pre-feasibility report 1.0 executive summary

Amendment in Environmental Clearance with respect to increase in Waste Heat Power Generation Capacity

from 20 MW to 30 MW near Village Benkanhalli, Taluka Sedam, District Gulbarga, Karnataka. Pre-Feasibility

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Shree Cement Ltd., Unit: Karnataka Cement Project

Pre-Feasibility Report

1.0 EXECUTIVE SUMMARY

Environment Clearance for installation of Integrated Cement Project capacity

Clinker - 2.4 MTPA, Cement - 4.0 MTPA, Captive Power Plant - 44 MW & Captive

Limestone Mine - 3.8 MTPA, 551.36 ha near Villages Kodla & Benkanhalli, Taluka

Sedam, District Gulbarga, Karnataka by M/s. Shree Cement Ltd., Unit: Karnataka

Cement Project was granted vide letter no. J-11011/458/2008-IA-II (I) dated 19th

Sept. 2012.

Due to development of energy efficient technologies for recovery of waste heat for

power generation without use of fuel, company is proposing amendment in

Environmental Clearance under the Provision of Section 7(ii) of EIA Notification

2006 with respect to increase in Waste Heat Power Generation Capacity from 20

MW to 30 MW without changing the Clinker Capacity of 2.4 Million TPA, Cement mill

VRM Capacity of 4.0 Million TPA, Captive Power Plant 2x22 MW and Residential

Colony of 400 near village Benkanhalli, Taluka Sedam, District Gulbarga, Karnataka.

EXISTING AND PROPOSED CAPACITIES:-

Unit Existing EC Granted Capacity

Additional Capacity

Total Capacity

Clinker (Million TPA)

2.4 Nil 2.4

Cement (Million TPA)

4.0 Nil 4.0

CPP (MW) 44 (2x 22 MW) Nil 44 (2x 22 MW)

GPP(MW) 20 10 20

Residential Colony Nos. of

Household: 400

Nil Nos. of Household:

400

SALIENT FEATURES OF THE PROJECT

S.N. Particulars Details

1 Locations of the plant

A. Village Benkanhalli

B. Taluka Sedam

C. District Gulbarga



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D. State Karnataka

E. Land Survey Nos. Plant (173.32 Ha.)

Khasra Nos.: 249, 278, 279, 280, 281, 291,

292, 293, 294, 290, 289, 295, 296, 301,

302, 303, 305, 300, 304, 299, 297, 298,

288, 335, 334, 333, 332, 338, 339, 340,

341, 360, 359, 358, 357, 356.

Topo-sheet No. 56 G/4, 56 G/8, 56 H/5 & 56 H/1

2

Plant Site: Latitude 17° 02’ 16.43”N to 17° 03’ 25.91” N

Longitude 77° 12’ 46.07” E to 77° 13’ 55.73” E

3 Temperature Min: 07 ° C, Max : to 47° C

4 Mean Annual Rainfall 700 – 800 mm

5 Nearest National Highway SH-15 (2.5 km in East direction)

SH-126 (6.0 km in SW direction)

NH-218 approx 46 km from the project

site

6 Nearest Railway Station Malkhaid (15 km from the project site)

7 Nearest Airport Hyderabad (160 km from the project site)

8 Nearest city /Town Sedam (15 km in NNE direction)

9 Reserved / Protected Forest

within 10km radius (Boundary

to boundary distance)

Yadagir Reserve Forest(9.1 km in SW from

the project site)

10 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)

Kagina River at about 25 km from the

project site.

11 Water requirement & Source Water requirement for plant, Mine &

colony is as under:

Existing

Proposed Total Water

Required

2000 Nil 2000

Source: Ground Water

12 Soil Type Black cotton

13 Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]

14 Capital cost Rs 79.73 Crores

15 EMP Capital and recurring cost No additional cost for EMP will be

required for the proposed expansion of

WHRS.



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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

Company Profile

Shree Cement Limited (SCL) is energy conscious and environment friendly

business organization, started its journey in the year 1979, and today it is among

India's leading cement manufacturing companies. Having witnessed an exponential

growth since last three decades, our endeavor continues to expand our capacity in

the cement and power sector.

Cement Manufacturing Facilities

Presently, our cement production capacity stands at 29.3 Million tonnes. The

Company’s Cement and Clinker manufacturing facilities are located at Beawar & Ras in

Rajasthan and Raipur in Chhattisgarh. It has split grinding units at seven locations viz.

Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in Uttarakhand, Aurangabad in

Bihar, Bulandshahr in Uttar Pradesh and Panipat in Haryana.

Power Generation Facilities

Total Thermal Power Plants Capacity of the Company is 607 MW (including 102 MW

Waste Heat Recovery Green Power Capacity which is the largest capacity of Green

Power in the entire world cement industry excluding China). Power generated from

captive power plants is primarily utilized in its own cement plants and excess is sold

to the Govt., Discoms, etc.

Products

The Company pursues with multi-brand portfolio strategy consisting of three brands

viz; Shree Jang Rodhak Cement, Bangur Cement and Rockstrong Cement. The Company

currently enjoys the highest market share in Rajasthan, Delhi and Haryana and

possesses distinguished top position in states of Punjab, West Uttar Pradesh and

Uttarakhand.

Corporate Sustainability

At SCL, sustainability is an integral part of business and forms the core of future

growth strategy. We have always envisioned a growth which is inclusive and aimed

towards total prosperity of all the stakeholders. We have inculcated sustainability as a



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business culture and all our efforts attempt to focus upon fostering innovation,

ensuring prosperity, creating happiness and building trust in people.

Sustainability has led us towards the enrichment of corporate values through

innovation and sound business practices. This approach has helped us to proactively

address challenges to our growth. Integration of sustainability in our day to day

business activities has helped us in identifying, analyzing, implementing control

measures and mitigating the multiple risks that SCL faces. Sustainable business

practices have endorsed optimal utilization of resources which enhances stakeholders’

value.

Responsible towards the community

We believe that a company's prosperity is linked with its neighboring communities.

We better the lives of the communities that surround our operations either on our

own or in partnership with government bodies and the community at large.

Empowerment of communities and upliftment of their lifestyle and social strata is in

central element of our approach that is deeply engrained into our business. The vision

is to become a catalyst to positive change in the society.

Our approach towards development of the local community has been focused on the

below priority areas:

Healthcare

Education

Infrastructure development

Livelihood generation

Women empowerment

Recognitions

First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.

First Cement Company of the World to fetch Certified Emission Reductions (CER’s)

on its Clean Development Mechanism project “Optimal Utilization of Clinker”.

First Indian cement company to issue Corporate Sustainability Report following

the highest level “A+” for reporting triple bottom line performance

New World Sustainability Champions by the World Economic Forum (WEF)



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Ranked 2nd Best Company in the World on Carbon-Related Metrics by Carbon

Disclosure Project during 2015-16

World’s First Cement Company to achieve Whitehopleman 5-Star Ranking, UK.

Government of India recognized in-house R&D center

Awards

2017-18 Best Performer in terms of energy saving under Perform, Achieve and

Trade Scheme by Bureau of Energy Efficiency for Beawar and Ras units

2017-18 First prize in Cement Sector in “Rajasthan Energy Conservation Award

2017” instituted by Rajasthan Renewable Energy Corporation Limited

2017-18 Best improvement in thermal energy performance (Ras, Rajasthan) 2015-

16

2017-18 NCCBM Award for Best Quality Excellence for the year 2016-17

2017-18 NCCBM Award for Best Quality Excellence for the year 2015-16

2017-18 Best Employer 2016 Award by the Employers Association of Rajasthan

2017-18 Supply Chain and Logistic Excellence (SCALE) Award 2017 by CII

2017-18 Forbes India Magazine Entrepreneur of the year award to Syt. H.M.

Bangur, MD

2017-18 Second Rank for Excellence in Community Impact by Society of Human

Resource Management

2017-18 Third Rank Employer with Best Health & Wellness Initiatives by Society of

Human Resource Management

2017-18 Global Sustainability Awards in Platinum Category by Energy &

Environment Foundation, New Delhi.

2017-18 National award for Cost Management 2016 by Institute of Cost

Accountants of India

2017-18 India’s top 5 companies to work for in the Manufacturing and Production

sector and ranked 65th among India’s top 100 companies to work for by Great

Place to Work.

2017-18 State Level Bhamashaha Samman for Corporate Social Responsibility

2017 by Government of Rajasthan.

2016-17 CSR Excellence Award 2017 by Department of Industries, Government of

Rajasthan.

2016-17 EY Entrepreneur of the year award to Syt. H.M. Bangur, MD



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2016-17 Golden Peacock HR Excellence Award for 2016 by Institute of Directors.

2016-17 Environment Excellence Award 2016 under the category "Excellence in

Implementation of New Environmental Norms-Existing TPPs" instituted by

"Mission Energy foundation"

2016-17 Supply Chain and Logistic Excellence (SCALE) Award 2016 by CII

2016-17 Certificate for Asia Sustainability Reporting Awards 2016 by CSR Works

Singapore

2016-17 Sustainability Disclosure Leadership Award 2016 by World CSR Congress

2016-17 Best Employer 2015 Award by the Employees Association of Rajasthan

2016-17 Excellence in Community Impact by Society of Human Resource

Management, India

2016-17 Overall Excellence in Procurement and Outstanding Procurement Team

by CPO forum India by Institute for Supply Management and Conference Asia

2016-17 Golden Peacock Environment Management Award by Institute of

Directors.

2016-17 State Level Bhamashaha Samman for Corporate Social Responsibility

2016 by Government of Rajasthan

2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable

Energy & GHG Emission Reduction by CII

2016-17 National award for Cost Management by Institute of Cost Accountants of

India.

(ii) Brief description of nature of the project

M/s. Shree Cement Ltd., Unit: Karnataka Cement Project is proposing amendment in


2006 with respect to increase in Waste Heat Power Generation Capacity from 20

MW to 30 MW without changing the Clinker Capacity of 2.4 Million TPA, Cement

Capacity of 4.0 Million TPA, Captive Power Plant 2x22 MW and Residential Colony of

400 near village Benkanhalli, Taluka Sedam, District Gulbarga, Karnataka.

As per EIA Notification dated 14th Sep, 2006, as amended on 1st December 2009,

the project falls under Category “A”.



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

With respect to the importance of the project to the nation, it can be well said that

expansion of waste heat recovery power plant will result in to conservation of fuel

i.e. coal and also a ecofriendly technology.

To meet the demand of power in existing cement plant, we are proposing

expansion of Waste Heat recovery System with latest energy efficient technologies.

(iv) Demand – Supply Gap

Total power requirement of existing and already proposed cement plant along with

limestone mine & residential colony will be met from proposed expansion of waste

heat recovery power plant.

(vi) Export Possibility

Not feasible.

(vii) Domestic market

Waste heat recovery power will be for captive use in existing integrated cement

plant, limestone mine and residential colony.

(vii) Employment Generation (Direct and Indirect) due to the project sourcing

No additional manpower will be required for the proposed expansion. Existing

manpower is as given below:

Unit Manpower

General Shifts Total

(A) (B) (A + B)

Implementation phase - - 137

Operation phase 188 310 498

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any

Interlinked project is captive limestone mines near village Kodla & Benkanhalli,

Taluka Sedam, District Gulbarga, Karnataka. EC has already granted as integrated

project.



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(ii) Location (map showing general location, specific location, and project

boundary & project site layout) with coordinates:



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Key Plan



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Plant Layout



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(iii) Details of alternative site consideration and basis of selecting the

proposed site particularly the environmental considerations gone sound be

highlighted.

No alternate site has been considered for the proposed project.

Following are the main criteria, considered largely as near-ideal conditions, for

locating a cement plant of desired capacity:

Availability of suitable limestone for the manufacture of cement. Availability of land Availability of Transport & Communication. Proximity to the market.

(iv) Size or magnitude of operation

M/s. Shree Cement Ltd., Unit: Karnataka Cement Project is proposing amendment in


2006 with respect to increase in Waste Heat Power Generation Capacity from 20 MW

to 30 MW without changing the Clinker Capacity of 2.4 Million TPA, Cement Capacity

of 4.0 Million TPA, Captive Power Plant 2x22 MW and Residential Colony of 400 near

village Benkanhalli, Taluka Sedam, District Gulbarga, Karnataka.

The process includes basic raw material requirement, sizing of equipment, utilities

and services, infrastructure facilities and sources of waste generation, their quantity,

treatment and safe disposal of the waste.

(V)-1 Project description with process details

Required measures to increase the waste heat power generation are as follows:

Sr No.

Descriptions Present Conditions

New Improved Conditions

Recurring Benefits

(MW)

1 Higher temp and DP of Hot gases are maintained in the Kiln by changing the cooler plate of KILN. This is helping in getting higher steam flow which in turn improves

AQC Boiler FG Temp is around 550°C and Dp is around 100mmwc.

AQC Boiler FG Temp is around 625°C and Dp is around 125 mmwc hence power generation improved by 7.5 Kwh/Mt of

2.36



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Power generation clinker

2 Reuse of Hot gases back in the cooler. So additional waste heat is available for power generation.

Heat Available for AQC boiler inlet without HAR is around 141Kcal/Kg clinker

Heat Available for AQC boiler inlet with HAR is around 157 Kcal/Kg clinker

3.00

4 Special technology will be used for reduction in False air the boiler

We are using asbestos/kevelor cloth with sodiun silicate as sealent

New Air seal technology will be used for better sealing

0.50

5 New turbine will be effcient turbine only . Heat rate better than 3200 kcal/kwh

Existing Turbine heat rate is 3450 kcal / Kwh

New Turbine Heat Rate is 3200 Kcal/Kwh

1.24

6 Better insulation of the kiln and boiler area so radiation losses will be reduced

LRB (thickness as per calculation for ambient+15°C)

1. Thickness will be increased for Ambient+10°C. 2. Ceremic fiber blanket will be used

1.62

7 Additional superheater in AQC boiler to increase steam temperature as well as will capture more waste heat

Steam temp is below 440°C

Steam Temp will be 480°C

1.30

Total 10.0

Process Description of Existing and Already Proposed Cement Plant:

Crushing of limestone at the mine site. Preblending of crushed limestone. Drying – cum-grinding of raw materials. Homogenization of raw meal in a blending silo. Clinkerization of the raw meal in a rotary kiln with preheater and

precalcinator. Clinker Grinding, storage and packing



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Operations of dry process plant are detailed as follows:

Crushing of Limestone

The ROM Limestone is fed to crusher Wobler, where +90 mm part is fed into crusher,

and is crushed to -90 mm size. The -90 mm size from crusher Wobler is fed to

Secondary screen where (-6mm/-10mm/ -25mm) part is rejected, while + size

material is added to Crushed -90 mm Limestone.

Blending of raw meal and Storage of kiln feed The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical

conveyors. The variation in the quality of raw meal is reduced by using continuous

blending silo.

Preheater, Precalcinator, Kiln

In a cyclone preheater system, an efficient heat transfer takes place, when finely

dispersed raw material particles when they come in contact with hot gases from kiln.

The preheater is multi stage cyclone system connected with gas ducts and meal

chutes. The raw meal is fed into top stage gas duct and is carried by hot gas steam

into cyclone. The material gets separated from gas in cyclones and then travels

downwards and through meal chute is discharged into next lower stage gas duct. In

this way, material comes into contact with high temperature gases and gets

preheated and partially calcined and then enters the precalcinator.



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In the precalcinator, further calcination takes place by firing pulverised coal and then

material is discharged to the kiln. The feed travels down as the kiln rotates. The

chemical reaction completes when the material reaches the burning zone and cement

clinker is formed.

Cooling of Clinker

The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a

high efficiency grate cooler. The cooled clinker is then transported to clinker storage

silo by a set of Deep Bucket Conveyor (DBC).

Coal and pet coke crushing and Grinding

Coal is highly abrasive, therefore, its crushing is done usually in a roll crusher. The

same system is proposed to be used.

Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because

of saving in energy and better drying capacity VRM is proposed for use.

Cement Grinding (VRM and Ball Mill)

For OPC production, clinker with gypsum will be ground in mill. In PPC production,

clinker with gypsum and fly ash will be ground in mill. In PSC production, clinker

with gypsum and slag will be ground in mill. For grinding the above products, hot air

is required, for which the Hot Air Generator will be installed along with coal and

Petcoke mill.

Cement Storage and Packing

The ground cement is conveyed to cement silos for storage of different types of

cement from where it is extracted and packed in HDPE bags by electronic rotary

packing machines and dispatched to consumers by road and railway. Mechanized

loading system for loading of packed bags on trucks and wagon is envisaged.

Wagon Tippler and Railway siding

Coal and pet coke will be received by road and railway. For unloading / handling of

coal and pet coke fully mechanized system of wagon tippler and truck tippler will be

installed at the site. Also cement and clinker will be dispatched by road and railway.



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(V)-2 Process Description of Waste Heat Recovery Power Plant

Waste heat is available from the expelled gases of Pre-Heaters (PH) and Air Quenched Coolers

(AQC) of clinker unit. The main energy used in cement plant consists of heat energy and

electrical energy and about 90% of the total energy is used as heat energy in clinker burning

process. In the clinker burning process, a large amount of heat is consumed for burning

limestone at more than 1450oC to form clinker. From the total heat consumed in the burning

process, around 55% is for burning process and the rest 45% is discharged as sensible heat

through the exhaust gases of Pre-Heater(PH), AQC, radiation and sensible heat carried out by

clinker.

However, around 10% of the heat, extracted from the PHs and AQCs, is used in drying the raw

material and coal while grinding. The rest 35% is generally emitted to the atmosphere as

waste heat. For reutilization of this wasted heat from the exhaust gases of the PH and AQC,

Waste Heat Recovery System is used to generate the electrical power.

Considering the above one Waste Heat Recovery Boiler (WHRB) installed at kiln Pre-heater

and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in each Units. Steam

generated by each boiler is fed to steam turbine for Electricity generation. In normal condition

the flue gas from the top of the Pre-heater directly goes to bag house. Now the flue gas from

the top of the Pre-heater goes to the WHRB and after that it enters the Bag house. A typical

heat flow in cement plants with waste heat recovery system is shown below:

Gas flow without WHRS:



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Gas flow with WHRS:

Design Basis for WHRB

S.N. Description Unit Existing Proposed

AQC PH AQC PH

Clinker Capacity

MTPA 2.4

1 Flue gas flow Nm³/Hr 300000 350000 450000 350000

2 Inlet temperature

ºC 600 275 625 275

3 Specific heat kcal/Nm³c 0.32 0.362 0.32 0.362

4 Exhaust Gas temperature

ºC 80 125 80 125



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5 Heat Available

Crore Kcal/Hr

4.99 1.90 7.85 1.90

6 Total Heat Available

Crore Kcal/Hr

6.89 9.75

7 Max. Heat (Low Grade Energy) available

MW 80.15 113.35

8 Generation MW 20.0 30.0

V.3 Process Description of Power Generation Process (Air Cooled) – (2x22 MW)

In Proposed Captive thermal Power Plant, power will be generated by the utilization

of thermal energy of steam in turbine that in turn rotates an alternator. The steam

will be generated in the boiler by combustion of various fuels. In [roposed Power

Plant, Pet coke/Coal will be used as the fuel & will be combusted in the boiler to

generate steam. The generated steam will be utilized to rotate the Steam Turbine,

which in turn will rotate an alternator.

Coal/Petcoke will be transported by truck at power plant site and then the trucks

will be unloaded by truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will

be fed to the coal crusher to be crushed into required size through the vibro feeder

that regulates the flow. The crushed coal/petcoke will be fed into the boiler bunkers

through the conveyor belt.

After receiving coal/petcoke in the boiler bunkers, the coal/petcoke will be fed to the

boiler furnace through the rotary/drag chain feeders in controlled quantities. The

coal/petcoke will be combusted in the furnace & the resulted heat will be utilized to

heat water & convert it into steam. The flue gases that will be generated on the

burning of fuel will be passed over the tubes of economizer & air pre-heater, to

utilize the heat carried by the flue gases going outside, otherwise heat will go waste.

Now, the flue will gases pass through the ESP (Electro Static Precipitator) to

chimney. In case of higher Sulphur contents, FGD will be used.

Water will be received by PTP (Pre-treatment Plant) from the existing resources.

Here, water will be treated to get the desired quality and then it will be treated with

lime & Dolomite in the High Rate Solid Contact Clarifier. Then clarified water will be



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fed to the RO plant where its properties will fine tuned to the desired quality for DM

system. In DM plant the desired properties of water will be obtained and this DM

water will be fed into the boiler for steam formation. The cooling tower will be fed

with the RO water for its replenishment. The generated steam in boiler at desired

parameters will be fed to the turbine through the control valve. In turbine the

thermal energy of steam will be utilized to rotate it. The turbine in turn will rotate

an alternator (electric generator). The generated electricity is evacuated from the

alternator through the bus bar arrangement.

V.6 COLONY DETAILS

A residential colony is under installation which common for cement plant and mine.

radius buffer zone which includes suitable accommodation for about 400 personnel,

dispensary, shopping complex, guest house, school, etc.

Equipment Details- Cement Plant

Equipment Selection

A list of equipment and storages capacities are given below. In selecting a particular

type of equipment or storage for the project, among others, the following issues have

been considered:

Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues



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MAJOR EQUIPMENT AND STORAGE CAPACITIES

Equipment/Storage Unit Capacity

Limestone Crusher tph 1300

Stacker t ph 1700

Raw Mill (VRM) tph 700

Raw meal storage t 1 x 20,000

Rotary Kiln tpd 7,500

Clinker Storage t 1 x 50,500

Coal Stockpile t 23,000

Coal Mill (VRM) tph 100

Gypsum Storage t 9,200

Fly ash Storage t 65,000

Cement Grinding(VRM) tph 700

Cement Silos t 6 x 11,000

Packer tph 4 x 240

2 x 22 MW Captive power plant

Unit-1 Unit-2

A BOILER

1 Type AFBC/CFBC AFBC/CFBC

2 Pressure kg/cm2. A 89 89

3 Temperature deg C 535 535

4 Flow (*) ( Kg/hr ) 100000 100000

5 Fuel (Coal/Pet coke) Type Petcoke Petcoke

6 Fuel quantity at MCR TPD 233 233

B TURBINE & GENERATOR

1 Generator power Kw 22000 22000

2 Generator voltage Kv 11 11

3 Steam Pressure kg/cm2. A 88 88

4 Steam Temperature deg C 530 530

5 Steam Flow (*) ( Kg/hr ) 90000 90000

C AIR COOLED CONDENSER

1 Steam Pressure kg/cm2. A 0.15 0.15



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2 Steam Temperature deg C 54 54

3 Steam Flow (*) ( Kg/hr ) 70000 70000

D FUEL HANDLING SYSTEM

1 Storage Shed Capacity Tons 10000

2 Capacity TPH 100

3 Truck tippler capcity Tons 100

E LIME HANDLING SYSTEM

1 Capacity TPH 30

F ASH HANDLING SYSTEM

1 Type Dense Phase

system

2 Fly Ash Capacity TPH 10 10

3 Bed Ash Capacity TPH 5 5

4 Fly Silo capacity M3 250

5 Bed Ash silo Capacity M3 90

6 ESP Field Nos 3 3

7 Chimney Height Mtr 96

G WATER TREATMENT PLANT

1 Raw water cum fire water

tank m3 3500

2 RO water stream Nos 2

3 RO water capacity m3/hr 13.07

4 DM water Capacity m3/hr 10.4

H COMPRESSED AIR PLANT

1 Type Screw Compressor

2 Quantity of compressor Nos 5

3 Capacity of each compressor CFM 830

4 FIRE FIGHTING PLANT

5 Type As per TAC guidelines

6 Firefighting water tank

capacity m3 3500

7 FF pumps Nos 3



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(vi) Raw material required along wit9+h estimated quantity, likely source,

marketing area of final products, mode of transport of row material and

finished product.

Raw material requirement for Clinkerization

S.

No.

Raw

Material

Source

(Distance)

Mode of

Transportation

Basis Quantity (Million TPA)

Existing Proposed Total

1. Lime

Stone

Captive mines

adjacent to

plant site in

dist. Gulbarga

(1-3 Km)

By road up to

crusher

1.6

T/ T of

clinker

3.8 Nil 3.8

2. Iron Ore Bellary,

Kamatgi,

Bagalkot (300

Km)

Road 0.015 T/ T of

clinker

0.036 Nil 0.036

3. Bauxite Belgaum,

Kolapur, Goa,

(450 Km)

Road 0.044T/ T of

clinker

0.105 Nil 0.105

4. Coal/Pet

coke

Singarini Coal

deposits (300

Km) or

Imported South

Africa/

Indonesia Coal

Road / Rail 0.1616 T/ T

of clinker

0.387 Nil 0.387

Jamnagar pet

coke (1400

Km) /Pet coke

Road / Rail 0.10 T pet

coke / T of

clinker

0.24 Nil 0.24

5. Gypsum RCF, Mumbai

(550 Km) or

Nagaur (Raj.),

Salem &

Coimbator,

Tamilnadu

Road 0.05 T / T of

cement

0.2 Nil 0.2

6. Fly Ash Raichur

Thermal Power

Station

(150 Km)

Road 0.35 T/T of

cement

1.4 Nil 1.4



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COAL /PET COKE & LIME REQUIREMENT FOR 2*22 MW

Unit Pet Coke

(TPD)

Indian Coal

(TPD)

SA Coal

(TPD)

Lime

Requirement

(TPD)

22 MW 1st Boiler

(AFBC / CFBC Boiler)

233 373 287 73

22 MW 2nd Boiler

(AFBC / CFBC Boiler)

233 373 287 73

Total Existing 466 747 574 146

Proposed Nil Nil Nil Nil

Total 466 747 574 146

(vii) Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

Fly ash generated from CPP and other nearby thermal power plants will be

utilized in cement manufacturing.

There would be no solid waste generation from the cement plant. However,

material collected by the dust collectors (Bag Filters) will automatically be

recycled in the process.

There will be no discharge outside the project premises.

(viii) Availability of water its source, energy /power requirement and source should

be given.

Water Consumption Details (KLD)

S. No. Unit Peak

Demand

(m3/day)

Waste water

generation

(m3/day)

Remarks

1. Cement Plant 1000 Nil No waste water is expected to be

generated from Cement Plant as dry

process will be used for cement

manufacturing.

2. Captive Power

Plant

400 100 Effluent water will be used in Ash

Quenching after proper treatment.

3. Drinking, Utility

& Plantation

450 300 Domestic waster water will be

treated in STP and will be recycled

for Green Belt development and

cement plant process within the

plant premises.



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A. Total (A) 1850 400

4. Water balance for Limestone Mining

5. Dust

suppression

105 - The domestic waste water will be

disposed off in soak pit via septic

tank.

Workshop discharge will be passed

through oil/grease water separator

tank for separation of oil contents

and also soil contents. The clear

water will be used in crusher for

dust suppression.

6. Drinking &

Utility

15 10

7. Green Belt 20 -

8. work shop 10 10

B. Total (B) 150 20

9. Grand Total

(A+B)

2000 420

Power Demand

The total power requirement for the integrated unit has been estimated to be around

35 MW. During Implementation Phase power will be procured from KSEB, while SCL

also proposes to set up its own Captive Power Plant (CPP) with a capacity of 44 MW

(2 x 22 MW) which will be the source for power during Operation Phase.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

There would be no waste water discharge outside the plant.

No industrial waste would be generated in operation phase.

Used oil will be generated from plant machinery/Gear boxes and DG set which will

be sold out to the CPCB authorized recycler.

4.0 Site Analysis

(i) Connectivity

Nearest National Highway is NH-218 which is 46 kms from site. It thus, has

excellent road connectivity.

Approximate road distance from major town i.e. Sedam is 17 km

The nearest railway station is the Malkhaid, approximately 15 kms from the site.

The nearest airport is at Hyderabad (160 kms)

The site is well connected with communication facilities like telephone, fax,

wireless & telex and as such, no constraints are envisaged in this aspect as the

Tehsil and District headquarters are approachable from the site.



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(ii) Land from Land use and land ownership

The land requirement is estimated at about 173.32 ha for the plant & colony and out

of which plantation will be done on 57.2 ha (33% of total land). Adequate land is

available at the proposed site. It is relatively plain and not much of development

work is needed. Almost entire land is covered by sand.

(iii) Topography

The terrain in the area proposed for plant location is generally flat. As such, only a

nominal lumpsum provision for site grading and leveling has been considered in the

cost estimate.

(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.

Environmental Settings of the Area

S.No. Particulars Details

1 Temperature Min: 07 ° C, Max : to 47° C

2 Relative Humidity

08:30 hrs. - 28% - 49 %

17:30 hrs. - 20 % - 29 %

3 Mean Annual Rainfall 700 – 800 mm

4 Nearest National Highway NH-218 approx 46 km from the project

site

5 Nearest Railway Station Malkhaid (15 km from the project site)

6 Nearest Airport Hyderabad (160 km from the project

site)

7 Nearest city /Town Sedam town at about 17 km from the

project site

8 Reserved / Protected Forest

within 10km radius

(Boundary to boundary

distance)

Yadagir Reserve Forest(9.1 km in SW

from the project site)

9 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)

Kagina River at about 25 km from the project site.



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10 Nearest Hill Ranges --

11 Water requirement & Source Water requirement for plant & colony is

as under:

Existing

Proposed Total Water

Required

2000 Nil 2000

Source: Ground Water

12 Soil Type Black

13 Nearest Town / City Zone – II [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Boundary wall, Plant and office building are under construction.

(vi) Soil Classification

The district has mainly the Black soil.

(vii) Climatic data from secondary sources

The area has generally moderate climate. The temperature variation is from 7oC to

47oC at the average annual rainfall in the area is about 700-800 mm. The relative

Humidity remain in the range of 20% - 49 %.

5. Planning Brief

(i) Planning Concept (Type of industries, facilities, transportation etc.) Town and

Country Planning/Development Authority classification.

Proposed plant expansion falls under Red Category. Transportation of raw material

and final product will be done via existing road and rail network ,however concrete

road will be developed within the proposed project area.

(ii) Population Projection

Temporary influx of people will be there, as the managerial and supervisory staff will

be hired from distant locations. A projection may be made by a governmental

organization, or by those unaffiliated with a government.

(iii) Land use planning


of which plantation will be done on 57.2 ha (33% of total land).



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(iv) Assessment of infrastructure demand (Physical & Social)

SCL will assess the demand of infrastructure (Physical & Social) in nearby area of the

proposed site and will be developed in under corporate social responsibilities

programs.

(v) Amenities/Facilities

SCL will develop the Amenities/Facilities in nearby area of the proposed project site

as per requirement of local people of the nearby area under Corporate Social

Responsibilities programs.

6) Proposed Infrastructure

(i) Industrial Area (Processing area)


of which plantation will be done on 57.2 ha (33% of total land).

(ii) Residential Area (Non processing area)

A residential colony is under installation which common for cement plant and mine.

radius buffer zone which includes suitable accommodation for about 400 personnel,

dispensary, shopping complex, guest house, school, etc.

(iii) Green Belt

Greenbelt will be developed in 57.2 ha i.e 33% of the total area of the proposed

project.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct

and indirect employment opportunities in the region including ancillary development

and supporting infrastructure.

The expansion of proposed plant will lead to the development of certain local

ancillary facilities and consequent employment opportunities. Further, it will also

lead to the development of market, trade centers, activities etc. In addition to the

above, SCL has a track record of engaging the local communities and extending

several social services to the nearby villages.



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(v) Connectivity

Nearest National Highway is NH-218 which is 46 kms from site. It thus has

excellent road connectivity.

Approximate road distance from major town i.e. Sedam is 17 km

The nearest railway station is the Malkhaid, approximately 15 kms from the site.

The nearest airport is at Hyderabad (160 kms)

The site is well connected with communication facilities like telephone, fax,

wireless and telex and as such, no constraints are envisaged in this aspect as the

Tehsil and District headquarters are near to the site.

(vi) Drinking Water

This is proposed to be sourced from groundwater which will be treated in RO unit.

(vii) Sewerage system

The domestic effluent generated will be treated in Sewage Treatment Plant (300

KLD).

Process flow diagram of STP plant



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Quality of STP Treated water

Parameters Quality of Raw Sewage

Quality of Treated Sewage

pH 6.0 to 8.0 6.5 to 7.8

BOD 300 ppm 10 ppm

COD 400 ppm 50 ppm

TSS 300 ppm 10 ppm

O & G 50 ppm 10 ppm

Process description of STP plant

Bar screen chamber followed by collection-cum-equalization tank followed by

Fluidized Aerobic Bed Reactors (FAB) (2 Nos.) will be provided with coarse air

bubble diffusion system followed by Tube Settler Tank in the STP. The clear

supernatant after disinfecting by chlorination will be passed through dual filter and

activated Carbon filter before will be collected in the treated water tank. The sludge

generated from the FAB will be passed through sludge digester and dried and the

filtrate will be collected and sent back to the equalization tank and the dried cakes

will be used as manure. The treated water will be used for plantation activities.

(viii) Industrial Waste management

No industrial wastewater will be generated from cement plant. However, wastewater

generated from RO unit shall be reused for dust suppression and plantation.

(ix) Solid waste management

There will be no solid waste generation from the cement plant. However,

material collected by the dust collectors (Bag Filters) will automatically be

recycled in the process.

Fly ash generated from CPP will be utilized in cement manufacturing.

(x) Power requirement and source

The total power requirement for the integrated unit has been estimated to be around

35 MW. During Implementation Phase power will be procured from KSEB, while SCL

also proposes to set up its own Captive Power Plant (CPP) with a capacity of 44 MW

(2 x 22 MW) which will be the source for power during Operation Phase.

7.0 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 laborer (brief outline to be

given)



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Not Applicable

8.0 Project Schedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion (time schedule

for the project to be given)

18 months from the date of start of work.

(ii) Estimated project cost along with analysis in terms of economic viability of the

project

The total investment for the proposed project works out to approximately Rs 79.73 Crores.

The estimated Investment Cost for the project is based on the requirement of fixed and non-

fixed assets.

The details of total investment are shown in the table below.

Sr NO

Descriptions Capital Cost involved (Rs. in lacs)

1 Higher temp and DP of Hot gases are maintained in the Kiln by changing the cooler plate of KILN. This is helping in getting higher steam flow which in turn improves Power generation

50

2 Reuse of Hot gases back in the cooler. So additional waste heat is available for power generation.

300

4 Special technology will be used for reduction in False air the boiler

25

5 New turbine will be effcient turbine only . Heat rate better than 3200 kcal/kwh

7,329

6 Better insulation of the kiln and boiler area so radiation losses will be reduced

70

7 Additional superheater in AQC boiler to increase steam temperature as well as will capture more waste heat

199

Total 7973 Rs. 79.73 Crores

9.0 Analysis of proposal

The state of Andhra will get revenues in terms of taxes, local people will get

opportunity in terms of indirect employment and business opportunity like

transport of Cement to the market, fly ash transport. In short ,nearby people will get

opportunity to improve their livelihood.



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10.0 ENVIRONMENTAL MANAGEMENT PLAN

10.1 Air Pollution Control

Particulate emission from various stacks and material transfer points will be the

main pollutant from the cement plants. Adequate preventive measures to keep the

pollution level of particulate emission to less than 30 mg/Nm3 will be provided.

Measures taken for control of fugitive emission include:-

All major sources of air pollution will be provided with Bag house/ Bag

filters/ESP/ water spraying to keep emissions below permissible limits for the

PM emissions.

Clinker will be stored in clinker silos.

Regular water sprinkling on haulage road and transportation of material will be

done by covered container.

Proper maintenance of vehicles will be done regularly.

Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.

10.2 Solid and Hazardous Waste Generation

No solid waste will be generated from the cement manufacturing process.

Dust collected from various air pollution control equipment will be recycled

completely in process.

STP Sludge will be utilized as manure for green belt development within the

plant premises.

Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.

10.3 Waste Water Management

No industrial waste water will be generated from the Cement Plant.

Domestic waste water from colony & plant will be treated in the STP & treated

water is being/ will be utilized for green belt development.

Rain water harvesting will be practiced at plant area.

RO reject water will be used for dust suppression, synthetic gypsum

manufacturing and mill spray.

10.4 Noise Pollution Control

Proper maintenance, oiling and greasing of machines at regular intervals will be

done to reduce generation of noise.



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Personal Protective Equipments like earplugs and ear defenders will be

provided to the workers exposed to high noise level.

Green Belt of appropriate width inside the pant premises and at plant boundary

will be developed.

Regular monitoring of noise level will be carried out.

10.5 Green Belt Development

The land requirement is about 173.32 ha for the plant & colony and out of

which plantation will be done on 57.2 ha (33% of total land).

Green belt along with the road & plant boundary will be developed.

Local species will be planted as per CPCB guidelines.

10.7 Socio Economics Measures

SCL is committed to contribute in the development of basic infrastructure for the

local area like education, Health & family welfare, women empowerment, Natural

resource management, water conservation, roads construction etc. For socio-

economic development of the nearby village, we have “Shree Rural Development

Society” to survey the basic infrastructure needs of the villagers like education,

medical, drinking water for human beings and animal, roads, plantation and rain

water harvesting etc and accordingly financial assistance will be provided by the

company to the local authority.

11.0 CONCLUSION

Proposed project will result in growth of the surrounding areas by increased direct

and indirect employment opportunities in the region including ancillary

development and supporting infrastructure. Special emphasis on Financial and Social

benefits will be given to the local people including tribal population, if any, in the

area. Development of social amenities will be in the form of medical facilities,

education to underprivileged and creation of self-help groups. No adverse effect on

environment is envisaged as proper mitigation measure will be taken up for the

same.

*******

pre-feasibility report 1.0 executive summary

Documents