PRE-FEASIBILITY REPORT
ofSONADIH CEMENT PLANTP.O.-Raseda, Dist.-Baloda Bazar-Bhatapara,Chhattisgarh
ForINCREASE OF PRODUCTIONCLINKER FROM 3.5 MTPA TO 5.1 MTPACEMENT FROM 1.0 MTPA TO 3.0 MTPA
(BY INSTALLATION OF UNIT – III)
&INSTALLATION OF 90 MW COAL BASEDTHERMAL POWER PLANT
By
LAFARGE INDIA LIMITED.
Table of Contents
1. Executive summary2. Introduction of the project/ Background information3 Project Description.4 Site Analysis5. Planning Brief.6 Proposed Infrastructure7. Rehabilitation and Resettlement (R & R) Plan.8. Project Schedule & Cost Estimates9. Analysis of Proposal (Final Recommendations).
1.0 EXECUTIVE SUMMARY
Lafarge India Limited (LIL), is operating Sonadih Cement Plant atRaseda , near Sonadih village, Balodabazar Tehsil of Raipur District inChhattisgarh State. The plant is located in an area of 91.886Hectares (Ha). The production capacity of the plant is 3.5 MillionTonnes Per Annum (MTPA) of Clinker & 1.0 MTPA of Cement. Part ofClinker produced will be sent to Mejia Grinding Unit located atAmdanga Village, Bankura District, West Bengal&Jojobera inJharkhand. Clinker is transported by the railway wagons fromSonadih to Mejia & Jojobera Plants.
LIL proposes to increase the clinker production capacity of the cementplant from 3.5 Million Tonnes Per Annum (MTPA) to 5.1 MTPA byinstalling a third line (Unit – III) of 1.6 MTPA clinker productioncapacity. Cement production after expansion will be increased from1.0 to 3.0 MTPA. Additionally, it is proposed to set up a 90 MW Coalbased Thermal Power Plant to meet the power requirement of thecement plant.
The proposed new unit will be located within the existing cementplant complex. No additional land or site is required. Keeping in viewof utilizing some of the common existing infrastructure, LIL proposesto locate Unit – III adjacent to the existing Unit – II.
The principal raw materials are Limestone, Coal, iron ore & sand.
Limestone will be met from Captive limestone mines of LIL which islocated adjacent to the plant.
The present power requirement of 41 MVA is met from CSEB grid. Theproposed thermal power plant of 90 MW will meet the total powerrequirement for 5.1 MTPA clinker production I e & 3.0 MTPA CementIe 66 KVA . LIL has installed DG sets of 16 MW capacities as standbyunits for supply of power during contingency.
Present water consumption is 3700 m3/day and is sourced fromSeonath River. Additional water requirement is about 1000 m3/daymaking the total water requirement of the plant to 4700 m3/day. Thisrequirement will be met from Seonath River. LIL has been permittedto draw about 4800 m3/day of water from river Seonath.
Wastewater generated from the power plant will be treated and usedin the cement plant.
Present domestic wastewater generation from the plant and colony is250 m3/day. Additional waste water generation is estimated to bemaximum of about 40 m3/day.
LIPL is operating a full-fledged sewage treatment plant (STP) designedfor a maximum load of 550 m3/day with the following units. STPcapacity is adequate for taking additional wastewater of 40 m3/day.
No solid waste generation from the plant. Ash generated from thepower plant will be consumed in cement plant.
There is no wild life sanctuary, national park, eco-sensitive areawithin the 10 km radius of the project site.
Existing infrastructure include railway siding and well developedroads, storm water drains with adequate storage space for clinker andflyash and parking area
All infrastructure facilities such as education, health facilities andother social facilities are adequate at nearest populated area
Additional quarters of 25 (nos) will be provided
Green belt in an area of 30.32 ha has been developed inside the plantboundary as per statutory norms.
Dust collected from air pollution control equipment is 100% recycledin process and there are no solid wastes in cement plant. Ashgenerated in power plant will be consumed in cement plant.
LIL has well-defined CSR policy to Carryout social development andwelfare measures in the surrounding villages. Under CSR activity LILhad carried out community development projects, in the fields ofhealth, education and environmental preservation, in and around theplant.
The capital cost, for the proposed production enhancement project,works out to Rs 1645 crore
2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(I) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
Lafarge India headquarters at Mumbai, is the leader in buildingmaterials and implement a strategy of sustainable development ineach of its activities. The Group’s expertise in efficient industrialprocesses generates value, protects environment, shows respect forsocieties and cultures and is sparing in its use of natural resourcesand energy. By focusing on the development and advancement ofbuilding materials, Lafarge places the customer at the core of itsstrategy and offers the construction industry and the general publicinnovative solutions that will bring more safety, comfort and beauty toour everyday lives.
The Group’s expertise in efficient industrial processes generate value,protects the environment, shows respect for societies & cultures andis sparing in its use of natural resources and energy.
Lafarge India Ltd. was formed in the year 1999 and it startedoperation in India by acquiring Cement Division of Tata Steel withintegrated cement plant located at Sonadih, Dist.: Raipur, State:Chattisgarh & grinding unit at Jojobera, Dist.: Jamshedpur, State:Jharkhand. Subsequently, in the beginning of the year 2001 it alsoacquired Raymond Cement Plant situated in Dist.: Bilaspur State:Chattisgarh and this plant is now renamed as Arasmeta CementPlant. Lafarge India commissioned a green field project at Distt.Chhittorgarh in Rajasthan in 2013.
Lafarge India Ltd is operating 1.5 MTPA of Fly-Ash Cement grindingstation which is a State-of-the-art cement grinding unit based onlatest and most eco-friendly technology adjacent to Thermal PowerStation of Damodar Valley Corporation, Mejia, District Bankura WestBengal and is committed to grow with the environment. The unit isutilising bulk quantity of Fly –Ash generated by Mejia Thermal PowerStation (MTPS) of Damodar Valley Corporation in an eco-friendlymanner thus is instrumental in abating the Pollution in the region.
Sonadih Cement plant has been in existence since 1993 and wasacquired by LIL from Tata Iron And Steel Company (TISCO) on 1stNovember 1999. At present clinker production capacity is 3.5 MTPA.
At present 20% clinker produced is utilized at Sonadih Cement Plantfor manufacturing of Pozzolana Portland Cement while 80% clinker issent to Jojobera grinding unit of LIL located at Jamshedpur formanufacturing of Portland Slag Cement and Portland PozzolanaCement (PPC). Mejia Grinding Unit also receives clinker from SonadiPlant.
LIL is committed to produce quality cement by adopting qualitysystems and eco-friendly manufacturing process. The majorachievements of LIL at Sonadih are discussed hereunder.
1. Achieved ISO 9002 certification for quality standards in the year1997.
2. Achieved ISO 14001 certification from IRQS in the year 1999.3. Achieved OHSAS 18001 certification from M/S Indian Register
Quality Systems in the year 2002.4. Achieved several awards for the conservation of electrical energy
in the plant.
(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT.
In the process of enhancement of cement capacity looking in to thedemand, LIL, has proposed expansion of the cement plant for increaseof clinker production capacity from 3.5 MTPA to 5.1 MTPA byinstalling one more process line of 1.6 MTPA clinker productioncapacity. Cement production after expansion of the cement plant willbe increased from 1.0 to 3.0 MTPA. To support the cement plant withuninterrupted power, it is proposed setup 90 MW Coal based powerplant within the existing cement plant complex.
(iii) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THECOUNTRY AND OR REGION
It is expected that, the Cement demand will grow at much higher ratethan the national average. The bulk distribution of cement in theregion is likely to see a high growth due to a number of new Ready
Mix concrete plants and projects. Considering this, LIL proposes toincrease Cement production capacity
Opportunities for the Industry
Though India ranks second in the world in cement production, its percapita annual consumption is very low. Per capita consumption inIndia has grown from a low level of 70 Kg to around 110 kg over thelast 8 years, which is still way behind the world per capitaconsumption of 307 Kg (as of 2003). Cement Industry has growthpotential not only within the country but also for exports to theneighbouring countries. With Indian growth rate rising, theopportunities for the industry seem to be large.
Cement consumption in the coming years is likely to get a fillip fromGovernment initiatives for housing and infrastructure:
• State highway development projects being undertaken by somestates
• 10,000 kms of additional highways (25% concrete)• Rural roads construction• Housing finance growing by over 25-30% annually• IT parks and SEZ zones development in proximity to metros
(iv) DEMAND- SUPPLY GAP.
Market demand and projections
Cement growth is expected to be above the GDP growth of thecountry, which is expected to be around 8% for the coming years. TheIndian cement Industry is poised for a period of significant growth andthe demand for cement is expected to match the current availabilityby the end of the current fiscal. Cement demand has registered aCAGR of about 8.5% over the last decade. In fact, at the current levelsof growth, the cement industry may have to add over 90 Million Tonsof cement capacity to meet the demand for cement over the next 5years.
Cement companies were operating at levels below capacity in the pastbut with the demand and supply reaching equilibrium, almost allplants are working at above 90% capacity. The rate of growth in
cement demand is growing at a faster pace as compared to thecapacity expansion. This will improve the realizations of the industryin the coming year.
(V) IMPORTS VS. INDIGENOUS PRODUCTION.
India is self sufficient to meet the demands of the market with theGDP projected at 10 % in the coming decades and in view of theinfrastructure. Facilities going across the region the growth rate ofdemand will increase to meet the expansion of new proposal aremuted.
(VI) EXPORT POSSIBILITY
No export is proposed
(VII) DOMESTIC/EXPORT MARKETS.
The entire production is envisaged for the domestic market.
(VIII) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TOTHE PROJECT
Additional employment of about 50 is proposed.
3 PROJECT DESCRIPTION
(I) TYPES OF PROJECT INCLUDING INTERLINKED ANDINTERDEPENDENT PROJECT, IF ANY
The Cement Plant is interlinked with its Captive Limestonemine, a newly proposed Mine (ML -1) at Sonadi.
(II) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFICLOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUTWITH COORDINATES.
Sonadih Cement Plant is located near Sonadih village of BalodabazarTehsil in Raipur District, Chhattisgarh State. Fig – 1 shows thelocation map of the plant site. The plant is geographically locatedbetween 21o43’ to 21o45’ North latitude and 82o12’ to 82o14’ EastLongitude. The area is covered under the Survey of India ToposheetNos. 64 k/1 and 64 k/2 (1:50000) scale.
Plant site is bounded by Sonadih village in the north; Khapri andDamru villages in the east; Raseda and Rasedi villages in the southand Dhabadih and Bairdih villages in the western direction. RiverSeonath, a tributary to the river Mahanadi is located at a distance of1.0 m from the plant boundary.
Fig – 2 shows the Key Map of the Plant site. Table 1 gives the salientfeatures of the Plant site.
The study area of 10 km radius (Fig –3) falls under the jurisdiction ofBalodabazar Tehsil of Balodabazar Bhatapara Distt. Chhattisgarh.
The nearest railway station is Bhatapara on the South EasternCentral Railway located at about 32 km from the plant site. Bhataparais well connected with Kolkata and Mumbai by the Broad Gaugerailway lines of the South Eastern Central Railway. The site is alsowell connected with Bilaspur by metal road and by railway line viaBhatapara Station. The nearest airport is Raipur located at a distanceof 110 km.
The cement plant has township and is accessible through the StatePWD road connecting Bhatapara and Balodabazar through a link road
RAIPUR & BALODABAZAR-BHATAPARA
Bhatapara
Siari
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KankiSamoda
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INDIA
LOCATION MAP
CHHATISGARH
FIG - 1
Kanker
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JanjgirRaigarh
Jashpur
SurgujaKoriya
BilaspurKawardha
Rajnandgaon
Korba
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LEGEND
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STATE HIGHWAY
TALUK HEADQUARTER
DISTRICT HEADQUARTER
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STREAMS
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MINE SITE
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TREKKING ROUTES
6
Note:- Not to Scale
N
PLANT SITE
PLANT SITE
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SCALE2km10
SPOT HEIGHT
Balodabazar-Bhatapara District, Chchattisgarh, India.
LEGEND
RIVER
SETTLEMENTS
ROADS
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Near Sonadi Village, P.O.Raseda, Balodabazar Tehsil
M/s. LAFARGE INDIA LIMITED
PREPARED BY
SECUNDERABAD
CLIENT :
KEYMAP
FIG - 2
TITLE :
SONADIH CEMENT PLANTPROJECT :
STREAMS / TANKS
PLANT SITE
MINE SITE
TABLE - 1SALIENT FEATURES OF THE PLANT SITE
Feature DetailsAltitude 246 m above mslLongitude 82o12’ to 82o14’ ELatitude 21o43’ to 21o45’ NVillage, Tehsil, District, State Sonadih, Baloda Bazar Tehsil, Baloda
bazaar-Bhatapara distt.,ChhattisgarhMax. Mean Temperature, oC. 44.0 oCMin Mean Temperature, oC.. 14.0 oCRelative Humidity, % 58Annual rainfall, mm 800-1000PredominantWind directions
Winterseason
N & NE
Summerseason
WNW-W-WSW Sector
Monsoonseason
NE-E-SE sector
Topography Flat Terrain with gentle undulationsSoil Type Clayey & LoamyNearest River Seonath riverNearest Highway None within 10 km radiusNearest Road PWD road to Raipur at 15 kmNearest Railway station BhataparaNearest Railway Junction BilaspurNearest Village Sonadih/RasedaNearest City RaipurNearest Industries Ambuja Cement Limited - 14.26 km - SSW
Sree cement Limited- 12.76 km - SSWRawan Cement Works - 25.75 km - SSWEmami cement Plant - 14.79 km - SSW
Nearest Air port Raipur at 110 kmNearest Forest Mohtara Reserve Forest at 2 kmNearest State Boundaries None within 10 kmSensitive places None within 10 kmHistorical places None within 10 km
*all distances mentioned in the above table are aerial distances
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of about 9 km length. The site is well connected with Raipur andBilaspur towns. Balodabazar town is situated about 15 km from theplant and township area. The site is approachable from Raipur townlocated about 110 km from Sonadih by the State PWD road.
(III) DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASISOF SELECTING THE PROPOSED SITE, PARTICULARLY THEENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BEHIGHLIGHTED.
The proposed new units will be located within the existing cementplant complex No additional land or site is required. Keeping in view ofutilizing some of the common existing infrastructure, LIL proposes tolocate Unit – III adjacent to the existing Unit – II. Hence no alternatesite is considered.
(IV) SIZE OR MAGNITUDE OF OPERATION.
Present Clinker production capacity : 3.5 MTPAClinker production capacity after expansion : 5.1 MTPA (total)Present cement production : 1.00 MTPACement production capacity after expansion : 3.00 MTPA (Total)
A new production line of 1.6 MTPA will be installed
A 90 MW Coal based power plant also will be installed.
(V) PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATICDIAGRAM/FLOW CHART SHOWING THE PROJECT LAYOUT,COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN.PROJECT DESCRIPTION AND PROCESS DETAILS:
CEMENT PLANT
The process largely comprises of
A. Crushing the limestoneB. Raw Mix preparationC. Raw mix homogenizationD. Coal preparationE. Calcination and Clinkerisation
Description of each of the above operation is detailed below :
Limestone raised from the Mines is crushed and stacked before beingreclaimed by reclaimer. The reclaimer discharges the blendedlimestone to a hopper. There are two more hoppers for sand and ironore. The Sand and iron ore are transported to their hoppers through abelt conveyor system from the stockyard.
Raw materials are extracted from the respective hoppers with the helpof speed controlled weigh feeders to maintain the requiredcomposition of the raw meal. The weigh feeders discharge on acommon belt which feeds to the vertical mill where it is ground andthus raw meal is produced. Fineness of the raw meal is maintained byregulating the speed of separator, which is mounted on the top ofvertical mill. The raw meal produced is stored in the blending silowhere the same gets blended as a result of feeding and extractionoperation. The raw meal is extracted in the regulated manner and fedto suspension preheater and precalciner through pneumatic transportsystem, where raw meal is preheated and calcined to around 90%before it enters the kiln. Calcined raw meal is clinkerised at around1450oC in the kiln and stored in clinker silo. Required thermal energyis provided by firing pulverized coal, which is obtained from thevertical coal mill, after crushing it in coal crusher and pre blending itin coal blending system.
THE PROJECT:
MINING OF LIMESTONE: Limestone will be raised from the newmine (i.e ML-I Limestone Mine) located at a distance of 5 km awayfrom plant, involving advanced opencast mining technology. Drillingwill accomplished by ECM-645 Top hammer drill machine capable ofdrilling blast hole of 102/112 mm dia. Scientific and Eco-friendlyblasting is done by ANFO, Slurry and Emulsion explosives with DownThe Hole shock tube Delay Detonators of EXEL-200 & 250 milliseconds, Noiseless trunk line detonators (NTD) of 17ms and 42msconnectors and Cord relays so as to have negligible impact on thenearby dwellings.
Heavy earth moving equipments such as dozer, shovel, front endloader & bucket excavator will be made use for loading the dumpers.The dumpers haul the boulders to Limestone crusher hopper.
CRUSHING : Crusher reduces the size of limestone from 1.7 Cu. M to(-) 80 mm size. A new crusher of 800 TPH will be installed at mine.Limestone from the mine will be conveyed through closed conveyor.
STACKER & RECLAIMER
The existing stacker will be extended to build new piles for the newline and one Bridge Reclaimer of 400 TPH will be added to reclaim thematerial. Stacker & Reclaimer will help to improve the pre-blending inthe ratio 1:10.
RAW MILL
Iron ore, sand, ARM will be transported through conveyor belts andstored in different hoppers. The material composition shall bemaintained with the help of weigh feeders as per the raw mix design.Vertical roller mill comminutes the raw-mix to a fineness of 15%residue on 90 microns sieve and 2-3% residue on 212 microns sieve.Raw meal shall be conveyed to blending silo. The capacity of the rawmill in the new line i.e Unit – III is 400 tph.
CONTINUOUS BLENDING SILO
LIL proposes to provide a blending silo of 15000 t capacity isequivalent to the requirement of 2.5 kiln days or approx. 1.0 daysactive storage. Along with the basic function of storage, the blendingof raw meal takes place for homogenization for minimizing thevariation in quality. The kiln feed, which shall be extracted from Siloand made to reach a point of preheating initiation by pre-heater ofBelt bucket elevator.
PRE HEATER, KILN, COOLER
For the proposed clinkerisation capacity of 4800 tpd, a rotary kiln inconjunction with a six stage single string pre heater – pre claciner andgrate cooler is envisaged. A Bag house will be installed for dedustingof raw mill/kiln system. Water spray in preheater downcomer ductwill be installed to reduce the temperature of gases during the directoperation.
Fine coal will be used in the Kiln for calcination. With the unique andtypical formation of different temperature zones in the Rotary Kiln, theraw meal undergoes various physicochemical reactions reaching astage of sintering. Burning zone promotes the sintering leading toformation of clinker ultimately. Clinker at temperature of 1200-1250C. passes through Grate Cooler provided with Fans. Quenching of airthrough Clinker bed in the Cooler results in cooling of Clinker till 100C. Deep Pan Conveyor to Clinker Storage Silo shall mechanicallyconvey it.
COAL MILL
The main fuel for the generation of heat and burning operation isCoal. Raw coal from yard shall be crushed to less than 30 mm size.It shall be conveyed through Belt Conveyors to raw coal hoppers andthen allowed the same for grinding in Coal Mill to a fineness of 15%residue on 90 Microns sieve and 2% residue on 212 Microns sieve.The fine Coal ground by Coal Mill shall be conveyed to fine coal bin.
The fine Coal shall be fired in to Kiln as well as Precalciner as per therequirement on the weighing basis on Poldos-SC and pneumaticallyconveyed to Kiln and Precalciner. LIL will install a coal mill of 36 tphcapacity under Unit – III. The total coal consumption in the Kiln isestimated to be about 1500 tpd.
COAL HANDLING
A new coal crusher of 120 tph capacity is proposed. A new linear coalpre blending stock pile of 4 X 2000 tonnes is considered with astacker and side reclaimer.
CEMENT MILL
Two Cement Mills each of 210 TPH will be installed for producing thecement.
CAPTIVE POWER PLANT:
The proposed Coal based power generation capacity of LIL is 90 MW.The coal required is received from South Eastern Coal fields. It is aircooled condensate plant and the water requirement for the same is
about 750 m3/day. 360 TPH Steam generator, with 90 MW Turbinewill be provided.
(VI) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY,LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS/S,MODE OF TRANSPORT OF RAW MATERIAL AND FINISHEDPRODUCT.
The principal raw materials are Limestone, iron ore, sandstoneand clay.
RAW MATERIAL REQUIREMENT – UNIT – III
Raw materialQuantity (MTPA)
Unit – III Source
Limestone2.4
Own LimestoneCaptive mines
Coal/Petcoke
CementPlant 0.24
SECL Coal Mines/Refineries
PowerPlant -90 MWcoalbasedpowerplant 0.40
Sand 0.10 Private PartyIron ore/ 0.02 Private Party
alternative raw material 0.04 Private PartyGypsum 0.10 Private Party
The major raw material, limestone will be met from ML-I, new Captivelimestone mine of LIL which is located in vicinity.
Part of the clinker produced in the plant will be utilized for cementproduction and balance clinker is transported by the railway wagonsfrom Sonadih to Mejia & Jojobera Cement Plants.
(VII) RESOURCES OPTIMIZATION/ RECYCLING AND REUSEENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEF OUTLINED.
LIL after expansion will produce clinker of 5.1 MTPA and 3.0 MTPAcement. Balance clinker will be sent to LIL Mejia & Jojobera Grindingunits.
The dust collected in Pollution Control Equipment is recycled intoprocess.The waste water generated from Power plant will be used in cementplant & the raw water requirement thus is reduced to that extent.
(VIII) AVAILABILITY OF WATER ITS SOURCES, ENERGY /POWERREQUIREMENT AND SOURCES SHOULD BE GIVEN,
Power: The present power requirement of 41 MVA is met from CSEBgrid. Additional Power requirement is 25 MVA for Unit – III and thetotal power requirement of complex ie 66 MVA is met from theproposed Coal based Thermal Power Plant. LIL has installed DG setsof 16 MW capacity as standby units for supply of power duringcontingency.
Water: Present water consumption is 3700 m3/day and is sourcedfrom Seonath River. Additional water requirement is about 1000m3/day for new unit of Cement Plant & 90 MW Power plant. Thisrequirement will be met from Seonadh River
(IX) QUANTITY OF WASTES TO GENERATED (LIQUID AND SOLID) ANDSCHEME FOR THEIR MANAGEMENT/DISPOSAL.)
No solid waste generation from the plant. Ash generated (0.160MTPA) from the power plant will be consumed in cement plant .
Waste water generated in power plant is reused in cement plant
Present domestic wastewater generation from the plant and colony is250 m3/day. Additional waste water generation is estimated to bemaximum of about 40 m3/day.
LIPL is operating a full-fledged sewage treatment plant (STP) designedfor a maximum load of 550 m3/day with the following units. STPcapacity is adequate for taking additional wastewater of 40 m3/day.
(X) SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY WHICHGIVE INFORMATION OF EIA PURPOSE.
Not applicable.
4 SITE ANALYSIS
(I) CONNECTIVITY
The nearest railway station is Bhatapara on the South EasternCentral Railway located at about 32 km from the plant site. Bhataparais well connected with Kolkata and Mumbai by the Broad Gaugerailway lines of the South Eastern Central Railway. The site is alsowell connected with Bilaspur by metal road and by railway line viaBhatapara Station. The nearest airport is Raipur located at a distanceof 110 km.
(II) LAND FORM, LAND USE AND LAND OWNERSHIP.
The proposed new units will be located within the existing cementplant complex of 91.886 Ha. No additional land or site is required.Keeping in view of utilizing some of the common existinginfrastructure, LIL proposes to locate the new units within the existingcement plant complex
(III) TOPOGRAPHY (ALONG WITH MAP)
It is a flat land and the average elevation is 246 m above MSL. Fig – 3shows the 10 km radius around the plant site
(IV) EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREAUNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OFTHE PROJECT TO PERIPHERY OF THE FORESTS, NATIONALPARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATERBODIES (DISTANCE FORM THE HFL OF THE RIVER), CRZ. INCASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THEGAZETTE NOTIFICATION SHOULD BE GIVEN)
The proposed new units will be located within the existing cementplant complex. The land breakup of the plant is given below
LAND BREAKUPArea (ha)
Cement Plant 7.3434Limestone stock pile 0.9660Coal storage area 2.8030Other raw material storage area 0.9401DG sets 0.5926Roads 2.1084Greenbelt 24.70Area for PPC silo 0.0517Clinker Storage 4.6983Vacant Space available for expansion( Unit-III is proposed here)
47.950
Total area of land 91.8867
There is no wild life sanctuary, national park, eco-sensitive areawithin the 10 km radius of the project site.
(V) EXISTING INFRASTRUCTURE.
Existing infrastructure include railway siding and well developedroads, storm water drains with adequate storage space for clinker andflyash and parking area
(VI) SOIL CLASSIFICATION
Predominantly clayey soil
(VII) CLIMATIC DATA FROM THE SECONDARY SOURCES.
In general the climate of this area is dry. Summer starts from mid ofFebruary and continues up to first week of June, when the monsoonbreaks. The monsoon continues till the end of October. Winter isbetween November and middle of February. The peak of summer is inMay. The maximum temperature is about 49oC. During the coldmonths of December the temperature falls to 8oC.
The average annual rainfall observed based on the 10 years IMD datais 1118.3 mm. More than 85% of the rainfall is received during themonsoon season. On an average there are about 65 rainy days in a
year. The maximum numbers of rainy days occur in the months ofJuly-August.
(VIII) SOCIAL INFRASTRUCTURE AVAILABLE.
All infrastructure facilities such as education, health facilities andother social facilities are adequate.
5. PLANNING BRIEF.
(I) PLANNING CONCEPT (TYPES OF INDUSTRIES, FACILITIES,TRANSPORTATION ETC) TOWN AND COUNTRYPLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION
The proposed new unit will be located within the existing cement plantcomplex No additional land or site is required. Keeping in view ofutilizing some of the common existing infrastructure, LIL proposes tolocate the new units within the existing cement plant complex. Thesite is well connected by Rail, road and air network.
(II) POPULATION PROJECTION.No increase in population is anticipated due to increase of production
(III) LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC)
Land use breakup is given in following table:
LAND BREAKUPArea (ha)
Cement Plant 7.3Limestone stock pile 1.0Coal storage area 2.8Other raw material storage area 0.9DG sets 0.6Roads 2.1Greenbelt 30.2Area for PPC silo 0.1Clinker Storage 4.7Vacant Space available for expansion( for Unit-III and power plant) 42.5
Total area of land 91.9
Fig – 4 shows the location of new units i.e., Unit – III and Power plant withinthe existing cement plant complex.
FIGURE – 4PLANT LAYOUT
(IV) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL &SOCIAL)
No additional infrastructure is required. The following equipment ofUnit – III and power plant will be installed
S.No. Equipments Capacity Nos.1. Raw mill 400 tph 12. Rotary Kiln in conjunction with preheater -
precalciner and grate cooler5000 tpd 1
3. Coal Mill 50 tph 14. Raw meal blending silo- continuous flow 15000 t 15. Clinker silo 70000 t 16. Limestone blending stockpile – expansion by: 2 x 30000 t 1
a. Reclaimer- new, Bridge type 400 tph 1b. Stacker-modified to slewing type or twin boom
type850 tph -
7. Gypsum storage- Covered hall 2500 t 18. Cement Mill 220 tph 29. Captive Power Plant 360 TPH boiler
90 MWTurbine
1
(V) AMENITIES/ FACILITIES.
All infrastructure facilities such as education, health facilities andother social facilities are adequate at nearest populated area
6 PROPOSED INFRASTRUCTURE
(I) INDUSTRIAL AREA (PROCESSING AREA)
LIL proposes to locate Unit – III and power plant within the existingcement plant complex.
(II) RESIDENTIAL AREA ( NON PROCESSING AREA)
Additional quarters of 25 (nos) will be provided
(III) GREEN BELT.
Green belt in an area of 30.2 ha has been developed inside the plantboundary
(IV) SOCIAL INFRASTRUCTURE.
LIL has well-defined CSR policy to Carryout social development andwelfare measures in the surrounding villages. Under CSR activity LILhas initiated community development projects, in the fields of health,education and environmental preservation, in and around the plant.
(V) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/ WATER WAYS ETC)
Adequate facilities with railway siding and roads are existing. Noadditional connectivity is required
(VI) DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OFWATER)
Additional water of 1000 m3/day will be required and the same will bemet from River Seonath
(VII) SEWERAGE SYSTEM.
Present domestic wastewater generation from the plant and colony is250 m3/day. Additional waste water generation is estimated to bemaximum of about 40 m3/day.
LIPL is operating a full-fledged sewage treatment plant (STP) designedfor a maximum load of 550 m3/day with the following units. STPcapacity is adequate for taking additional wastewater of 40 m3/day.
(VIII) INDUSTRIAL WASTE MANAGEMENT.
No industrial wastewater generation from the cement process.Wastewater generated from the power plant will be treated and usedin the cement plant
(IX) SOLID WASTE MANAGEMENT
Dust collected from air pollution control equipment is 100% recycledin process and there is no solid waste in cement plant.
Ash generated (0.160 MTPA) in power plant will be consumed incement plant.
(X) POWER REQUIREMENT & SUPPLY / SOURCE.
The total power demand will be met from Captive power plant.
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN.
(I) POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OFTHE PROJECT AFFECTED PERSONS INCLUDING HOMEOUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEFOUTLINE TO BE GIVEN).
Not applicable, since the plant is already existing and new unit will belocated within the existing cement plant complex.
8. PROJECT SCHEDULE & COST ESTIMATES
(I) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATEOF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BEGIVEN)
Construction activity will involve installation of new processequipment listed above
(II) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMSOF ECONOMIC VIABILITY OF THE PROJECT
Total capital Investment Cost is Rs. 1645 Crores and Rs. 90 crores willbe spent for Environmental Management Plan.
The estimated investment Cost for the project has been based on therequirement of fixed and non-fixed assets for cement plant.
The financing of the project has been considered on the basis ofEquity and Term Loans from Financial Institutions. The debt: equityratio has been considered as 1: 0.2.
Interest on Term Loan has been considered at 12%. Since most of theinfrastructure is existing, it is has been assumed to be repaid over 6years after a moratorium of 3 years.
The project exhibits a good internal Rate of Return on total investmentof 17.2%. The IRR on equity is calculated as 23.8%.
Various sensitivity analyses indicate reasonable project and cashbreak-even percentages. In view of the acceptable level of returns, theproject is financially feasible.
9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
(I) FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ONTHE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBALPOPULATION, IF ANY IN THE AREA
The capital cost, for the proposed production enhancement project,works out to Rs. 1645 Crores.
Based on the growing demand for Cement over the next 10 years, theproximity of the project location to these markets is an advantage withrespect to reduction in freight of cement to these markets. Thefinancial viability also show a good Rate of return from the project.Considering the above LIL is planning to go ahead with the project,once it gets all the statutory approvals for this enhancement project.
