PRE FEASIBILITY REPORT

FOR

EXPANSION OF CEMENT PLANT

with

CLINKER PRODUCTION ; 1.6 MTPA to 2.6 MTPACEMENT PRODUCTION – 0.9 MTPA TO 2.0 MTPA

at

NCL INDUSTRIES LTD.,Mattapalli Village, Matampalli Mandal

Nalgonda District, Telangana

Table of Contents

Executive Summary 03

1. Introduction Of The Project/ Background Information 06

2. Project Description 10

3. Site Analysis 17

4. Planning Brief 25

5. Proposed infrastructure 26

6. Rehabilitation and resettlement (R & R) Plan 29

7. Project schedule & Cost Estimates 30

8. Analysis of proposal (Final Recommendations) 31

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

NCL INDUSTRIES LTD. (NCL)

NCL INDUSTRIES LTD. (NCL), is operating a Cement Plant with aClinker production capacity of 1.6Million Tonnes Per Annum(MTPA)at Mattapalli village, Mattampalli mandal of Nalgonda District.,Telangana .

The cement plant was established in the year 1984 with a clinkerproduction capacity of 200 TPD. The quality of cement produced byNCL has an outstanding demand in the market. Over a period of time,NCL has enhanced the clinker production capacity to present level of4800TPD (1.60 MTPA).

NCL is involved in manufacturing of various grades of cements: i.e

a. Ordinary Portland Cementb. IRST-53S Cement for Indian Railwaysc. Portland Pozzolana Cement

The limestone requirement of the cement plant is met from miningleases located at Mattapalli, Sultanpur Thanda and Gundlapallivillages.

NCL received Environmental Clearance vide MOEF letter no. J-11011/576/2008-IA.II(I) dt 15-12-2009 (Annexure-I)

The current status of various units of NCL along with installedproduction capacities are given below:

OVERVIEW OF PRODUCTION CAPACITIES OF NCLInstalled capacity

MTPA1 Clinker Production Capacity 1.602 Cement Production Capacity 0.903 Captive Limestone Mining 2.55

PRESENT PROPOSAL

NCL now proposes to increase clinker production capacity from 1.60to 2.60 MTPA and cement production from 0.9 to 2.00 MTPA byinstalling a new unit. With increase of clinker production capacity, thelimestone requirement increases 2.55 MTPA to 3.9 MTPA.

NCL proposes to meet the above additional limestone requirementfrom three captive limestone mining leases. The mining leases extendsover an area of 541.88 acres, in Mattapalli, Sultanpur thanda andGundlapalli villages in Mattamapalli Mandal, Nalgonda Dist.Telangana .

The present proposal pertains to obtaining environmental clearancefor the following

INCREASE OF PRODUCTIONProduction (MTPA)

BEFOREEXPANSION AFTEREXPANSIONCEMENT PLANT Clinker 1.60 2.60

Cement 0.90 2.00

NCL complex is located in an area of 48.12 Ha

Need for the project and its importance to the country and orregion.

The cement market has growth potential due to the centralgovernment liberalization policies and new schemes for housing, roadprojects. Cement demand growth is anticipated to be about 9 to 10%increase mainly through National Highway road projects, HousingProjects (1.3 million houses in rural & 0.7 million in urban areas).Continuous demand for exports to China and other South-East Asiancountries along with the increased requirement of the domestic sectorhave led all the cement manufacturers in the country to plan forincreased capacities.

So with a view to capture growing opportunity demand, themanagement NCL wants to take up the section wise capacitybalancing and optimization. The proposed expansion will enable the

company to maximize its profitability by optimum utilization oftechnology, manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficientequipment , better fuel, financial charges and other fixed overheads onaccount of large scale economics due to higher volume of productionand sales.

It would also enable the company to withstand against theconsiderable competitive pressure from large-scale units in thecountry and also to create wider brand loyalty for the product.

The increase of production within the existing plant is based on thefollowing considerations

• Proximity of the site to captive limestone mines and abundantavailability of reserves.

• Market demand• Availability of land – no further land is proposed to be acquired• Availability of existing infrastructure.

Upcoming Railway line by South Central Railways (SCR) is underconstruction connecting Mellacheruve & Janpahad . NCL has got in-principle approval from SCR for own railway siding. This rail way linewill help in transporting cement from the cement plant to the marketand obtaining raw materials like coal, gypsum and other additives,etc.

NCL cement plant is supported by their captive Limestone mines.. Tomeet the additional limestone requirement of Cement Plant afterproposed new line,. The production capacity of limestone mines will beaugmented. The proposal is being submitted to MoEF separately fornecessary environmental clearance.

The best fuel combination considered is imported coal. The indigenouscoal is envisaged to be sourced from Singareni Colleries after linkageis received . Till then the imported Coal will be sourced.. Coal isbrought to the plant by trucks./by rail in future

The present water requirement fof the plant is 670 m3/day and issourced from Krishna river. .

Additional Water requirement for proposed Unit is 230 m3/day andwill be met from Krishna river.

The project is based on Clinkerization factor of 1.50 on kiln feed basiswith specific heat consumption of 725 Kcal/ kg clinker.

No solid waste generation from the plant.

There is no wild life sanctuary, national park, eco-sensitive areawithin the 10 km radius of the project site.

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available.

No additional quarters construction is proposed.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 250 m3/day. Treateddomestic wastewater is 100% reused for greenbelt development withinNCL cement plant complex.

Greenbelt is maintained in about 33 % of the total area.

The peak power consumption in the NCL Cement plant complexincluding mine is 18 MW. Power requirement is met from grid. Anadditional power of 12MW is required for the proposed expansionproject.

Plant expected to be commissioned in 14 months from date ofcommencement of construction

Total capital Investment Cost is Rs. 200 crores.

1.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

i) Identification of project and project proponent. In case ofmining project, a copy of mining lease / letter of intentshould be given.

NCL, is operating a Cement Plant with a Clinker production capacity of1.60 Million Tonnes Per Annum(MTPA) at Mattapalli village,Mattampalli mandal of Nalgonda District., Telangana .

NCL cement plant is supported by their captive limestone mines

NCL present installed capacity of cement plant is 1.6 million tonnesper annum (MTPA) of clinker and 0.9 MTPA of cement. NCL ismanufacturing Ordinary Portland Cement (OPC), and PortlandPozzolana Cement (PPC).

To meet the increasing demand of cement, both in the domestic andinternational markets, NCL is proposing to setting up a newproduction line with the clinker production capacity of 1.0 MTPA. Theestimated total cost of the project is Rs. 200 Crores.

ii) Brief description of nature of the project

NCL is now proposing to setting up a new production line with theclinker production capacity of 1.0 MTPA and cement productioncapacity of 1.1 MTPA.

iii) Need for the project and its importance to the country and orregion.

The cement market has growth potential due to the centralgovernment liberalization policies and new schemes for housing, roadprojects. Cement demand growth is anticipated to be about 9 to 10%increase mainly through road projects (Golden Quadrilateral), HousingProjects (1.3 million houses in rural & 0.7 million in urban areas).Continuous demand for exports to China and other South-East Asiancountries along with the increased requirement of the domestic sectorhave led all the cement manufacturers in the country to plan forincreased capacities.

So with a view to capture growing opportunity demand, themanagement NCL wants to take up the section wise capacitybalancing and optimization. The proposed expansion will enable thecompany to maximize its profitability by optimum utilization oftechnology, manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficientequipment , fuel, financial charges and other fixed overheads onaccount of large scale economics due to higher volume of productionand sales.

It would also enable the company to withstand against theconsiderable competitive pressure from large-scale units in thecountry and also to create wider brand loyalty for the product.

The increase of production within the existing plant is based on thefollowing considerations

• Proximity of the site to captive limestone mines and abundantavailability of reserves.

• Market demand• Availability of land – no further land is proposed to be acquired• Availability of existing infrastructure.• Upcoming Railway line by South Central Railways (SCR) is

under construction .This rail way line will help in transportingcement from the cement plant to the market and obtaining rawmaterials like coal, gypsum and other additives, etc.

Demand – supply Gap

In the recent budget speech the Hon’ble Finance Minister and PrimeMinister have emphasized on development of Infrastructure, housing,Irrigation, etc., all over the country. Per capita consumption of cementin India is only 180 kgs against the world average of about 340 kgswhereas per capita consumption in China (a developing nation likeIndia) is 1000 kgs.

India’s cement Industry recorded a growth in demand of 8.4% during2012-13. With highest importance being given by Central and StateGovernments for development of infrastructure in the Country i.e.,National High-ways, State highways, Rural road net work, housingsector, 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% perannum. However, as many units approximately with a capacity of 70-80 Million MT will enter into production during next two years, therewill be a mismatch between supply and demand for some period.Accordingly, the boom enjoyed by the cement industry will be overnow and it may see intense competition for next 2-3 years. However,in the long run, considering expected high level growth on Indianeconomy, the prospects of cement industry are expected to be bright.

Now State and Central Governments are providing thrust forinfrastructure development and housing to the poor people. Also Govt.is giving incentives for construction of own houses by the middle classpeople. Cement is one of the main commodities for construction ofstructures, houses and infrastructures. Thus continued growth ofcement industry is expected for next few decades.

Growth of infrastructure, Irrigation and housing scenarioautomatically drives the increased requirement of Cement in themarket.

v) Imports Vs. Indigenous production

India is self sufficient to meet the demands of the market with theGDP projected at 10 % in the coming decades and in view of theinfrastructure.

The end product being cement, the importance of the project isdetailed below with respect to cement demand.

India is self sufficient to meet the demands of the market with theGDP projected at 10% in the coming decades and in view of theinfrastructure.

vi) Export possibility

No export of cement outside the country is planned.

vii) Domestic / export markets

This new line project is proposed to meet the domestic marketsdemand.

viii) Employment generation (direct and indirect) due to theproject.

50 additional employees are required

2. PROJECT DESCRIPTION

i. Type of project including interlinked and interdependentprojects, if any

The present proposal is setting up new kiln within existing CementPlant area of NCL located at Mattapalli Village, Nalgonda Dist, inTelangana , in area of 48.12 Ha.

To meet the limestone requirement of Cement Plant after proposednew line, the existing mines’ production will be enhanced .

ii. Location (map showing general location, specific location, andproject boundary & project site layout) with co-ordinates.

The Cement plant is located near Mattapalli Village, MattampalleMandal, Nalgonda District, Telangana. The site falls between 79045’ to79050’ East longitude and 16040’ to 16045’ North latitude with anaverage msl of 60 m above msl. The area falls within Survey of IndiaToposheet no. 56 P/14 [1:50000 scale].

The area is well connected by roads from Kodada & Huzurnagar.Vijayawada is the main city which is located at a distance of 135 kmfrom the Plant Site.

Limestone mines fall under the revenue limits of Mattapalli,Pedaveedu and Gundlapalli villages in Mattamapalli Mandal, NalgondaDist. Telangana. .

Fig-1 shows the location map of the Plant Site.

River Krishna flows at a distance of 0.5 km south of the plant site. ThePlant Site is located at a distance of 40 km away from the NationalHighway [NH-9] connecting Vijayawada-Hyderabad.

The key map showing the location of captive mines and the cementplant are shown in Fig – 2

The reserved forests located within the 10 km radius of the cementplant and mines are Sultanpur Reserve Forest, Tangeda R F,Regulagadda R F and Gurrambodu Reserve Forests

The nearest airport is Gannavaram at a distance of 155 km from thePlant site.Due to availability of rich limestone deposits, major cement plants,which are located within 10 km, are given below

DETAIL OF CEMENT PLANTS IN STUDY AREA

• Sagar Cements Ltd – 7.6 km - NE• Myhome Cement Ltd. – 10.00 Km

There are no national parks/wild life sanctuaries/eco sensitive zoneswithin 10 km radius of the cement plant and mine sites.

Fig-3 shows the 10 km radius around Cement plant. Salient featuresof the plant site are given in Table-1.2.

iii. Details of alternate sites considered and the basis of selectingthe proposed site, particularly the environmental considerationsgone into should be highlighted.

As the expansion is proposed in the existing premises, no alternatesite considered or proposed for the proposed project

iv. Size or magnitude of operation

With the proposed expansion , the clinker production will be 2.6 MTPAand Cement at 2.0 MTPA.

NCL is manufacturing blended cement. viz., Ordinary PortlandCement (OPC)) and Portland Pozzolana Cement (PPC).

Manufacturing Process:

Limestone Mining: Mechanized mining of lime stone is done by deephole drilling, nonel blasting, excavation and hauling. The blasted limestone of size less than 1000mm will be transported to lime stonecrusher for crushing.

Limestone Crushing: A single Rotor Impact Crusher is installed toreduce limestone size from 1000 mm to 75mm.

Stacking & Reclaiming: The crushed lime stone is stackedlongitudinally with stacker as per the required quality given by QualityControl Dept. The capacity of stock pile is 80000T. After forming thestockpile, the reclaimation will be started. The total process ofstacking and reclaiming is called chevron method.

Raw material grinding: Blended lime stone will be reclaimed and willbe filled into raw material hopper in the Vertical Roller Mill (VRM)section. Laterite (out source material) and corrective limestone will befilled into laterite hopper and corrective limestone hopper respectively.All the three materials with the required ratio are conveyed throughthe weigh feeders and belt conveyors to Vertical Roller Mill, wheregrinding takes place.

VRM within built system of separator will grind the raw materials 75mm size to 17%R on 90 micron size. The product called Raw meal iscollected in cyclones and Pulse jet BH and transported through airslides and bucket elevator and stored in blending Silo.

Coal Crushing & Grinding: Raw Coal unloaded from open trucks toyard and transported by Belt Conveyors to crusher where the size isreduced from 100mm to 15 mm and conveyed to raw coal hopper

through conveyor belts. Vertical roller mill (VRM) pulverizes raw coalto fine coal with fineness of 16%R on 90 microns, which is collected inBag Filter. The fine coal is further conveyed mechanically to fine coalbins and transported to kiln and calciner pneumatically (through FKpumps) for firing.

Pyro-Processing: This system consists of Rotary Kiln with 6 stagePre-heater and In-line Calciner. Raw meal from Silos is conveyedthrough pre-heater. Fine coal is fired through burner pipe into kilnand into pre-calciner. The material is 90 to 92 % calcined beforeentering into kiln and balance calcination, Pre burning and sinteringtakes place in the kiln for ensuring completion chemical reactions.Clinker formed is cooled in Static grate coolers with high pressurefans. The clinker after cooling is transported mechanically to clinkerstorage tanks.

Cement Grinding: Clinker from clinker storage tank is conveyed toclinker hopper. Gypsum is filled into gypsum hopper. Closed CircuitTube Mill with dynamic separator grinds clinker and gypsum in aratio of 95:5 respectively. The product, called Ordinary Portlandcement (OPC) is conveyed mechanically to cement storage silos.

Similarly Clinker, Fly Ash, gypsum in a ratio of 63: 32: 5 respectivelyare ground in the Vertical roller Mill to make Portland PozzolanaCement (PPC), Portland slag cement (PSC) & Portland PozzolanaCement (PPC) 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 areloaded to the trucks through belt conveyors and loaders.

The Plant is well automated and operated form Central Control Roomand Control system is based on PLC.

Quality Control: All the raw materials, in- process and products arecarried out by means of XRF and XRD of PAN Analytical. Thepreventive measures are taken to ensure the consistent and bestquality is achieved. Material testing is undertaken on calibratedinstruments 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 themarket and customers like Readymix concrete, Industries andBuilders are preferring our product very well.

Process Control: The plant operation through Siemens Automation isequipped with Expert Control Systems (ECS), comprising the SDRsystem. PIDs with closed loops systems are intact and PLC is inadvanced modern system. Fuzzy logic from FLS is also adopted forsmooth and consistent operation of the plant. The process parameteris designed by the experts and is operated by qualified andexperienced engineers. The deviations are minimized and thetolerances are limited. This is resulting in achieving the productivity interms of best quality, optimal production and energy conservation(thermal as well as electrical).

vi. Raw material required along with estimated quantity, likelysource, marketing area of final products, mode of transport of rawmaterial and finished product.

The raw material required for production of clinker is Limestone, Ironore, Bauxite and Coal. Available limestone reserves of existing mines.The requirement of raw material per annum on an average for theproduction clinker and cement at capacity of 2.6 MTPA is presented inTable-2.

Table-2Raw Material Requirement

Sl.No.

Material QuantityMTPA

Source Locality

1 Limestone 3.90 Mattapalli,Gundlapalli@Sultanpurtanda

2 Gypsum 0.130 Coromandal Fertilisers.,Visakhapatnam3 Dry Fly ash 0.640 Vijayavada Thermal Power

Station,Vijayavada4 Coal) 0.50 Imported5 Bauxite/laterite 0.20 Maharastra /Belgaum

For obtaining raw materials like coal, gypsum, additives andtransporting cement from the cement plant to the market well

connected roads are available. The National Highway (NH-65)connecting Hyderabad –Vijayavada is at a distance of about 35 km.

vii. Resource optimization / recycling and reuse envisaged in theproject, if any, should be briefly outlined.

Available limestone reserves of existing mines which cater to limestoneneeds of Cement Plant

Limestone from all the three mines is blended to arrive at the properfeedable quality (subjected to the receipt of quality of coal) andsupplied to Cement plant for optimum utilization of resources.

Cooling water circuit is close circuited, thereby ensuring no generationof wastewater. The process, selected envisages re-cycling all thematerial collected in the pollution control equipment wherebyensuring no generation of solid waste.

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

Water

Water is not required for the cement manufacturing process. Water isrequired for cooling, dust suppression, sanitary facilities andgardening. Water requirement for proposed line is 230 m3/day,bringing the total consumption of complex to 900 m3/day. The sourceof water is River Krishna.

Power

The peak power consumption in the NCL Cement plant complexincluding mine is 18 MW. Total power requirement for the NCL cementplant complex is met from Grid. Additional power required is about12 MW.

xi. Quantity of waste to be generated (liquid and solid) andscheme for their management / disposal.

In cement plant water is used for cooling, gas conditioning and rawmaterial addition at various stages. This water is totally absorbed in

the process or will be subjected to evaporation and hence nowastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 250 m3/day. Treateddomestic wastewater is 100% reused for greenbelt development withinNCL cement plant complex.

No solid waste will be generated from the cement plant. The dustcollected in the pollution control devices is being 100% recycled backto the process.

Schematic representations of the feasibility drawing which giveinformation of EIA purpose.

3. SITE ANALYSIS

i. Connectivity

The Cement plant is located near Mattapalli Village, MattampalleMandal, Nalgonda District, Andhra Pradesh.

The area is well connected by roads from Kodada & Huzurnagar.Vijayawada is the main city which is located at a distance of 135 kmfrom the Plant Site.

ii. Land form, land use and land ownership.

Break-up of present land use of existing cement plant is given inTable-1 and NCL cement plant layout is shown in Figure-4. Noadditional land acquisition will be required for proposed new line.Proposed Unit will be located in an area of about 5 ha within theexisting cement plant area.

iii. Topography (along with map)

The existing NCL Cement plant site is located at an elevation of 60 mabove MSL.

The Cement plant is located near Mattapalli Village, MattampalleMandal, Nalgonda District, Telangana. The site falls between 79045’ to79050’ East longitude and 16040’ to 16045’ North latitude with anaverage msl of 60 m above msl. The area falls within Survey of IndiaToposheet no. 56 P/14 [1:50000 scale].

The area is well connected by roads from Kodada & Huzurnagar.Vijayawada is the main city which is located at a distance of 135 kmfrom the Plant Site.

River Krishna flows at a distance of 2.0 km south of the plant site. ThePlant Site is located at a distance of 40 km away from the NationalHighway [NH-9] connecting Vijayawada-Hyderabad.

The reserved forests located within the 10 km radius of the cementplant and mines are Sultanpur Reserve Forest, Tangeda R F,Regulagadda R F and Gurrambodu Reserve Forests

The nearest airport is Gannavaram at a distance of 155 km from thePlant site.

There are no national parks/wild life sanctuaries/eco sensitive zoneswithin 10 km radius of the cement plant

LOCATION MAPFIG - 1

INDIA

Warangal

TELANGANA

Nalgonda

Khammam

Adilabad

KarimnagarNizambad

Medak

Rangareddi

Mahabubnagar

PLANT SITE

LEGEND

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PROJECT :

TITLE : KEY MAP

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FIG-4 PLANT LAYOUT

iv. Existing land use pattern (agriculture, non-agriculture, forest,water bodies (including area under CRZ), shortest distances fromthe periphery of the project to periphery of the forests, nationalpark, wild life sanctuary, eco sensitive areas, water bodies(distance from the HFL of the river), CRZ, in case of notifiedindustrial area, a copy of the Gazette notification should begiven.

The existing cement plant is located in Mattapalli Village. Noadditional land will be required for proposed expansion project.

• There are no national parks or wildlife sanctuary within 10 km of thesubject plant area.

• No ecologically sensitive area such as tropical forests, biospherereserves, important lakes or coastal area rich in coral formation fallwithin 10 km of the plant area.

• There are no sensitive places of notified archaeological, historical ortourist importance within 10 km from the plant area.

v. Existing Infrastructure

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available.

TABLE – 1.2SALIENT FEATURES OF THE CEMENT PLANT

Village, District, StateMattapalli village,Nalgonda District,Telangana

Maximum Temperature 48 oCMinimum Temperature 13 oCRelative Humidity, % 48-84 %Annual rainfall, mm 600 mm

Land availability,120 Acres(48.12 ha)

Nearest River Krishna River – 0.50 km

Nearest HighwayN H 9 Connecting Hyderabad –Vijayawada – 36.3 km

Nearest R. S. Mattampalli – 8 km

Nearest IndustriesSagar Cements Ltd – 7.6 km - NEMyhome Cement – 10.00 km

Nearest Village Mattapalli – 2.00 km – SNearest City Vijayawada -135 km

Nearest Air portVijayawada – 135 km

Nearest Forest

Sultanpur RF – adjacent Tangeda R F – 1.3 km Regulagadda RF – 4.0 km Gurrambodu RF – 2.9 km

Historical placesNone Within 10kmRadius

* Distances mentioned are aerial distances

vi. Soil Classification

The proposed new line will be located in existing plant area. Noadditional land will be required for proposed new line.

Soil in the area is found to be sandy clayed in texture with sandpercentage in the range between 20-60%, silt between 18-41% andclay 22-44%.

vii. Climate data from secondary sources

The tropical climate of the region is manifested in hot and humidsummer, moderately monsoon and mild winter seasons. May is thehottest month in the year. The maximum temperature during the daytime was recorded as 46 0C and December the coldest with thetemperature during the day time falling down to about 310C. Thenight temperature in winter can be as low as 120C. The months ofDecember, January & February are considered to have pleasantclimate.

viii. Social infrastructure available

A well-equipped Occupational Health center is provided at colony,which has full time male and lady medical officers assisted, bycompounders and nurses. Necessary free medicines and medical aid isavailable for the company employees.

A good canteen is provided for the benefit of the employees. Thecanteen serves tea & snacks at subsidized rates to the employees.

Adequate number of shelters with fans, drinking water etc. for takingfood and rest are provided for the benefit of the employees.

Safe hygienic drinking water is provided at the plant. Drinking waterfacility is available near rest shelters.

A full-fledged Training hall is available in the NCL cement plantcomplex. The training to workmen is provided on basics as well as forrefreshers.

The employees are provided with well-designed houses havingelectricity and water connections.

For the education facility of employee’s children School is provided atour colony.

4. PLANNING BRIEF

i. Planning concept (type of industries, facilities, transportationetc) town and country planning / development authorityclassification.

This is expansion project of existing cement plant within the presentNCL cement plant complex. Additional civil structures will berequired for proposed unit .

ii. Population projection

The total manpower at the existing plant is 370. 50 additionalmanpower is required.

Apart from the jobs, the company provided medical and educationalfacilities to the employees which were availed by the people aroundthe plant. Adequate recreational facilities for the staff of the companyand the local people were created.

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

This is expansion project of existing cement plant. The present landuse pattern of the existing NCL cement plant complex is given inTable-1. No additional land will be required for proposed expansionproject

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 andother social facilities are adequate at district headquarter which sitemakes the region adequate in amenities.

5. PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

The following are the major equipment proposed under the newproduction line

MainMachinery

Item Type Capacity

LimestoneCrusher

Single stageimpactor typeCrusher

900 tph

LimestoneStacker

Luffing Boom TypeStacker

900 tph

LimestoneReclaimer

Bridge TypeReclaimer

500 tph

Raw MaterialGrinding

VRM 330 tph

Coal Grinding Vertical Roller Mill 40 tphPreheater /Calciner

Single String six Stage Preheater withInline Precalciner - 3000 tpd

Kiln Rotary Kiln - 3000 tpdClinker Cooler Grate Cooler – 3000 tpd

CementGrinding

Ball Mill withRoller press as pregrinder

130 tph

Packing Plant Rotary Packer 100 tphMainStorages

Item Type CapacityLimestone Stockpile

LongitudinalStockpile

2x 40000 t

ChemicalgypsumStockpile

Open stockpile 3000 t

Raw Meal Silo RCC 10000 tFly Ash Silo RCC 3000 tClinker Silo RCC 25000 tCement Silo RCC 8000 t

ii. Residential area (non-processing area)

Residential colony is located nearer to the plant. The Waste waterfrom colony and plant is treated in the Sewage Treatment Plant.

iii. Greenbelt

NCL has already developed greenbelt in an area of 16 ha in andaround the NCL cement plant complex. NCL is taking up more areaunder greenbelt development programme.

iv. Social infrastructure

NCL has well defined CSR policy to Carryout social development andwelfare measures in the surrounding villages. Under CSR activityNCL will initiate community development projects, in the fields ofhealth, education and environmental preservation, in the study areaaround the plant as is done in their existing units.

v. Connectivity (traffic and transportation road/rail/metro/waterways etc)

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected roads are available. The National Highway (NH-65)connecting Hyderabad-Vijayavada is at a distance of about 35

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

The existing cement plant is having safe drinking water facility. ROwater is supply to all the employee and contract workmen.

vii. Sewerage System

Existing STP will be utilized for treatment of domestic wastewater afterexpansion 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. Alsothe cooling water will be through a closed circuit system. The onlywaste water generated will be domestic waste water from residentialtownship and the same will be treated in STP and used for green beltdevelopment.

Hazardous wastes like spent oil from construction equipment, DG setsetc., generated in small quantities during construction andoperational phase would be appropriately stored & handled andproperly disposed off in accordance with the provisions of theHazardous Waste Management Rules, 2010.

ix. Solid waste Management

No solid waste is generated from the cement plant. The dust collectedin the pollution control devices is being 100% recycled back to theprocess.

x. Power requirement & Supply/Source.

The peak power consumption in the NCL Cement plant complexincluding mine is 18 MW. Total power requirement for the NCL cementplant complex is met from grid. An additional power of 12 MW isrequired for the proposed expansion project.

6. REHABILITATION AND RESETTLEMENT (R&R) PLAN

The new Unit is coming up in the existing complex owned by NCL andthe R&R does not arise.

7. PROJECT SCHEDULE & COST ESTIMATES

The project is expected to be completed in a period of 14 months fromthe date of receipt of all the approvals from statutory authorities. Theestimated cost of the project is Rs. 200 crores.

8. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)

The capital cost, for the proposed production enhancement project,works out to Rs. 200 crores. Financial institutions will be funding theproject.

Growth of infrastructure, Irrigation and housing scenarioautomatically drives the increased requirement of Cement in themarket. Based on the growing demand in the South East region of thecountry for Cement over the next 10 years, the proximity of the projectlocation to this market is an advantage with respect reduction infreight of cement to these markets. The financial viability also show agood Rate of return from the project. Considering the above NCL isplanning to go ahead with the project, once it gets all the statutoryapprovals for this enhancement project.