PRE FEASIBILITY REPORT For Expansion of Cement Plant...

PRE FEASIBILITY REPORT

For

Expansion of Cement Plant Increase of Production

CLINKER: 3.50 to 6.50 MTPA CEMENT: 3.07 to 7.60 MTPA (Optimization of UNIT-I, II & III AND Installation of New Unit-IV)

M/S. ORIENT CEMENT LTD. (An ISO 9001:2008, IS:18001:2007 and

ISO:14001:2004 Company)

Devapur -Village, Mandal-Kasipet District Mancherial ; Telangana State

Table of Contents

Chapter – 1 Executive Summary

Chapter – 2 Introduction of the Project / Background Information

Chapter – 3 Project Description

Chapter – 4 Site Analysis

Chapter – 5 Planning Brief

Chapter – 6 Proposed Infrastructures

Chapter – 7 Rehabilitation And Resettlement (R & R) Plan

Chapter – 8 Project Schedule & Cost Estimates

Chapter – 9 Analysis of Proposal (Final Recommendations)

Annexures

Annexure-I; Combined EC for Unit –I,II&III.

Annexure-II; EC for the Mines

Figures

Figure-1 Location Map

Figure-2 Topographical Map

Figure-3 Cement Plant Layout

CHAPTER – 1

EXECUTIVE SUMMARY

1. Executive Summary

Orient Cement Ltd., (OCL) is operating a Cement Plant with three

manufacturing units at Devapur village, Kasipet Mandal and Mancherial

District of Telangana State.

Consented Clinker production capacity (Environmental Clearance Obtained) of

OCL is 3.50 million tonnes per annum (MTPA). OCL now proposes to

increase clinker production capacity of Unit – I, II and III marginally by

optimization and de-bottlenecking. At the same time it proposes to install a

new unit i.e. Unit-IV of 2.50 MTPA Clinker production capacity. The total

clinker production of OCL after modernization of three units and installation of

new unit will be 6.50 MTPA

.

The earlier Environmental Clearance for 3.50 MTPA issued vide letter no. J-

11011/266/2007-IA II(I) dt 6-9-2007 is attached as Annexure-I

OCL Cement plant is supported by existing Coal based Captive power plant of

50 MW. It is now proposed to setup a Waste Heat Recovery Power Plant of 25

MW to meet the additional Power requirement.

Part of additional clinker produced after proposed expansion will be

transported to OCL Cement grinding unit located at Jalgaon, Maharashtra.

Required main raw material, limestone is supplied by the Andhra Pradesh

Mineral Development Corporation Limited (APMDC) from the Devapur

Limestone Mine-I, located in the vicinity of Cement Plant i.e. Devapur

Limestone Mine.

The Limestone requirement is met from adjacent APMDC Devapur Limestone

mine spread over an extent of 210 Ha. The limestone production capacity of

the mine will be increased from 5.3 to 6.0 MTPA for meeting the requirement of

the existing units. For the proposed new unit i.e. Unit-IV, the requirement will

be met from the TSMDC newly proposed mine of 275 Ha, lying adjacent to the

existing mine.

The Environmental Clearance for the existing mines was issued by Ministry

vide Lr. No; J-11015/234/2007-IA II(I) dtd. 16-102007. Attached as

Annexure-II

Expansion of the cement plant will be taken up within the existing OCL cement

plant complex of 425.89 Acres. About 11 acres of land will be acquired for the

proposed expansion. Already 216 acres was developed under Green belt.

Water requirement of the plant will increase from 1895 m3/day to 4095

m3/day. Whole water requirement will be met from Mine Pit. Ground water

requirement permission also will be taken from Statutory Authority. Coal

requirement of plant will increase from 0.30 MTPA to 0.55 MTPA and is met

from Coal linkage source (Singareni Collieries Limited)/imported, the fact that

the unit is located in Coal belt area of Southern India.

Pet coke will be used for Cement plant as fuel.

The existing colony of OCL is adequate and no additional quarters are

proposed.

The estimated total cost of the project is around Rs. 2100 Crores, for clinker

and cement expansion, of which Rs. 45 Crores will be spent for Environmental

Management Plan.

Present Power requirement is 45 MW and for expansion it will be additional 40

MW. This additional Power requirement will be met from the proposed WHRB

and Grid.

Limestone mineThe lease area is located in Ralli Reserved Forest Luxetipet

Range,Macherial Division ,Kazipet Mandal , Adilabad Dist, AP .It is well

connected with rail and road network . The mine is connected by black top

road connecting the State Highway No 16 between Bellampally and Manchiryal

.The nearest railway line is at Bellampally at distance of 18km from the mines.

Machiryal is also another railway station located at a distance of -33 km.

Nagpur and Hyderabad Airports are at equivalent distance of 280 km from the

mines.

The limestone mining lease at Devapur lies in between latitudes N 19° 01'

52.8" - N 19° 01' 58.4" & longitudes E 79° 19' 12.1" - E 79° 20' 29.4" and is

covered by Survey of India Topo Sheet number 56 M/8 and 56 N/5

The mine hosts about 42 million tonnes of Limestone. And the Mine life will

be about 7 years.

Out of the total 210 Ha, 168.590 Ha will be broken and 41.41 ha is Non

mineral zone and 7.5m safety zone , and this area is under greenbelt.

The broken area will be partly backfilled and part will be under water

reservoir.

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It is proposed now to enhance the Limestone production from the present

mine from 5.3 to 6.0 MTPA and the proposal is separately filed with the

Ministry .

Post Mining Land Use Pattern

Sl No Details of Land use Area in ha

Opencast Working Area ( Ultimate Pit Area)

1 Total broken up area@@ 176.990

A Water Body 23.750

B Existing Dumps with Plantation 13.450

C Existing plantation ( other than Dumps pit area ) 8.169

D Proposed plantation ( Plan period) 2.480

Conceptual Period 25.565

E Area of Broken out Benches 100.836

Out side Working Area

2 Total Unbroken Area 33.010

a Plantation ( Including Avenue Plantation and 20.840

others )

b 7.5 ML barrier 8.400

c Main Haul Road( Cement Road) 1.600

d Other Roads 0.920

e Conveyor Belt 0.350

f Infrastructure( Crusher, Shelter Room, First Aid 0.900

Room, ANFO Shed, site office, Temple

etc

3 Total Lease Area (1+2) 210.00

The surface plan of the mine is attached as Plate-1

CHAPTER – 2

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.

M/s. Orient Cement (OC) was established in the year 1981 by eminent and

illustrious industrial house of C. K. Birla Group.

The company is engaged in cement manufacturing and limestone mining,

having wide experience in the field of cement manufacturing and has two

cement plants accredited with ISO: 9001- 2008, IS: 18001:2007 & ISO:

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14001:2004. It is a professionally managed and well established cement

manufacturing company enjoying the confidence of consumers because of

its superior quality product and excellent customer service. The company is

running cement plants and mines elsewhere in the country with latest eco-

friendly technology.

Orient Cement., (OC) is operating a Cement Plant with three manufacturing

units at Devapur Village, Kasipet Tehsil, Mancherial District, Telangana

State.

Consented Clinker production capacity (Environmental Clearance Obtained)

of OCL is 3.50 million tonnes per annum (MTPA). Present clinker

production of OCL is 3.50 MTPA from three units i.e. Unit – I, II & III. Unit –

IV Clinkerisation unit of 2.5 MTPA is under proposal. OCL proposes to

increase clinker production capacity of Unit – I, II and III marginally by

optimization and de-bottlenecking. The total clinker production of OCL after

expansion of Unit – I, II, III and post operation of Unit – IV will be 6.50 MTPA

clinker capacity.

OCL Cement plant is supported by existing Captive Power Plant. OCL

proposes to increase the present power generation capacity of 50 MW to 75

MW by installation of New waste heat recovery Power Plant of 25 MW

capacity.

Part of additional clinker produced after proposed expansion will be

transported to OCL cement grinding unit at Jalgaon, Maharashtra.

Required main raw material limestone is supplied from APMDC limestone

Mine located in the vicinity of Cement Plant i.e. Devapur Limestone Mine-I

spread over an extent of 210 Ha. The limestone production capacity of the

mine will be increased from 5.3 to 6.0 MTPA. The Unit-IV limestone

requirement will be met from TSMDC new Limestone mine i.e. Devapur

Limestone Mine-II.

The capacity details of OCL at present and proposed is given below

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PRODUCTION CAPACITY (MTPA)

Cement Plant

Present Consented Capacity as per MoEF (EC Obtained)

MTPA

Capacity after proposed enhancement (EC Requested)MTPA

Clinker Cement Power (MW)

Clinker Cement Power (MW) (TPD) (TPD)

Unit –I

3.50 3.07 2 x 25

MW

4.00

3.07

1.03 75

(Additional

capacity

with WHRB

Unit –II

Unit –III

Unit-IV - 2.50 3.50

Total 3.50 3.07 6.50 7.60

OCL implemented Quality Management System as per ISO 9001:2000 in

year 2005 and re-certified in 2009 to the requirements of ISO 9001:2008.

OCL is also certified for Environmental Management System as per

international standard requirement of ISO 14001:2004 in June 2011.

Required main raw material limestone is supplied from its captive limestone

mine located in the vicinity of Cement Plant viz, Devapur Limestone Mine is

spread over an area of 210 Ha with Limestone reserves of about 40 million

tonnes. Present Limestone production is 5.3 MTPA and the enhancement

will be from 5.3 to 6.0 million tonnes per annum, For Unit-IV, the raw

material will be met from New TSMDC Mine.

The estimated total cost of the project is Rs. 2100 Crores, for clinker and

cement expansion.

ii) Brief description of nature of the project

Cement Plant has present consented production capacity of Clinker 3.5

MTPA and Cement 3.07 MTPA, respectively. OCL is now proposing for

production capacity enhancement by Optimization and de-bottle necking of

Unit – I, II & III.

Similarly, the Power generation capacity and the Limestone production from

mine will increase.

The details of the cement plant capacities after the proposed expansion is

presented below

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PRODUCTION CAPACITY (MTPA)

Cement

Plant

Present Consented Capacity as

per MoEF (EC Obtained)

MTPA

Capacity after proposed

enhancement (EC Requested)

MTPA

Clinker Cement Power

(MW)

Clinker Cement Power (MW)

(TPD) (TPD)

Unit –I

3.50 3.07

2 x 25

MW

3.50

3.07

1.03 75 (25MW

through

WHRB)

Unit –II

Unit –III

Unit-IV - 2.50 3.50

Total 3.50 3.07 6.50 7.60

Present Limestone production is 5.3 MTPA and the enhancement will be

from 5.3 to 6.0 million tonnes per annum from existing mine. Balance 3.75

MTPA will be met from the proposed mine of 275 Ha.

The proposal is being submitted to MoEF separately for necessary

Environmental Clearance.

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

OCL wants to take up the section wise capacity balancing and optimization

of Unit- I, II& III. The proposed expansion will enable the company to

maximize its profitability by optimum utilization of technology, manpower,

present infrastructure and capital.

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The cost of production will substantially reduce due to reduction in cost of

power, 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 – only 11 acres of land is proposed to be acquired

Availability of existing infrastructure.

iv) Demand – Supply Gap

In the recent budget speech the Hon’ble Finance Minister and Prime

Minister have emphasized on development of Infrastructure, housing,

Irrigation, etc., all over the country. Per capita consumption of cement in

India is only 180 Kgs against the world average of about 340 Kgs whereas

per capita consumption in China (a developing nation like India) is 1000

Kgs.

India’s cement Industry recorded a growth in demand of 8.4% annually,

With highest importance being given by Central and State Governments for

development of infrastructure in the Country i.e., National High-ways, State

highways, Rural road net work, housing sector, construction of dams, canal

net work for irrigation, development of power sector which require huge

quantity of cement, demand growth in future is expected to be about 8% to

9% per annum. However, as many units approximately with a capacity of

70-80 Million MT will enter into production during next two years, there will

be a mismatch between supply and demand for some period. Accordingly,

the boom enjoyed by the cement industry was e over now and it may

experiencing intense competition for last 2-3 years. However, in the long

run, considering expected high level growth on Indian economy, the

prospects of cement industry are expected to be bright.

Now State and Central Governments are providing thrust for infrastructure

development and housing to the poor people. Also Govt. is giving incentives

for construction of own houses by the middle class people. Cement is one of

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the main commodity for construction of structures, houses and

infrastructures. Thus continued growth of cement industry is expected for

next few decades.

Growth of infrastructure, Irrigation and housing scenario automatically

drives the increased requirement of Cement in the market.

v) Imports Vs. Indigenous production

Not applicable. This is production enhancement project of existing Cement

Plant.

vi) Export possibility

Not applicable. This is production enhancement project of existing Cement

Plant to meet the domestic demand.

vii) Domestic / export markets

This is production enhancement project of existing Cement Plant to meet the

domestic markets demand.

viii) Employment generation (direct and indirect) due to the project.

This is only production enhancement project, hence only indirect

employment may be generated due to the proposed project.

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CHAPTER – 3

PROJECT DESCRIPTION

i. Type of project including interlinked and interdependent projects, if

any

The present proposal is for production enhancement of Cement Plant Unit-I,

II & III of OCL located at Devapur village. It is proposed to increase the

clinker production capacity of existing lines I, II and III from 3.50 MTPA to

4.00 MTPA by optimization and de-bottlenecking and installation of a new

Unit-IV for 2.50 MTPA.

To meet the limestone requirement of Cement Plant, Unit- I, II & III, it is

proposed for production enhancement of Devapur Limestone Mine

(interlinked project) increase of limestone production from 5.3 MTPA to 6.00

MTPA without increase in mining lease area. Mine is adjacent to the Cement

Plant.

Unit-IV limestone capacity 3.75 MTPA will be met from the proposed mine

of 275 Ha.

Similarly the power generation also will be increased from 50 to 75 MW, with

installation of a new Waste Heat Recovery power plant of 25 MW.

ii. Location (map showing general location, specific location, and

project boundary & project site layout) with co-ordinates.

The existing cement plant is located in Devapur Village, Kasipet Mandal of

Mancherial District of Telangana State, geographically bounded by North

Latitudes from 19°00’15” to 19°03’16” and East longitudes from 79°18’30” to

79°21’44” in the Survey of India topo sheet no. SK-133.

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The locational details are given in Table.

Feature Details

Altitude 256 m above msl

Village, Tehsil, District,

State

Devapur Village, Kasipet Mandal, Mancherial

District, of Telangana State, India..

Area 222.0 Ha

Max. Temp. 0C 47.2

Min. Temp. 0C 7.8

Relative Humidity % 25- 82

Annual rainfall 1107.0 mm

IMD Station Ramgundam – 29.0 km - E

Nearest water bodies Devapur Vagu – 2.6 km – ENE

Ralla Vagu – 5.3 km – ENE

Nearest Highway National Highway (NH-16) - Nizamabad –

Jagdalpur – 15.2 km - S

Nearest Railway station Mandamarri RS which 12.9 km in ESE

Bird

sanctuaries/National

Parks

None within 10 km radius

Nearest Industries DEVEPUR LIMESTONE MINE – 0.1 km - W

DEVEPUR LIMESTONE MINE –II – 0.5 km - SSW

Nearest Villages Devapur – 0.1km – N

Rampur – 0.7 km – E

Mallapur – 0.1 km – S

Maddimadagu – 1.0 km – SE

Gadapur – 0.9 km - SE

Nearest Town Karimnagar – 66.5 km - SSW

Inter State Boundary Telangana – Maharashtra – 54.0 km – E

Nearest Air port Rajiv Gandhi International Airport (Shamshabad)

– 218.0 km – SW

Nearest Forest Rali RF - 0.1 km - W

Waripet RF – 8.3 km -ENE

Tandur RF – 7.7 km -N

Historical places None within 10 km radius

The location map of the site, 10 km radius of study area and layout is

shown in Fig-1, Fig-2 and Fig-3 respectively.

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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.

The present proposal is for enhancement of production from Unit- I, II & III

of OCL located at Devapur Village Kasipet Mandal of Mancherial District of

Telangana. Hence, no alternate site considered or proposed for the proposed

expansion.

iv. Size or magnitude of operation

OCL present consented capacity is 3.50 MTPA Clinker production and 3.07

MTPA Cement production.

OCL is manufacturing two types of blended cement. viz., Ordinary Portland

Cement (OPC) and Portland Pozzolana Cement (PPC) at Devapur unit.

Manufacturing Process:

Limestone Mining: Mechanized mining of lime stone is done by deep hole

drilling, controlled 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 of L&T make is

installed to reduce limestone size from 1000 mm to 50mm.

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 2x40,000 MT for unit- I, II& III and 2x40,000 MT for

unit-IV. After forming the stockpile, the reclamation 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 either Vertical Roller Mill (VRM) or

Hydraulic Roller Press (HRP) section. Laterite (out source material) and

corrective limestone will be filled into laterite hopper and corrective

limestone hopper respectively. All the three materials with the required ratio

are conveyed through the weigh feeders and belt conveyors to either VRM or

HRP, where grinding takes place.

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VRM/HRP within built system of separator will grind the raw materials 75

mm size to 15 to 17% on 90 micron size. The product called Raw meal is

collected in cyclones and Pulse jet Bag House and transported through air

slides and bucket elevator and stored in blending Silo.

Pet coke / Coal Crushing & Grinding: Pet Coke / Raw Coal unloaded from

open trucks to yard and transported by Belt Conveyors to crusher where the

size is reduced from 300 mm to 50 mm and conveyed to raw coal hopper

through conveyor belts. Vertical roller mill (VRM) pulverizes raw coal to fine

coal with fineness of 16%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 6 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

completion of chemical reactions. Clinker formed is cooled in Static 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 combined with HRP or VRM 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 Vertical roller Mill or Ball mill HRP combined circuit to make

Portland Pozzolana Cement (PPC), Portland slag cement (PSC) if slag is used

instead of fly ash which is conveyed mechanically to cement storage silos.

Cement Packing: Electronic Packers (16 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.

The Plant is well automated and operated form Central Control Room and

Control system is based on DCS.

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Quality Control: All the raw materials, in- process and products are carried

out by means of XRF and XRD of Thermo fisher. 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 Ready mix concrete, Industries

and Builders prefer our product very well.

Process Control: The plant operation through a reputed vendor Automation

is equipped with Expert Control Systems (ECS). PIDs with closed loops

systems are intact and DCS is an advanced modern control system. Fuzzy

logic from the equipment supplier 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).

Power Plant: The existing power generation capacity of OCL is 50 MW, with

the following details

S.No Power Mode Capacity (MW)

1 Thermal ( Coal /Petcoke fired) 50

2 Waste Heat recovery based, for all units

(Proposed )

25

Total 75

The total power generation from the above sources is 50 MW. OCL will

install Waste Heat recovery Power Plant of 25 MW.

The Fuel requirement at present is:

Power Fuel Quantity (T/day)

50 MW Coal 1200

Proposed 25 MW WHRB NIL

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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, Laterite

and Bauxite. Limestone reserves of existing mine (Devapur) are about 25

million tonnes as on date in the present mining area which is spread in area

of 210 ha. and inferred limestone reserve in the new mining area of 275 ha.

is about 44.5 million tonnes. The requirement of raw material per annum for

the production of clinker at full capacity of 6.5 MTPA Clinker and 7.60 MTPA

cement is presented

DETAILS OF RAW MATERIAL

Raw Material Quantity per annum (in MTPA) Mode of Transpor

t

Before Expansion After Expansion Sourced from

Limestone

requireme

nt

Captive 5.3 9.75

Captive

Mines Road

Coal/Petco

ke

Cement

plant

0.30 (IND)

0.18 USA

0.30 (IND)

0.126 (US)- Pet

coke

0.55 - IND

0.30 USA

(OR)

0.51 - IND

0.21 - Pet

coke

SCCL,

USA,

ESSAR

Road

/

Rail

Power

plant 0.35 0.35

Laterite - 1 0.13 0.22 Warangal

Area Road

Laterite - 2 0.05 0.088 Warangal

Area Road

Al. Laterite 0.13 0.22 Rajamund

ry Rail

Gypsum 0.093 0.23 Gujarat /

Imported

Road

/Rail

Fly ash for PPC 0.55 1.7 Captive

/STPP

Road

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 site is well connected from the state high way between

Mancherial and Bellampalli. OCL has provided railway siding for

transportation of coal and finished product.

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vii. Resource optimization / recycling and reuse envisaged in the

project, if any, should be briefly outlined.

Waste water get generated in the Power plant is recirculated in the Power

plant and DM plant waste use in our plant premises plantation after

treatment.

No waste water generation from the cement plant. Waste water from Power

plant is recycled in cement plant.

The process, selected envisages re-cycling all the material collected in the

pollution control equipment whereby ensuring no generation of solid waste.

The system was remodeled to utilize high calorific value hazardous waste

(organic liquid hazardous waste as alternative fuel in kiln system.

viii. Availability of water its source, energy / power requirement

Water is required for cooling, dust suppression, sanitary facilities and

gardening. The water requirement for OCL at present is 1895 m3/day. The

source of water is rain water from mine pit. The total water requirement

after expansion of cement plant and operation of Unit – IV&NEW Power

plant will be about 4095 m3/day. This requirement will be met from mine

pit.

xi. Quantity of waste to be generated (liquid and solid) and scheme for

their management / disposal.

No industrial waste water is likely to be generated during cement

manufacturing process. The plant is a zero effluent discharge unit.

Therefore, proposed expansion of Cement Plant will not pose any adverse

impact on the ground water resources of the area.

Domestic Sewage generated from the colony & office toilets will be treated in

existing STP & treated water will be used for horticultural activities. The

outlet characteristic of the treated water is such that it can be used in

secondary purposes like toilet flushes, floor washings, green belt

development etc. Rain water harvesting is being practiced at plant and

colony area. Training and awareness programmes on water conservation

measures will also be organized for the locals.

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

Dust collected from air pollution control equipment is being totally recycled

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in process. Sludge from Sewage Treatment Plant (STP) (Capacity 250 KLD)

is being used as manure for green belt development. In addition to this 3 x

250 KLD STP are under installation. Fly ash generated from captive power

plant will be utilized in cement manufacturing process.

x. Schematic representations of the feasibility drawing which give

information of EIA purpose.

The location map of the site, 10 km radius of study area and layout is

shown in Fig-1, Fig-2 and Fig-3 respectively.

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CHAPTER – 4

SITE ANALYSIS

i. Connectivity

The existing cement plant is located in Village Devapur Village Kasipet

Mandal of Mancherial District of Telangana.



are available. National highway (NH-63) is connecting the site and State

Highway between Mancherial and Bellampalli is connecting the plant site.

Nearest railway Station is Bellampalli Railway Station at 19 km away from

existing site connected to various places of Central & South Central Railway.

A railway siding connects the plant to Mandamarri Railway Station , which

is about 24 km from Plant site.

ii. Land form, land use and land ownership.

The existing cement plant is located in the own land of OCL Devapur Village

Kasipet Mandal of Mancherial District of Telangana. Break-up of present

land use of existing OCL cement plant complex is given

S.No. Location present After expansion

(Area in acres)

1 Plant Area 168.56 194.38

A Builtup Area including

power plant

65.48 90.0

B Greenbelt Area 77.24 77.24

C Roads,Natural Nalah

and parking

25.84 27.14

D New land to be

procured

11.0

2 Township 257.35 242.53

A Builtup Area 20.24 25.24

B Greenbelt Area 167.04 167.06

C Roads,Natural Nalah

and vacant land

70.05 50.23

3 Total Project Area 425.89 436.91

A Total builtup area 85.72 115.24

B Greenbelt area 244.30 244.30

C % Greenbelt area 56.60 56.60

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OCL cement plant complex layout is shown in Figure-3. About 11 acres of

land will be procured for proposed expansion project.

iii. Topography (along with map)

The area is already in industrial use. The site is plain land. No more leveling

is required.

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 Devapur Village Kasipet Tehsil of

Mancherial District of Telangana state. . Break-up of present land use of

existing OCL cement plant complex is given above . No additional land will

be required for proposed expansion project.

v. Existing Infrastructure


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

available. A railway siding connects the plant to Mandamarri Railway

Station , which is about 24 km

Cement plant is having a dedicated 132 KV overhead line from Power grid

and 2x25 50 MW captive thermal power plant with in the cement plant for

uninterrupted power supply. Same power is being supplied to the mine also.

A new power plant based on waste heat is proposed for a capacity of 25 MW.

vi. Soil Classification

Soil in the area is found to be clayey in texture

vii. Climate data from secondary sources

The climate of the area is typical of the continental interior of India. The area

falls in the western side of Telangana state. . It has low rainfall and exhibits

hot dry climate.

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The area has an average rain fall of 1200 mm. The area experience

temperature of 48.5oC maximum and 6oC minimum. Relative humidity of

the area range from 16 % minimum to 90 % maximum.

The wind direction is predominantly from ENE direction. Wind speed during

this period varied from 3 km/hr to 25 km/hr.

viii. Social infrastructure available

A well-equipped Occupational Health center is provided at our 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.

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 mines. Drinking water facility

is available near rest shelters.

A full-fledged Training hall is available in the OCL 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

colony.

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CHAPTER – 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 existing OCL

cement plant complex. No additional land will be required for proposed

expansion project and the expansion will be carried out in the existing plant

only.

ii. Population projection

Another 150 workmen will be employed.

iii. Land use planning (breakup along with greenbelt etc)

The present land use pattern of the existing OCL cement plant complex is

given in Table-4. No additional land will be required for proposed expansion

project

iv. Assessment of infrastructure demand (physical & social)

This is expansion project within OCL cement plant complex. No physical &

social infrastructure is envisaged for the proposed project expansion project.

v. Amenities / Facilities

Existing amenities and facilities sufficient even after proposed expansion

project.

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CHAPTER -6

PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

No additional infrastructure is proposed for the proposed production

enhancement. It is proposed to increase the clinker production capacity

from 3.50 MTPA to 6.50 MTPA by Optimization and de-bottle necking and

installation of Unit-IV.

Major modifications envisaged for production enhancement

Modification of pre-heater cyclones

Modification of Cooler Inlet

Up-gradation of TAD

Strengthening of coolers

Upgradation of kiln drives

A new power plant WHRB of 25 MW will be installed with all necessary

infrastructures.

ii. Residential area (non-processing area)

Existing amenities and facilities are sufficient.

iii. Greenbelt

OCL has already developed greenbelt in an area Of 241 acres in and around

the OCL cement plant complex. OCL is taking up more area under greenbelt

development programme.

iv. Social infrastructure

Existing social infrastructure will be serving the plant operations.

v. Connectivity (traffic and transportation road/rail/metro/water ways

etc.)



are available. A railway siding connects the plant to Mandamarri Railway

Station, which is about 24 km from Plant site.

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vi. Drinking water management (source & supply of water)

The existing cement plant is having safe drinking water facility.

vii. Sewerage System

Domestic waste water generated from Cement plant/Colony is being treated

in STP and treated water is being used for green belt development /

Horticulture activities.

viii. Industrial waste management

No industrial waste water is being generated from the Cement Plant.

ix. Solid waste Management

No solid waste is being generated from the cement manufacturing process.

Solid waste generated from Power Plant i.e., Flyash is totally consumed in

cement plant.

Dust collected from various pollution control equipments is being recycled

back to the process.

STP Sludge is being utilized as manure for green belt development within

the plant premises.

Fly ash from Captive Power Plant will be used for making PPC.

x. Power requirement & Supply /Source.

The power requirement for both unit-I, II& III will be sourced from Captive

Power Plant. Unit-IV will source power from new WHRB plant. .

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CHAPTER – 7

REHABILITATION AND RESETTLEMENT (R & R) PLAN

i. Policy to be adopted (central / state) in respect of the project

affected persons including home oustees, land oustees and landless

labourers (a brief out line to be given).

The proposal is for production enhancement of existing Cement Plant and

installation of new Line with WHRB within OCL cement plant complex near

Devapur village, Mancherial District of Telangana State. 11 acres of

additional land will be procured for proposed expansion project within the

guidelines and practices of R&R policy.

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CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES

i. Likely date of start of construction and likely date of

completion (time schedule for the project to be given).

The subjected production enhancement project of Cement Plant i.e. Unit- I,

II & III and New line IV of 2.5 MTPA along with the new waste heat recovery

power plant of 25 MW is expected to be completed in a period of 24 months

from the date of receipt of all the approvals from statutory authorities.

ii. Estimated project cost along with analysis in terms of economic

viability of the project.

The estimated cost of the project is Rs. 2100 crores for Cement plant and

Waste Heat Recovery Plant.

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CHAPTER – 9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

i. Financial and social benefits with special emphasis on the benefit to

the local people including tribal population, if any, in the area.

The capital cost, for the proposed production enhancement project, works

out to Rs. 2100 crores for Cement plant. The funding is met from financial

institutes with the required equity contribution from OCL. With the IRR at

15 to 18%, the buyback is in Six years.

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 these markets 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, OCL is planning to go ahead with the project, once it

gets all the statutory approvals for this enhancement project.

PRE FEASIBILITY REPORT For Expansion of Cement Plant...

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