Post on 24-Feb-2018
FOR
Integrated Cement Plant
Clinker Production 2.4 Million TPA,
Cement Production 4.0 Million TPA,
Captive Power Plant 25 MW
&
Waste Heat Recovery Power Generation 15 MW
Near village –Pedagarlapad,
Mandal - Karempudi,
District-Guntur,
Andhra Pradesh
PROPOSED BY
M/s SHREE CEMENT LIMITED
APRIL 2014
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
1
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
Shree Cement Ltd. is proposing expansion of integrated cement plant (2.4
Million TPA Clinker, 2x2.0 Million TPA Cement, 25 MW Captive Thermal
Power Plant & 15 MW Waste Heat Recovery Power Generation) near
village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
SALIENT FEATURES OF THE PROJECT
S.No. Particulars Details
1 Locations of the plant
A. Village Near village Pedagarlapad,
Tehsil- Karempudi
B. District Guntur
C. State Andhra Pradesh
D. Land Survey Nos. Plant (100.49 ha)
645-647, 650, 652-658, 898-902,
910-920, 922-925, 930-946, 963
Colony (42.30 ha)
660-665, 691-694, 696, 699-
702,876-877,896
Topo-sheet No. 56P/10
2
Plant Site: Latitude 16 30' 51" N to 16 31' 25" N
Longitude 79 43' 48" E to 79 44' 40" E
3 Temperature Min:16.4° C, Max : 32.4° C
4 Relative Humidity
08:30 hrs. - 68% - 94 %
17:30 hrs. - 58 % - 75 %
5 Mean Annual Rainfall 1083 mm
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
2
6 Nearest National Highway NH-9 (54 km in NE Direction)
7 Nearest Railway Station Nadikudi 4.5 Km
8 Nearest Airport Vijayawada 114 Km
9 Nearest city /Town Dachepalli at a distance of ~5.1
km. in North direction
10 Reserved / Protected Forest
within 10km radius
(Boundary to boundary
distance)
Kakirala Reserved Forest: 11
km in S direction.
Madinapadu Reserved
Forest: 11.5 km in NNW
direction.
Daida Reserved Forest: 13.5
km in SW direction.
Fairly dance mixed forest: 12
km in SSE direction
11 Nearest Surface Water
bodies
Krishan River – 15.5 km from
proposed plant site & mine
site.
Nagajuna sagar right bannk
canal or Jawahar Canal:
About 7.5-10 km in SE & S
direction.
12 Nearest Hill Ranges --
13 Water requirement & Source 1500 KLD for both plant and
mining.
Source: Ground Water
14 Soil Type Black cotton
15 Nearest Town / City Zone – II [as per IS 1893 (Part-I):
2002]
16 Capital cost Rs. 1234 Crores
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
3
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
Shree Cement Limited (SCL) is the largest producer of cement in Northern
India with a production capacity of 13.5 million tonne per annum. It
started its operations in 1985 with 0.6 million ton capacity at Bangur
Nagar, Beawar in Ajmer, Rajasthan and has rapidly expanded its
operations to reach the present production capacity of 13.5 million
tonne. The principal promoter of the company is Bangur Group, which is
a respected business house of India.
The company pursues multi-brand portfolio strategy which consists of
three offers viz. viz. Shree Ultra Jung Rodhak Cement, Bangur Cement
and Rockstrong Cement.
The company has its manufacturing operations at Beawar, district Ajmer
and Ras in Pali district and a split grinding unit at Khushkhera, Suratgarh &
Jobner in Rajasthan and Laksar in Uttrakhand.
Total Thermal Power Plants Capacity of the Company is 570 MW
(including 56 MW Waste heat recovery power plants known as Green
power which is the largest capacity of Green Power in the entire world
cement industry except China). The power generated from these plants
is primarily utilized for consumption in its own cement plants as well as to
sell for community use.
Shree Cement have set a vision to be a major player in the Cement
Industry and have embarked upon a committed expansion programme
to further enhance its market share in various other states of India with an
objective to achieve 25 MTPA cement capacity.
Company Profile
Shree Cement Limited (SCL), having presence in the Cement and Power
sectors, is an energy efficient and environment friendly organization.
Incorporated in 1979, the company today is the largest cement player of
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
4
North India and ranked among the top six cement groups in the country.
The principal promoters of the company are the Bangur Group, which is
a respected business house of India.
Cement manufacturing facilities
The Company has its manufacturing operations at Beawar (3.0 mpta)
and Ras (3.0 mtpa) in Ajmer and Pali district in Rajasthan. It has split
grinding units at four locations viz. Khushkhera (3 mpta), Suratgarh (1.2
mtpa), Jobner (1.5 mtpa) in Rajasthan and Roorkee (1.8 mtpa) in
Uttrakhand taking the total cement capacity of the Company to 13.5
MTPA.
Power generation facilities
Total Thermal Power Plants Capacity of the Company is 570 MW
(including 56 MW Green Power Capacity which is the largest capacity of
Green Power in the entire world cement industry except China). The
power generated from these plants is primarily utilized for consumption in
its own cement plants as well as to sell to outside parties.
Products
The Company's pursues multi-brand portfolio strategy which consists of
three brands viz Shree Ultra Jung Rodhak, Bangur Cement and
Rockstrong Cement.
The company currently has the highest market share in Rajasthan, Delhi
and Haryana and distinguished positions at the top in Punjab, West Uttar
Pradesh and Uttarakhand.
Financial strength
The Company has consistently posted all round growth in its operations.
Its operating margin is one of the highest in the World Cement industry.
The performance highlight of the Company for the year 2010-11, 2011-12
and 2012-13 is as under:
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
5
Particulars Year ending
30th June
Year ending
30th June
(15 months)
Year ending
31st March
FY 13 FY 12 FY 11
Cement Production (In Lac MT) 123 142 94
Cement and Clinker Sale ( Lac
MT)
125 149 103
Net Sales (Rs. Cr.) 5590 5799 3454
Operating Profit (EBIDTA) – Rs. cr. 1749 1809 1010
Net Profit (Rs. Cr.) 1004 618 210
Basic & Diluted EPS (In Rs.) 288 178 60
Cash EPS (In Rs.) 406 429 237
Capacity enhancement made by the Company over last few years has
enabled the Company to post consistent strong volume and revenue
growth. Efficiency in Company’s Operation and rationalization of power
and fuel cost resulted in growth in Operating and Net Profit of the
Company.
Corporate Sustainability
SCL always strives to sustain its reputation as a respected corporate
citizen. It acknowledges that its operations have multiple impacts on the
environment and communities in which it operates. It has embedded the
sustainability principles in all its activities and pursues this as an integral
part of its business operations. Shree has been on a continuous drive for
‘greening’ of its processes so that its operations put the minimum burden
on the earth's finite resources. The installation of company’s waste heat
recovery plants (Green Power Plants), ACC etc. steps in this direction.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
6
Service towards the community
SCL has displayed good corporate citizenship by providing assistance
and funds for natural calamities, education programs and institutions,
AIDS awareness, preventive medicine, eye camps, drinking water
projects, among others. The company engages in a continuous dialogue
with community leaders.
Recognitions
First Indian Cement Company to join Cement Sustainability Initiative of
WBCSD.
First Indian Cement Company to be Member of World Economic
Forum.
First company in the World to use innovative techniques to utilize 100%
petcoke in its operations.
First Cement Company of the World to fetch Certified Emission
Reductions (CER’s) on its Clean Development Mechanism project
“Optimal Utilization of Clinker”.
First Indian cement company to issue Corporate Sustainability Report
following the highest level “A+” for reporting triple bottom line
performance
New World Sustainability Champions by the World Economic Forum
(WEF)
Government of India recognized in-house R&D centre.
Awards
2013-14 NCCBM Award for Second Best Quality Excellence for the
year 2012-13
2013-14 NCCBM Award for Second Best Quality Excellence for the
year 2011-12
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
7
2013-14 Best HR strategy in Line with Business by World HRD congress
2012-13 International Green Hero by The Green Organization, London
2012-13 Golden Peacock Business Excellence Award for the year 2013
2012-13 State Level Productivity Excellence Award 2012- 13 Best
Corporate Social Responsibility Practice Award by BSE
2012-13 Global HR Excellence award for organization with Innovative
HR practices at World HRD congress
2012- 13 Global HR Excellence award for HR research of the year at
World HRD congress
2012-13 Mother Teresa Corporate Citizen Award by Loyola Institute of
Business Administration, Chennai
2012-13 Nirmata Rajya Mitra Award by the Department of Taxation for
the year 2011-12
2012-13 International Green Apple Gold award and Green Hero Title
by Green Organization, London
2012-13 CSR award by Suratgarh Municipality to SGU
2012-13 Dainik Bhaskar Green Idol award
2012-13 First Prize for Energy conservation during mines environment &
conservation week by IBM
2012-13 Skoch Digital inclusion award 2012
2012-13 Financial Express – Emergent Venture India Green Business
Leader Award, 2011-12
2011-12 Jal Star Award by Dainik Bhaskar for the year 11-12
2011-12 Nirmata Rajya Mitra Award by the Department of Taxation for
the year 2010-11
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
8
2011-12 Productivity merit award for HR Innovative Practices for the
year 2009-10
2011-12 Greentech HR Gold award for best Strategy in HR practices
2011-12 CII-ITC sustainability award commendation certificate for
significant achievement.
2011-12 First Prize for Noise & Ground vibrations during mines
environment & conservation week by IBM
2011- 12 First prize for overall performance in 25th Mines Safety Week
under Director General of Mines safety, Ajmer region to Ras mines
UIT Bhiwadi award to KKG unit for CSR activities
2011-12 National awards for Excellence in Water Management 2011 as
“Water Efficient Unit” by CII
2011-12 NCCBM Award for Environment Excellence for the year 09-10
2011-12 NCCBM Award for Second Best Quality Excellence for the
year 09-10
2011-12 NCCBM Award for Second Best Quality Excellence for the
year 10-11
2011-12 Certificate of Excellence Award by The Employers Association
of Rajasthan
2011-12 National award for cost management by Institute of Cost and
Works Accountants of India
Best Innovation Award Gold by CIOL Dataquest Enterprise C-Change
Enterprise Awards 2011
2011-12 Second prize of Bhiwadi Manufacturer’sAssociation BMA
Award -R.L. Rajgarhia Award for Energy Conservation 2010 to KKGU.
2011-12 Jamnalal Bajaj award for Fair Business Practices
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
9
Rationale for setting up the Cement project
Shree Cement Ltd. is proposing 2.4 Million TPA Clinker, 4.0 Million TPA
Cement, 25 MW Captive Power Plant & 15 MW Waste Heat Recovery
Power Generation Near village Pedagarlapad, Mandal-Karempudi,
District- Guntur (Andhra Pradesh). SCL has selected the state of Andra
Pradesh to set up integrated Cement plant. Andra Pradesh is a fast
growing cement market and this has been the primary reason for the
selection of this state. Presently, SCL have two integrated cement plant
and three split grinding unit in the state of Rajasthan. This unit shall cater
to cement demand of Chhattisgarh, W.B., Bihar and M.P.
Project Concept & Capacity
Shree Cement Ltd. is proposing 2.4 Million TPA Clinker, 4.0 Million TPA
Cement, 25 MW Captive Power Plant & 15 MW Waste Heat Recovery
Power Generation Near village Pedagarlapad, Mandal-Karempudi,
District- Guntur (Andhra Pradesh) for manufacturing of Ordinary Portland
cement (OPC) and Pozzolona Portland Cement (PPC).
A 1000 KVA DG set / 2*500 KVA DG se will be installed for plant lighting
purpose if CPP and grid power fail. In addition to above a synthetic
gypsum manufacturing unit of capacity 65 TPH shall be installed to meet
the gypsum requirement.
(ii) Brief description of nature of the project
Shree Cement Ltd. is proposing 2.4 Million TPA Clinker, 4.0 Million TPA
Cement, 25 MW Captive Power Plant & 15 MW Waste Heat Recovery
Power Generation Near village Pedagarlapad, Mandal-Karempudi,
District- Guntur (Andhra Pradesh).
As per EIA Notification dated 14th Sep, 2006 as amended on 1st
December 2009, the project falls under Category “A”.
(iii) Need for the project and its importance to the country and or region.
Estimates of future demand and supply at the national, regional and
state level to examine the market position of the proposed plant. The sale
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
10
volumes and the sale realizations that could be achieved have also
been assessed.
(iv) Demand – Supply
Company sells cement mainly in North India. Based on economic growth
and other factors, we expect that cement growth to be around 9% from
2012-13. The market situation is given below.
Demand In Million MTPA
Particulars 10-11A 11-12A 12-13P 13-14P 14-15P 15-16P
Cement Demand
( 9% growth from
11-12 onwards)
40.67 44.98 49.03 53.44 58.25 63.49
Net Export to
other regions 11.46 12.26 13.36 14.57 15.88 17.31
Total Demand 52.13 57.24 62.39 68.01 74.13 80.80
Supply In Million MTPA
Particulars 10-11A 11-12A 12-13P 13-14P 14-15P 15-16P
Opening Capacity 62.56 66.36 67.56 71.86 74.46 76.46
Additions:
India Cement, Banswara,
Rajasthan
1.80
JP Associate, Panipat,
Haryana (GU)
0.50
Shree Cement,
Jaipur,Rajasthan (GU)
1.50
Birla Corp, Chandaria,
Rajasthan
1.20
JK Lakshmi, Jhajjar,
Haryana (GU)
0.55
Wonder Cement,
Nimbehara
2.5
Mangalam Cement 1.25
Lafarge, Chittor, Rajasthan 2.60
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
11
Ultratech Nagour,
Ambuja- Marwar & Sidhi
Vinayak, Near Jaitaran)
2.00 4.00
Total Additions 3.80 1.20 4.30 2.60 2.00 4.00
Capacity at the end of
the Year
66.36 67.56 71.86 74.46 76.46 80.46
Avg. Capacity 63.80 66.66 69.99 73.78 75.21 78.21
Cap. Utilization 82% 93% 92% 93% 93% 92%
Cement Production
(Supply)
52.13 61.77 66.15 68.92 71.35 73.34
Note: Cement Production for new units has been taken 50% of for first 12 Months, 80%
in next 12 months and 95% thereafter. For existing capacity, utilization has been taken
as 95%.
(v) Demand – Supply Gap. In Million MTPA
Particulars 10-
1
1
A
11-12A 12-13P 13-14P 14-15P 15-16P
Cement Demand ( 9%
growth from 11-12
onwards)
40.67 44.98 49.03 53.44 58.25 63.49
Net Export to other
regions
11.46 12.26 13.36 14.57 15.88 17.31
Total Demand (A) 52.13 57.24 62.39 68.01 74.13 80.80
Total Supply (B) 52.13 61.77 66.15 68.92 71.35 73.34
Surplus/(Deficit) (A-B) - 4.53 3.76 0.91 -2.77 -7.46
(vi) Export Possibility
South Region is expected to have a higher demand as compared to the
current supplies. Hence it is expected that in the near future, export of
cement does not seem to be viable.
(vii) Domestic/export market
There shall be a deficit of cement production in the North Region which
will be an advantage for player setting up the plant in the region. The
details have been mentioned in point (c) of Demand – supply.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
12
(vii) Employment Generation (Direct and Indirect) due to the project sourcing
SCL follows the “son of the soil” policy, wherein the maximum possible
staffing is from local area. Only where skills are not available locally will
staff be hired from outside.
Estimated manpower requirement
Sn Department Manpower No. of persons
General Shift
1 Plant Unit head (Overall) 1 -
1.1 Technical Technical head 1
1.1.1 Mechanical Manager 2
Engineer 1 4
Foreman 8 6
Crusher operator - 3
Crusher attendant - 3
Additive crusher attendant - 3
Draftsman/ designer 2 -
Fitter 8 6
Compressor house
operator 1 6
Water supply operators - 6
Welder 8 6
Turner 1 -
Khalasi 2 4
Loader driver 1 4
Dumper driver 2 -
Crane operator 1 -
1.1.2 Electrical Manager 1 -
Engineer 2 -
Foreman 4 8
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
13
Power distribution foreman - 4
Electrician 2 8
Helper 2 8
1.1.3 Instrumentation Manager 1 -
Engineer 2 -
Foreman 4 8
Mechanic 2 8
1.1.4 Process Manager 1 -
Engineer 2 4
CCR operator - 8
Pyro attendent - 8
Mills attendent - 8
Helper 1 4
1.1.5 Quality control Manager 1 -
Chemist 2 -
Analyst 2 4
Gauger 2 -
Sampler 2 4
1.1.6 Civil Manager 1 -
Engineer 1 -
Masons 1 -
Carpenter 1 -
Plumber - 4
1.1.7 Technical cell Manager 1 -
Engineer
2 -
1.1.8 Packing plant Manager 1
Logistic 1 -
Supervisor 2 -
Tally checker 3
Operator - 6
Loaders - 20
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
14
1.2 Commercial Commercial head 1 -
Manager 2 -
1.2.1 Stores and
Purchase Officers 3 -
Staff 10 -
1.2.2 Personnel and Manager 1 -
Administration Officer 2 -
Staff 4 -
Receptionist 1 -
1.2.3 EDP Manager 1 -
Staff 3 -
1.2.4 Excise Officer 1 -
1.2.5 Accounts Manager 2 -
Officer 1 -
Staff 6 -
1.2.6 Secretaries Staff 6 -
1.2.7 Security Officer 1 -
Guards 4 21
1.2.8 Dispensary Doctor 2 -
Staff 2 4
1.2.9 LMV Driver 5 8
1.2.10 Telephone
exchange Operator 1 -
1.2.11 Guest house Staff 1 -
Attendants 1 4
1.3 Marketing Marketing head 1 -
Manager -Logistic 1 -
Officer 1 -
Assistant 1 -
Marketing field 10 50
Total 158 255
Grand Total 413
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
15
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects if
any
No interlinked / interdependent project is involved.
(ii) Location (map showing general location, specific location, and
project boundary & project site layout) with coordinates
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
16
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
17
Key Plan
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
18
(iii) Details of alternative site consideration and basis of selecting the
proposed site particularly the environmental considerations gone
sound be highlighted.
No alternate site has been considered for the proposed project.
Following are the main criteria, considered largely as near-ideal
conditions, for locating a cement plant of desired capacity:
Availability of suitable limestone for the manufacture of cement.
Availability of power, coal & water.
Scope for expansion.
Availability of Transport & Communication.
Nearness to market.
Vicinity of social infrastructural facilities such as market center,
educational institution, local transport, entertainment centers,
medical facilities, etc.
The land required for mining, plant and township should not be a
part of declared forest area.
(iv) Size or magnitude of operation
Shree Cement Ltd. is proposing 2.4 Million TPA Clinker, 2x2.0 Million TPA
Cement, 25 MW Captive Power Plant & 15 MW Waste Heat Recovery
Power Generation Near village Pedagarlapad, Mandal-Karempudi,
District- Guntur (Andhra Pradesh) for manufacturing of Ordinary Portland
cement (OPC) and Pozzolona Portland Cement (PPC).
The process includes basic raw material requirement, sizing of
equipment, utilities and services, infrastructure facilities and sources of
waste generation, their quantity, treatment and safe disposal of the
waste.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
19
(V)-1 Project description with process details
The dry process essentially consists of the following unit operation steps:
Crushing of limestone at the mine site.
Preblending of crushed limestone.
Drying – cum-grinding of raw materials.
Homogenization of raw meal in a blending silo.
Clinkerisation of the raw meal in a rotary kiln with preheater and
precalcinator.
Grinding, storage and packing
Various operations of dry process plant are detailed as follows:
Crushing of Limestone
The ROM Limestone is fed to crusher Wobler where +90 mm part is fed
into crusher, where it is crushed to -90 mm size. The -90 mm size from
crusher Wobler is fed to Secondary screen from where (-6mm/-10mm/ -
25mm) part is rejected, while + size material is added to Crushed -90 mm
Limestone.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
20
Blending of raw meal and Storage of kiln feed
The ground raw meal is conveyed to blending-cum-storage silo(s) by
mechanical conveyors. The variation in the quality of raw meal is
reduced by using continuous blending silo.
Preheater, Precalcinator, Kiln
In cyclone preheater system, an efficient heat transfer takes place to
finally dispersed raw material particles when they come in contact with
hot gases from kiln. The preheater is multi stage cyclone system
connected with gas ducts and meal chutes. The raw meal is fed into top
stage gas duct and is carried by hot gas steam into cyclone. The
material gets separated from gas in cyclones and then travels
downwards and through meal chute is discharged into next lower stage
gas duct. In this way, material comes into contact with high
temperature gases and gets preheated and partially calcined and then
enters the precalcinator.
In the precalcinator, further calcination takes place by firing pulverised
coal and then material is discharged to the kiln. The feed travels down
as the kiln rotates. The chemical reaction completes when the material
reaches the burning zone and cement clinker is formed.
Cooling of Clinker
The clinker is discharged from kiln at around 1000 Deg. C temp. and is
cooled in a high efficiency grate cooler.
The cooled clinker is then transported to clinker storage silo by a set of
Deep Bucket Conveyor (DBC).
Coal and pet coke crushing and Grinding
Coal is highly abrasive, therefore, its crushing is done usually in a roll
crusher. The same system is proposed to be used.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
21
Grinding of coal is done either in air swept ball mill or in vertical roller mill.
Because of saving in energy and better drying capacity VRM is
proposed for use.
Cement Grinding (VRM and / or Ball Mill)
Similarly of the raw material grinding system, the grinding of clinker into
cement is based on the following technologies:
Ball mill
Roller press with ball mill.
Vertical roller mill.
In India, cement grinding is conventionally done by ball mill in close
circuit using high efficiency separators. However, due to nearly 25-30 %
saving in power, the use of roller press for pre-grinding followed by
grinding in closed circuit ball mill (semi-finish grinding mode) has been
used in most of the recently installed plants. The performance feedback
on the installation of VRM for cement grinding is still awaited and yet to
establish as a proven technology. Hence, based on the performance of
VRM, it is proposed to install both VRMs or Both Ball mills with roller press
or one VRP with one ball mill & roller press.
Cement Storage and Packing
The ground cement is conveyed to cement silos for storage of different
types of cement from where it is extracted and packed in HDPE bags by
electronic rotary packing machines and dispatched to consumers by
road and railway. Mechanized loading system for loading of packed
bags on trucks and wagon is envisaged.
Wagon Tippler and Railway siding
Coal and pet coke will be received by road and railway. For unloading /
handling of coal and pet coke fully mechanized system of wagon
tippler and truck tippler will be installed at the site. Also cement and
clinker will be dispatched by road and railway.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
22
(V)-3 Process Description of Waste Heat Recovery Power Plant (15 MW)
There is a good amount of waste heat available from the expelled gases
of Pre-Heaters (PH) and Air Quenched Coolers (AQC). The main energy
used in cement plant consists of heat energy and electrical energy and
about 90% of the total energy is used as heat energy in clinker burning
process. In the clinker burning process, a large amount of heat is
consumed for burning limestone at more than 1450 degree C to form
clinker. From the total heat consumed in the burning process, around
55% is for burning process and the rest 45% is discharged as sensible heat
through the exhaust gases of Pre-Heater(PH), AQC, radiation & sensible
heat carried out by clinker.
However, around 10% of the heat, extracted from the PHs & AQCs, is
used in drying the raw material and coal while grinding. The rest 35% is
generally emitted to the atmosphere as waste heat. For reutilization of
this wasted heat from the exhaust gases of the PH & AQC this Waste
Heat Recovery System is used to generate the electrical power. A
typical heat flow in cement plants with waste heat recovery system is
shown below
Considering the above we have decided to install one Waste Heat
Recovery Boiler (WHRB) at kiln Pre-heater and one Waste Heat
Recovery Boiler (WHRB) at AQC (Mid tap-off) in each Units. Steam
generated by each unit make combined and fed to steam turbine for
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
23
Electricity generation. In this scheme Waste Heat Recovery Boiler
(WHRB) at Kiln Pre-heater will be installed. In normal condition the flue
gas from the top of the Pre-heater directly goes to ESP / bag house.
Now the flue gas from the top of the Pre-heater will go to the WHRB and
after that it will enter to ESP / Bag house.
Design Basis for WHRB
S.N. Boiler Unit Kiln String AQC
1 flue gas flow Nm3/h 370000 217000
2 I/L temp deg C 300 600
3 sp. Heat kcal/deg
C/Nm3
0.362 0.32
4 O/L temp deg C 150 80
5 heat available Kcal/h 20091000 36108800
6 Total heat available Cr Kcal/h 5.62
7 Power potential MW 65.3
8 Power gen @ 23%
conversion
Mw 15.0
V.5 Process Description of Power Generation Process (Air Cooled) – (25 MW)
In Proposed Captive thermal Power Plant, power will be generated by
the utilization of thermal energy of steam in turbine that in turn rotates an
alternator. The steam will be generated in the boiler by burning of
various fuels. In Proposed Power Plant, Pet coke/Coal will be used as the
fuel & it will burn in the boiler to generate steam. The generated steam
will utilize to rotate the Steam Turbine, which in turn rotates an alternator.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
24
Coal/Petcoke will be transported by truck at over power plant site than
trucks will be unloaded by truck tippler in the Coal/Petcoke bunker. The
Coal/Petcoke will feed to the coal crusher to crush it to the required size
through the vibro feeder that regulates the flow. The crushed
coal/petcoke will fed the boiler bunkers through the conveyor belt.
After received coal/petcoke in the boiler bunkers, the coal/petcoke will
be fed to the boiler furnace through the rotary/drag chain feeders in the
controlled quantities. The coal/petcoke will burn in the furnace & the
resulted heat will be utilized to heat water & convert it into steam. The
flue gases that will be generated on the burning of fuel will pass over the
tubes of economizer & air pre-heater to utilize the heat carried by the
flue gases going outside, otherwise heat will go waste. Now the flue
gases pass through the ESP (Electro Static Precipitator) to chimney.
On waterside, water will be received by PTP (Pre-treatment Plant) from
the existing resources. Here water will treat to get the required quality
than it will be treated with lime & Dolomite in the High Rate Solid
Contact Clarifier. Then clarified water will be fed to the RO plant where
its properties will fine tuned to the required quality for DM system. In DM
plant the required properties of water will be obtained and this DM
water will feed to the boiler for the purpose of making steam. The
cooling tower will feed with the RO water for its replenishment.The
generated steam in boiler at required parameters will be fed to the
turbine through the control valve. In turbine the thermal energy of steam
will utilize to rotate it. The turbine in turn rotates an alternator (electric
generator). The generated electricity is evacuated from the alternator
through the bus bar arrangement.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
25
Ash Generation & SO2 emission from 25 MW Boiler
Parameters Pet Coke
Indian
Coal
Imported
Coal
Ca CO3
CaO CO2
Ultimate Proximate
100 56 44
C 85.1 87.1 21.5 44
1.8 1 0.8
H2 2.7 # #
N2 0.4 # #
S
O2
SO2
S 5.0 5.5 2 1.5
32 32 64
Moisture 1.1 0.6 12 10
1 1 2
Ash 0.8 1.1 36 16
O2 1.9 # #
CaO SO2
1/2 O2
CaSO4
GCV 8010.0 8212.0 5000 6500
56 64 16 136
Boiler eff 80% 80% 80%
0.9 1.0 0.3 2.1
Sulphur
Cap 80%
Kg/ hr TPD Kg/ hr Kg/ hr
Kg/Hr TPD
Feed rate (
Pet Coke ) 12500 300 20025 15404
SO2
Generation 1250.0 30.0
Ash
Generation
due ash in
pet coke 140 3 5599 1914
CaO reqd 1093.8 26.3
Gypsum 1594 38 # #
CaCO3 Reqd 2441.4 58.6
Unreacted
lime 488 12 # #
as 60 % cap 1953.125 46.9
Unburnt @
15 % 1596 38 215 339
unreacted
lime stone 488.3 11.7
Total Ash 3818 92 5814 2253
CaSO4 gen 1593.8 38.3
Fly Ash @
70 % of
total ash 2673 64 4070 1577
Total CaSO4
and CaCO3 2082.0 50.0
Bed Ash @
30 % of
total ash 1145 27 1744 676
SO2 Emission 250.0 6.0
Stack Height H (Mtr) = 14 (Q) ^0.3
H = 73 Mtrs
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
26
25 MW TECHNICAL DETAILS
A BOILER 25 MW CPP
1 Type
AFBC / CFBC
2 Pressure kg/cm2. A 120
3 Temperature deg C 535
4 Flow (*) ( Kg/hr ) 110000
5 Fuel Type Petcoke / Coal
6 Fuel quantity at MCR TPD 233
B TURBINE & GENERATOR
1 Generator power Kw 25000
2 Generator voltage Kv 6.6
3 Steam Pressure kg/cm2. A 88
4 Steam Temperature deg C 535
5 Steam Flow (*) ( Kg/hr ) 103000
C AIR COOLED CONDENSER
1 Steam Pressure kg/cm2. A 0.15
2 Steam Temperature deg C 54
3 Steam Flow (*) ( Kg/hr ) 85000
D FUEL HANDLING SYSTEM
1 Storage Shed Capacity Tons 5000
2 Capacity TPH 100
3 Truck tippler capcity Tons 100
E LIME HANDLING SYSTEM
1 Capacity TPH 30
F ASH HANDLING SYSTEM
1 Type Dense Phase system
2 Fly Ash Capacity TPH 10
3 Bed Ash Capacity TPH 5
4 Fly Silo capacity M3 125
5 Bed Ash silo Capacity M3 50
6 ESP Field Nos 3
7 Chimney Height Mtr 73
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
27
Equipment Details- Cement Plant
Equipment Selection
A list of equipment and storages capacities are given below. In
selecting a particular type of equipment or storage for the project,
among others, the following issues have been considered:
Equipment costs
Energy consumption
Raw material characteristics
Sizes in which the equipment is available
Lead times for particular types of equipment
Operating experience with various types of equipment
Ease of operation of equipment
Product to be manufactured
Site conditions
Local skills available
Environmental issues
PLANT AND EQUIPMENT SIZING
1) Crusher
Capacity – 1200 TPH & 450 TPH (secondary Crusher)
2) Stacker & Reclaimer
Lime stone Stacker – 1650 TPH
Lime stone Reclaimer – 1400 TPH
Coal and Gypsum stacker – 150 TPH, each
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
28
Coal Reclaimer – 150 TPH
3) Raw Mill (VRM)
Capacity - 500 TPH
4) Cement Mill (VRM or Ball Mill with Roller Press or VRM + BM with
RP)
Capacity - 2 x 325 TPH
5) Coal & Pet coke Mill
Capacity – 50 TPH
6) Kiln & Cooler with 6 stage pre heater
7000 TPD clinker
7) Packer
2x4 nos
2x16 spouts double discharge type
2x325 tph
Major Storages
Limestone Stock pile : 240000 T
Iron ore hopper : 3000 T
Clinker stockpile/Tank : 75000 T
Coal storage : 200000 T
Gypsum storage : 20000 T
Cément Silo : 4 * 7500 T
Fly Ash : 2*5000 T
(vi) Raw material required along with estimated quantity, likely source,
marketing area of final products, mode of transport of row material and
finished product.
Raw material requirement for Clinkerization
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
29
Raw
Material
Source
Basis 2.4 Million TPA Clinker
& 4.0 Million TPA
Cement Production
Million TPA
Lime
Stone Captive Mines
1.5
T/ T of clinker 3.6
Iron Ore Bellary, Kamatgi,
Bagalkot
0.015 T/ T of
clinker 0.036
Bauxite Kadapa , Warangal
(A.P)
0.044T/ T of
clinker 0.105
Coal/
Pet coke
Singarini Coal deposits /
Imported South Africa/
Indonesia Coal
0.1616 T/ T of
clinker 0.387
Jamnagar pet coke /
/Pet coke
0.10 T pet coke /
T of clinker 0.24
Gypsum
Salem & Coimbator,
Tamilnadu & Nagaur
(Raj.),
0.05 T / T of
cement 0.2
Fly Ash Vijayawada 0.35 T/T of
cement 1.4
(vii) Resources optimization/ recycling and reuse envisaged in the
project, if any, should be briefly outlined.
Fly ash generated from CPP will be utilized in cement
manufacturing.
No solid waste generation from the cement plant. However,
material collected by the dust collectors (Bag Filters) will
automatically be recycled in the process.
There will no discharge outside the project premises.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
30
(viii) Availability of water its source, energy /power requirement and source
should be given.
Water
The estimated requirement of water for industrial activities and domestic
activity would be around 1500 m3/day. Good quality potable water is
available in the proposed site. The Ground water is proposed to be
used.
Water Consumption Details (KLD)
Unit
Peak
Demand
(m3/day)
Waste water
generation
(m3/day)
Remarks
Cement Plant 550 Nil
No waste water is expected to be
generated from Cement Plant as
dry process will be used for cement
manufacturing.
CPP + WHRS 300 75 Effluent water will be used in Ash
Quenching after proper treatment.
Drinking,
Utility
& Plantation
500 400
Domestic waste water will be
treated in STP and will be recycled
for Green Belt development and
cement plant process within the
plant premises.
Total 1350 475
Water balance for Limestone Mining
Dust
suppression 125 -
The domestic waste water will be
disposed in soak pit via septic tank.
Workshop discharge will be passed
through oil/grease water separator
tank for separation of oil contents
and also soil contents. The clear
water will be used in crusher for dust
suppression.
Drinking &
Utility 15 10
work shop 10 10
Total 150 20
Grand Total 1500 495
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
31
Power Demand
Total power requirement will be 31.3 MW (Source- Proposed CPP 25MW and WHR 15
MW)
7000 TPD x 62 KWH
1. Demand for Clinkerization --------------------------- = 18.0 MW
24 Hrs x 1000
14000 TPD x 24 KWH
2. Demand for : ----------------------------- = 14.0 MW
Cement Production 24 Hrs x 1000
3. Power load at Colony : 0.25 MW
Total Power Demand : 18.0 +14.0+0.25 = 32.25 MW (approx.)
(ix) Quantity of waste to be generated (liquid and solid) and scheme for
their management/disposal
No waste water discharge outside the plant.
No industrial waste shall be generated in operation phase.
Used oil & grease will be generated from plant machinery/Gear boxes
and DG set (1000 KVA or 2 X 500 KVA) which will be sold out to the
CPCB authorized recycler.
4.0 Site Analysis
(i) Connectivity
Nearest National Highway is NH-9 which is 54 kms from site. It thus has
excellent road connectivity.
Approximate road distance from major towns i.e. Guntur is 90 km
The nearest railway station is the Nadikudi, approximately 4.5 kms from
the site.
The nearest airport is at Vijayawada (114 kms)
The site is well connected with communication facilities like
telephone, fax, wireless and telex and as such, no constraints are
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
32
envisaged in this aspect as the Tehsil and District headquarters are
near to the site.
(ii) Land from Land use and land ownership
The land requirement is estimated at about 142.79 ha for the plant &
colony and mining lease area is 283.585 ha.
Adequate land is available in the proposed site. It is relatively plain and
not much of development work is needed. Almost entire land is covered
by sand.
(iii) Topography
The general topography of the lease area is almost flat and gradually
sloping towards N-E part of the lease area by and large the area is
plane country. The general ground level of the area ranges from 95 to
111 Mtrs. above the mean sea level (MSL).The flat lands in a major part
show stony waste outcropping Limestone mainly. The mine area with
minimum mRL of 95 Mtrs and maximum of 111 Mtrs. ML area has a
surface relief of about 16 Mtrs spread over an area of 283.585 hectare.
The area is drained by the Naguleru Vagu Stream in west. It flow
northwards in black cotton soil region and join the Krishna River. Krishna
forms the natural boundary between Guntur and Nalgonda. The
drainage pattern of this area is sub dendritic in nature. No perennial
nallahs or streams are seen within the lease area.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water
bodies (including area under CRZ)), shortest distances from the
periphery of the project to periphery of the forests, national park, wild life
sanctuary, eco sensitive areas, water bodies (distance from the HFL of
the river), CRZ. In case of notified industrial area, a copy of the Gazette
notification should be given.
Environmental Settings of the Area
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
33
S.No. Particulars Details
1 Temperature Min:16.4° C, Max : 32.4° C
2 Relative Humidity
08:30 hrs. - 68% - 94 %
17:30 hrs. - 58 % - 75 %
3 Mean Annual Rainfall 1083 mm
4 Nearest National Highway NH-9 (54 km in NE Direction)
5 Nearest Railway Station Nadikudi 4.5 Km
6 Nearest Airport Vijayawada 114 Km
7 Nearest city /Town Dachepalli at a distance of ~5.1
km. in North direction
8 Reserved / Protected Forest
within 10km radius
(Boundary to boundary
distance)
Kakirala Reserved Forest: 11
km in S direction.
Madinapadu Reserved
Forest: 11.5 km in NNW
direction.
Daida Reserved Forest: 13.5
km in SW direction.
Fairly dance mixed forest: 12
km in SSE direction
9 Nearest Surface Water
bodies
Krishan River – 15.5 km from
proposed plant site & mine
site.
Nagajuna sagar right bannk
canal or Jawahar Canal:
About 7.5-10 km in SE & S
direction.
10 Nearest Hill Ranges --
11 Water requirement & Source 1500 KLD for both plant and
mining.
Source: Ground Water
12 Soil Type Black cotton
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
34
13 Nearest Town / City Zone – II [as per IS 1893 (Part-I):
2002]
(v) Existing Infrastructure
As the project is new, so the proposed site is a vacant land presently no
industrial infrastructure exists.
(vi) Soil Classification
The district has mainly the Black cotton soil.
(vii) Climatic data from secondary sources
The area has generally moderate climate. The temperature variation is from
16.4oC to 32.4oC. The average annual rainfall in the area is about 1083 mm.
The relative Humidity in the area is about 58% - 94 %
5. Planning Brief
(i) Planning Concept (type of industries, facilities, transportation etc.) Town
and country Planning/Development authority classification.
Proposed industry is cement industry (Red Category). Transportation of
raw material and final product will be done via existing road and rail
network and cement concrete road will be developed within the
proposed project area.
(ii) Population Projection
Temporary influx of people will be there as the managerial and
supervisory staff will generally be outsider. A projection may be made by
a governmental organization, or by those unaffiliated with a
government.
(iii) Land use planning
The land requirement is estimated at about 142.79 ha for the plant &
colony. About 47 ha of the total project area will be covered under
green belt & plantation.
(iv) Assessment of infrastructure demand (Physical & Social)
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
35
SCL will assess the demand of infrastructure (Physical & Social) in nearby
area of the proposed site and will be developed in under corporate
social responsibilities programs.
(v) Amenities/Facilities
Shree Cement Limited will develop the Amenities/Facilities in nearby
area of the proposed project site as per requirement of local people of
the nearby area under corporate social responsibilities programs.
6) Proposed Infrastructure
(i) Industrial Area (processing area)
The land requirement is estimated at about 142.79 ha for the plant &
colony. Out of which plantation will be done on 47 ha (33% of total land)
land.
(ii) Residential Area (Non processing area)
Colony for staff will be constructed. The total colony area will be 78.10
Acre (31.6 ha approx.
(iii) Green Belt
Greenbelt will be developed in 47 ha i.e 33% of the total area of the
proposed project.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by
increased direct and indirect employment opportunities in the region
including ancillary development and supporting infrastructure.
The installation of proposed plant will lead to the development of certain
local ancillary facilities and consequent employment opportunities.
Further the proposed cement project will also lead to the development
of market, trade centers, activities etc.
In addition to the above, SCL has a track record of engaging the local
communities and extending several social services to the nearby villages.
(v) Connectivity
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
36
Nearest National Highway is NH-9 which is 54 kms from site. It thus has
excellent road connectivity.
Approximate road distance from major towns i.e. Guntur is 90 km
The nearest railway station is the Nadikudi, approximately 4.5 kms
from the site.
The nearest airport is at Vijayawada (114 kms)
The site is well connected with communication facilities like
telephone, fax, wireless and telex and as such, no constraints are
envisaged in this aspect as the Tehsil and District headquarters are
near to the site.
(vi) Drinking Water
This is proposed to be sourced from ground water which will be treated
in RO unit.
(vii) Sewerage system
The domestic effluent generated will be treated in Sewage Treatment
Plant (400 KLPD).
Process flow diagram of STP plant
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
37
Quality of STP Treated water
Parameters Quality of Raw
Sewage
Quality of Treated
Sewage
pH 6.0 to 8.0 6.5 to 7.8
BOD 300 ppm 10 ppm
COD 400 ppm 50 ppm
TSS 300 ppm 10 ppm
O & G 50 ppm 10 ppm
Process description of STP plant
Bar screen chamber followed by collection cum equalization tank
followed by Fluidized Aerobic Bed Reactors (2 Nos.) will be provided
with coarse air bubble diffusion system followed by Tube Settler Tank in
the STP. The clear supernatant after disinfecting by chlorination will be
passed through dual filter and activated Carbon filter before will be
collected in the treated water tank. The sludge generated from the FAB
will be passed through sludge digester and dried and the filtrate will be
collected and sent back to the equalization tank and the dried cakes
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
38
will be used as manure. The treated water will be used for plantation
activities.
(viii) Industrial Waste management
No industrial waste water will be generated from cement plant. However
waste water generated from RO unit shall be reused for dust suppression
and plantation.
(ix) Solid waste management
No solid waste generation from the cement plant. However,
material collected by the dust collectors (Bag Filters) will
automatically be recycled in the process.
Fly ash generated from CPP will be utilized in cement
manufacturing.
(x) Power requirement and source
The estimated power requirement for the plant and colony will be 31.55
MW, for which a captive thermal power plant of 25 MW and waste heat
recovery power plant of 15 MW capacities are proposed to be set up.
Till installation of the proposed captive thermal power plant, the
required power will be received from grid.
7.0 Rehabilitation and Resettlement (R & R) Plan
(i) Policy to be adopted (Central/State)in respect of the project affected
persons including home oustees, land oustees and landless laborer
(brief outline to be given)
Not Applicable
8.0 Project Schedule and Cost Estimates
(i) Likely date of start of construction and likely date of completion (time
schedule for the project to be given)
18 months from the date of start of work.
(ii) Estimated project cost along with analysis in terms of economic viability
of the project
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
39
The total investment for the proposed project works out to
approximately Rs 1234 Crores. The estimated Investment Cost for the
project has been based on the requirement of fixed and non-fixed
assets.
The details of total investment are shown in the table below.
S. No. Description Total cost, (Rs. In Lacs)
1 Land (Plant & Colony) 7000
2 Site Development 3000
3 Buildings & infrastructures 12500
4 Furniture & office
equipments etc
500
6 Plant and Machineries 62500
7 Captive Power Plant
(25 MW)
8000
8 Waste Heat Recovery
Power Plant (15 MW)
6000
9 Residential Colony 10000
10 Railway siding 3000
11 Wagon tippler and stacker
reclaimer from rail siding
5000
Total cost 117500
Contingency (5%) 5875
Total project cost 123375 or 1234 Cr.
9.0 Analysis of proposal
The state of Andhra will get revenues in terms of taxes, local people will
get opportunity in terms of indirect employment, business opportunity
like transport of Cement to the market, fly ash transport, in short nearby
people will get opportunity to improve their livelihood.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
40
10.0 ENVIRONMENTAL MANAGEMENT PLAN
10.1 Air Pollution Control
Particulate emission from various stacks and material transfer points is the
main pollutant from the cement plants. Adequate preventive measures
to keep the pollution level of particulate emission to less than 50 mg/Nm3
are provided.
Measures taken for control of fugitive emission include:-
Water spray system in the Limestone crushing section
Water sprinkling system in the Limestone preblending (reclaiming)
Bag filters at all material transfer points
Concreting roads and vacuum sweeping
Covered unloading hoppers
Silo for clinker, cement and fly ash storage
Covered shed for storage of gypsum
Open storage with water sprinkling for pet coke / coal storage
Open storage for laterite / iron ore.
Pollution Control Measures for Stack Emission (Stack Emission: 50 mg/Nm3)
S.No Source Pollution Control
Equipment
Stack
Ht.
(m)
Stack
Dia
(m)
Temp.
°C
Total Air
Vol.
m3/Hr
1 Raw Mill & Kiln Bag House
150 5.0 240 1350000
2 Coal Mill Bag House 60 1.6 120 160000
3 Clinker Cooler ESP 60 4.3 275 763000
4 Cement Mill-I
Bag House 40 2.8 120 875000
5 Cement Mill-II
Bag House 40 2.8 120 875000
6 Boiler 25 MW ESP 75 2.3 160 225000
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
41
Bag Filters / ESP for Control of Emission (Design PM < 50 mg/Nm3)
S.No. Location Collection
Area (m2)
Vent / Stack
Level (m) Flow
(m3/Hr)
Temp at bag filter
inlet (deg C)
A Crusher
1 for primary crusher
circuit 827 11.7 58000 50
2 for secondary crusher
circuit 84 11.7 6000 50
3
At transfer tower 1
(From LS Crusher to
stacker)
113 10 7500 50
4
At transfer tower 2
(From LS Crusher to
stacker)
113 10 7500 50
5
At transfer tower 3
(From LS Crusher to
stacker)
113 10 7500 50
B Stacker reclaimer
6 transfer tower (after LS
reclaimer) 113 6 7500 50
7 transfer tower (after
coal reclaimer) 113 6 7500 50
8 transfer tower (Near
Coal Mill) 113 8 7500 50
C LIME STONE HOPPER
9 At feed hopper top 227 40 15000 50
10 At feed hopper bottom 170 12 10000 50
D Wagon tippler
11 At Wagon Tippler 340 25000 50
12
transfer tower -
1(towards Coal/gypsum
Crusher)
113 8 7500 50
13
transfer tower -
2(towards Coal/gypsum
Crusher)
113 8 7500 50
E COAL - GYPSUM
CIRCUIT
14 Bulk Receiving unit 2 x 340 Ground
Level
2 x
25000 50
15 Transfer Tower (BRU to
Coal/gypsum Crusher) 113 7500 50
F Raw Mill
16 at Raw Mill building top 170 35 10000 100
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
42
17 for raw meal transport 227 15 15000 100
18 RABH (Bag House) 32468 150 1350000
140 Deg. C
compound opration
& 240 Deg. C direct
opration
G CF Silo
19 silo top bag filter 227 65 15000 100
20 for silo extraction 113 11.2 7500 100
21 for kiln feed bin 227 37 15000 100
H PreHeater
22 bag filter PH top 170 138 10000 100
I Cooler & Clinker Silo
23 Cooler ESP 13632 49 763000
100 deg. C With
WHRS & 275 deg. C
without WHRS
24 clinker tank top 50 35000 100
25 Belt Conveyor (Below
Clinker tank) 113
Ground
Level
7500 100
26 Belt Conveyor (Below
Clinker tank) 113 7500 100
27 Belt Conveyor (Below
Clinker tank) 113 12000 100
28 Belt Conveyor (Below
Clinker tank) 113 12000 100
29 Belt Conveyor (Below
Clinker tank) 113 12000 100
30 Belt Conveyor (Below
Clinker tank) 113 12000 100
31 Belt Conveyor (Below
Clinker tank) 113 12000 100
32 Belt Conveyor (Below
Clinker tank) 113 12000 100
33 Belt Conveyor (Below
Clinker tank) 113 12000 100
34 Belt Conveyor (Below
Clinker tank) 113 7500 100
35 Belt Conveyor (Towards
cement Mill Hopper) 113 10 7500 100
36 at transfer tower bulk
wagon loading (Clinker) 113 10 7500 100
37 at transfer tower bulk
wagon loading (Clinker) 113 10 7500 100
38 at transfer tower bulk
wagon loading (Clinker) 113 10 7500 100
39 at clinker loading
hopper top 170 8 10000 100
40 at clinker rail loading
hopper top 170 10000 100
J Coal Mill
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
43
41 Raw Coal hopper 227 40 15000 50
42 coal mill bag filter (Bag
House) 2655 63 160000 120
43 Fine coal bin 170 36 10000 50
CEMENT MILL-1 CIRCUIT
K Fly ash Handling
44 Above fly ash silo 170 43.9 12500 70-90
45 Fly ash collecting bin 84 16.5 6000 70-90
46 Silo feeding Bucket
elevator 62 6.85 4000 70-90
L Cement Mill Hopper
47 Belt conveyor & hopper
venting 227 34 15000 70-90
48 Belt conveyor & hopper
venting 170 34 12000 70-90
49 Hopper Extraction 227 10 15000 70-90
M Cement Mill
50 BE, BC & bin 227 15 15000 70-90
51 BE, BC & bin 284 42 20000 70-90
52 For Air slides 113 20 7500 70-90
53 Cement mill bag house 16000 42 875000 120
N Cement Silo Feeding &
Extraction
54 PPC silo top 2 x 113 43.5 2 x 7500 70-90
55 PPC Silo bin 84 17.15 6000 70-90
O Packing Plant
56 For packer air slide 113 14 7500 70-90
57 For packer 4 x 540 41.5 4 X
40000 70-90
58 For accessories of
packing plant 4 x 284 41.5
4 X
20000 70-90
59 For bulk loading storage
bin 84 25 5000 70-90
CEMENT MILL-2 CIRCUIT
P Fly ash Handling
60 Above fly ash silo 170 43.9 12500 70-90
61 Fly ash collecting bin 84 16.5 6000 70-90
62 Silo feeding Bucket
elevator 62 6.85 4000 70-90
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
44
Q Cement Mill Hopper
63 Belt conveyor & hopper
venting 227 34 15000 70-90
64 Belt conveyor & hopper
venting 170 34 12000 70-90
65 Hopper Extraction 227 10 15000 70-90
R Cement Mill
66 BE, BC & bin 227 15 15000 70-90
67 BE, BC & bin 284 42 20000 70-90
68 For Air slides 113 20 7500 70-90
69 Cement mill bag house 16000 42 875000 120
S Cement Silo Feeding &
Extraction
70 PPC silo top 2 x 113 43.5 2 x 7500 70-90
71 PPC Silo bin 84 17.15 6000 70-90
T Packing Plant
72 For packer air slide 113 14 7500 70-90
73 For packer 4 x 540 41.5 4 X
40000 70-90
74 For accessories of
packing plant 4 x 284 41.5
4 X
20000 70-90
75 For bulk loading storage
bin 84 25 5000 70-90
S.No Location of Bag Filter Qty (Nos)
No. of Bags Total Collection Area(M2)
Design Temp ( 0C )
1 Coal transfer tower & Grizzle hopper
1 110 145.2 50
2 Lime stone grizzle hopper 1 42 55.44 50 3 Lime Stone Crusher House 1 180 238 50 4 Coal Crusher House 1 289 381.5 50
5 Between transfer tower and bunker
1 208 275 50
6 Between transfer tower and bunker
1 121 160 50
10.2 Solid Waste Generation
No solid waste will be generated in cement manufacturing process.
Dust collected from air pollution control equipment will be 100%
recycled in the cement manufacturing. Ash and bed ash generated
from CPP will be utilized in cement unit.
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
45
10.3 Waste Water Management
No waste water will be generated from Cement Plant as dry process
technology will be used for cement manufacturing. Initially there will be
only discharge from office toilets and canteen which will be disposed
off in soak pits via septic tank. After completion of project work STP shall
be installed and treated water will be used for plantation. In mine area
waste water generated from work shop during washing of HEMM
contains dust and oil contents will be used for dust suppression in
crusher after separation of oil and grease.
10.4 Noise Pollution Control
The high noise generating machineries are Raw mill, Coal mill, Cooler
fans and Compressors etc. The noise level in the nearby area of these
machineries will be around 95 to 110 dB (A). The persons working in the
work zone area use ear plugs. To maintain the overall noise level less
than 85 dB (A) in the plant area and less than 70 dB (A) at the plant
boundary the following measures are taken:-
Following management plan will be implemented:
Proper maintenance and lubrication of plant machineries
Plantation all around plant premises.
Installation of compressors in closed building
10.5 Hazardous Waste Management
Used oil will be generated as hazardous waste from the machineries
which will be sold to CPCB authorized dealer.
10.6 Green Belt Development
Approx. 142.79 ha of land is proposed for the project. Out of which
plantation will be done on 47 ha (33% of total land) land. Local native
species will be planted.
10.7 Socio Economics Measures
2.4 Million TPA Clinker, 4.0 Million TPA Cement, 25 MW Captive Power Plant & 15 MW Waste Heat
Recovery Power Generation Near village Pedagarlapad, Mandal-Karempudi, District- Guntur (Andhra
Pradesh)
Pre-Feasibility Report
46
Shree Cement is committed to contribute in the development of basic
needs of the local area like education, Health & family welfare, women
empowerment, Natural resource management, water conservation,
roads etc. For socio-economic development of the nearby village, we
have “Shree Rural Development society” to survey the basic
infrastructure needs of the villagers like education, medical, drinking
water for human beings and animal, roads, plantation and rain water
harvesting etc and accordingly financial assistance will be provided by
the company to the local authority.
11.0 CONCLUSION
Proposed project will result in growth of the surrounding areas by
increased direct and indirect employment opportunities in the region
including ancillary development and supporting infrastructure. Special
emphasis on Financial and Social benefits will be given to the local
people including tribal population, if any, in the area. Development of
social amenities will be in the form of medical facilities, education to
underprivileged and creation of self-help groups.
No adverse effect on environment is envisaged as proper mitigation
measure will be taken up for the same.