PRE FEASIBILITY REPORT For EXPANSION OF CEMENT...
Transcript of PRE FEASIBILITY REPORT For EXPANSION OF CEMENT...
PRE FEASIBILITY REPORT
For
EXPANSION OF CEMENT PLANT
With
INCREASE OF PRODUCTION CLINKER: 1.5 to 4.0 Million Tonnes per Annum CEMENT: 2.0 to 4.6 Million Tonnes per Annum
& INCREASE OF WASTE HEAT RECOVERY
POWER PLANT: 10 MW to 20 MW
By
PENNA CEMENT INDUSTRIES LTD., Boyareddypalli Village, Yadiki Mandal, Anantapur
District, Andhra Pradesh.
Table of Contents
1. Executive Summary 03
2. Introduction Of The Project/ Background Information 06
3. Project Description 10
4. Site Analysis 17
5. Planning Brief 25
6. Proposed infrastructure 26
7. Rehabilitation and resettlement (R & R) Plan 29
8. Project schedule & Cost Estimates 30
9. Analysis of proposal (Final Recommendations) 31
Figure
Table-1 Salient features of project
Table-2 Land breakup
Figure
Figure-1 Location Map
Figure-2 Key Map
Figure-3 Topographical Map
Figure-4 Cement Plant Layout
Annexures
Annexure – I Copy of MoEF Clearance
1. EXECUTIVE SUMMARY
PENNA CEMENT INDUSTRIES LTD (PCIL)
Penna Cement is one of the largest privately held cement companies in
India, with an installed cement capacity of 7 Million Tonnes Per
Annum.
Founded in 1991, Penna Cement has established itself as one of the
most trusted cement brands, with significant footprints in southern
and western India. Our clientele ranges from small house owners to
established real estate developers and from various state governments
to global construction majors.
Over the last two decades, PCIL had grown organically by developing
in-house expertise and capabilities, across the entire value chain in
the cement industry. All PCIL cement plants are equipped with state-
of-the-art technology, enabling the company to deliver the superior
quality products.
PENNA CEMENT INDUSTRIES LTD (PCIL) is operating a Cement
Plant with a Clinker production capacity of 1.5 Million Tonnes Per
Annum (MTPA) at Boyareddypalli Village, Yadiki Mandal, Anantapur
District, Andhra Pradesh.
Penna Cement manufactures a wide range of cement including
Ordinary Portland Cement (OPC 53 grade and 43 grade), Portland
Pozzolana Cement (PPC), Portland Slag Cement (PSC).
The limestone requirement of the cement plant is met from Gudipadu
Limestone mine located at Gudipadu, Yadiki Mandal, Anantapur
District, Andhra Pradesh.
PCIL received Environmental Clearance vide MOEF letter no. J-
11011/351/2006-IA-II(1) dt 18-05-2007 (Annexure-I)
The current status of various units of PCIL along with installed
production capacities are given below:
OVERVIEW OF PRODUCTION CAPACITIES OF PCIL
Installed capacity MTPA
1 Clinker Production Capacity 1.50
2 Cement Production Capacity 2.00
3 Captive Limestone Mining 2.30
PCIL has obtained CFE and operating 10 MW Waste Heat Recovery
power plant from APPCB and project in under installation stage. PCIL
now proposes to increase clinker production capacity from 1.50 to 4.0
MTPA and cement production from 2.00 to 4.6 MTPA by enhancing
the Unit-I production capacity from 1.5 to 1.65 MTPA and by
installing a new line of 2.35 MTPA. With increase of clinker production
capacity, the limestone requirement increases from 2.30 to 5.30
MTPA.
PCIL proposes to meet the additional limestone requirement from
same captive limestone mining lease. The mining lease extends over
an area of 392.62 Ha., in Gudipadu, Yadiki Mandal, Anantapur
District, Andhra Pradesh.
The present proposal pertains to obtaining environmental clearance
for expansion of the cement plant as per the following table:
PRODUCTION CAPACITY (MTPA)
Unit
Present approved Capacity as per
MoEF EC (MTPA)
Capacity after proposed expansion (MTPA)
Clinker Cement Clinker Cement
Cement Plant
Unit –I 1.5 2.0 1.65 2.0
Unit –II (new unit)
- - 2.35 2.6
Total 1.5 2.0 4.00 4.6
Waste Heat Recovery based Power Plant,
MW 10 20
PCIL complex is located in an area of 60 Ha. The new unit will be
located within the existing cement plant complex as shown in the Lay
out plan.
PCIL cement plant is supported by their captive Limestone mines to
meet the additional limestone requirement of proposed expansion. The
production capacity of limestone mines will be augmented. The
proposal is being submitted to MoEF separately for necessary
environmental clearance.
The present water requirement of the plant is 930 m3/day and is
sourced from borewells & mine pit within the plant site. Additional
Water requirement for the proposal is 500 m3/day which will be met
from mines pit.
The project is based on Clinkerization factor of 1.50 on Raw Meal
basis with specific heat consumption of 740 Kcal/ kg clinker.
There is no wild life sanctuary, national park, eco-sensitive area
within the 10 km radius of the project site.
For transporting cement from the cement plant to the market and
obtaining raw materials like coal, gypsum and other additives, well
connected road and railway siding is available.
No additional quarter’s construction is proposed.
No solid waste generation from the plant. Only Wastewater generated
is only from domestic activities at cement plant and residential colony.
A full-fledged sewage treatment plant (STP) is in operation designed
for a maximum load of 250 m3/day. Treated domestic wastewater is
100% reused for greenbelt development within PCIL cement plant
complex.
Greenbelt is maintained in about 33 % of the total area.
The peak power consumption in the PCIL Cement plant complex
including mine is 25 MW. Power requirement is met from grid. An
additional power of 15 MW is required for the proposed expansion
project. Totaling 40 MW. Internal Power generation from WHR will be
20MW. There will not be any additional power requirement.
Plant is expected to be commissioned in 18 months from date of
commencement of construction
Total capital Investment Cost is Rs. 800 crores.
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. IN
CASE OF MINING PROJECT, A COPY OF MINING LEASE / LETTER
OF INTENT SHOULD BE GIVEN.
PENNA CEMENT INDUSTRIES LTD (PCIL) is operating a Cement
Plant with a Clinker production capacity of 1.5 Million Tonnes Per
Annum (MTPA) & 10MW WHR Power Plant at Boyareddypalli Village,
Yadiki Mandal, Anantapur District, Andhra Pradesh.
PCIL present installed capacity of cement plant is 1.5 million tonnes
per annum (MTPA) of clinker and 2.0 MTPA of cement & 10MW WHR
Power Plant. PCIL is manufacturing Ordinary Portland Cement (OPC),
and Portland Pozzolana Cement (PPC).
To meet the increasing demand of cement, both in the domestic and
international markets, PCIL is proposes to increase production of
clinker capacity to 4.0 MTPA and cement production to 4.6 MTPA &
20MW Power.
ii) Brief description of nature of the project
The project is cement plant with present clinker production of 1.5
MTPA and cement of 2.0 MTPA. The proposal is for increase of clinker
production to 4.0 MTPA and cement production capacity to 4.6 MTPA
& 20MW Power.
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 road projects (Golden Quadrilateral), Housing
Projects (1.3 million houses in rural & 0.7 million in urban areas).
Continuous demand for exports to China and other South-East Asian
countries along with the increased requirement of the domestic sector
have led all the cement manufacturers in the country to plan for
increased capacities.
So with a view to capture growing opportunity demand, the
management PCIL 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, fuel, financial charges and other fixed overheads on
account of large scale economics due to higher volume of production
and sales.
It would also enable the company to withstand against the
considerable competitive pressure from large-scale units in the
country and also to create wider brand loyalty for the product.
The increase of production within the existing plant is 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.
Demand – supply Gap
Cement demand in India is expected to increase due to government’s
push for large infrastructure projects, leading to 45 million tonnes of
cement needed in the next three to four years1.
India's cement demand is expected to reach 550-600 Million Tonnes
Per Annum (MTPA) by 2025. The housing sector is the biggest demand
driver of cement, accounting for about 67 per cent of the total
consumption in India. The other major consumers of cement include
infrastructure at 13 per cent, commercial construction at 11 per cent
and industrial construction at nine per cent.
To meet the rise in demand, cement companies are expected to add 56
million tonnes (MT) capacity over the next three years. The cement
capacity in India may register a growth of eight per cent by next year
end to 395 MT from the current level of 366 MT. It may increase
further to 421 MT by the end of 2017. The country's per capita
consumption stands at around 190 kg.
The Indian cement industry is dominated by a few companies. The top
20 cement companies account for almost 70 per cent of the total
cement production of the country. A total of 188 large cement plants
together account for 97 per cent of the total installed capacity in the
country, with 365 small plants account for the rest. Of these large
cement plants, 77 are located in the states of Andhra Pradesh,
Rajasthan and Tamil Nadu & Telangana
v) Imports Vs. Indigenous production
India is self sufficient to meet the demands of the market with the
GDP projected at 10 % in the coming decades and in view of the
infrastructure.
The end product being cement, the importance of the project is
detailed below with respect to cement demand.
India is self sufficient to meet the demands of the market with the
GDP projected at 10% in the coming decades and in view of the
infrastructure.
vi) Export possibility
No export of cement outside the country is planned.
vii) Domestic / export markets
The expansion of cement plant will meet the domestic markets
demand.
viii) Employment generation (direct and indirect) due to the
project.
100 additional employees are required.
3. PROJECT DESCRIPTION
i. Type of project including interlinked and interdependent
projects, if any
The present proposal is setting up new kiln and by enhancing the
present kiln production capacity, within existing Cement Plant area of
PCIL located at Boyareddypalli Village, Yadiki Mandal, Anantapur
District, Andhra Pradesh in area of 60 Ha.
To meet the limestone requirement of Cement Plant after proposed
project, the existing mines’ production will be enhanced.
ii. Location (map showing general location, specific location, and
project boundary & project site layout) with co-ordinates.
The Cement plant is located near Boyirredipalli Village, Yadiki Mandal,
Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The site
falls between A) 15° 3'35.20"N- 77°56'52.51"E B) 15° 3'51.44"N-
77°56'52.03"E C) 15° 3'52.10"N- 77°57'12.06"E D) 15° 3'35.82"N-
77°57'12.55"E North latitude and East Longitude with an average
altitude of 276m above MSL. The area falls within Survey of India
Toposheet no. 57/E/16 [1:50000 scale].
Fig-1 shows the location map of the Plant Site.
Nearest railway line connecting Rayalacheruvu - Tadipatri of South
Central Railway line is located at a distance of 11.1 km to WSW
direction from the site. Key map showing the location of various
features around the Plant site is shows in Fig – 2. Tadipatri is major
town is located at a distance of 17.8 km in SSE direction.
The National Highway (NH-44) connecting Dhone - Gooty is located at
a distance of about 29.5 km in WNW direction. The State Highway
(SH-57) connecting Bellary– Nellore is located at a distance of about
3.0 km in Southern direction.
The nearest railway station is located at Tadipatri which is 17.7 km in
SSE direction.
A N D H R A P R A D E S H
L O C A T IO N M A P
C h it to o r
S P S R N e llo re
P ra k a sa m
G u n tu r
K r is h n a
K u rn o o l
A n a n ta p u r
Y S R K a d a p a
W e s t G o d a v a r i
E a s t G o d a v a r i
V is h a k h a p a tn a m
V iz ia n a g a ra m
S r ik a k u la m
IN D IA
O b a la p u ra m
P a ltu ru
H o n n u ra
N im b a g a llu
B e lu g u p p a
K a n e k a llu
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A m a ra p u ra m
H e m a v a th i
R o lla
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K a ly a n d u rg
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R a y a la ch e ru v e Y a d ik i
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G a r la d in n e
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K a d ir i
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G u ttu ru P a tn a mP a m u d u rt i
B u k k a p a tn a m
R a m g ir i
S h r i S a ty a S a i
T e m p le
N a g a sa m u d ra m
C h a n n e k o tta p a lle
7
7
A N A N T A P U R D IS T R IC T
P L A N T S IT E
N o te :- N o t to S c a le
N
L E G E N D
R A IL W A Y T R A C K
R IV E R
R O A D
D IS T R IC T B O U N D A R Y
M A JO R R O A D
T A L U K H E A D Q U A R T E R
D IS T R IC T H E A D Q U A R T E R
T O W N
N A T IO N A L H IG H W A Y
P C IL P L A N T S IT E
7
T E M P L E
F IG - 1
2 k m10
S E C U N D E R A B A D
P re p a re d b y
T IT L E :
C L IE N T :
K E Y M A P
S C A L E
M /s . P E N N A C E M E N T IN D U S T R IE S L T D .,
C E M E N T P L A N T
N
P R O JE C T :
B o y ire d d y p a lli V illa g e , Y a d ik i M a n d a l, A n a n th a p u r D is tr ic t , A n d h ra P ra d e sh
C h in ta la y a p a lli
K u n d a n a k o ta
K u r la p a lli
B o y ir re d ip a lli
V ira re d d ip a lli
K a m a la p a d u
T irn a m p a lli
C h ik k e p a lli
N it tu ru
S iv a ra m a p u ra m
K o tta p a lli
T im m a p a lli
3 9 6
3 6 9
3 7 6
3 9 8
G u d ip a d u
C O L O N Y
P C IL P L A N T S IT E
1 .1 k m
0 .6 k m
0 .5 k m
2 .2 k m
2 .2 k m
2 .9 k m
S E T T L E M E N T S
S P O T H E IG H T S
S T R E A M S / T A N K S
R O A D S
L E G E N D
D IS T R IC T B O U N D A R Y
3 9 6
C O L O N Y
P C IL P L A N T S IT E
F IG - 2
Penneru River – 11.4 km – S and Maruna Vagu – 8.9 km – WSW are
the nearest waterbodies in the 10 km radius of the plant site.
Yadiki RF is the Nearest Forests at a distance of 8.4 km in WNW
dirsction. The Nearest Airport from the Plant site is Kadapa Airport –
106.1 km – SE
Due to availability of rich limestone deposits, major cement plants,
which are located within 10 km are BMM Cements Limited – 3.0 km –
ENE and Ultratech Cement – 7.5 km – SE
There are no national parks/wild life sanctuaries/eco sensitive zones
within 10 km radius of the cement plant and mine sites.
Fig-3 shows the 10 km radius around Cement plant. Salient features
of the plant site are given in Table-1.
TABLE – 1
SALIENT FEATURES OF THE CEMENT PLANT
Feature Details
Altitude 276 m above msl
Longitude Latitude
A) 15° 3'35.20"N- 77°56'52.51"E B) 15° 3'51.44"N- 77°56'52.03"E C) 15° 3'52.10"N- 77°57'12.06"E D) 15° 3'35.82"N- 77°57'12.55"E
Village, Tehsil, District, State
Boyirredipalli Village, Yadiki Mandal, Tadipatri Taluka, Ananthapur District of Andhra Pradesh.
Annual rainfall 725 mm
Nearest water bodies Penneru River – 11.4 km – S Maruna Vagu – 8.9 km - WSW
Nearest Highway The National Highway (NH-44) connecting Dhone – Gooty-29.5km-WNW The State Highway (SH-57) connecting Bellary– Nellore - 3.0 km in Southern direction.
Nearest Railway station Tadipatri RS - 17.7 km - SSE
Inter State Boundary Andhra Pradesh – Karnataka – 85.5km - W
Nearest Industries BMM Cements Limited – 3.0 km – ENE Ultratech Cement – 7.5 km - SE
District Head Quarter Ananthapur – 55.9 km - SW
Nearest Town Tadipatri – 17.8 km – SSE direction.
Nearest Air port Kadapa Airport – 106.1 km – SE Tirupati ( Renigunta ) Airport – 236 .0km - SE
Nearest Forest Yadiki RF - 8.4 km - WNW
Nearest Wild life Sanctuaries
None within 10 km Radius
* All distances mentioned in the above table are aerial distances.
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iii. Details of alternate sites considered and the 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
With the proposed expansion, the clinker production will be 4.0 MTPA
and Cement at 4.6 MTPA & 20MW Power from WHR.
PCIL is manufacturing blended cement. viz., Ordinary Portland
cement (OPC)) and Portland Pozzolana Cement (PPC)/ Portland Slag
Cement.
Manufacturing Process:
Limestone Mining: Mechanized mining of lime stone is done by deep
hole drilling, nonel blasting, excavation and hauling. The blasted lime
stone of size less than 1000mm will be transported to lime stone
crusher for crushing.
Limestone Crushing: A single Rotor Impact Crusher is installed to
reduce limestone size from 1000 mm to 75mm.
Stacking & Reclaiming: The crushed lime stone is stacked
longitudinally with stacker as per the required quality given by Quality
Control Dept. The capacity of stock pile is 60000 T. After forming the
stockpile, the reclaimation will be started. The total process of
stacking and reclaiming is called chevron method.
Raw material grinding: Blended lime stone will be reclaimed and will
be filled into raw material hopper in the Vertical Roller Mill (VRM)
section. Laterite, Iron Ore and corrective limestone will be filled into
hoppers. All the materials with the required ratio are conveyed
through the weigh feeders and belt conveyors to Vertical Roller Mill,
where grinding takes place.
VRM with inbuilt system of separator will grind the raw materials 75
mm size to 18% R on 90 micron size. The product called raw meal is
collected in cyclones and RABH and transported through air slides
and bucket elevator and stored in blending Silo.
Coal Crushing & Grinding: Raw Coal unloaded from open trucks by
wagon tippler through rakes to yard and transported by Belt
Conveyors to crusher where the size is reduced from 100mm to 25
mm and conveyed to raw coal hopper through conveyor belts. Vertical
roller mill (VRM) pulverizes raw coal to fine coal with fineness of 10%
R on 90 microns, which is collected in Bag Filter. The fine coal is
further conveyed mechanically to fine coal bins and transported to
kiln and calciner pneumatically (through FK pumps) for firing.
Pyro-Processing: This system consists of Rotary Kiln with 5 stage
Pre-heater and In-line Calciner. Raw meal from Silos is conveyed
through pre-heater. Fine coal is fired through burner pipe into kiln
and into pre-calciner. The material is 90 to 92 % calcined before
entering into kiln and balance calcination, Pre burning and sintering
takes place in the kiln for ensuring complete chemical reactions.
Clinker formed is cooled in grate coolers with high pressure fans. The
clinker after cooling is transported mechanically to clinker storage
tanks.
Cement Grinding: Clinker from clinker storage tank is conveyed to
clinker hopper. Gypsum is filled into gypsum hopper. Closed Circuit
Tube Mill with dynamic separator grinds clinker and gypsum in a
ratio of 95:5 respectively. The product, called Ordinary Portland
cement (OPC) is conveyed mechanically to cement storage silos.
Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectively
are ground in the Ball Mill to make Portland Pozzolana Cement (PPC),
Portland slag cement (PSC) & Portland Pozzolana Cement (PPC) which
is conveyed mechanically to cement storage silos.
Cement Packing: Electronic Packers (12 spout- double discharge)
automatically fill the PP bags or paper bags of 50 Kg. These bags are
loaded to the trucks through belt conveyors and loaders/Rail
The Plant is well automated and operated form Central Control Room
and Control system is based on PLC.
Quality Control: All the raw materials, in- process and products are
carried out by means of XRF and XRD of PAN Analytical. The
preventive measures are taken to ensure the consistent and best
quality is achieved. Material testing is undertaken on calibrated
instruments for both Physical and Chemical parameters all the time.
The people involved in this stream are highly qualified and
experienced and quality conscious. The product is well accepted in the
market and customers like Readymix concrete, Industries and
Builders prefer our product very well.
Process Control: The plant operation through Automation is
equipped with Expert Control Systems (ECS), comprising the SDR
system. PIDs with closed loops systems are intact and PLC is in
advanced modern system. Fuzzy logic from FLS is also adopted for
smooth and consistent operation of the plant. The process parameter
is designed by the experts and is operated by qualified and
experienced engineers. The deviations are minimized and the
tolerances are limited. This is resulting in achieving the productivity in
terms of best quality, optimal production and energy conservation
(thermal as well as electrical).
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, Bauxite and Coal. Available limestone reserves of existing mines.
The requirement of raw material per annum on an average for the
production clinker and cement as mentioned above is presented in
below table.
RAW MATERIAL REQUIREMENT (MTPA)
PRESENT EXPANSION Source
Limestone 2.3 5.30 Captive mines
Iron ore 0.02 0.05 Bellary / Hospet
Laterite 0.08 0.18 Veldurty, Rajahmundry
Gypsum 0.10 0.23
SPIC and Sterlite Industries,
Tuticorin, EID Pary India
Ltd., Chennai & Coramandel
Fertilizers Ltd., Vizag
Coal 0.26 0.56
Singareni Collieries Company
Ltd/ Imported Coal/Petcoke
from USA
Slag 0.50 1.14 Jindal Steel and SJK Steel
Ash
requirement
for PPC
0.10 0.23
Rayalaseema Thermal Power
Station and Jindal Power
Plant, AP Genco , Power Plant
, Nellore
For obtaining raw materials like coal, gypsum, additives and
transporting cement from the cement plant to the market well
connected roads & rails are available. The National Highway (NH-44)
connecting Dhone – Gooty is located at a distance of about 29.5 km in
WNW direction.
vii. Resource 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 mine 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
Water
Water is required for cooling, dust suppression, sanitary facilities and
gardening. The present water requirement of the plant is 930 m3/day
and is sourced from borewells within the plant site. Additional Water
requirement for the proposal is 500 m3/day. The source of water is
borewell/mine pit.
Power
The peak power consumption in the PCIL Cement plant complex
including mine is 25 MW. Total power requirement for the PCIL
cement plant complex is met from Grid. Additional power required is
about 15 MW and it also is sourced from grid and WHR Power Plant.
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. A full-fledged sewage treatment plant (STP) is
in operation designed for a maximum load of 250 m3/day. Treated
domestic wastewater is 100% reused for greenbelt development within
PCIL cement plant complex.
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.
x. Schematic representations of the feasibility drawing which give
information of EIA purpose.
4. SITE ANALYSIS
i. Connectivity
The Cement plant is located near Boyareddypalli Village, Kamalapadu
Panchayath Yadiki Mandal, Anantapur District, Andhra Pradesh.
The area is well connected by road and rail. The National Highway
(NH-44) connecting Dhone – Gooty is located at a distance of about
29.5 km in WNW direction. The nearest railway station is located at
Tadipatri which is 17.7 km in SSE direction.
ii. Land form, land use and land ownership.
Break-up of present land use of existing cement plant is given in
Table-2 and PCIL cement plant layout is shown in Fig-4. No
additional land acquisition will be required for proposed new line.
TABLE-2
LAND AVAILABILITY
S.No.
Area (ha.)
Before expansion
After expansion
1 Plant area and roads 25 30
2 Colony with infrastructure 8 9.6
3 Parking area 5 1
4 Greenbelt 16 19.4
5 Vacant Land 6 -
Total 60 60
iii. Topography (along with map)
The existing PCIL Cement plant site is located at an elevation of 268 m
above MSL.
The Cement plant is located near Boyirredipalli Village, Yadiki Mandal,
Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The site
falls between A) 15°3'35.20"N- 77°56'52.51"E B) 15°3'51.44"N-
77°56'52.03"E C) 15°3'52.10"N- 77°57'12.06"E D) 15°3'35.82"N-
77°57'12.55"E North latitude and East Longitude with an average
altitude of 276m above MSL. The area falls within Survey of India
Toposheet no. 57/E/16 [1:50000 scale].
FIG – 4
PLANT LAYOUT
EX
IST
ING
PO
WE
R=
54
33
1 H
P
PR
OP
OS
ED
PO
WE
R=
12
HP
TO
TA
L P
OW
ER
= 5
43
43
HP
Nearest railway line connecting Rayalacheruvu - Tadipatri of South
Eastern Railway line is located at a distance of 11.1 km to WSW
direction from the site. Tadipatri is major town is located at a distance
of 18.1 km in SSE direction.
The area is well connected by road and rail. The National Highway
(NH-44) connecting Dhone – Gooty is located at a distance of about
29.5 km in WNW direction. The nearest railway station is located at
Tadipatri which is 17.7 km in SSE direction.
Penneru River – 11.4 km – S and Maruna Vagu – 8.9 km – WSW are
the nearest waterbodies in the 10 km radius of the plant site.
Yadiki RF is the Nearest Forests at a distance of 8.4 km in WNW
dirsction. The Nearest Airport from the Plant site is Kadapa Airport –
106.1 km – SE
Due to availability of rich limestone deposits, major cement plants,
which are located within 10 km are BMM Cements Limited – 3.0 km –
ENE and Ultratech Cement – 7.5 km – SE
There are no national parks/wild life sanctuaries/eco sensitive zones
within 10 km radius of the cement plant and mine sites.
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 Boyareddypalli Village. No
additional land will be required for proposed expansion project.
There are no national parks or wildlife sanctuary within 10 km of
the subject plant area.
No ecologically sensitive area such as tropical forests, biosphere
reserves, important lakes or coastal area rich in coral formation
fall within 10 km of the plant area.
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/rail is available.
vi. Soil Classification
The proposed new line will be located in existing plant area. No
additional land will be required for proposed new line.
Soil in the area is found to be clayey in texture with clay percentage in
the range 40 - 70%.
vii. Climate data from secondary sources
The tropical climate of the region is manifested in hot and humid
summer, moderately monsoon and mild winter seasons. May is the
hottest month in the year. The maximum temperature during the day
time was recorded as 45.6 0C and December the coldest with the
temperature during the day time falling down to about 34.40C. The
night temperature in winter can be as low as 6.70C. The months of
December, January & February are considered to have pleasant
climate.
viii. Social infrastructure available
A well-equipped Occupational Health center is provided at colony,
which has full time male and lady medical officers assisted, by
compounders and nurses. Necessary free medicines and medical aid is
available for the company employees.
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 PCIL cement plant
complex. The training to workmen is provided on basics as well as for
refreshers.
The employees are provided with well-designed houses having
electricity and water connections.
For the education facility of employee’s children School is provided at
our colony.
5. 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
PCIL cement plant complex. Additional civil structures will be required
for proposed unit.
ii. Population projection
The total manpower at the existing plant is 550. 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 greenbelt etc.,)
This is expansion project of existing cement plant. The present land
use pattern of the existing PCIL cement plant complex is given in
Table-2. No additional land will be required for proposed expansion
project
iv. Assessment of infrastructure demand (physical & social)
Few additional housing facility will be created within the existing
colony.
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. PROPOSED INFRASTRUCTURE
i. Industrial area (processing area)
The following are the major equipment proposed under the new
production line
Main Machinery
Item Type Capacity
Limestone
Crusher
Single stage
impactor type
Crusher
900 tph
Limestone
Stacker
Luffing Boom Type
Stacker 900 tph
Limestone
Reclaimer
Bridge Type
Reclaimer 500 tph
Raw Material
Grinding VRM 380 TPH
Coal Grinding Vertical Roller Mill 45 TPH
Preheater /
Calciner
Single String 5 Stage Preheater with
Inline Precalciner - 5000 TPD
Kiln Rotary Kiln - 3000 tpd
Clinker Cooler Grate Cooler – 3000 tpd
Cement
Grinding
Ball Mill with
Roller press as pre
grinder
200 TPH
Packing Plant Rotary Packer 100 tph
Main Storages
Item Type Capacity
Limestone Stock
pile
Longitudinal
Stockpile 2x 30000 t
Chemical
gypsum
Stockpile
Closed stockpile 3000 t
Raw Meal Silo RCC 10000 t
Fly Ash Silo RCC 2000 MT
Clinker Silo RCC 40000 MT
Cement Silo RCC 2 X 8000 t
ii. Residential area (non-processing area)
Residential colony is located nearer to the plant. The Waste water
from colony and plant is treated in the Sewage Treatment Plant.
iii. Greenbelt
PCIL has already developed greenbelt in an area of 16 ha in and
around the PCIL cement plant complex. PCIL is taking up more area(4
Ha)under greenbelt development programme.
iv. Social infrastructure
PCIL has well defined CSR policy to Carryout social development and
welfare measures in the surrounding villages. Under CSR activity
PCIL 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.
v. 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. The National Highway (NH-7) Dhone –
Gooty is located at a distance of about 29.5 km in WNW direction.
vi. Drinking water management (source & supply of water)
existing cement plant is having safe drinking water facility. RO water
is supply to all the employee and contract workmen & surrounding
villages.
vii. Sewerage System
Existing STP will be utilized for treatment of domestic wastewater after
expansion of project.
viii. 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 from residential
township and the same 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.
ix. 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.
x. Power requirement & Supply/Source.
The peak power consumption in the PCIL Cement plant complex
including mine is 25 MW. Total power requirement for the PCIL
cement plant complex is met from grid. An additional power of 15 MW
is required for the proposed expansion project.
7. REHABILITATION AND RESETTLEMENT (R&R) PLAN
The new Unit is coming up in the existing complex owned by PCIL and
the R&R does not arise.
8. PROJECT SCHEDULE & COST ESTIMATES
The project is expected to be completed in a period of 18 months from
the date of receipt of all the approvals from statutory authorities. The
estimated cost of the project is Rs. 800 crores.
9. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)
The capital cost, for the proposed production enhancement project,
works out to Rs. 800 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 show a
good Rate of return from the project. Considering the above PCIL is
planning to go ahead with the project, once it gets all the statutory
approvals for this enhancement project.