At Khrew village, District., Pulwama, J &...

Trumboo Industries Pvt. Ltd. (TIPL) At Khrew village, District., Pulwama, J & K

Pre Feasibility Report

M/s Trumboo Industries Pvt. Ltd. 1

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s Trumboo Industries Pvt. Ltd. (TIPL) is operating a Cement Plant with a production

capacity of 1000 Tonnes Per Day (TPD) at Khrew village, District., Pulwama, J & K . The

cement plant was established in the year 2004 with a cement production of 1000 TPD. The

quality of cement produced by TIPL has an outstanding demand in the market. Now TIPL is

intended to enhance the cement production capacity up to 2000TPD.

The limestone requirement of the cement plant is met from captive mining leases located at

Khrew District Pulwama, J & K.

Table 1 Site Details

S. NO. PARTICULARS DETAILS

1. Nature & Size of the Project Proposed enhanced Cement production capacity

(2000TPD) by M/s Trumboo Industries Pvt. Ltd. (TIPL)

2. Category of the Project

As per EIA Notification dated 14th September, 2006, as

amended on 1st December, 2009; the project falls under

Category A, Project.

3. Location details

Khasra No. 189, 190, 196-208, 238-246

Village Khrew

Tehsil Pampore

District Pulwama

State J & K

4.

Latitude 340317.5E

Longitude 730055.9N

Toposheet No. 43N/4

5. Project Cost

6. Total Cost of Project 200 Crores

Proposed M/s Trumboo Industries Pvt. Ltd.

at Khrew village, District- Pulwama, J & K



1.3 ENVIRONMENT MANAGEMENT PLAN

(i) Air Pollution Control

All major sources of air pollution are being/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.

Greenbelt will be developed along the plant premises as dust preventive barrier.

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

(ii) Water Pollution Control

No industrial waste water will be generated from the proposed cement plant Unit.

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

utilized for green belt development and dust suppression.

Rain water harvesting will be practiced at plant.

(iii) Noise Pollution Control

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

done to reduce generation of noise.

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 Grinding unit premises and at the plant

boundary will be developed.

Regular monitoring of noise level will be carried out.

(iv) Solid /Hazardous Waste Management

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

Dust collected from various air pollution control equipments will be recycled

completely in process.

Used/Spent oil (Hazardous Waste) will be utilised for lubrication in machines,

chains, etc. Remaining quantity will be sold to CPCB authorised recyclers.





(v) Green Belt Development/Plantation

Green belt will be developed in 33% of the plant area.

Green belt development along with the road & plant boundary will be done which

will attenuate noise level, arrest dust and improve the surrounding environment.

Local species will be planted as per CPCB guidelines.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

M/s Trumboo Industries Pvt. Ltd. (TIPL) is operating a Cement Plant with a

production capacity of 2000 Tonnes Per Day (TPD) at Khrew village, District

Pulwama, J & K . The cement plant was established in the year 2004 with a cement

production of 1000 TPD. The quality of cement produced by TIPL has an outstanding

demand in the market. Now TIPL is intended to enhance the cement production

capacity up to 2000TPD.

The limestone requirement of the cement plant is met from captive mining leases

located at Khrew District Pulwama, J & K.

(ii) Brief description of nature of the project

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

2009; the project falls under Category A, Project.

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

The cement market has growth potential due to the central government liberalization

policies and new schemes for housing, road projects. Cement demand growth is

anticipated to be about 9 to 10% increase mainly through National Highway road

projects, Housing Projects. Continuous demand for exports has led all the cement

manufacturers in the country to plan for increased capacities. So with a view to

capture growing opportunity demand, the management TIPL wants to take up the

section wise capacity balancing and optimization. The proposed expansion will enable

the company to maximize its profitability by optimum utilization of technology,

manpower, present infrastructure and capital. The cost of production will

substantially reduce due to power efficient equipment, better fuel, financial charges

and other fixed overheads on account of large scale economics due to higher volume





of production and sales.

The increase of production will be based on the following considerations

Proximity of the site to captive limestone mines and abundant availability of reserves.

Market demand

Availability of land no further land is proposed to be acquired

Availability of existing infrastructure.

(iv) Demand- Supply Gap & Imports vs. Indigenous production

In the State of J & K, the consumption of cement is much more than the production

and the cement has to be transported from faraway places outside the state to meet

the gap in the demand and supply of the cement. Apart from the demand of

cement for industries, housing and other construction activities, Central/State

Govt. has undertaken major and minor irrigation and hydel projects which require

large quantity of cement for their completion. The project thus enjoys an almost

assured market.

(v) Export Possibility

No export of cement outside the country is planned.

(vi) Domestic / Export Markets

This project is proposed to meet the domestic markets demand.

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

100 additional employees are required

3.0 PROJECT DESCRIPTION

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

The present proposal is setting up new kiln within existing Cement Plant area of

TIPL located at) at Khrew village, District- Pulwama, J & K, To meet the limestone

requirement of Cement Plant after proposed new line, the existing mines production

will be enhanced.

There are no Interlinked and independent projects





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

& project site layout) with coordinates

Figure 1: Location Map

iii) Details of alternative sites consideration and basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted.

As the expansion is proposed in the existing premises, no alternate site considered

or proposed for the proposed project.

(iv) Size or magnitude of operation

Manufacturing Process:





Process Technology Description

Cement manufacturing process described in section wise manner as under:

Limestone Crushing

50. Run of mines (ROM) limestone is transported to the plant using tipper trucks.

The ROM limestone is unloaded in the hopper of the limestone crusher and

transported to the double impactor crusher by an apron feeder. To maintain a

buffer stock, ROM limestone will be taken to uncovered storage for use during

peak winter season. A hammer crusher will be employed to crush the raw material

to -25 mm size. Crushed limestone is taken to the limestone bunker. Limestone

from the bunker is extracted by set of weigh feeders and delivered to a set of belt

conveyor for further feeding to the raw mill.

Raw Material Drying & Grinding

Based on the raw mix design three raw material hoppers have been provided in

the raw mill department. Hoppers are covered and vented through a dust filter.

Raw materials and additives are withdrawn from the hoppers by electronic weigh

feeders to maintain its proportion as per raw mix design. Discharge from the

weigh feeders is conveyed by a belt conveyor and is fed to a ball mill for grinding

of raw material. After grinding coarse fraction is separated and returned to the mill

by the classifier followed by air slide and impact scale. Material thus separated is

further ground inside the mill while the fines i.e. product is sucked by the

Separator ID fan through a battery of cyclones where the product is separated from

the gas stream.

Raw Meal Homogenizing & Kiln Feed System

In raw mill department various raw meal components are proportioned, however,

the composition of raw material varies over a period. The variation in the raw

material composition is controlled and evened out such that it is acceptable to kiln

for a stable operation.

A continuous homogenizing & storage silo of RCC is provided for homogenizing

the raw meal Blended materials from continuous flow silo is conveyed by air slide

and discharged to a bucket elevator which, in turn, discharges it to a load cell

hopper known as kiln feed bin. Controlled materials discharged from the kiln feed





bin is sampled for quality control and fed to bucket elevator for feeding to pre

heater.

Recirculation system is provided at the discharge of bucket elevator which takes

the material back to the blending silo when kiln is not operating for a short

duration. Kiln feed bin and bucket elevator is vented by separate dust filter.

v) Project Description with Process Details

A single stream of five stage pre heater of the latest proven high efficiency, low

pressure drop design with in-line precalciner is provided for preheating of raw

meal. Pre heater consists of a system of cyclones connected with gas ducts. The gas

is sucked by the pre heater fans through the kiln and pre heater system. Raw meal

is introduced in the gas duct to the to stage cyclone. Gas and raw meal are

intimately mixed as they enter the gas duct. The heat exchange between the gas

and raw meal takes place in the gas ducts and separation of the heated raw meal

takes place in the cyclones. This separated raw meal is fed to the gas duct of the

next stage cyclone.

Raw meal from Stage-IV cyclone is fed to the precalciner. Fuel and combustion air

are fed to the precallciner at a point, where they are all intensely mixed and

combustion of fuel takes place and the heat is transferred to raw meal. The gas

velocities and length of the pre calciner duct are so arranged that the required

degree of precalcination is easily achieved.

The combustion air for the fuel fired in pre calciner is taken from the cooler Ist

grate through dust settling chamber and tertiary air duct.

The pre calcined raw meal (about 90% pre calcination) enters the Stage- V cyclone

of the pre heater and is separated and fed to the kiln inlet.

The kiln is equipped with a three channel burner. Control on the axial air and swirl

air allows for a precise control on the flame under all conditions. Kiln is fired with

pulverized coal and latest design swirl chamber burner has been provided for

generation of low Nox and greater heat transfer.

The clinker formed in the kiln is cooled in a third generation reciprocating grate

cooler with maximum heat recovery by addition of cooling air, from the red hot

clinker and subsequent utilization of the same as tertiary air in the calciner.





Secondary air required for combustion in kiln I sucked by pre heater fan from

cooler. This reduces the overall energy consumption for the clinkerisation process.

Adequate number of cooling air fans are provided to supply necessary cooling air.

An Electrostatic precipitator has been provided for dedusting of dust laden cooler

gas to meet pollution norms and the gas is vented to the atmosphere. The spillage

from the cooler is collected in the hopers below the grates and discharged to the

drag chain conveyor.

The cooled clinker is discharged to a deep bucket conveyor. Spillage from the

cooler as well as the dust collected in the ESP hopper is also discharged to the same

deep bucket conveyor for further transport to clinker stockpile.

Clinker Storage, Grinding and gypsum crushing

Clinker from the grate cooler is stored in a tent type storage hall with central

column for minimizing dust generation. Clinker is extracted using set of vibrating

feeders and delivered to a pair of belt conveyor followed by common belt for

gypsum & clinker for taking to cement mill feed hopers.

The system provided consists of one no. closed circuit clinker grinding system with

ball mill. Proportioned quantity of clinker and gypsum to be ground is extracted

from the hopers by electronic weight feeder. Mixture of clinker & gypsum thus

extracted is transported to the ball mill by a belt conveyor.

Ground material from the mill is discharged via an air slide to a bucket elevator

which in turn discharges it to a high efficiency separator. The material is fed into

the centre of the distribution plate and evenly dispersed throughout the separating

chambers. The finished material is collected in externally mounted high efficiency

cyclones. The coarse material from the separator is fed back to the mill via an air

slide and a solid flow meter.

The separated finished material is fed to the cement transport system by air slides.

Mill venting is achieved by a bag dust filter along with other auxiliary vents.

Cement Storage & Packing

The cement produced is stored in RCC float bottom type silo. For feeding the

cement to the packing section air slide and bucket elevator is used. Cement from

the bucket elevator is discharged to the vibrating screen. Foreign materials, if any





are separated in the vibrating screen and cement is dropped to the packer bin

located below. 1 No Electronic rotary packing machine is installed. Bagged cement

is delivered to the two plat form mounted type truck loaders for loading on trucks.

(vi) Raw material required along with estimated quantity, likely source, marketing

area of final products, mode of transport of raw material and finished product.

The raw material required for production of clinker is Limestone, Iron ore, and

Coal.

The additional requirement of raw material per annum on an average for the

production clinker and cement at capacity of 1000 MTPA is presented in Table.

Table-2

Raw Material Requirement

S. No. Material Quantity in tonne

1 Lime Stone 4300

2 Gypsum 175

3 Coal 700

4 Iron ore 60

5 Clay/Silica 1000

For obtaining raw materials like coal, gypsum, additives and transporting cement

from the cement plant to the market well connected roads are available.

Pulwama located in the north-west side of Srinagar,15 km away from it and on the

western side of Jammu-Srinagar National Highway from where the plant is 10 km

away and is connected by a moderately (20 ft.) wide road.

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

should be briefly outlined.

Available limestone reserves of existing mines which cater to limestone needs of

Cement Plant

Limestone from the two mines is blended to arrive at the proper feedable quality

(subjected to the receipt of quality of coal) and supplied to Cement plant for

optimum utilization of resources. Cooling water circuit is close circuited, thereby





ensuring no generation of wastewater. The process, selected envisages re-cycling all

the material collected in the pollution control equipment whereby ensuring no

generation of solid waste.

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

given.

a) Water Requirement and Source

Water is not required for the cement manufacturing process. Water is required for

cooling, dust suppression, sanitary facilities and gardening.

b) Power Requirement and Source

The peak power consumption in the TIPL Cement plant complex including mine is 18

MW. Total power requirement for the TIPL cement plant complex is met from Grid.

Additional power required is about 12 MW.

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

management/disposal

In cement plant water is used for cooling, gas conditioning and raw material

addition at various stages. This water is totally absorbed in the process or will be

subjected to evaporation and hence no wastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plant and

residential colony.

No solid waste will be generated from the cement plant. The dust collected in the

pollution control devices is being 100% recycled back to the process.

Schematic representations of the feasibility drawing which give information of

EIA purpose.

4.0 SITE ANALYSIS

(i) Connectivity

S.No. Particulars Description

1) Village, Tehsil, District, State -Near Village Kherw, District Pulwama, J & K.

2) Longitude and Latitude 730055.9N 340317.5E

3) Land 40 Hectares Required





4) Land status Barran Land

5) Most Populated area Khanmao 3.28km SW), Wuyan 5.63km (SSW),

Andorssa,7.14km(S)

6) Nearest High Way NH-1A, 8.27 km (South WEST)

7) Nearest Village khrew

8) Nearest Town Pulwama

9) Nearest Air Port Srinagar

10) Location of National parks /Wildlife Sanctuary within 10 km radius of the

project site

There is a Dachigam National forest at a distance of 5.2 km (North)

(ii) Land from Land use and Land ownership

Break-up of present land use of existing cement plant is given in Table-1. No

additional land acquisition will be required for proposed new line. Proposed Unit

will be located in an area of about 5 ha within the existing cement plant area.

(iii) Topography (along with Map)

The Cement plant is located near Khrew Village, District, Pulwama, J & K. The site

falls between 340317.5E East longitude and 730055.9N North latitude. The area falls

within Survey of India Toposheet no. 56P/14 [1:50000 scale]. The area is well

connected by roads from Khrew.

(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

The existing cement plant is located in Khrew Village. No additional land will be

required for proposed expansion project.

Dachigam national parks is located at 5.2km away from the site

There are no sensitive places of notified archaeological, historical or tourist

importance within 10 km from the plant area.





(v) Existing Infrastructure

For transporting cement from the cement plant to the market and obtaining raw

materials like coal, gypsum and other additives, well connected road is available.

(vi) Soil classification

The geological formations of the mining area in order of their natural sequence from top to

bottom are as follows;

S. No. Formation Age

1. Recent deposit, scree, talus and clay Recent

2. Kerewas (Clay, Silt and Sand) Pleistocene

3. Triassic formations

a) Upper (predominantly Calcareous)

b) Middle (Calcareous & Argillaceous)

c) Lower (Siliceous & Calcareous)

4. Zewan series-Bottom argillaceous Top

calcareous

Permian

5. Gangamopteris beds (represented b

NAVACOULITE)

Permocarboniferous

6. Panjal traps Permocarboniferous

Panjal traps forms the core of Vaster Van ranges extending from Mandekhapal to Lodu and

towards south eastern parts of the area under report. Zewan series and Gangmopetris beds form

fringe deposits on Panjal trap. Lower and Middle Triassic formation are seen on Jawalamukhi

ridge in Khrew. Upper triassics have a very large development in the area and form the main

ranges extending from Khunmuh in the west to Bathyan in the east. The limestone deposits of

Sulnran-Satpatri from a part of this formation. Broadly speaking, the Triassic formations of the

area under discussion (extending from Khunmuh to in the west Bathyan in the east) possibly

presents the NE limb of a major fold, SW limb of which is faulted along its axis running SW of

line joining village Wuyan and Mandekhpal and finally concealed under huge thickness of

kerawa formation. The exposure formation the NE limbs of anticline are further thrown into

secondary folds, sometimes over turned. The folds are usually faulted along axis. The generalized





strike of the formation (NW-SE) varies from place to place due to flexuring of bands both on

minor and major scale.

(vii) Climatic data from secondary sources

The site falls adjoining to the alpine and temperate region of the Jammu and Kashmir state.

Temperature varies considerably from month to month. The minimum air temperature drops

below 0C, at times, it can go down to -5 to -7C. Ground frost is a common phenomenon during

mid-winter. The rise in temperature is gradual when the air has high moisture content with the

sky remaining overcast; the rise is however steep when the sky is clear and there is less moisture

content in the air. The maximum air temperature goes upto 32C.On annual basis, the maximum

rainfall occurs in the months of July and August, however the rainfall extends from June to

September. The minimum rainfall occurs in the post monsoon season (November and

December). The average annual rainfall in study area is about 700 mm.

(viii) Social Infrastructure available

A good canteen is provided for the benefit of the employees. The canteen serves tea &

snacks at subsidized rates to the employees.

Adequate number of shelters with fans, drinking water etc. for taking food and rest are

provided for the benefit of the employees. Safe hygienic drinking water is provided at

the plant. Drinking water facility is available near rest shelters.

A full-fledged Training hall is available in the TIPL cement plant complex. The training

to workmen is provided on basics as well as for refreshers.

5.0 PLANNING BRIEF

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

country Planning/ Development authority classification.

This is expansion project of existing cement plant within the present TIPL cement plant

complex. Additional civil structures will be required for proposed unit.

(ii) Population Projection

The total manpower at the existing plant is 370. 100 additional manpower is required.

Apart from the jobs, the company provided medical and educational facilities to the

employees which were availed by the people around the plant. Adequate recreational

facilities for the staff of the company and the local people were created.





(iii) Land use planning (breakup along with green belt etc.)

This is expansion project of existing cement plant. The present land use pattern of the

existing TIPL cement plant complex is given in Table-1. No additional land will be

required for proposed expansion project.

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

No additional housing facility will be created.

(v) Amenities/Facilities

All infrastructure facilities such as education, health facilities and other social facilities

are adequate at district headquarter which site makes the region adequate in amenities.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

The following are the major equipment proposed under the new production line.

(ii) Green Belt

TIPL has already developed greenbelt in the cement plant complex. TIPL is taking up

more area under greenbelt development programme.

(iii) Social Infrastructure

TIPL has well defined CSR policy to Carryout social development and welfare measures

in the surrounding villages. Under CSR activity TIPL will initiate community

development projects, in the fields of health, education and environmental preservation,

in the study area around the plant as is done in their existing units.

(iv) Connectivity (traffic and transportation road/rail/metro/water ways etc)

For transporting cement from the cement plant to the market and obtaining raw

materials like coal, gypsum and other additives, well connected roads are available.

(v) Drinking Water Management

The existing cement plant is having safe drinking water facility. RO water is supply to

all the employee and contract workmen.

(vi) Industrial Waste management





The production of cement will be based on completely dry process; hence no process

waste water will be generated from the plant. Also the cooling water will be through

a closed circuit system. The only waste water generated will be domestic waste

water which will be treated in STP and used for green belt development.

Hazardous wastes like spent oil from construction equipment, DG sets etc.,

generated in small quantities during construction and operational phase would be

appropriately stored & handled and properly disposed off in accordance with the

provisions of the Hazardous Waste Management Rules, 2010.

(viii) Solid Waste Management

No solid waste is generated from the cement plant. The dust collected in the

pollution control devices is being 100% recycled back to the process.

(ix) Power requirement and supply/source

The peak power consumption in the TIPL Cement plant complex including mine is

18 MW. Total power requirement for the TIPL cement plant complex is met from

grid. An additional power of 12 MW is required for the proposed expansion project.

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 labourers (a brief outline to be

given).

The expansion is within the existing complex owned by TIPL and the R&R does not

arise.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

The project is expected to be completed in a period of 14 months from the date of receipt of

all the approvals from statutory authorities. The estimated cost of the project is Rs. 200

crores.

9.0 ANALYSIS OF PROPOSAL (final recommendations)

The capital cost, for the proposed production enhancement project, works out to Rs. 200

crores. Financial institutions will be funding the project.





Growth of infrastructure, Irrigation and housing scenario automatically drives the

increased requirement of Cement in the market. Based on the growing demand in the South

East region of the country for Cement over the next 10 years, the proximity of the project

location to this market is an advantage with respect reduction in freight of cement to these

markets. The financial viability also shows a good Rate of return from the project.

Considering the above TIPL is planning to go ahead with the project, once it gets all the

statutory approvals for this enhancement project.

10.0 CONCLUSION

There will be no impact on the land use pattern by the proposed project of cement plant in

the area. M/s. Trumboo Industries Pvt. Ltd. (TIPL) is operating a Cement Plant with a

production capacity of 2000 Tonnes Per Day (TPD) at Khrew village, District-Pulwama, J &

K is of utmost importance to the area/region. Proposed project will result in growth of the

surrounding areas by enhancing opportunity in indirect employment in the region

including ancillary development and supporting infrastructure. Development of social

amenities will be provided in the form of medical facilities, education to underprivileged

and creation of self help groups. Project proponent is committed to provide better

infrastructural facilities such as education, medical, clean drinking water, maintenance of

approach roads in nearby areas of the plant site. Adequate measures will be adhered to

keep the pollution level within prescribed standards. The state government will get

revenue in the form of royalty from selling of product, sales tax/VAT, income tax etc. will be

addition. The operation of the proposed project of cement Plant unit will bestow various

social and economic benefits to the local communities of the area. Thus the proposed

project of cement plant will prove beneficial to the area.

At Khrew village, District., Pulwama, J &...

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