PRE FEASIBILITY REPORT
For
Increase
Of
Clinker production capacity from 2.5 MTPA to
3.4 MTPA
Cement (OPC/PPC/PSC/Composite Cement) &
GGBS capacity from 4.8 MTPA to 6.0 MTPA and
installation of 1X18 Captive Power Plant
At
BILAKALAGUDUR VILLAGE, GADIVEMULA MANDAL,
KURNOOL DISTRICT, ANDHRA PRADESH
Of
M/s JSW Cement Limited
TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES
LIST OF ANNEXURES
S. No. CONTENTS
1.0 Executive Summary
2.0 Introduction Of The Project/Background Information
3.0 Project Description
4.0 Site Analysis
5.0 Planning Brief
6.0 Proposed Infrastructure
7.0 Environmental Management Measures Incorporated in the Project
8.0 Rehabilitation and Resettlement (R & R) Plan 9.0 Project Schedule & Cost Estimates
10.0 Analysis Of Proposal
FIGURE NO TITLE
Fig-1 Location Map
Fig-2 Key Map
Fig-3 Study area map of 10 km radius
Fig-4 Google Earth Imagery of the Plant Site
Fig-5 Process Flow Diagram with Proposed Modifications
Fig-6 Process flow diagram of Captive Power Plant
Fig-7 Process flow sheet with EMP
Fig-8 Water Balance for Expansion
Fig-9 Layout of the Existing Cement Plant
NO TABLE
1 Proposed Expansion Project Activity
2 Salient Features of the Plant Site
3 Capacity details of pollution control equipment
4 Adequacy Of Air Pollution Control Equipment For Enhanced Capacities
5 Raw Material Requirement
6 Raw Material Requirement – Cement (OPC/PPC/PSC/Composite
Cement) & GGBS 7 Land Breakup
S. No. ANNEXURE
Annexure - I Environmental Clearance of the Plant
Annexure - II Environmental Clearance of the Captive Limestone Mine
CHAPTER - 1
EXECUTIVE SUMMARY
JSW Cement Limited, an Indian based registered company at Mumbai
evaluated the feasibility of expansion of its existing clinker capacity from 2.5
MTPA to 3.4 MTPA and Cement (OPC/PPC/PSC/Composite Cement) &
GGBS capacity from 4.8 MTPA to 6.0 MTPA and installation of 1X18 MW
Captive Power Plant at Bilakalagudur Village, Gadivemula Mandal, Kurnool
District, Andhra Pradesh in order to cater to the increasing market demand.
JSWCL received the first Environmental Clearance vide MOEF letter no. J-
11011/889/2007-IA-II(I) dt 25.08.2008 for 2.0 MTPA clinker, Portland Slag
Cement (PSC – 1.1 MTPA), Ordinary Portland Cement (OPC – 1.1 MTPA)
production and Captive Power Plant (CPP – 2x18=36MW). Environmental
Clearance was received for the enhancement of Clinker Production (2 to 2.5
MTPA) and change in product mix from 4.8MTPA (1.1 MTPA OPC &
3.7MTPA of PSC) to 4.8 MTPA of OPC/PSC/GGBS and amendments thereof
dated 06.06.2017. (Enclosed as Annexure – I). The project was
implemented and is on stream. However, the power generation capacity was
installed for 1x18 MW only. The Environmental Clearance vide MOEF letter
no. J-11011/159/2010-IA II(I) Dated 13.05.2011 was received for the
expansion of cement grinding unit from 2.2 MTPA to 4.8 MTPA
The present proposal is for increasing the clinker production from 2.5 MTPA
to 3.4 MTPA and the cement (OPC/PPC/PSC/Composite Cement/GGBS
production from 4.8 to 6.0 MTPA installation of 1X18 MW Captive Power
Plant. The plant spreads over an area of 263.05 Ha No additional land will
be required for the proposed expansion.
The major raw material, limestone will be sourced from the captive
limestone mine. The limestone requirement of the plant after the proposed
expansion will be 4.95 MTPA which will be met from the Captive Limestone
Mining Lease located at 1.0 km distance from the plant. The Captive
Limestone mine spreads over an area of 350.57 Ha. The Environmental
Clearance (EC) for the captive mine was granted by MOEFCC vide Letter.
No; J-11015/800/2007.IA.II (M), dated 21st April, 2008 for 7.0 MTPA
limestone production. The mine was opened and extraction is going on.
Facilities like canteen, rest room, transport, indoor games facilities etc. have
already been provided in the existing plant as basic facilities to workers. No
other additional facilities are proposed.
The present water requirement is 2000 m3/day. Additional water
requirement for the expansion proposal is 550 m3/day. JSWCL has
obtained permission for the withdrawl of 4500m3/day water from state
ground water authority.
No waste water will be generated from the cement manufacturing process.
Approximately 84m3/day of waste water will be generated from the Captive
Power Plant. Waste water will be suitably treated and the treated water will
be used internally for dust suppression. Approximately 4m3/day of domestic
waste water will be generated which will be treated in the existing STP and
the treated water will be used for plantation and horticulture. No waste
water will be discharged outside the premises. “Zero Discharge” will be
maintained.
Present peak power requirement of the cement plant is 40MW. Presently the
power requirement is met from the existing 18MW power plant and the
power grid. Additional power requirement will be 8.5 MW and the same will
be sourced from the new 1X18MW Captive Power Plant and APCPDCL with a
dedicated 132 kV overhead grid line.
An additional manpower of 80 persons will be employed for the operational
phase.
There are no wild life sanctuaries, national parks, elephant/tiger reserves
within 10km radius of the study area.
The expansion will be implemented within 18 months from the date of
receipt of Environmental clearance as well as Consent to Establish from the
State Pollution Control Board.
An indicative estimated capital cost of the proposed expansion is Rs 420
Crores including the preoperative expenses, contingency and interest during
construction.
CHAPTER – 2
(i) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
O. P. Jindal Group is the Principal / Promoter shareholder in JSW
CEMENT LIMITED, an Indian based registered company, in Mumbai.
JSW has an integrated cement manufacturing plant in Nandyal, A.P,
India. The group has four cement grinding units in Vijayanagar, adjacent
to JSW steel plant near Bellary, Karnataka, Dolvi, Maharashtra, Salboni,
West Bengal, Jaipur and Odisha.
These Units have a combined capacity of 14.0 Million Tons Per Annum
(MTPA). JSW Cement is leading the way in promoting PSC variant of
cement in India. Portland Slag Cement (PSC) also known as green cement
as it generates least amount of CO2 during production and also generates
least heat during concreting.
PSC (Portland Slag Cement) produced by JSW Cement, can be used as
replacement to Ordinary Portland Cement (OPC) during concreting and is
being widely used in the coastal cities. PSC can replace OPC in use which
also makes economic sense for the RMC manufactures.
JSW Cement Limited, an Indian based registered company at Mumbai
evaluated the feasibility of expansion of its existing clinker capacity from
2.5 MTPA to 3.4 MTPA and Cement (OPC/PPC/PSC/Composite Cement)
& GGBS capacity from 4.8 MTPA to 6.0 MTPA and installation of 1X18
MW Captive Power Plant at village Bilakalagudur, Mandal Gadivemula,
District Kurnool (A.P.) in order to cater to the increasing market demand.
(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT
JSWCL received the first Environmental Clearance vide MOEF letter no.
J-11011/889/2007-IA-II(I) dt 25.08.2008 for 2.0 MTPA clinker, Portland
Slag Cement (PSC – 1.1 MTPA), Ordinary Portland Cement (OPC – 1.1
MTPA) production and Captive Power Plant (CPP – 2x18MW). ). Later, the
Environmental Clearance vide MOEF letter no. J-11011/159/2010-IA
II(I) Dated 13.05.2011 was received for the expansion of cement grinding
unit from 2.2 MTPA to 4.8 MTPA. Environmental Clearance was received
for the enhancement of Clinker Production (2 to 2.5 MTPA) and change in
product mix from 4.8MTPA (1.1 MTPA OPC & 3.7MTPA of PSC) to 4.8
MTPA of OPC/PSC/GGBS and amendments thereof dated 06.06.2017.
The Environmental Clearance (EC) for the captive mine was granted by
MOEFFCC vide Lr. No; J-11015/800/2007.IA.II (M), dated 21st April,
2008 for 7.0 MTPA limestone production. (Enclosed as Annexure – II)
JSWCL is presently producing Clinker of 2.5 MTPA and finished product
Cement of 4.8 MTPA with Product Mix of Ordinary Portland Cement
(OPC), Portland Slag Cement (PSC), OPC and PSC/ Ground Granulated
Blast Furnace Slag (GGBS) and operating with the 1X18MW power plant.
The present proposal for capacity expansion is given as in Table-1.
TABLE- 1
PROPOSED EXPANSION PROJECT ACTIVITY
Present
Capacity
Proposed
Expansion
Capacity
After
Expansion
Clinker Production (MTPA) 2.50 0.9 3.4
Cement Production (MTPA)
OPC/PPC/GGBS/PSC/
Composite Cement)
4.80 1.2 6.0
CPP (MW) 1X18 1X18 36
Captive Limestone Mine (MTPA) 7.0 Nil 7.0
As the hot gases are utilized in hot air generator, attached to Slag Mill for slag drying, the power generation through the waste heat gases is not
possible.
Additional clinker will be transported to group companies at Vijayanagar
(near Bellary), Salboni (West Bengal) through rail or road.
As per Environmental Impact Assessment (EIA) Notification dated 14th
September 2006, proposed project falls under category “A” of project
activity 3(b) and requires prior Environmental Clearance (EC) to be
obtained from Ministry of Environment, Forest & Climate Change
(MoEF&CC) before the commencement of ground activity.
(iii) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE
COUNTRY AND OR REGION
JSW Cement proposes for increasing the clinker production from 2.5
MTPA to 3.4 MTPA and the cement (OPC/PPC/PSC/CC/GGBS
production from 4.8 to 6.0 MTPA and installation of 1X18 MW Captive
Power Plant in the existing premises. The additional clinker, if available,
will be supplied to its cement grinding units located in different states.
Cement is an essential ingredient for the modern building construction.
The new generation cement plant in India now employs the latest
technology for better efficiency, energy conservation and economics of
large capacity production. The improved market conditions witnessed
recently, after a grip of recession over a long period, are expected to
continue due to high priority being given by the Government to housing
and infrastructure and also in view of the massive investment proposed
in industry and rural sectors. Therefore, there is an urgent need to
increase the production capacity in the country in spite of severe
resource constraints. Hence, the present proposal will cater to the
increased demand of cement in the country and region.
DEMAND – SUPPLY GAP
India is the second largest producer of cement in the world. No wonder,
India's cement industry is a vital part of its economy, providing
employment to more than a million people, directly or indirectly. Ever
since it was deregulated in 1982, the Indian cement industry has
attracted huge investments, both from Indian as well as foreign
investors.
India has a lot of potential for development in the infrastructure and
construction sector and the cement sector is expected to largely benefit
from it. Some of the recent major initiatives such as development of 98
smart cities are expected to provide a major boost to the sector.
The housing and real estate sector is the biggest demand driver of
cement, accounting for about 65 per cent of the total consumption in
India. The other major consumers of cement include public
infrastructure at 20 per cent and industrial development at 15 per cent.
In Budget 2018-19, Government of India announced setting up of an
Affordable Housing Fund of Rs 25,000 crore under the National Housing
Bank (NHB) which will be utilised for easing credit to homebuyers. The
move is expected to boost the demand of cement from the housing
segment.
Cement production and consumption has been increasing over the
decade in line with the rapid growth in the building and construction
industry. Further, the per capita consumption has been increasing over
the decade, as demand for cement continues to increase in civil
construction activities.
India's cement demand is expected to reach 550-600 million tonnes per
annum (MTPA) by 2025. The Indian cement industry has thus been one
of pioneers of the reforms process with many of the initial reforms being
initiated in this sector. After the liberalization and globalization of the
Indian economy, the cement industry has been growing rapidly at an
average rate of 8 percent.
Demand - Supply projection for cement on National and State basis
reveals that there exists an imbalance between availability and demand of
cement particularly in southern region. Cement is the most important
construction material manufactured to accounting for about 90% of the
gross value of production of non-metallic building materials. The cement
industry is a pioneer modern manufacturing industry in Andhra Pradesh.
After bifurcation of united Andhra Pradesh in Andhra Pradesh and
Telangana, a huge development activities have been emerged out. A new
capital city of Andhra Pradesh at Amaravati is planned and designed like
ultra-modern city of 21st century where several development activities are
presently underway.
Enhancing clinker production capacity in the region will have significant
effects on development of infrastructure facilities and consumption of
cement in A.P. The Company will manufacture GGBS and various grades
of cement, thus increasing access of its products to construction sector.
iv. IMPORTS VS INDIGENOUS PRODUCTION
Imports are not feasible.
v. EXPORT POSSIBILITY
As reflected from the study above, the cement market is expected to have
a higher demand compared to the current supplies. Hence it is expected
that in the near future, export of cement does not seem to be viable.
vi. DOMESTIC / EXPORT MARKETS
Demand in target Cement market for the proposed capacity enhancement would be mainly in south Indian states.
vii. EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE
PROJECT
Presently, it employs 800 people. Additional manpower required for the
proposed expansion project during its operation will be 80 persons.
Employment opportunities will be created during construction and
commissioning of the project. However, due to increase in clinker &
cement production, additional indirect employment opportunities will
also be created. Maximum possible recruitments will be done from local
area. Only where skills are not available locally, people will be hired from
outside.
CHAPTER – 3
PROJECT DESCRIPTION
i. TYPE OF PROJECT INCLUDING INTERLINKED AND
INTERDEPENDENT PROJECTS, IF ANY
M/s JSW Cement Limited proposes for increasing the clinker production
from 2.5 MTPA to 3.4 MTPA and cement (OPC/PPC/PSC/CC/GGBS
production from 4.8 to 6.0 MTPA and installation of 1X18 MW Captive
Power Plant in the existing premises.
Interlinked Projects: None. Environmental Clearance for 7.0 MTPA
limestone mining was already obtained from MoEF&CC.
ii. LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC
LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT)
WITH COORDINATES
The JSWCL Cement Plant is located at Bilakalagudur village, Gadivemula
mandal, Kurnool District, Andhra Pradesh. Average altitude of plant site
is about 260 m above mean sea level and is located between
15°40'30.74” to 15°41'39.49” North Latitude and 78°27'10.27” to
78°28'12.96” East Longitude. The plant is part of Survey of India Topo
sheet No. 57/I/6 (Scale: 1:50000).
Nearest railway line connecting Kurnool – Nandyal of South Central
Railway line is located at a distance of 23.0 km to Southern direction
from the site. Kurnool is major town located at a distance of 47.0 km in
WNW. Location map showing plant is shown in Fig-1.
The National Highway (NH-18) connecting Kurnool – Nandyal is located
at a distance of about 21.1 km in SW direction.
The key map of the plant is shown in Fig – 2.
The State Highway (SH-27) connecting Atmakur – Velugodu is located at
a distance of about 9.8 km in Eastern direction, The nearest railway
station is located at Nandyal RS which 23.0km in Southern direction.
There are no wild life sanctuaries, national parks, elephant/tiger reserves
within 10km radius of the study area.
Nearest Settlements to the Plant Site are:
Bilakalaguduru – 1.2 km – W
Regadaguduru – 2.5 km – NE
Pesaravayi – 3.3 km – SE
Bujanuru – 1.9 km – WSW
Gadivemula – 3.4 km – W
Nearest Forest to Plant Site is Gani RF located at 3.1 km in SW direction
No industries are located within 10 km radius. Study area map of 10 km
radius is shown in Fig-3. Salient features of the plant site is given in
Table – 2.
Fig – 4 shows the Google Earth Imagery of the plant site.
ANDHRA PRADESH
LOCATION MAP
Chittoor
SPSR Nellore
Prakasam
GunturKrishna
Kurnool
Anantapur
YSR Kadapa
West Godavari
East Godavari
Vishakhapatnam
Vizianagaram
Srikakulam
FIG - 1
INDIA
KURNOOL DISTRICT
PLANT SITE
Halvi
Kosigi
Kuppagallu
Adoni
Gudikallu
Emmiganuru
Nendavaram
Nagaladinne
MantralayamMadhavaram
Ulindakonda
Kodumuru
Kuruva
Varakallu
Uyyalavada
Ramallakota
Kalava
GanjNamuru
Gandigargevula
Bandi Atmakuru
Santajuturu
Nandyal
Mahanandi
Chelima
SirvelYalluruLliuruKottapeta
Koilkuntla
Sanjamula
Uyyalavada
Nandipadu
Kolimigundla
Neraducharla Owk
Garladinne
JonnagiriPyapaliMaddikeraChintakunta
Alur
Molagavalli
Hosuru
Tuggali
PattikondaChanugondla
Dhone
Devanakonda
Karivemula
Veldurti
Hebbeli
Holalagondi
Guduru
Gonegandla
Polukollu
GargeyapuramMiduturu
Kambalapalle
VelugoduRegadiguduru
Rollapenta
Peddacheruvu
Srisailam
Pratakota
Pagidyala
Nandikotkur
Betamcherla
Rangapuram
Banganapalle
Chagalamarri
Mutyalapadu
Allagadda
Ahobilam
Rudravaram
Timmanayanipeta
Aspari
Kurnool
Nagarpatnam
Atmakuru
7
18
7
LEGEND
RAILWAY TRACK
RIVER & CANAL
ROAD
DISTRICT BOUNDARY
STATE HIGHWAY
TALUK HEADQUARTER
DISTRICT HEADQUARTER
TOWN
STREAMS
NATIONAL HIGHWAY
PLANT SITE
18
Note:- Not to Scale
N
B.S.ENVI-TECH (P) LTD.,
CLIENT :
TITLE :
SECUNDERABAD
PREPARED BY
KEYMAP
SCALE
2km10
FIG - 2
LOCATION :
M/s. JSW CEMENT LIMITED
N
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Para
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261
LEGEND
SETTLEMENTS
SPOT HEIGHT
RIVER
FOREST
CANALS
STREAMS/ TANKS
ROADS
PLANT SITE
Kurnool District, Andhra Pradesh.
Bilakalaguduru Village, Gadivemula Mandal,
Pesaravayi
Regadaguduru
Bujanuru
BilakalaguduruGadivemula
Korrapoluru
Allagadda
Grandhivemula
Somapuram
2611.2km
1.9km
3.4km
3.3km
2.5km
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PLANT SITE
03
SCALE
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To
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9.6
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250
250
230
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310
300
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328
370
280
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261
TABLE – 2
SALIENT FEATURES OF THE PLANT
Feature Details
Altitude 260 m above msl
Latitude 15°40'30.74” N to 15°41'39.49” N
Longitude 78°27'10.27” E to 78°28'12.96” E
Village, Tehsil, District,
State
Bilakalaguduru Village, Gadivemula Mandal,
Kurnool District of Andhra Pradesh.
Max. Temp. 0C 45.6
Min. Temp. 0C 6.7
Relative Humidity % 25-77
Annual rainfall 726 mm
IMD Station Kurnool
Topography Plain
Soil Type Black Cotton Soil
Nearest water bodies Kunderu River – 1.8 km - WSW Kurnool Cuddapah Canal – 2.8 km – E Gal Eru – 7.1 km - ESE
Nearest National Highway
The National Highway (NH-18) connecting Kurnool – Nandyal – 21.1 km – SW
The State Highway (SH-27) connecting Atmakur – Velugodu – 9.8 km – E
Nearest Railway station Nandyal RS – 23.0 km - S
Nearest Industries None within 10 km Radius
Nearest Villages Bilakalaguduru – 1.2 km – W
Regadaguduru – 2.5 km – NE
Pesaravayi – 3.3 km – SE
Bujanuru – 1.9 km – WSW
Gadivemula – 3.4 km - W
Nearest Town Kurnool – 47.0 km - WNW
District Head Quarter Kurnool – 47.0 km - WNW
Nearest Port Area Krishnapatnam Port – 237 km – SE
Inter State Boundary Andhra Pradesh – Telangana – 91.0 km – NW
Nearest Air port Hyderabad (Shamshabad) – 170 km – N
Nearest Forest Gani RF – 3.1 km – SW
Historical places None within 10 km radius
* All distances mentioned in the above table are aerial distances.
iii DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF
SELECTING THE PROPOSED SITE, PARTICULARLY THE
ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE
HIGHLIGHTED
The proposed project is expansion within the existing plant premises of
JSW Cement Limited, village Bilakalagudur, Mandal Gadivemula, District
Kurnool (A.P.), no alternative sites were considered.
iv. SIZE OR MAGNITUDE OF OPERATION
The present proposal is for increasing the clinker production from 2.5
MTPA to 3.4 MTPA and the cement (OPC/PPC/PSC/CC/GGBS
production from 4.8 to 6.0 MTPA and installation of Captive Power Plant
within the existing premises.
v. PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC
DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT,
COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN)
JSW Cement Limited proposes to enhance clinker, cement and power
generation capacity by installing one additional raw mill, one coal/pet
coke mill, additional / modification of preheater string, one secondary
crusher and modification in the existing limestone crusher, raw mill, coal
mill, clinker cooler, minor modification in cement & slag mill circuits,
installation of one packer and installation of fly ash feeding system,
storage silos and installation of 1X18 MW Captive Power Plant. The
following modifications are summarized as follows:
Section Activities proposed for capacity expansion
Limestone Crusher
Modification of existing primary crusher Installation of Secondary crusher
Raw Mill Installation of additional Raw Mill of 250 TPH capacity Modifications in material feeding system (additional
Limestone hopper and modification in existing hoppers) Modification in Bag house
Pre-heater Installation of additional pre-heater string Modification of existing pre-heater string
Section Activities proposed for capacity expansion
Kiln & Cooler Modification in Kiln inlet Existing Clinker cooler to be modified / new cooler to be
installed to match the enhanced clinker production capacity
Modification in Cooler Bag house
Coal/Petcoke Mill
Installation of additional coal/petcoke mill of 80/44 TPH for coal/ pet coke grinding
Modification in Coal mill Bag house
Cement & Slag Mill
Change in product mix to enhance cement grinding capacity
Following modifications in existing Cement & Slag Mill are proposed:
Provision of fly ash handling system Silos for fly ash, PPC and Composite Cement silos with
conveying arrangements Separator internals modification with hard faced plates
for increased availability Modification of cake breaker at roller press discharge for
better grinding and separation efficiency Roller press feed chutes modification for improved
material distribution to rollers Modification of elevators for capacity enhancement
Packing One additional packer of 240 TPH with adequate pollution control equipment
Captive Power Plant
Installation of 1X18 MW CPP with the following major equipment and systems:
NAME OF THE MAIN EQUIPMENT DETAILS
1 Boiler 80TPH CFBC Boiler
2 Turbine and Generator 18MW Steam Turbine Generating
Set
3 ESP & Ash Handling system ESP attached to boiler.
Pneumatic handling system for
pumping flyash.
4 Water Treatment Plant 1X5cu.m DM Plant
5 Coal Handling plant and Coal Stock Pile 40TPH Coal Handling Plant &
5000 MT capacity coal stock piles
6 Air cooled condenser 55 TPH Air cooled Condenser
7 Air compressors 2 nos. of 450 CFM & 2 nos. 1450
CFM Capacity
PROCESS DESCRIPTION OF CLINKER & CEMENT MANUFACTURING
PROCESS
The clinker manufacturing process involves the following steps/
activities:
Limestone is sourced from Captive mine and crushed in an impact
crusher. Crushed limestone is stacked into a stockpile from where
it is conveyed to hoppers through stacker and reclaimer.
Required additives are also stacked and conveyed to respective
hoppers
Pre-defined quantities of limestone and additives is fed into Raw
Mill for fine grinding,
The finely ground raw meal which is a mixture of limestone and
additives is stored in Raw Meal silo.
Coal / pet coke alone or in combination is finely ground and stored
in bins.
Fuel is fired into the kiln through main burner and also through
calciner burner to maintain burning zone temp. at about 1400 –
1450 ºC.
Raw meal (kiln feed) is fed to preheater through bucket elevator.
The kiln feed is calcined in the preheater and enters the kiln where
it is converted into clinker at about 1400 – 1450 ºC.
Hot clinker discharges into Clinker Cooler where it is cooled down
to around 150 ºC and hot gases from cooler are used in slag mill
for slag drying.
Clinker after cooling is conveyed through pan conveyor and finally
stored in a silo.
Granulated Blast Furnace Slag received from the JSW Steel,
Bellary will be heated with hot air and moisture free slag is
pumped into silos for manufacturing slag cement/Ground
Granulated Blast Furnace Slag.
Fig - 5 shows the process flow diagram with proposed modifications.
FIG – 5
PROCESS FLOW DIAGRAM SHOWING THE PROCESS
MODIFICATIONS
PROCESS DESCRIPTION OF CAPTIVE POWER GENERATION
Circulating Fluidized Bed Combustion (CFBC) technology boilers
have been envisaged for 18 MW CPP. The key features of CFBC
technology are as follows:
Fuel combustion in the Circulating Fluid Bed systems takes place in the
vertical combustion Chamber Furnace. Proper sized fuel is fed into the
system and is burnt at relatively low temperature around 900ºC. The bed
material in the combustor consists primarily of fuel ash. The average
particle size of the bed material is in the range of 50-300 microns.
The bed material is fluidized by preheated primary air introduced through
air nozzles at the bottom of the bed, and by the flue gas generated during
combustion. The air and gas flow upwards with a relatively high velocity,
filling the entire combustor with suspended solids. They have a high
concentration at the fluidizing grate and decrease continuously towards
the top of the combustor. The combustion gas entrains a considerable
portion of the solids in the combustor and carries them over to the Recycle
Cyclone where the entrained bed materials are separated from the gas.
The larger portions of the bed material are continuously returned to the
bed by recycle loop. The very high internal and external circulating rates of
solids, characteristic of the circulating fluid bed, result in consistently
uniform temperatures throughout the combustor and the solids recycle
system. Due to the high circulation rates a uniform temperature profile in
the combustion system is achieved preventing temperature peaks.
The soilds proceed through the combustor at a much lower velocity than
the gas due to high slip velocity between gas and solids. Solids residence
times in the order of minutes are obtained for each cycle of solids
circulation. The long residence and contact times, coupled with the small
particle sizes and efficient heat and mass transfer rates, produce high
combustion efficiency. The long residence time along in combination with
temperature allow both the decomposition of limestone and the
subsequent capture of sulphur and formation of gypsum.
Combustion air is introduced into the combustor at two stages. About forty
percent of the combustion air is passed as primary fluidizing air through
the grate at the bottom, and the balance is admitted as secondary air
through multiple ports in the side walls of the combustor. The combustion
proceeds in two zones: a primary reducing zone in the lower section of the
combustor, and complete combustion using excess air in the upper
section. This staged combustion, at controlled low temperatures, effectively
suppresses NOx formation.
The fluidizing nozzles for combustor seal pots and ash cooler are all of
“capped nozzle” design, which has been utilized successfully in our CFB
boilers. The capped nozzle design has the advantage to minimize the back
sifting of ash through the nozzle into the wind box. This design is very
reliable and is recommended standard.
Flue gas resulting from combustion of the fuel, and the entrained solids,
exit the combustor at temperature in the upper portion of the combustor
water wall and enters into recycling Cyclones designed to remove over 99%
of the solids entrained by the gas from combustion chamber. The cyclones
are equipped with vortex finder for optimum separation efficiency.
The bed material separated by the recycling cyclone are collected in the air
fluidized Seal Pots. The collected balance of bed material at standpipe of
seal pot (lower pressure than furnace) is returned directly into the furnace
lower part at higher pressure through return leg of seal pot due to pressure
seal provided by the seal pot at essentially the furnace exit temperature.
Hot flue gas at around 900ºC. Exits the recycling cyclone and enters the
convective pass. The convective pass includes superheater and economizer
sections of the steam generator. At the end of the economizer section the
flue gas and the remainder of the entrained solids, not separated in the
recycling cyclone, are cooled.
The flue gases are further cooled down at the exit of the preheater, while
primary and secondary air are, at the same time preheated in counter flow
direction. The cooled flue gases, then passes through an electrostatic
precipitator, when the particulate matter are removed to the extent
required for final dust emission control and collected in the ash hoppers.
Fig 6 shows the process flow diagram of the Captive Power Plant.
FIG – 6
PROCESS FLOW DIAGRAM OF CAPTIVE POWER PLANT
TABLE – 3
CAPACITY DETAILS OF MAJOR POLLUTION CONTROL EQUIPMENT
S. No
Section
Material handling (TPD) Present
Rated Capacity
Operating hours /day
Modification Proposed
Present Proposed
(total) Present
Proposed
1 Limestone crusher
11025 14700 1200 TPH 10 13 Minor modification
2 Raw Mill 11250 15000 760 TPH 20 20 Installation of new raw mill with capacity of 250 TPH
3 Kiln 7500 10000 7500 TPD 24 24 Installation of new preheater of 3000 TPD
4 Cooler 7500 10000 7500 TPD 24 24 New cooler to meet 10000 TPD
5 Coal mill / Pet Coke mill
50/18 TPH
80/44 TPH 50 / 18 TPH
20 20 Installation of additional new coal mill/petcoke mill of 80/44 TPH
6 Slag Mill 440 TPH 440 TPH 440 TPH 20 22 Increase in operating hours
7 Cement Mill – Roller Press
220 TPH 220 TPH 220 TPH 20 22 Increase in operating hours as well as change in product mix
8 Cement Mill – Ball Mill
80 TPH 80 TPH 80 TPH 20 22 Increase in operating hours as well as change in product mix
9 Packer 720 TPH 960 TPH 720 TPH 20 20 Installation of one additional packer of 240 TPH
10
CPP 18MW 36MW 18MW 24 24 Installation of new 1X18 MW CPP
TABLE – 4 ADEQUACY OF AIR POLLUTION CONTROL EQUIPMENT FOR ENHANCED
CAPACITIES
APCE Design Capacity
(m3/hr)
GAS VOLUME (m3/hr.) Modification Proposed for expansion
Present After proposed Expansion
Limestone crusher
99550 85000 99550 Minor modification
Raw Mill 780000 502312 780000
Minor modification.
Kiln
Raw Mill New 400000 Nil 400000
Installation of new bag house with a capacity of 400000 m3/hr
Cooler 500000 410080 700000
New cooler will be installed. To handle additional 200000 m3/hr volume new bag house with stack to be installed.
Coal mill / Petcoke mill 162000 124080 250000
Addition of new coal or petcoke mill in place of existing mill and upgradation of existing bag house with fan
Slag Mill 270000 266039 270000 Minor Modification
Cement Mill – Roller Press
270000 266039 270000 Minor Modification
Cement Mill – Ball Mill
62000 61155 62000 Minor Modification
Packer 10000 Nil 10000 Installation of new bag filter with a capacity of 10000m3/hr
CPP Boiler 88501 Nil 88501 Installation of New ESP
Fig - 7 shows the process flow sheet with EMP.
FIG - 7
MIN
ES
LIM
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TO
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CR
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ST
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LR
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EB
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MP
vi. RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY,
LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCT/S, MODE
OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT
Raw material requirement for the proposed expansion is given in the
Table-5
TABLE-5
RAW MATERIAL REQUIREMENT FOR CLINKER PRODUCTION & 1X18MW CPP
S.
No. Raw material
Existing
requirement
(TPA)
Additional
requirement for
the proposed
expansion (TPA)
Total
requirement
after proposed
expansion (TPA)
Source
Distance
/Transportatio
n
1. Limestone 3650000 1304842 4954842 Captive Mine 1 km
2. Aluminous Laterite
193750 45932 239682 Kerala 850 km
3. Flue Dust 77500 31322 108822
JSW Steel,
Bellary 250 km
4. B.F Slag 0 18706 18706
JSW Steel,
Bellary 250 km
5. Red Mud 0 12474 12474 Belgam 540 km
6.
Coal*
Cement
Plant 337500 121500 459000
Imported/
indigenous
237 km
(Krishnapatnam
Port) Power
Plant 90000 90000 180000
7. Pet Coke* 240000 86400 326400 Indigenous 750 km
*Coal and Pet Coke can be used in combination depending on process & quality requirements
TABLE- 6
RAW MATERIAL REQUIREMENT – CEMENT (OPC/PPC/PSC/COMPOSITE CEMENT) & GGBS
S.
No.
Raw
material
Existing
requirement (TPA)
Additional
requirement
for the
proposed expansion
(TPA)
Total
requirement
after proposed expansion
(TPA)
Source Distance
/Transportation
1. Clinker 2500000 900000 3400000 Captive -
2. GGBS 2960000
134000 3094000
JSW Steel,
Bellary
250 km
3. Fly ash 0 330000 330000 CPP/Nearby 250 km
4. Gypsum 125000
13800 138800
Imported/
Chemical
400 km
SALIENT FEATURES OF THE LIMESTONE MINE
S.
No.
Description Features
1 Location of Limestone Mining Lease area Bilakalaguduru Village, Gadivemula
Mandal, Kurnool District of Andhra Pradesh
2 Total Area of Mining Lease (ha) 350.57
3 Mineable limestone reserves (in million
tonnes) in the mining lease area
58.33 MT
4 Clinker Production capacity (MTPA) 3.4
5 Mineral zone thickness (in m) 30
6 Recovery, % 95
7
Average Grade of limestone, %
a SiO2 % 45.10
b CaO % 3.6
8 Method of mining Open Cast Mechanised
9 Expected mine life (years) 12 years
10 Operating days/year 300
The limestone mine adjacent to the cement plant.
vii. RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED
IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED
No waste water will be generated from the cement manufacturing process
& “Zero Discharge” will be maintained.
Domestic effluent generated will be treated in the existing STP and the
treated waste water will be utilized for green belt development.
Around 175 TPD of Flyash and Bottom Ash will be generated from the
Captive Power Plant and the same will be used for manufacturing PPC &
Composite Cement. However, Sewage sludge will be generated from STPs
and the same will be used as manure in horticulture/green belt
development.
viii. AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER
REQUIREMENT
The total additional requirement of fresh water for the proposed clinker
expansion will be 550 m³/day and the same will be sourced from the
existing Bore wells for which JSW Cement Ltd. has already obtained
permission from the state groundwater authority. No additional
permission will be required.
FIG - 8
WATER BALANCE FOR EXPANSION
Present peak power requirement of the cement plant is 40MW. Presently
the power requirement is met from the existing 18MW power plant and
the power grid.
Additional power requirement will be 8.5 MW and the same will be
sourced from the new CPP and APCPDCL with a dedicated 132 kV
overhead grid line.
ix. QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID)
AND SCHEME FOR THEIR MANAGEMENT / DISPOSAL
6m3/day Domestic Waste water will be treated in the STP and the treated water will be utilised for green belt development.
Approx 84m3/day of effluent from CPP will be generated which will be suitably treated and the treated water will be used for suppression.
No effluent will be discharged outside the project premises.
Additional 5KLD of Used Oil will be generated and sold to authorised recycler.
175 TPD of Fly Ash and bed ash for CPP will be generated and the
same will be used for PPC and Composite Cement Manufacturing. No solid waste will be discharged from the plant. Dust collected by
the air pollution control equipment (Bag house & Bag filters) will be fully recycled back to the process.
x. SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING
WHICH GIVE INFORMATION OF EIA PURPOSE
CHAPTER – 4
SITE ANALYSIS
i. CONNECTIVITY
The plant is located at village Bilakalagudur, Mandal Gadivemula,
District Kurnool in the state of Andhra Pradesh (A.P.).
The nearest railway line connecting Kurnool – Nadyal of South Central
railway is located at a distance of 23 km to southern direction from the
site. Kurnool is a major town located at a distance of 47 km in WNW
direction. The National Highway (NH-18) connecting Kurnool – Nandyal is
located at a distance of about 21.1 km in SW direction. The state
highway (SH-27) connecting Atmakur – Velugodu is located at a distance
of about 9.8 km in Eastern direction.
The nearest railway station is Nandyal and is about 23 km in southern
direction. The nearest Airport is Rajiv Gandhi International Airport,
Hyderabad is about 170 km in the north direction from the plant site.
ii. LAND FORM, LAND USE AND LAND OWNERSHIP
The total land available with JSW Cement is 263.05 Ha. Plant area does
not cover any forest land. The expansion is planned to be executed
within the existing premises and as such no additional land will be
acquired.
The Cement Plant complex is located in an area of 263.05Ha. Layout of
the existing cement plant along with colony is shown in Fig - 9
TABLE - 7 LAND BREAKUP
Area (Ha)
CEMENT PLANT
Cement Plant Built up area 80.85
Solar Plant 10.17
Area for proposed expansion 5.0
Vacant (for future expansion) 62.65
Road area 3.43
CPP 3.43
Area of Plantation 95.95
colony 5.0
TOTAL AREA 263.05
iii. TOPOGRAPHY (ALONG WITH MAP)
The topography of the project area is more or less flat without
undulations. The site is located at an elevation of 260 m above Mean sea
level (MSL).
iv. EXISTING LAND USE PATTERN (AGRICULTURE, NON-
AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER
CRZ), SHORTEST DISTANCES FROM THE PERIPHERY OF THE
PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK,
WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES
(DISTANCE FROM THE HFL OF THE RIVER), CRZ, IN CASE OF
NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE
NOTIFICATION SHOULD BE GIVEN
This is an expansion project and shall be carried out within the existing
plant premises. Approx. 5 acre of additional space will be used for
establishment of additional equipment required for the proposed
expansion. Remaining land use will not alter. 33% of the area has
already been converted into greenbelt.
FIG-8
LAYOUT OF THE EXISTING CEMENT PLANT
v. EXISTING INFRASTRUCTURE
LAND
The integrated cement plant (i.e including power plant and colony) will be
located in an area of 263.05 hectares.
POWER
Present peak power requirement of the cement plant is 40MW. Presently
the power requirement is met from the existing 18MW power plant and
the power grid.
Additional power requirement will be 8.5 MW and the same will be
sourced from the new CPP and APCPDCL with a dedicated 132 kV
overhead grid line.
WATER
Present Water requirement is 2000m3/day .Water will be sourced from
the existing bore wells. JSW Cement has obtained due permission from
the state government for withdrawal of groundwater up to 4500m3/day.
Approximately 550 m3/day of water will be required for the proposed
expansion.
FUEL
Coal required for the plant is received from Krishnapatnam Port.
TYPICAL QUALITY OF COAL
Constituents Range
Fixed carbon (%) 33-46.00
Ash content (%) 15.06
Volatile matter (%) 28.0-30.5
Calorific value (Kcal/Kg) 6280
Moisture content (%) 8-16
Sulphur content (%) 0.3- 0.6
AIRPORT
The nearest Airport is Rajiv Gandhi International Airport, Hyderabad is
about 170 km from the plant site.
RAIL
The nearest railway line connecting Kurnool – Nadyal of South Central
railway is located at a distance of 23 km to southern direction from the
site.
COMMUNICATION
Communication facilities such as telephone, tel-fax and internet are
available in vicinity of the plant site location.
vi. SOIL CLASSIFICATION
The soil in the area are of sandy loam and sandy clay
vii. CLIMATIC DATA FROM SECONDARY SOURCES
The study area lies in tropical region where climate is characterized by
very hot summers and cool winters. The annual temperature ranges from
a maximum of 45.6°C to a minimum of 16°C. The average annual rainfall
as recorded at IMD observatory at Kurnool is 726 mm. The South-west
monsoon lasts from mid-June to mid-September and the area gets more
than 80% of the annual rainfall during this period.
viii. SOCIAL INFRASTRUCTURE AVAILABLE
Nearest city is Kurnool. Telephone and medical facilities are available in
the nearby area. Educational Institutions, Technical Institute for skill
up-gradation, Dispensary etc. Almost all the villages in the buffer zone
are electrified.
CHAPTER – 5
PLANNING BRIEF
i. PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES
TRANSPORTATION ETC.,) TOWN AND COUNTRY PLANNING/
DEVELOPMENT AUTHORITY CLASSIFICATION
The Cement Plant along with Captive Power Plant is already existing in
the rural area of Bilakalagudur Village, Kurnool District and the
proposed expansion takes place in the same existing premises. The Plant
comes under the jurisdiction of Bilakalagudur Village Panchayath.
The present proposal is for increasing the clinker production from 2.5
MTPA to 3.4 MTPA and the cement (OPC/PPC/PSC/CC/GGBS)
production from 4.8 to 6.0 MTPA and the installation of 1x18 MW CPP.
The plant spreads over an area of 263.05 Ha and no additional land will
be required.
ii. POPULATION PROJECTION
With the establishment of proposed project infrastructure, social
development will simultaneously take place. Project will contribute for
rising up of the population to some extent and shall create job
opportunities (during construction and commissioning phase) and
economic upliftment of the area. Plant activities will also boost the
ancillary industries, business and market establishments. The whole set
up will invite both skilled and unskilled workers from outside. This may
likely to result in increase in the population density.
iii. LAND USE PLANNING (BREAKUP ALONG WITH GREENBELT ETC.)
The integrated cement plant (i.e including power plant and colony) will be
located in an area of 263.05 hectares.
LAND BREAKUP
Area (Ha)
CEMENT PLANT
Cement Plant Built up area 80.85
Solar Plant 10.17
Area for proposed expansion 5.0
Vacant (for future expansion) 62.65
Road area 3.43
CPP 3.43
Area of Plantation 95.95
colony 5.0
TOTAL AREA 263.05
iv. ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)
Company will assess the demand of infrastructure (Physical & Social) in
nearby area of the proposed site and the same will be developed under
corporate social responsibilities programs.
v. AMENITIES / FACILITIES
Facilities like canteen, rest room, transport, indoor games facilities etc.
have already been provided in the existing plant as basic facilities to
workers. No other additional facilities are proposed.
CHAPTER – 6
PROPOSED INFRASTRUCTURE
i. INDUSTRIAL AREA (PROCESSING AREA)
The proposed expansion will be done within the existing premises. The
existing road and other infrastructure will be utilized for raw material
and final products transportation. The site is equipped with all other
necessary infrastructure.
ii. RESIDENTIAL AREA (NON-PROCESSING AREA)
Residential colony partly completed and the balance is yet to come up
iii. GREENBELT
33% of the project area has already been developed into greenbelt in line
with the CPCB guidelines for greenbelt development. Polygamy plantation
has been done while growing mostly native species which are more
adaptive to the local climate and surroundings.
iv. SOCIAL INFRASTRUCTURE
Company will assess the demand of infrastructure (Physical & Social) in
nearby area of the proposed site and the same will be developed under
corporate social responsibilities programs.
v. CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD / RAIL/
METRO/WATER WAYS ETC.)
The nearest railway line connecting Kurnool – Nadyal of South Central
railway is located at a distance of 23 km to southern direction from the
site. Kurnool is a major town located at a distance of 47 km in WNW
direction. The National Highway (NH-18) connecting Kurnool – Nandyal is
located at a distance of about 21.1 km in SW direction. The state
highway (SH-27) connecting Atmakur – Velugodu is located at a distance
of about 9.8 km in Eastern direction.
The nearest railway station is Nandyal and is about 23 km in southern
direction. The nearest Airport is Rajiv Gandhi International Airport,
Hyderabad is about 170 km in the north direction from the plant site.
vi. DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER)
Drinking water will be sourced from the existing bore wells. JSW Cement
has obtained due permission from the state government for withdrawal of
groundwater. No additional permission for water drawl is required to be
obtained.
vii. SEWERAGE SYSTEM
The STP is designed for a maximum load of 50KLD with the BOD of 150 -
200 mg/L for raw sewage and after treatment less than 20 mg/L.
SEWAGE TREATMENT PLANT (STP)
STP of 50 KLD capacity has been commissioned in plant premises with
following units
a. Bar screen
b. Equalization tank
c. Aerobic Digester
d. Secondary Settling tank
e. Pre Filtration tank
f. Treated water tank
g. Equipment Room
Treated water is being used for their green belt development and dust
suppression purpose. No waste water is discharged to outside the plant
premises and they are adopting a zero discharge concept. The existing
STP will be utilized for the expansion as well.
viii. INDUSTRIAL WASTE MANAGEMENT
No additional solid and liquid waste will be generated from the industrial
processes.
ix. SOLID WASTE MANAGEMENT
Solid waste generated is disposed after segregating the waste into bio-
degradable and non-degradable.
Dust collected in the air pollution control equipment from the cement
and power manufacturing process will be recycled back to the system.
Approx. 175 TPD of Flyash & Bedash will be generated from CPP and the
same will be utilized for manufacturing PPC & Composite Cement.
Kiln refractories : 80 to 100 tonnes per annum and it will be disposed for
recycling.
Approx. 5 KL per annum of Spent Oil/ Used grease will be generated due
to the proposed expansion. The used oil/ grease will continue to be sold
to the authorized vendors as per applicable Hazardous Wastes
(Management, Handling & Transboundary) Rules.
x. POWER REQUIREMENT & SUPPLY / SOURCE
Present peak power requirement of the cement plant is 40MW. Presently
the power requirement is met from the existing 18MW power plant and
the power grid.
Additional power requirement will be 8.5 MW and the same will be
sourced from the new CPP and APCPDCL with a dedicated 132 kV
overhead grid line.
CHAPTER - 7
ENVIRONMENTAL MANAGEMENT MEASURES INCORPORATED IN
THE PROJECT
AIR POLLUTION
JSWCL has integrated the Environmental management with the
manufacturing process. Cement manufacturing at JSWCL cement plant
is a compound process with Vertical Roller Mill for Raw mill which helps
in energy conservation. Additionally kiln operation is being controlled
through fully automated, which takes action for coal firing based on
various advanced information and also can take action by seeing the
parameters in less than a minute time. By adopting this technology,
JSWCL has avoided tripping of ESP.
Details of the pollution control systems provided are given in following
table:
LIST OF POLLUTION CONTROL SYSTEMS IN THE PLANT
Process Unit Pollution Control
Equipment
Cement plant
Rawmill/Kiln Bag house
Coal mill Bag filter
Cooler Bag house
Cement Mill Bag filter
Slag Mills Bag filter
CPP ESP
Bag Filters are designed to control dust emission up to 30 mg/Nm3 are
provided to Kiln & Raw mill, Cement Mill, Cooler, Crusher, Slag mills and
Storage Silos for control of particulate emissions. The existing PCEs will
be modified to meet the additional load.
All the flue gas outlets are provided with state of art air pollution control
equipment with control efficiency of 99.8-99.9 % to maintain the
particulate emission level below 30 mg/Nm3. The cement dust collected
in the pollution control devices is recycled back to the cement
manufacturing process.
Ventilation systems are provided with bag filters in the plant. All the
pollution control equipment are designed to meet outlet particulate
emission of less than 30 mg/Nm3 for particulate matter.
Interlocking facility has been provided in the pollution control
equipment.
All the material handling systems are covered with aprons.
JSWCL will be achieving the increase in production of clinker by
modification of process units. All the pollution control equipment in the
cement plant is in place for various units as per requirement.
All transfer points and storage silos are provided with dust collection
and extraction systems for effective control of fugitive emissions. All
the installed pollution control equipment are designed for <30
mg/Nm3.
The dust collected from the pollution control equipment is being
recycled back into the process.
Clinker is being stored in clinker silo to control fugitive emissions.
Gypsum and additives are being stored in covered storage sheds
All raw material transfer conveyor are covered with GI sheets.
All internal roads in the plant are cement concreted.
To ensure and reduce impact of transport on the surrounding
environment, raw materials and cement is transported in trucks covered
with tarpaulin.
Transport vehicles are periodically checked for Pollution Under Control
certificate from approved RTA agencies.
Suitable bag filters are installed to control the fugitive emissions
generated during material transfer, packing, loading and unloading.
Raw materials such as Gypsum, Aluminous Laterite/ Flue dust are
stored in the covered sheds.
Fugitive emissions in the work zone are regularly monitored. Bag filters
are provided at all transfer points of raw material conveying, stacking,
packing of finished product etc. in order to control fugitive emissions.
Most of the roads are concrete paved. Water spraying is carried out to
control fugitive emission all around the stock yard and loading/
unloading areas.
Fully covered conveyors are provided for material conveying throughout
the plant.
NOISE POLLUTION
Noise levels generated in the cement plant are confined within the
boundary and with attenuation after greenbelt and construction of
boundary wall, the impact of noise levels on surroundings is negligible.
The noise levels are being monitored and efforts are being made to
maintain the noise levels within the prescribed limits. Grinding of raw
material and finished products is performed by Roller Press that
generates less noise compared to traditional ball mills. Grinding of raw
material and finished products is performed by Roller Press that
generates less noise compared to traditional ball mills. Single chamber
ball mill for cement grinding; i.e. no crushing chamber to create high
noise during cement grinding.
WATER POLLUTION
The wastewater generation from the Captive power plant operation
includes cooling tower blow down, boiler blow down, filter backwash, DM
plant rinsing water, and Service Water.
DM wastewater after neutralization and service water after oil and grease
removal is diluted with other wastewater streams of the power plant. The
wastewater is recycled for reuse in the process, dust suppression and
greenbelt development.
SOLID WASTE MANAGEMENT
Solid waste generated from the plant is disposed after segregating the
waste into bio-degradable and non-degradable.
RAINWATER HARVESTING MEASURES
16 nos. of recharge cum bore wells to harvest the runoff from the storm
water drains inside factory premises. The location of structures is given
in the following table:
S.
No.
Nomenclature Type of str. Location
1 RWHS # 1 Recharge cum Injection well Near Crusher Bldg.
2 RWHS # 2 Recharge cum Injection well Near Crusher Bldg.
3 RWHS # 3 Recharge cum Injection well Between Petron Office & Crusher
4 RWHS # 4 Recharge cum Injection well Near Petron Office
5 RWHS # 5 Recharge cum Injection well Backside of Canteen near scrap yard
6 RWHS # 6 Recharge cum Injection well Opp. RM Silo
7 RWHS # 7 Recharge cum Borewell Near Project Office
8 RWHS # 8 Rooftop Central Stores Building
9 RWHS # 9 Rooftop Bilakalagudur School Bldg.
10 RWHS # 10 Mine Pit Mine working pit (Southern Side)
11 RWHS # 11 Percolation tank # 1 with
recharge cum borewell
North east lease boundary
(towards village BKLGDR)
12 RWHS # 12 Percolation tank # 2 with recharge cum borewell
North east lease boundary (towards village BKLGDR)
13 RWHS # 13 Percolation tank # 3 with recharge cum borewell
North east lease boundary (towards village BKLGDR)
14 RWHS # 14 Recharge cum Injection well Near MRSS Bld
15 RWHS # 15 Recharge cum Injection well New Sec Bld
16 RWHS # 16 Recharge cum Injection well Near LC -2 Bld
Rainwater structures implemented at cement plant have a potential to
harvest rainwater to the tune of 524499 m3/annum at 715 mm of annual
average rainfall.
CHAPTER – 8
REHABILITATION AND RESETTLEMENT (R & R) PLAN
i. POLICY TO BE ADOPTED (CENTRAL / STATE) IN RESPECT OF THE
PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND
OUSTEES AND LANDLESS LABOURERS (A BRIEF OUT LINE TO BE
GIVEN)
No additional area is required for the expansion, hence Rehabilitation
and Resettlement is not involved. Thus no adverse impact is anticipated.
Socio Economic Status in the study area is found to be moderate with
respect to livelihood, amenities etc., Transport and other infrastructural
facilities such as market centers, business establishment, recreation etc.,
in the area were improved.
Employment potential both direct and indirect coupled with business
opportunities and strong social commitment of the company in the form
of better educational and medical facilities would result in enhancement
in the status and standard of living of the local populace resulting in
positive impact.
CHAPTER – 9
PROJECT SCHEDULE & COST ESTIMATES
i. LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF
COMPLETION
Implementation schedule: 18 months from the date of receipt of
Environmental clearance as well as Consent to Establish from the State
Pollution Control Board.
ii. ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF
ECONOMIC VIABILITY OF THE PROJECT.
An indicative estimated capital cost of the proposed expansion is INR 420
Crores including the preoperative expenses, contingency and interest
during construction.
The estimated investment Cost for the project has been based on the
requirement of fixed and non-fixed assets for both cement plant and
thermal power plant.
The financing of the project has been considered on the basis of Equity
and Term Loans from Financial Institutions. The debt: equity ratio has
been considered as 1: 0.2.
The project exhibits a good Internal Rate of Return of 17.2% on total
Investment. The IRR on equity is calculated to be 13.36 % (after tax).
CHAPTER – 10
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
i. FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON
THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL
POPULATION, IF ANY, IN THE AREA
The socio-economic benefits of the proposed project are as follows:
JSWCL is continuously contributing toward welfare & community
development activities under its CSR programmes not only at villages
where it is operating its units but also in other parts of Andhra Pradesh.
Focus areas of JSWCL are :
Health
Education
Women empowerment
Cleanliness
Rural Development
Safety
As JSW strongly believes that it is a part of the larger community where it
operates, the company has taken cognizance of the cultural ethos and
socio economic environment of the locality where its plants are located.
With this approach, JSW shall consider the following general measures
for the socio – economic upliftment / welfare of the nearby villages:
Local infrastructure development
Social Afforestation
Extending support to games, sports and culture to local community
Health and medical facilities
Social awareness program will further improve the quality of life and
standard of living such as sanitation and hygiene, HIV Prevention Program
etc.
Implementation of adult education and female education program in the
villages surrounding the project area.
Financial assistance to talented and poor students for higher studies.
(Management /Engineering / Medical studies etc.)
ANNEXURE - I
ANNEXURE – II
