in adequate settling pond and will be taken to rain water

harvesting pond.

6.8 Solid Waste Management

No hazardous waste will be generated either in the process or pollution control facilities.

Dust collected from bag houses will be 100% recycled in the process and there will be no

solid wastes in the plant. Waste oil in small quantities will be generated from gear box and

other machineries and will be disposed off to authorized recyclers registered with Pollution

Control Board.



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CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 The proposed project site is a barren land where no human habitations are exists. Therefore,

there is no chance of any displacement of persons from their land and hence Rehabilitation

and Resettlement Policy is not applicable for the proposed project.



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CHAPTER – 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

In the cement industry, any one of the following three alternate modes of project execution

is adopted:

Turnkey

Semi Turnkey

Packaged procurement mode

In the turnkey mode, there is one implementing agency for the project having the total

responsibility. Hence, the project cost is the highest and at the same time, control on timely

execution is also high. The project cost is minimum in the last mode, also known as shopping

mode, where different items (major machinery or auxiliary; clubbed section wise or type

wise) of the project form the different packages, which are considered for procurement.

Thus control on timely execution is lowest. The semi turnkey mode falls in between the

above two modes, having 4 to 6 packages for procurement and construction & erection and

is therefore the most preferred mode.

Based on the consideration of cost and time, the package procurement mode will be

followed by clubbing various activities to the extent possible.

Planning Of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project. Following activities will be given special attention.

Pre Project Activities

Management Approvals.

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups.

Selection of Consultants

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders



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Project Activities (Implementation Stage)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of Tender, Evaluation of tenders received and Order placement for

balance machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant

Statutory Clearances

The proposed project will require various statutory approvals and clearances from various

authorities of the Government. Some of these will be required before start of the

construction activities, while others would be required during the course of execution of the

project and upon completion of the project before commencing operations. Clearances

required for the proposed project shall be identified in due course and necessary action will

be taken to obtain the same.

Project Schedule

The total project implementation schedule is of 16 months from the date of approval and

the allotment of land and all other statutory clearances from the State / Central Government

The external agencies such as consultant, machinery suppliers, contractors of civil

construction and equipment will be selected carefully well in advance.

An effective project team has been formulated with an experienced Project Manager as its

leader.

Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:



Page 46

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in-house and from external agencies

A well chosen team of experienced personnel for project execution shall coordinate

the implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected for

detailed engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction and

erection work.

Effective project monitoring including project planning schedule and monitoring

shall be employed in this project. Timely execution and resources will be monitored

using computer based project monitoring tools. In case of deviations in project

progress, all possible corrective actions such as crashing of network etc. will be

carried out.

Effective monitoring and reporting procedure for review of progress and coordination

among various agencies shall be used. At least a monthly coordination meeting, if not

earlier, shall be held to closely monitor the project and take corrective action as required.

The schedule may vary depending on the project status

8.2 Project Cost

An indicative estimated capital cost of the proposed 0.14 MTPA Cement grinding Unit is Rs.

805.00 Lakhs. A broad break-up of the indicative estimate of the Project capital cost is

provided below:

Table 8.0 Project Cost

SL Description Rs. in Lakhs1 Land & Land Development 5.002 Building & Civil construction 80.00

3 Plant & Machinery, Electrical installation& other fixed assets 620.00

4 Pre-operative & preliminary expenses 25.005 Working Capital 75.00

Total 805.00



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Project Financials

The financial attractiveness of the project has been estimated as below:

Sl.No. Sources of Funds Cost in Lakhs

1 Promoters Capital 200.00

2 Term Loan 605.00

TOTAL 805.00

The projected financial viability of the project has been based on the following

considerations:

Price realizations in Bihar have been consistently good with the present retail selling

price of Cement being Rs.250/- per bag.

Fly Ash shall be available from nearest Steel Plant. The transportation of the fly ash

shall be achieved through road transport in Bulk Tankers.

Blended cements (PPC) shall constitute 100% of the product mix.

Table 8.1 Cost of Pollution control Equipment

Sl.No. HEADS ESTIMATED COST IN LAKHS

1 Air Pollution Control Devices 30.62

2 Environmental Lab 3.69

3 Environmental Monitoring & Management 2.35

4 Noise Pollution Control 2.00

5 Green Belt Development 6.08

Total 44.74 Lakhs

RECURRING COST PER ANNUM

1 Recurring Cost per Annum 10.54 Lakhs



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CHAPTER – 09

ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

9.1.1 Improvements in the Physical Infrastructure

HimalayaHeight Cement Pvt. Ltd. has envisaged a lot of infrastructure developmental works

in the periphery area.


Strengthening school buildings for free education.

Providing the drinking water facilities.

9.1.2 Improvements in the Social Infrastructure

Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program.

Provide & conduct the free eye & health check up programmes.

9.1.3 Employment

The project is going to create substantial employment and income for local people. Due to

this project activity, some person in the project area will be recruited as skilled, semi skilled

and unskilled workers by the company as per its policy. Therefore, substantial amount of

employment and income is likely to be generated for the local people. So, the project will

contribute in a positive manner towards direct employment in the project area. Some

employment potential benefits are given below:


Administration staff and Managerial staff.



9.2 Other Benefits

Development of the local area in terms of an enlarged market will provide the farmers

with a good outlet of their agricultural products to enjoy the price effect, which is likely to

be strong enough to offset the impending local inflations through real-balance effect.

Besides above, indirect benefits have also occurred to the region by way of increase in

industrial production.



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Relief

Operation and treatment expenses for poor people referred by authenticated

organizations.

Extend required help to different seva trusts at the time of natural calamity.

Thus, the proposed project will usher in the social and economic upliftment of the persons

living in the vicinity of the Project i.e. of society at large.

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